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BACKGROUND OF THE INVENTION
The present invention relates to a method for lifting large storage tanks off the ground by using pressurized bags.
Large storage tanks holding environmentally hazardous products require inspection and maintenance to prevent the products from leaking and contaminating the surrounding soil and ground water supplies. Contamination and pollution of soil and water in the area of the tank can cause the owner enormous cleanup expense. Also, the tank can settle into the ground causing water to form pools around the tank increasing the possibility of corrosion.
Inspection and maintenance of the tank requires temporarily draining the tank. It is important that maintenance be done quickly to minimize the loss of valuable storage space. Inspection of the tank floor from inside the tank is highly inaccurate and cannot detect a faulty foundation or corrosion under the tank.
The preferred prior art method to prevent or correct leakage from the tank is to lift the tank so as to inspect and repair the tank floor from underneath the tank. After the tank is lifted, the bottom of the tank floor can be inspected, sand blasted, repainted, and cathodic protection installed. While the tank is lifted, foundation problems can be rectified and the general condition of the foundation can be upgraded. The foundation can be raised to compensate for any settling that has occurred over time. Improvements such as an impervious layer, leakage detectors, and drainage systems can be installed on the tank foundation while the tank is lifted.
Prior methods for tank lifting have required "hot" work, such as welding and torch cutting on the tank to provide attachment points to the tank for the use of hydraulic lifts. This hot work requires degassing the tank to prevent explosions. In a crowded tank farm, the danger of explosion is always present or difficult to control. Moreover, if the tank to be lifted is very large, holes must be cut in the floor of the tank so that the hydraulic lifts can be placed under the center of the tank floor. Thus, there is a need for providing a procedure of lifting storage tanks without encountering the considerable disadvantages of the prior art methods.
BRIEF SUMMARY OF THE INVENTION
The present invention uses pressurized bags to lift the tank. The method is safe, economical, and efficient using only pressurized bags and timbers. No hot work is required so there is no fear of explosion. The bottom of the tank can be fully inspected once the tank has been lifted. Improvements such as sand blasting and painting the bottom of the tank floor and upgrading the foundation can be performed without requiring the tank be degassed. Only if the tank is severely corroded or leaking will hot work be performed requiring precautions against explosion.
In the present method, the tank is lifted a small distance by inflating bags placed under the tank. Then support timbers are placed under the tank and the bags deflated. The bags are then placed on new supports and inflated to raise the tank higher. Since the bags can raise the tank only a few inches in each lift, the lift and support steps are repeated until the tank is lifted to the required working height.
If a large tank is being lifted, structural requirement may necessitate lifting the floor also. Since the deflated bags are only about two inches thick, the relatively thin unpressurized bags can be slipped under the tank's floor to lift the tank floor as the tank is being lifted thereby eliminating the need to cut holes in the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a perspective view of a tank lifted by the method of the present invention and sitting on support members;
FIG. 1B is a top view of the tank of FIG. 1A;
FIG. 2 is a perspective view showing an unpressurized air bag under the edge of the tank of FIG. 1A according to the process of the present invention;
FIG. 3 is a perspective view showing the pressurized air bag of FIG. 2 lifting the tank off the ground with tank support members adjacent the bag;
FIG. 4 is a side view showing the unpressurized air bags raised on support members ready to begin another lift cycle;
FIG. 5 is a side view showing the pressurized air bags having further lifted the tank;
FIGS. 6A-6C are side, top and side views, respectively, showing the rocking method for breaking the suction under the tank in accordance with the present invention;
FIGS. 7A-7C show another process of the present invention providing air bags under of the center of the tank floor; and
FIG. 8 is a top view of a storage tank showing the fulcrum method of the present invention for lifting the tank using fewer bags and support members.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The object of the present invention is to lift a large storage tank 10 to a level shown in FIG. 1A, preferably 8-10 feet off the ground, so that work may be done on the underside of the tank floor and on the ground beneath the tank. Preferably the tank is supported by tank support members 20 consisting of several layers of a plurality of hardwood timbers, each layer being stacked crosswise with the immediate adjacent layers, as shown. Referring to FIG. 1B, the support members 20 are spaced around the periphery of the tank base 15 so as to maintain the tank in a stable, even position. Sufficient support members 20 are used so that selected members may be temporarily removed to enable the entire foundation to be worked on as needed.
Before a storage tank 10 can be lifted, the structural design and condition of the tank must be analyzed to determine the number and placement of lifting bags 12 and tank support members 20 to ensure the tank will be lifted safely and without damage. The analysis includes a determination of the size, weight and shape of the tank, the thickness of its walls, the type of material used, and the age and structural condition of the tank. Other factors to consider include wind loading, earthquake loading and bulk storage loading on the foundation.
Referring now to FIG. 2, the beginning of the process of the present invention to lift a storage tank is shown. Initially, it is usually necessary to break the suction between the bottom of the tank and the foundation. Therefore, the first lifting bags 12 are preferably placed under the tank 10 at or near the compensating plate 14 or service hole 16, where the tank wall is usually thickest and strongest. The lifting bags 12 are conventional rubber bags manufactured from reinforced interwoven layers of synthetic materials. They preferably are three feet by three feet square by one and one-half inches thick and have a safe working pressure of 120 pounds per square inch (psi). One preferred source for the bags is model V68 bags made by Manfred Vetter Gmbh in Zuelpich-Langendorf, Germany. It is also understood that other pressurized vessels may be used besides bags 12 which are suitable to provide hydraulic lifting according to the present invention.
The tank support members 20 are hardwood timbers and their size is determined by the height required to be lifted. The preferably size of the tank support members 20 is six inches by five inches by five feet long. The bag support members 22 are also of hardwood timber and their preferred size is six inches by five inches by three feet long. It is understood that other types of support members for the tank and the bags may be used as long as they are suitable to carry out the methods of the present invention.
The pressure required in the bag 12 to lift the tank 10 is controlled by using conventional valves and regulators. Any number of bags can be used at the same time to get complete control over the lifting so no undue stress is created on the tank. Preferably the bags are all filled from a central air supply. The lifting height is preferably controlled from 1/16 inch to twelve inches in any one lift. It is understood that bags 12 may also be filled with water or other fluid suitable to pressurize the bags.
As shown in FIG. 2, to place the lifting bags 12 under the tank 10, a hole three feet wide, extending eighteen inches under the tank and two inches deep into the ground 30, is dug out for each bag. Each bag 12 is then placed in a hole and connected to the control valves and regulators by air hoses 18. The bags 12 are slowly inflated with pressure while watching to see if the tank 10 is lifting away from the ground 30. If ground suction prevents the tank from lifting off the ground, the pressure is stopped at sixty psi and the pressure in the bags is allowed to pulsate to help break the suction. Should the suction not be broken at sixty psi, the pressure is increased by ten psi and the pulsating repeated until one hundred psi is reached. If the tank suction remains unbroken at one hundred psi, then more bags are inserted around the tank perimeter and the process repeated.
Referring now to FIG. 3, when the tank is six inches off the ground 30, tank support members 20 are inserted at calculated points on both sides of each of the bags 12 around the bottom periphery 15 of tank 10. The lifting bags 12 are then deflated by releasing the pressure to leave the tank 10 sitting on the tank support members 20.
As shown in FIG. 4, the bags 12 are removed from under the tank 10 and the bag support members 22 are placed in the same position as the bags. The bags 12 are placed on top of the bag support members 22 and inflated to one hundred psi which lifts the tank 10 another six to twelve inches. A second layer of tank support members 20 is placed cross-wise on top of the existing tank support members 20 as shown in FIG. 5. The bags 12 are then deflated and the tank 10 is supported on the new tank support timbers 20. This process is repeated until the tank 10 has been lifted to the required height off the ground 30, normally four to ten feet as shown in FIG. 1.
If the ground suction is severe, an alternative preferred rocking method can be used. This approach uses the weight of the tank 10 to break the remaining ground suction once one side has been lifted. Referring to FIGS. 6A and 6B, one or more bags 12 are placed under the adjacent side of the tank 10 below the compensating plate 14 as previously described and shown in FIG. 2. The bags 12 are pressurized until the adjacent side of the tank 10 is about six to eight inches off the ground 30. Then at least two rocking support members 24 are placed on the rim of the tank somewhat across from each other, each being about more than one-fourth of the tank circumference from the bags 12 where the tank 10 is only about two inches off the ground 30. One member 24 is placed in one direction more than one-fourth of the distance around the circumference from the bags and the other member 24 being placed the same distance in the other direction around the circumference from the bags. Preferably the supports are each placed about one-third of the circumference of the tank 10 from bags 12 on opposite sides, as best seen in FIG. 6b. Then bags 12 are depressurized and the weight of the tank 10 is used to lift the other side of the tank 10, thereby breaking any remaining ground suction that may exist under the tank 10, as shown in FIG. 6C.
FIGS. 7A to 7C show an alternative procedure for lifting large tanks that need the tank floor 15 supported in the center. This has been a particular problem in the prior art, any many holes are often cut into the bottom of large diameter tanks to provide the required support, using prior art methods.
Using the methods of the present invention, there is no need to cut holes in the tank floor. As shown in FIGS. 7A-7C, additional bags 12 are strategically placed under the floor of the tank 10 as well as around the periphery. As the tank is raised, bag support members are placed to raise the bags so as to continue to support the tank floor. Preferably the tank is raised using only the bags around the periphery of the tank as described above, and the bags under the floor are used primarily for support of the tank floor. When the tank 10 has reached the required height at the perimeter based on design stress calculations, additional bags 12 may be placed under the tank floor 15 as required.
Another preferred method of the present invention is the fulcrum method shown in FIG. 8. Using the fulcrum method, the tank 30 can be lifted to the required height using bags and timbers only at opposite ends of the tank. Thus, this procedure uses less bags and timbers than the previous described processes. One or more bags 32, which are identical to bags 12, are placed near each other under one side A of the tank 30. The bags 32 are then pressurized until side A of the tank is raised about eight inches. Two tank support members 34 are then placed on either side of the tank under the bottom rim 36 of the tank 30, less than one-fourth of the circumference from the bags 32. Then the bags 32 are depressurized and moved to the opposite side B of the tank 30. The opposite side B of the tank 30 is lifted and tank support members 35 are then placed under the opposite side B of the tank 30.
The bags 32 are then depressurized and moved back to side A on top of bag support members (not shown) such as member 22 shown in FIGS. 4 and 5. Preferably the bag support members are high enough so that as the bags 32 are pressurized they will raise tank side A above the tank support members 34. Members 34 are then increased in height to fit just under the tank 30 on side A. The bags 32 are then depressurized and placed under bag support members on side B similar to support member 22. Side B of the tank is lifted by pressurizing bags 32, building up tank supports 35 and depressurizing bags 32. The process is repeated moving the lifting bags to alternate sides of the tank until the tank has been raised to the desired height.
This fulcrum method enables lifting of the tank 30 using a part of the tank's weight as leverage. For example, by lifting tank 30 at side B after support members 34 are in place the lever arm length is shortened to the distance from the bags on side B to members 34 not to side A. Thus, the weight of the part of tank 30 between side A and members 34 provides leverage to help bags 32 lift tank 30 on side B. Bags 32 are then placed back at side A, on top of bag supports to raise the tank further. Leverage to assist this action is provided by the weight from the portion of the tank between supports 35 and side B.
Once the prescribed maintenance has been completed, the tank is lowered by reversing the above described processes.
Although the foregoing discloses preferred embodiments of the present invention, it is understood that those skilled in the art may make various changes to the preferred embodiments shown without departing from the scope of the invention.
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A method of lifting storage tanks by using pressurized bags and support members. Lifting the tank allows for visual inspection under the tank for corrosion to prevent leakage of environmentally hazardous chemicals stored in the tank. The lifting bags are placed under the tank, inflated, and support timbers placed under the raised tank. The bags are then deflated allowing the tank to rest on the support timbers. The deflated bags are raised by placing support timbers under the bags. The bags are again pressurized further raising the tank. The steps are repeated until the tank is lifted to the desired height. Ground suction is broken by raising one side of the tank with the lifting bags, placing supports as far as possible under the tank rim and depressurizing the bags to rock the other side of the tank off the ground. A fulcrum method is also applied to use the partial weight of the tank as a leverage force to alternately raise opposite sides of the tank.
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FIELD OF THE TECHNOLOGY
[0001] The present invention relates to data communication technologies, more particularly to a method and an apparatus for forwarding packet.
BACKGROUND OF THE INVENTION
[0002] Virtual Local Area Network (VLAN) is a booming technique, which divides equipment in a Local Area Network (LAN) not physically but logically into segments, and thereby implementing virtual working groups.
[0003] The IEEE 802.1Q standard draft defines a method for bearing several logical VLAN subnets on the same physical link. The IEEE 802.1Q adds four bytes into a standard IEEE802.3 Ethernet frame, wherein, the four bytes are called a Virtual Local Area Network Tag (VLAN Tag), as shown in FIG. 1 , which is a schematic diagram illustrating a structure of a virtual Ethernet frame based on the IEEE802.1Q. In the definition of the virtual Ethernet frame structure shown in FIG. 1 , a VLAN Tag is inserted between a source Media Access Control (MAC) address and a frame type. The VLAN Tag contains a type field of value 0x8100, which occupies two bytes and is used for identifying the Ethernet frame as a frame of the VLAN structure. The VLAN Tag also contains VLAN Identifier (VLAN-ID), which occupies 12 bits and can support 4096 VLAN instances.
[0004] Recently, with the widespread applications of the VLAN, especially in Metropolitan Area Networks (MANs), each user will use one VLAN, which has made the 4096 VLAN instances defined in the virtual Ethernet frame structure become a bottleneck of the network development.
[0005] In order to solve the problem, a QinQ technique, i.e. 802.1Q in 802.1Q technique for expanding the VLAN ID number is provided. It also can be called a VLAN stack technique. The QinQ technique satisfies the demand of networks by increasing the number of the VLAN ID.
[0006] The QinQ technique adds a 4-bytes VLAN Tag into the existing 802.1Q frame, i.e., adds a 4 bytes VLAN Tag, which is completely the same as that in the 802.1Q, closely behind the VLAN Tag in the 802.1Q, as shown in FIG. 2 . Under such a design concept and a scheme, the QinQ technique is completely compatible with all the characteristics of the original 802.1Q VLAN. Meanwhile, the added 12-bit VLAN ID makes the number of available VLAN IDs reach as high as 24 bits, therefore satisfying the demand for the VLAN ID under diversified circumstances.
[0007] In the related art, the QinQ technique is implemented as follows: a network device which supports the QinQ technique, such as a convergence switch, a router, a broadband access server, etc., receives an Ethernet packet with only one VLAN Tag sent by a user access device. It encapsulates another VLAN Tag into the packet according to a standard VLAN tagging technique, such as in-port number, or out-port number, before forwarding the packet to a backbone network.
[0008] The existing VLAN tagging techniques includes: port-based VLAN tagging techniques, MAC-based VLAN tagging techniques, network layer based VLAN tagging techniques and Internet Protocol (IP) multicast based VLAN tagging techniques.
SUMMARY OF THE INVENTION
[0009] The present invention provides a method for forwarding packet, so as to forward packet which carries a service feature, and it is possible for a network device in a backbone network to process the packet according to the service feature of the packet.
[0010] The present invention also provides an apparatus for forwarding packet, the apparatus makes it possible to forward packet, and the network device which received the packet can process the packet according to the service feature of the packet.
[0011] The technical scheme according to one aspect of the present invention is implemented as follows:
[0012] A method for forwarding packet includes:
[0013] configuring a corresponding relationship between a physical feature and a service feature of a packet;
[0014] receiving a packet, obtaining the physical feature of the packet;
[0015] finding the corresponding relationship between the physical feature and the service feature according to the obtained physical feature, and obtaining the service feature of the packet;
[0016] encapsulating the service feature of the packet into the packet, and forwarding the packet which has been encapsulated with the service feature.
[0017] Meanwhile, according to another aspect of the present invention provides an apparatus for forwarding packet, including a reception unit and a transmitter unit; wherein,
[0018] the reception unit, used for receiving a packet and obtaining a physical feature of the packet, and obtaining a service feature of the packet according to corresponding relationship between the physical feature and the service feature of the packet, and encapsulating the service feature of the packet into the packet;
[0019] the transmitter unit, used for transmitting a packet that has been encapsulated with a service feature.
[0020] By setting a corresponding relationship between the physical feature and the service feature of a packet, the method and the apparatus according to embodiments of the present invention obtains the service feature of a packet according to the physical feature of the packet after receiving the packet, and further encapsulates the service feature into the packet, then forwards the packet carrying the service feature. The method and the apparatus make it possible for a network device to process a packet directly according to the service feature of the packet, which may improve the processing efficiency of the packet. In addition, the method and the apparatus implements differential services for users, which may decrease the cost for processing the packet during operation, and improve the service management and service control abilities during operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic diagram illustrating a structure of an IEEE802.1Q-based virtual Ethernet frame;
[0022] FIG. 2 is a schematic diagram illustrating a structure of a QinQ data frame;
[0023] FIG. 3 is a basic flowchart in accordance with an embodiment of the present invention;
[0024] FIG. 4 is a flowchart according to an embodiment of the present invention;
[0025] FIG. 5 is a schematic diagram illustrating a frame structure with three layers of tags according to an embodiment of the present invention;
[0026] FIG. 6 is a schematic diagram illustrating a frame structure with multiple layers of tags according to an embodiment of the present invention;
[0027] FIG. 7 is a schematic diagram illustrating a structure of a forwarding apparatus according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] In order to make the technical solution and the advantages of the present invention clearer, the present invention will be described in detail hereinafter with reference to the accompanying drawings and embodiments.
[0029] In embodiments of the present invention, a corresponding relationship between the physical feature and the service feature of a packet is set. After receiving a packet, obtain the service feature according to the physical feature of the packet, and encapsulate the service feature into the packet.
[0030] Wherein, the physical feature of a packet includes: out-port number, MAC address, network address, IP multicast, or VLAN Tag. The service feature of a packet includes: service-related features, such as service type, or service priority, etc.
[0031] After the service feature corresponding to the packet is encapsulated into the packet, network devices can process the packet according to the service feature encapsulated in the packet.
[0032] A basic flowchart according to an embodiment of the present invention is shown in FIG. 3 , including the following steps:
[0033] Step 301 : receive a packet, and obtain the physical feature of the packet;
[0034] Step 302 : find the corresponding relationship between the physical feature and the service feature according to the obtained physical feature, and obtain service feature of the packet;
[0035] Step 303 : encapsulate the service feature of the packet into the packet, and forward the packet.
[0036] In the following embodiment, the first VLAN Tag of an Ethernet packet is taken as the physical feature of the Ethernet packet, and the second VLAN Tag is taken as the service feature of the Ethernet packet. Corresponding relationship between the first VLAN Tag and the second VLAN Tag of the Ethernet packet is set. The Ethernet packet will be shortened as packet hereinafter.
[0037] Wherein, the first VLAN Tag is the VLAN Tag defined by the 802.1Q. And the second VLAN Tag is: the second layer VLAN Tag encapsulated following the QinQ technique, and the second VLAN Tag can be encapsulated either in the inner layer or in the outer layer.
[0038] The corresponding relationship between the service feature, which is represented by the second VLAN Tag, and the first VLAN Tag is determined according to the requirements of practical operation circumstances and practical applications. Wherein, the corresponding relationship can be: the corresponding relationship between the service priority of the packet and the first VLAN Tag; or, the corresponding relationship between the service type of the packet and the first VLAN Tag, etc.
[0039] In this embodiment, the corresponding relationship between the second VLAN Tag and the first VLAN Tag is: the corresponding relationship between the service type of the packet and the VLAN identifier of the first VLAN Tag.
[0040] For example, under practical circumstances, if the value of the VLAN identifier carried in the VLAN Tag is between 1˜2K, it corresponds to Internet browse services. And the value between 2˜3K corresponds to SOHO services or commercial services, the value between 3˜4K corresponds to Voice over IP (VOIP) services or video services. Therefore, the corresponding relationship between the first VLAN Tag and the second VLAN Tag is: if the value of the VLAN identifier of the first VLAN Tag is between 1˜2K, the second VLAN Tag it corresponds is 1. And if the value is between 2˜3K, the second VLAN Tag it corresponds is 10, if the value is between 3˜4K, the second VLAN Tag it corresponds is 1000, etc. At this time, the value 1 of the second VLAN Tag represents Internet browse services; the value 10 of the second VLAN Tag represents SOHO services or commercial services; and the value 1000 of the second VLAN Tag represents VoIP services or video services.
[0041] The present embodiment illustrates the procedure of a convergence switch receiving a packet which is sent by a user access device and forwarding the packet to a network device in the backbone network. The procedure is shown in FIG. 4 , which includes the following steps:
[0042] Step 401 : a convergence switch receives a packet sent by a user access device.
[0043] Step 402 : the convergence switch processes the received packet according to packet receiving strategies.
[0044] Wherein, the packet receiving strategies includes diversified security inspections and bandwidth control strategies.
[0045] Step 403 : the convergence switch determines whether it supports the QinQ function, if it supports, goes to Step 404 ; otherwise, goes to Step 409 .
[0046] Step 404 : the convergence switch obtains the first VLAN Tag contained in the received packet.
[0047] Step 405 : search the corresponding relationship between the first VLAN Tag and the second VLAN Tag, and obtain the second VLAN Tag according to the first VLAN Tag.
[0048] For example, when the value of the VLAN identifier of the first VLAN Tag is between 1˜2K, the corresponding second VLAN Tag is 1, which representing Internet browse services. When the value of the VLAN identifier of the first VLAN Tag is between 2˜3K, the corresponding second VLAN Tag is 10, which representing SOHO services or commercial services. when the value of the VLAN identifier of the first VLAN Tag is between 3-4K, the corresponding second VLAN Tag is 1000, which represents VoIP services or video services.
[0049] Wherein, the corresponding relationship between the first VLAN Tag and the second VLAN Tag can be configured through command-line, network manager or other configuration methods, or can be a fixed strategy implemented by hardware or software.
[0050] Step 406 : encapsulate the obtained second VLAN Tag into the received packet.
[0051] Step 407 : forward the packet carrying the second VLAN Tag to the network device in the backbone network. During this procedure, the packet can also be processed according to packet transmission strategies. And the current procedure is ended.
[0052] Wherein, the packet transmission strategies include diversified security inspections and bandwidth control strategies.
[0053] Step 408 : end the current procedure.
[0054] The convergence switch can process each packet it receives according to the steps shown in FIG. 4 .
[0055] Since a second VLAN Tag is carried in the packet forwarded to the network device in the backbone network by the convergence switch, and the second VLAN Tag in the packet can identify the service type of the packet, the network device in the backbone network can process the packet according to the service feature of the packet. For example, if the service feature is the service priority, then the network device in the backbone network can first process the packets with higher priorities, which satisfies different requirement of users with different priorities.
[0056] In the present invention, except for encapsulating a service feature into the packet according to the physical feature of the packet, it is also possible to set corresponding relationships between the physical feature and at least one physical feature and/or at least one service feature according to the requirement of the practical circumstances. After the packet is received, at least one physical feature and/or at least one service feature are (is) encapsulated into the packet according to the corresponding relationships. Therefore, the packet can carry more information.
[0057] After the packet encapsulated with at least one physical feature and/or at least one service feature is received, the encapsulated at least one physical feature and/or at least one service feature are (is) removed, and the packet is forwarded.
[0058] Correspondingly, in the above embodiment, the QinQ technique can only support two VLAN Tags. Therefore, in order to carry more physical and/or service features, more VLAN Tags can be set into the packet, the number of the VLAN tags is equal to the number of the physical and/or service features to be encapsulated into the packet. According to the number of the physical and/or service features encapsulated in the packet, the number of the VLAN Tag can be three, four, or more. The format of the added VLAN Tag is the same as that of the original VLAN Tag in the packet. FIG. 5 is a diagram illustrating a frame structure of a packet with three VLAN Tags. FIG. 6 is a diagram illustrating a frame structure of a packet with multiple VLAN Tags. In addition, other information can also be carried in the packet by the additionally set VLAN Tags. And the number of the VLAN Tags is not limited.
[0059] When the convergence switch receives the packet with multiple VLAN Tags from the network device in the backbone network, it only needs to remove the encapsulated VLAN Tags layer by layer to finish the de-encapsulation, and then forwards the packet to the user access device.
[0060] In addition, an embodiment of the invention provides a packet forwarding apparatus corresponding to the packet forwarding method. The structure of the apparatus is shown in FIG. 7 , which includes a reception unit 71 and a transmitter unit 72 .
[0061] The reception unit 71 , used for receiving a packet and obtaining a physical feature of the packet; and obtaining a service feature of the packet according to the obtained physical feature; and encapsulating the service feature of the packet into the packet;
[0062] the transmitter unit 72 , used for transmitting a packet that has been encapsulated with a service feature.
[0063] Wherein, the reception unit 71 further includes a unit used for encapsulating at least one physical feature and/or at least one service feature into the packet. Accordingly, the transmitter unit 72 further includes a unit used for transmitting a packet containing at least one physical feature and/or at least one service feature.
[0064] When the apparatus needs to de-encapsulate a packet which has been encapsulated with at least one physical feature and/or at least one service feature, the reception unit 71 further includes a unit used for receiving a packet containing at least one physical feature and/or at least one service feature, and removing the at least one physical feature and/or at least one service feature contained in the packet. Accordingly, the transmitter unit 72 further includes a unit used for transmitting a packet whose physical feature and/or service feature have (has) been removed by the reception unit 71 ;
[0065] or, the transmitter unit 72 further includes a unit used for receiving a packet containing at least one physical feature and/or at least one service feature, and removing the at least one physical feature and/or at least one service feature contained in the packet. The reception unit 71 further includes a unit used for transmitting a packet whose physical feature and/or service feature have (has) been removed by the transmitter unit.
[0066] The forgoing embodiments are only the preferred embodiments of the present invention, which are not used to confine the protection scope of the present invention. Any changes and modifications maybe made by those skilled in the art without departing from the spirit and principle of this invention and therefore should be protected by the protection scope of this invention as set by the appended claim and its equivalents.
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A method for forwarding packet includes: configuring a corresponding relationship between a physical feature and a service feature of a packet; receiving a packet, obtaining the physical feature of the packet; finding the corresponding relationship between the physical feature and the service feature according to the obtained physical feature, and obtaining service feature of the packet; encapsulating the service feature of the packet into the packet and forwarding the packet. In addition, the present invention also discloses an apparatus for forwarding packet. The method and the apparatus of the present invention make it possible for a network device to process a packet directly according to the service feature of the packet, which improves the processing efficiency of the packet, and implement differential services for users, decreases the cost for processing the packet during operation, and improves the service management and service control abilities during operation.
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PRIORITY APPLICATION
[0001] Priority is claimed from U.S. Provisional Patent Application Ser. No. 61/335,711, filed Jan. 11, 2010, and said U.S. Provisional Patent Application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to the field of mobile communications and, more particularly, to promoting safety in use of mobile communication devices, such as cellular phones, by implementing safety-promoting action.
BACKGROUND OF THE INVENTION
[0003] Mobile communication devices, such as cellular telephones, are in widespread use throughout the world, and have many obvious benefits. However, certain uses of a cell phone by the operator of a moving vehicle can result in substantial distraction and concomitant safety hazard that risks injury or death to the user and the user's passengers, as well as occupants of other vehicles and pedestrians put in harm's way by a distracted operator. One example that has already become notorious, is cell phone “texting” by the operator of a motor vehicle.
[0004] The U.S. Patent Application Publication US2009/0224931 discloses a mobile device configured to have at least one function disabled when the speed of the mobile device exceeds a threshold. In an embodiment of the '931 Publication, when a determination is made that a mobile device is in motion above a threshold speed, a user interface on the device can notify the user of the device that a safety feature disabling the device or one or more functions of the device is about to be activated. The user can then be given an opportunity to prevent the safety feature from being activated and allow the mobile device to continue normal operation. The interface that notifies the user of the impending disablement of the mobile device might be a text-based message that appears on the display screen of the device, an automated voice message spoken by the device, an audible, visible, and/or tactile alarm signal, or some other type of output. As also described in the '936 Publication, upon receiving this notification, the user can provide an input into the mobile device to prevent the activation of the safety feature. For example, a driver who is willing to accept the safety risk of sending and receiving messages while driving may provide an input to override the safety feature. Alternatively, a passenger in an automobile being driven by another person or in a public transportation vehicle may not be an appropriate target for the safety feature and may choose to prevent the activation of the safety feature of the '931 technique.
[0005] The U.S. Patent Application Publication US200910240464 discloses a technique generally similar to that of the '931 Published Application. In an embodiment of the '464 Publication, frequency error distributions for Doppler shift measurements are used in determining the speed at which a mobile communication device is moving. Then, as in the '931 Publication, a determination is made as to whether a threshold speed has been exceeded, whereupon action can be taken.
[0006] While existing techniques, such as those described, are a step in the right direction, improvement is needed. For example, depending on various operational factors and safety assessments for individual situations, it may not be appropriate to provide an option to the operator of the mobile device. Further, the option itself, or implementation of a response thereto, may involve a degree of safety risk. Another shortcoming of existing approaches is the reliance on device speed alone in making a decision as to whether corrective action is necessary. It is among the objects of the invention to overcome these and other shortcomings or limitations of existing techniques.
SUMMARY OF THE INVENTION
[0007] It has been recognized in the prior art that the user of a mobile communication device may be a passenger in a moving vehicle. To date, the solution as been to give a passenger the option of overriding disabling controls or warnings resulting from detected speed of the mobile communication device. In accordance with a feature hereof, determination of driver/passenger status of the device user can, in many instances, be made with a relatively high probability, thereby providing greater flexibility of action.
[0008] In accordance with a first form of the invention, a method is set forth for controlling operation of an active mobile communication device, including the following steps: performing a first determination of whether said device is in a moving vehicle; performing a second determination of whether the user of said device is the vehicle operator; and producing a risk indication signal as a function of said first and second determinations. In an embodiment of this form of the invention, the of performing said second determination includes determining the relative position of said device in the vehicle. In this embodiment, the step of performing said second determination includes determining the presence of a proximity group of communication devices, and determining the relative position of said active mobile device in the proximity group. The determining of the relative position of said active mobile device can be performed at a plurality of successive times, and the relative positions obtained at a plurality of times can be interpolated to obtain a refined relative position. Also in this embodiment, the determining of the relative position of said active mobile device in said proximity group is performed with respect to the direction of motion of the proximity group.
[0009] In an embodiment of this first form of the invention the risk indication signal comprises a conditional disabling signal, and at least one function of said device is disabled in response to said risk indication signal when a predetermined condition has been met. In this embodiment, the predetermined condition includes at least one factor selected from the group consisting of geographical features at the location of the vehicle, traffic, weather conditions, and time of day. Also in this embodiment, the step of performing said first determination includes determining the speed of said moving vehicle, and the risk indication signal is also a function of said determined speed. In one embodiment, said first determination and/or said second determination are determined using probabilities, and the detecting of whether said probabilities exceed predetermined thresholds.
[0010] In an embodiment of this form of the invention, at least one function of said device is disabled in response to a risk indication signal. The at least one function can be a tactile input function, such as manual texting, which is dangerously distracting for a vehicle operator.
[0011] In an embodiment of a further form of the invention, a method is set forth for controlling operation of an active mobile communication device, comprising the steps of: performing a determination of whether said device is in a moving vehicle at a relevant location; and producing a risk indication signal as a function of said determination. A warning can be issued and/or at least one function of the device can be disabled in response to said risk indication signal. In an embodiment of this form of the invention, the risk indication signal comprises a conditional disabling signal, and at least one function of said device can be disabled in response to said risk indication signal when a predetermined condition has been met. The predetermined condition can include at least one factor selected from the group consisting of geographical location of the vehicle, weather conditions, and time of day.
[0012] Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a bock diagram of a mobile communication device used as an example of a type of device that will be subject to receiving risk indication signals or control signals in accordance with embodiments of the invention.
[0014] FIG. 2 is a simplified block diagram, partially in schematic form, of part of an existing type of GSM in conjunction with which embodiments of the invention can be implemented, and which includes a processor that can be programmed to implement techniques in accordance with embodiments of the invention.
[0015] FIG. 3 shows an example of a moving vehicle containing plural mobile communication devices, which is useful in understanding operation of an embodiment of the invention.
[0016] FIG. 4 , which includes FIGS. 4A and 4B placed one below another, is a flow diagram of a routine for controlling a machine processor for implementing embodiments of the invention.
DETAILED DESCRIPTION
[0017] Referring to FIG. 1 , there is shown a block diagram of a typical cell phone, it being understood that the features hereof are not dependent on use of any particular type of cell phone or other mobile communications device. The main computational subsystem is represented at 110 , and includes, inter alia, signal processing unit 102 and central processing unit (CPU) 104 . As is well known, specialized digital signal processing (DSP) chips are typically used for implementation of part of these functions. The device key pad and display are represented at 120 , and can typically include any suitable kind of input media and display media. A display controller circuit, for example including an LCD module controller, backlit driver, etc., is represented at 125 . An antenna 130 is coupled with transmitter circuitry 133 and receiver circuitry 135 , which are respectively coupled with the processor 110 via an IF stage 137 . A voltage-controlled oscillator 139 conventionally provides appropriate frequency signals to the IF stage. Microphone and speaker circuitry are represented at 141 and 143 , respectively. Power supply module 160 includes a charging circuit for the battery (not separately shown) and an appropriate voltage conversion circuit. Storage is represented at 170 , and will typically include, at least, a flash memory module.
[0018] Referring to FIG. 2 , there is shown a simplified diagram of part of an existing type of “GSM” or “global system for mobile communication” in conjunction with which embodiments of the invention can be implemented. As is well known, the GSM uses digital radio transmission to provide voice, data, and multimedia communication services. (It will be understood that the invention can operate in the content of any other suitable type of communication system.) Among other functions, the GSM of this example operates to coordinate and control the communication between mobile telephones (such as examples shown at 211 and 212 , with 211 being in vehicle 215 ), base stations/towers (such as examples shown at 225 and 226 ), and a mobile switching center represented at 240 . Servers and one or more central processors, represented at 260 , communicate with the mobile switching center 240 and with the internet, represented at 270 . Data bases, represented generally at 280 , are available to the central processor, directly and/or via internet. In an example hereof the central processor can be programmed to implement an embodiment of the technique of the invention.
[0019] Mobile device systems can detect location of active mobile devices (e.g., cell phones). Sometimes mobile devices can detect their own locations. This knowledge is acquired in substantially “real time” using information that can be obtained, for example, from satellites (GPS systems), relative locations of cell towers (triangulation), beacon systems, etc. Collecting this information over time (for at least two time instants) allows for the estimation of the velocity vector of mobile devices.
[0020] FIG. 3 shows an example of a moving vehicle 310 at times t 1 , t 2 , and t 3 . Three determined positions in the vehicle are represented by 311 , 312 , and 313 , respectively. In this example, the position 311 turns out to be the vehicle operator (driver) position, the position 312 turns out to be a passenger position, and position 313 turns out to be a “chip” (fixed in vehicle) position. (It will be understood, throughout, that references to a mobile communication device can also include an integrated circuit or chip that may, for example, be fixed in a vehicle, and which performs an essential function of the mobile communications device.) The crossed axes at each position represent uncertainly in position location of the mobile devices in this proximity group. The solid curved line 371 , the dashed curved line 372 , and the dotted curved line 373 , respectively represent the tracking of the three mobile devices (or “chip” in the case of 313 ), as a function of time, as the vehicle proceeds in a general direction of motion indicated by arrow 350 . The curves are constructed based on multiple measurement points to improve accuracy of the location (and relative location) of the respective mobile devices in the proximity group. (It will be understood that the timing associated with different mobile devices, which can be on different provider systems, may differ with respect to each other of with respect, for example, to a given universal clock, and that appropriate correction for such differences, including corrections for fundamental clock differences, delays, or the like, can be appropriately made.) The more separated the curves, the better distinction between location of mobile devices (or fixed points in the proximity group) can be achieved.
[0021] With no a priori knowledge, operator (e.g. driver) position may be obtainable by identifying a group of moving mobile devices (e.g. cell phones) that are moving at approximately the same speed at a relevant location, and maintaining approximately the same relative positions with respect to each other. The mobile devices (in this proximity group) are then likely to be located in the same vehicle, and the “left front” mobile device (e.g., cell phone) is likely to be the one used by the driver. (In some other countries or cases, e.g., mailman, it would be “right front”.) A way of detecting “front” is by finding the direction of motion. The system can detect that particular mobile device (e.g. cell phone) and apply desired action or restriction. In the case of a driver with no passengers, the mobile device (e.g. cell phone) in use is the mobile device used by the driver.
[0022] Identification of a vehicle operator in a proximity group can be aided by overlaying locations of mobile devices (e.g. cell phones) with available maps (satellite-based, or others, e.g. on-line maps): For example, if the mobile device appears to be moving on a railroad track, then it is probably used by a passenger and not by the vehicle operator. If the mobile device appears to be moving in an amusement park where the holder does not operate a vehicle but still moves, then there is no reason to implement safety promoting action.
[0023] Mapping can also be used to increase the probability of identifying the vehicle operator by determining the location of the mobile device relative to the center of a highway lane. If, for example, the mobile device is identified to be on the left of the center of the lane on which the vehicle is moving, then it means that it is more likely to be the mobile device used by the driver or a passenger behind the driver, and not by other people in the vehicle. This increases the probability of identifying the driver. Within the grouping, the “front” mobile device is likely to be used by the driver. Also, if there is no mobile device activity to the near right of the driver, then the mobile device activity is more probably coming from the driver himself/herself, since normally if there is more than one person in the car, that person is likely to sit next to the driver.
[0024] Mapping that includes a third dimension, namely altitude, can also be utilized to advantage. For example, based on geographical input and altitude, the presence of the active mobile communication device in an aircraft can be discerned, with appropriate restriction or limitation of use being applied.
[0025] FIG. 4 is a flow diagram of a routine for controlling the processor of FIG. 2 (and/or additional or alternative processors) to implement a technique in accordance with an embodiment of the invention for determining the use of an active mobile communication device by a vehicle operator in a situation where plural mobile communication devices, such cell phones, are present in a moving proximity group. The block 402 represents monitoring the location of an active mobile device, and the decision block 405 represents determination of whether the location is considered relevant. When this condition is met, the block 408 represents the monitoring of the speed of the active mobile device, it being understood that inquiry is continuously made (decision block 410 ) as to whether the monitored speed exceeds a predetermined threshold. If not, monitoring is continued. If so, however as represented by the block 415 , locations of mobile communications devices in a defined proximity group are determined. These operations will typically be performed in parallel for a multiplicity of devices at relevant locations (dashed arrows 420 ). The devices may be in use (active) or passive, but in a mode where positional determination can be implemented. The size of the proximity group, including uncertainties, can be modified, depending on positional map determination, which can indicate whether vehicular motion is more likely to be a private vehicle or public transportation such as may be indicated by a mapped railroad track region, a mapped bus lane, etc.
[0026] Next, inquiry is made (decision block 420 ) as to whether more than one device is involved. If not, the device is considered as having a substantial likelihood of being the vehicle operator (block 422 ). If so, the block 430 represents determination of velocity vectors for the mobile communication devices in the proximity group at reference times t 1 , t 2 , . . . (see the example of FIG. 3 ). Then, as described, initial values for the relative locations of the mobile devices in the proximity group (vehicle) can be determined at the referenced times (block 435 ). The block 445 represents an optional interpolation of measurements at the referenced times, t 1 , t 2 , . . . to minimize positional uncertainty and obtain refined locations of mobile communication devices in the proximity group (see, again, FIG. 3 and its accompanying description). Then, the block 455 represent the determination of the probability that the active device is being used by the person at the position of the vehicle operator.
[0027] Referring back to block 435 , the output thereof is also input to block 460 , which represents the retrieving of information from the data bases 280 (see FIG. 2 ) that is relevant to the latest location, for example, geography of the location, weather at the location, traffic, time of day, etc. These factors, together with the determined speed and the probability of use by a vehicle operator, are used, in the example of this embodiment, to determine the probability of a safety hazard (block 470 ). Then, as represented by the block 480 , determination is made based on the hazard probability and predetermined thresholds, of action to be taken. In the example of the present embodiment, these actions include sending a warning indication signal, issuing a conditional disabling signal, and, at the higher levels of probability of safety hazards, issuing a “hard” disabling signal.
[0028] The invention has been described with reference to particular preferred embodiments, but variations within the spirit and scope of the invention will occur to those skilled in the art. For example, it will be understood that other techniques, consistent with the principles hereof, can be used to detect a probability or certainty that the active mobile communication device is being utilized by the vehicle operator.
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A method for controlling operation of an active mobile communication device, including the following steps: performing a first determination of whether the device is in a moving vehicle at a relevant location; performing a second determination of whether the user of the device is the vehicle operator; and producing a risk indication signal as a function of the first and second determinations
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to monocomponent and two-component type developer for electrophotography to be used in electrophotographic copying apparatus and printers.
2. Description of the Related Art
Images are produced by electrophotographic copying apparatus and printers by first charging the surface of an electrostatic latent image bearing member, e.g., photosensitive member, with a uniform electric charge, exposing said surface to an exposure light pattern corresponding to the image of an original document, or writing on said surface with light having an output content, so as to thereby form an electrostatic latent image on said surface of the photosensitive member. The surface of the photosensitive member having the aforesaid electrostatic latent image is developed (rendered visible) by a developing device, and the developed toner image is then transferred onto a transfer medium.
The aforesaid developing device uses a monocomponent developing material comprising only a toner, or a two-component developing material comprising a toner and a magnetic carrier to develop the electrostatic latent image formed on the surface of the photosensitive member by uniformly contacting the surface of said photosensitive member. The toner in the aforesaid developing material normally comprises thermoset resin, coloring material, charge-controlling agent, and fluidizing agent and the like. The aforementioned two-component developing material comprises a toner and a magnetic carrier such as ferrite and the like.
Electrophotographic processes using the aforesaid developing materials have in recent years come to require high quality image production. A high degree of uniformity in the density of the solid portion of images is demanded in forming high quality images, such that excellent fluidity is required of the developing material and particularly the toner. Furthermore, improvement of image quality such as in image resolution, tone, or line reproducibility requires toner particles of very small particle diameter. However, as toner particle size becomes smaller, there is a corresponding reduction in toner fluidity which adversely affects developing material transportability, mixing characteristics and the like.
In order to eliminate the aforesaid disadvantages and improve fluidity, blocking resistance and the like, fluidizing agents are added. Fluidizing agents added to the toner use fine particles such as, for example, colloidal silica, titanium oxide, alumina and the like having a mean particle diameter of 10˜30 nm. The necessity of adding the aforesaid fine particle becomes greater in correlation with the smaller particle diameter of the toner and carrier. However, when a large amount of a fluidizing agent is used, said fluidizing agent is dispersed to the developing apparatus during developing so as to cause toner fogging and soiling of the interior of the image forming apparatus. Furthermore, when a nonmagnetic toner is used, dispersion of the toner itself outside the developing apparatus becomes prevalent.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide an electrophotographic developing material having excellent fluidity and capable of producing high quality images without dispersion of the toner and fine particles.
A further object of the present invention is to provide an electrophotographic developing material having excellent environmental stability, minimal electric charge reduction under conditions of high temperature and high humidity, and minimal electrical charge elevation under conditions of low temperature and low humidity.
A still further object of the present invention is to provide an electrophotographic developing material having a high degree of freedom in electrical physical properties such as electrical resistance and the like.
The aforesaid objects of the invention are accomplished by providing a developing material to which hydrophobic-processed fine magnetic particles with a mean particle diameter of 100 nm or less have been added.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In formulating the magnetic fine particles in the developing material, magnetic fine particles are added to the toner particles, and mixed by a Henschel mixer or the like so as to electrostatically adhere the magnetic fine particles to the surface of the toner particles.
The magnetic fine particles used in the developing material of the present invention have a mean particle diameter of 100 nm or less, preferably a mean particle diameter of 80 nm or less, and ideally a mean particle diameter of 50 nm or less. If the mean particle diameter of the magnetic fine particles exceeds 100 nm, fluidity is not effectively improved, whereas if the mean particle diameter of the magnetic fine particles is less than 80 nm, the effectiveness of the improvement of the developing material fluidity is enhanced, and particle adherence to the toner is strengthened with the effect that toner dispersion is prevented.
If the mean particle diameter of the magnetic fine particles exceeds 100 nm, the fluidity modification is not only ineffective, the magnetic fine particles have difficulty attaching to the surface of the toner particles and behave individually during the developing process. Even when the magnetic fine particles do adhere to the toner particles, said adherence is not uniform which markedly reduces effectiveness in preventing dispersion. Thus, developing material fluidity are improved, as are handling characteristics, mixing characteristics, image quality, and blocking resistance, by blending fine particles of predetermined diameter in the developing material. Furthermore, the fine particles are pulled to the magnetic sleeve via a small magnetic force because said fine particles are magnetic in character, such that dispersion of the toner supporting said fine particles is suppressed on a large scale.
The magnetic fine particles used in the developing material of the present invention are pretreated by a hydrophobic process, and impart a high degree of environmental stability to the developing material. That is, minimal electric charge reduction occurs under conditions of high temperature and high humidity, and minimal electrical charge elevation occurs under conditions of low temperature and low humidity, thereby enhancing the improvement of the fluidity. Furthermore, there is an extremely high degree of freedom in electrical physical properties such as electrical resistance and the like, and said properties can be adjusted in accordance with the characteristics of the developing material used. The extent of the hydrophobic nature of the magnetic fine particles is preferably 30% or more.
The degree of hydrophobicity was measured in the following manner. Fifty milliliters of demineralized water was poured into a beaker of 200 ml capacity, and 0.2 g of magnetic fine particles were added. As the suspension was mixed, methanol dehydrated with anhydrous sodium sulfate was slowly added from a buret, and the point at which the magnetic fine particles were not observed on the surface of the fluid was designated the end point. The degree of hydrophobicity was calculated, via the equation below, from the amount of methanol required to reach the aforesaid end point.
Degree of hydrophobicity (%)=C/(50+C)×100
(where C expresses the amount (ml) of methanol used.)
The hydrophobic agent used in the hydrophobic process of the aforesaid magnetic fine particles may be various types of coupling agents such as, for example, silane, titanate, aluminum, zirco-aluminum, and the like. Coupling agents containing fluorine, and coupling agents containing nitrogen compounds may also be used to improve electric charging characteristics. Furthermore, various combinations of coupling agents may be used in the aforesaid process.
Examples of useful silane coupling agents are fluorosilane, alkyl silane, alkoxysilane, silazane and the like. More specific examples of useful agents are (CH 3 ) 2 SiCl 2 , (CH 3 ) 3 SiCl, CH 3 Si(OCH 3 ) 3 , CH 3 Si(OCH 2 CH 3 ) 3 , (CH 3 ) 3 Si(OCH 3 ), (CH 3 ) 2 Si(OCH) 3 ) 2 , (CH 3 ) 2 Si(OCH 2 CH 3 ) 2 , Si(OCH 2 CH 3 ) 4 , Si(OCH 3 ) 4 , CH 3 (H)Si(OCH 3 ) 2 , CH 3 (H)Si(OCH 2 CH 3 ) 2 , (CH 3 ) 2 (H)Si(OCH 2 CH 3 ), (C 6 H 5 ) 2 Si(OCH 3 ) 2 (where (C 6 H 5 ) is a phenyl group here and hereinafter), (C 6 H 5 ) 2 Si(OCH 2 CH 3 ) 3 , (C 6 H 5 ) 2 Si(OCH 2 CH 3 ) 2 , (C 6 H 5 )Si(OCH 3 ) 3 , (C 6 H 5 ) 2 SiCl 2 , (C 6 H 5 ) 2 CH 3 SiCl, (C 6 H 5 )SiCl 3 , (C 6 H 5 ) (CH 3 )SiCl 2 , (CH 3 ) 3 SiNHSi(CH 3 ) 3 , CH 3 (CH 2 ) 17 Si(CH 3 )(OCH 3 ) 2 , CH 3 (CH 2 ) 17 Si(OCH 3 ) 3 , CH 3 (CH 2 ) 17 Si(OCH 2 H 5 ) 3 , CH 3 (CH 2 ) 3 Si(CH 3 ) 2 ClCH 3 (CH 2 ) 17 SiCl 3 and the like.
Examples of useful titanate coupling agents are listed below. ##STR1##
Examples of useful coupling agents containing fluorine are CH 3 (CH 2 )SiCl 3 , CF 3 (CF 2 ) 5 SiCl 3 , CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 , CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 , CF 3 (CF 2 ) 7 CH 2 CH 2 Si(OCH 3 ) 3 CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(CH 3 )Cl 3 , CF 3 (CH 2 ) 2 Si(OCH 3 ) 3 , CF 3 (CH 2 ) 2 Si(CH 3 )(OCH 3 ) 2 , CF 3 (CF 2 ) 3 (CH 2 ) 2 Si(OCH 3 ) 3 , CF 3 (CF 2 ) 5 (CH 2 ) 2 Si(OCH 3 ) 3 , CF 3 (CF 2 ) 6 CONH(CH 2 ) 2 Si(OC 2 H 5 ) 3 , CF 3 (CF 2 ) 6 COO(H 2 ) 2 Si(OCH 3 ) 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(OCH 3 ) 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(CH 3 )(OCH 3 ) 2 , CF 3 (CF 2 ) 7 SO 2 NH(CH 2 ) 3 Si(OC 2 H 5 ) 3 , CF 3 (CF 2 ) 8 (CH 2 )Si(OCH 3 ) 3 and the like.
Examples of useful coupling agents containing nitrogen compounds are CH 3 CH 2 (NH 2 )CH 2 NH(CH 2 )Si(OCH 3 ) 3 H 2 N(CH 2 ) 3 Si(OC 2 H 5 ) 3 , H 2 N(CH 2 ) 2 NH(CH 2 ) 3 Si(OCH 3 ) 3 , H 2 N(CH 2 ) 2 NH(CH 2 ) 3 Si(CH 3 )(OCH 3 ) 2 , H 2 N(CH 2 )NH(CH 2 ) 3 Si(OCH 3 ) 3 , H 2 N(CH 2 ) 2 NH(CH 2 ) 2 NH(CH 2 ) 3 Si(OCH 3 ) 3 , H 2 N(CH 2 ) 3 Si(OCH 3 ) 3 , C 6 H 5 NH(CH 2 ) 3 Si(OCH 3 ) 3 , H 2 N(C 6 H 4 )Si(OCH 3 ) 3 (where (C 6 H 4 ) is a phenyl group here and hereinafter), H 2 NCH 2 CH 2 NHCH 2 (C 6 H 4 )CH 2 CH 2 Si(OCH 3 ) 3 , H 2 NCH 2 (C 6 H 4 )CH 2 CH 2 Si(OCH 3 ) 3 , (C 5 H 4 N)CH 2 CH 2 Cl 3 (where C.sub. 5 H 4 N is a pyridine group) and the like.
In the hydrophobic process, the type of coupling agent, amount used, and other reaction conditions may be modified as necessary. The aforesaid coupling agents may be used individually, or used in combination of two or more types thereof. Furthermore, the aforesaid process may be performed two or more times.
Using a coupling agent as described above which has a long chain alkyl group is extremely effective in improving the hydrophobic property of the magnetic fine particles.
Various well known methods may be used in the hydrophobic processing of the magnetic fine particles using coupling agents. For example, in a dry process, the coupling agent may first be diluted using a solvent such as tetrahydrofuran (THF), toluene, ethyl acetate, methyl ethyl ketone and the like. The magnetic fine particles are forcibly mixed by a blender or the like, the aforesaid coupling agent diluent is added by drops, spray or the like until adequately mixed. Then, the mixture is moved to a vat or the like, and heated in an oven to dry. Thereafter, the mixture is again mixed and stirred a blender until adequately ground. The coupling agents may be used simultaneously in the same process, or in separate processes.
Alternatively, a wet process may be used. That is, the magnetic fine particles are immersed in an organic solvent containing the coupling agent, then, dried, or the magnetic fine particles may be dispersed underwater so as to form a slurry-like solution, which is then drips into an aqueous solution of the coupling agent, and thereafter the magnetic fine particles are settled out, dried by heating, and ground.
Magnetic Fine Particles
The aforesaid magnetic fine particle materials are not specifically limited inasmuch as various well known materials may be used. For example, when producing a black toner, magnetite which is itself black in color is used with a coloring agent. When producing a color toner, a metallic iron or the like having slight black wash material is used. Representative magnetic materials or magnetizable materials are, for example, metals having strong magnetic properties such as cobalt, iron, nickel and the like, metallic alloys such as aluminum, cobalt, iron, lead, magnesium, nickel, zinc, antimony, beryllium, bismuth, cadmium, calcium, manganese, selenium, titanium, tungsten, vanadium and the like, or compounds thereof, as well as oxides, sintered materials (ferrites) and other fine particles.
The magnetic fine particles used in the present invention preferably has a smallest diameter/a largest diameter ratio X such that X≧0.7. Furthermore, it is desirable that the insularity of the magnetic fine particles be an electrical resistance of 10 6 Ωcm or more, and preferably 10 8 ˜10 13 Ωcm. The fine particles may be manufactured by a vapor phase method or the like.
The amount of the magnetic fine particles used is 0.05 to 3 parts-by-weight (pbw), and preferably 0.1 to 1 pbw. When normally using an added fluidizing agent, the amount of magnetic fine particles is 0.05 to 2 pbw, and preferably 0.1 to 1 pbw.
The other constituents used in the developing material of the present invention such as binder resins, coloring agents, electrical charge-regulating agents and the like may all be well known conventional toner components.
Binder Resin
The binder resin used in the developing material of the present invention is not specifically limited inasmuch as a general purpose binder resin is used in the toner and developing material. For example, usable binder resins are thermoplastic resins such as polystyrene resin, poly(meth)acrylic resin, polyolefin resin, polyamide resin, polycarbonate resin, polyether resin, polysulfone resin, polyester resin, epoxy resin and the like, or thermosetting resins such as urea resin, urethane resin, urea resin, epoxy resin and the like, as well as copolymers, block copolymers, graft copolymers and polymer blends thereof.
The toner used in the high-speed copying apparatus popularized in recent years must quickly adhere to the transfer sheet and have high separability from the fixing roller. Desirable binder resins for use in the aforesaid high-speed copying apparatus are homopolymers or copolymers synthesized from styrene monomers, (meth)acrylic monomers, (meth)acrylate monomers, or polyester resin.
The molecular weight of the aforementioned binder resins is such that the relationships among the number-average molecular weight (Mn), weight-average molecular weight (Mw), and Z-average molecular weight (Mz) are 1,000≦Mn≦7,000, 40≦Mw/Mn≦70, 200≦Mz/Mn≦500, with 2,000≦Mn≦7,000 being preferable. Furthermore, oilless fixing toner preferably has a glass transition temperature of 55°˜80° C., softening point of 80°˜150° C., and contains gelation components at a rate of 5˜20 % by weight.
Translucent color toner may be provided with vinyl chloride resistance and translucence as a translucent toner, preferably via a polyester resin to maintain adhesion to OHP sheets. When the aforesaid polyester resin is used in a translucent toner, it is preferably a linear polyester having a glass transition temperature of 55°˜70° C. , a softening point of 80°˜150° C., number-average molecular weight (Mn) of 2,000 to 15,000, and a molecular weight distribution (Mw/Mn) of 3 or less.
A linear urethane-modified polyester produced by reacting di-isocyanate with a linear polyester resin may be used as a translucent color toner resin. The aforesaid linear urethane-modified polyester is a linear urethane-modified polyester resin produced by the reaction of 0.3˜0.95 mole of di-isocyanate with 1 mole of a linear polyester resin which consists of a dicarboxylic acid and diol, possesses a number-average molecular weight in the range of 2,000 to 15,000 and an acid value of 5 or less, and has the terminal groups thereof formed substantially wholly of hydoroxyl groups. The aforesaid resin has a glass transition temperature of 40°˜80° C. and an acid value of 5 or less. Examples of suitable resins are the aforementioned resins modified by graft copolymerization, block copolymerization or like processes of acrylics, aminoacrylic monomers and the like with linear polyesters, and having the same glass transition temperature, softening point and molecular weight characteristics as previously described.
Charge-Controlling Agent
Examples of useful positive charge-controlling agents are well known agents such as Nigrosine base azide EX (made by Orient Kagaku Kogyo K. K.), Oil Black (made by Chuo Gosei Kagaku K. K.) Quaternary Ammonium salt P-51 (Farben fabriken Bayer, Inc.), alkoxylated amin, alkyl amide and the like.
On the other hand, examples of useful negative charge-regulating agents are well known agents such as azo dyes of chromiume complex salt type of S-32, 33, 34, 35, 37, 38, 40 and 44 (made by Orient Kagaku Kogyo K. K.), AizenSpilon Black TRH and BHH (made by Hodogaya Kagaku K. K.), Kayasetto Black T-2 and 004 (made by Nippon Kagaku K. K.), dye of copper phthalocyanine series S-39 (made by Oriental Kagaku Kogyo K. K.) and the like.
The additive amount of the aforementioned charge-controlling agents may be suitably selected in accordance with the kind of toner, toner additives, kind of binder resin and the like, and depending on the toner developing process (monocomponent or two-component) used. For example, when the charge-controlling agent is added in inside the toner manufactured by a grinding process or suspension process or the like, the ratio of the charge-controlling agent is 0.1 to 20 pbw on the basis of 100 pbw of resin for toner composition, and is preferably 1 to 10 pbw. If the amount of charge-controlling agent is smaller than 0.1 part-by weight, the desired electrical charge amount is not obtained, whereas when the addition amount exceeds 20 pbw, the charge amount is unstable and reduces the fixing properties of the toner.
On the other hand, when the charge-controlling is adhered to the toner surface, the ratio of the charge-controlling agent is 0.001 to 10 pbw on the basis of 100 pbw of toner particles, preferably 0.05 to 2 pbw, and ideally 0.1 to 1 pbw. When the amount of charge-controlling agent used is less than 0.001 pbw, the charge amount is inadequate because very little charge-regulating agent is present on the surface layer of the toner particles, and when the charge-controlling agent amount exceeds 10 pbw, the adherence of the charge-controlling agent to the surface of the toner particles is insufficient such that said charge-controlling agent is released from the surface of the toner particles during use.
Examples of useful coloring agents combinable with the toner for electrostatic image developing of the present invention are all well known pigments and dyes used in conventional developing toners.
The aforesaid coloring agents may be used singly or in combination, normally at a ratio of 1 to 20 pbw on the basis of 100 pbw of binder resin, and preferably 1 to 20 pbw. When the amount of coloring material exceeds 20 pbw, toner adhesion is reduced, whereas when the amount is less than 1 pbw, the desired image density cannot be obtained.
All well known pigments and dyes used in conventional translucent color toners are usable as coloring materials when the toner of the present invention is a translucent color toner. For example, yellow pigments such as C.I.10316 (naphthol yellow S), C.I.11710 (Hansa yellow 10G), C.I.12720 (pigment yellow L) and the like.
Examples of useful red pigments are C.I.12055 (Sterling I), C.I.12075 (permanent orange), C.I.12175 (lithol fast orange 3GL) and the like.
Examples of useful blue pigments are C.I.74100 (metal-free phthalocyanine blue), C.I.74160 (phthalocyanine blue), C.I.74180 (fast sky blue) and the like.
The aforesaid coloring materials may be used singly or two or more types in combination. The amount of coloring material used is 1 to 10 pbw on the basis of 100 pbw binder resin contained in the toner particles, and preferably 2 to 5 pbw. When the amount of coloring material exceeds 10 pbw, toner adhesion and translucence are reduced, whereas when the amount of coloring material is less than 1 pbw, the desired image density cannot be obtained.
Fluidizing Agent
In addition to the previously described magnetic fine particles, a common fluidizing agent may be added to the developing material of the present invention to improve fluidity. Examples of useful fluidizing agents are inorganic fine particles such as silica, aluminum oxide, titanium oxide, magnesium fluoride, and the like, as well as organic fine particles as hereinafter described used singly or in combination.
The organic fine particles usable in the present invention may be various types of organic fine particles such as styrene, (meth)acrylic, benzoguanamine, melamine, teflon, silicone, polyethylene, polypropylene and the like, granulated by wet polymerization methods such as emulsion polymerization, soap-free emulsion polymerization, non-aqueous dispersion polymerization, as well as vapor-phase process and the like. The cleaning characteristics may be improved by adding the aforesaid organic fine particles.
Fluidizing agent is added in an amount of 0.05 to 1.0 pbw on the basis of the toner in this invention.
Other Additives
Offset inhibitors may be used together with the toner of the present invention to improve fixing characteristics. Examples of preferable offset inhibiting materials are various waxes, particularly low molecular weight polypropylene and polyethylene, or polyolefin waxes such as polypropylene oxide, polyethylene oxide and the like. The aforesaid waxes preferably have a number-average molecular weight (Mn) of 1,000 to 20,000, and a softening point (Tm) of 80° to 150° C. When the number-average molecular weight is less than 1,000, or the softening point is under 80° C., the wax does not uniformly disperse in the binder resin of the toner, such that only the wax is removed at the toner surface and resulting not only in unsatisfactory toner storage and developing but also producing filming and like soiling of the photosensitive member. Furthermore, when the number-average molecular weight Mn of said wax exceeds 20,000 or the softening point Tm exceeds 150° C., compatibility with the binder resin not only deteriorates but the expected high-temperature offset resistance and the like are not obtained. From the perspective of compatibility when used in combination with polar group binder resins, polar group waxes are preferable.
Carrier
When the toner of the present invention is used as a two-component developing material, the carrier may be a well known iron, ferrite and like carriers. Furthermore, coated carriers may be used wherein a core material of iron and ferrite is covered by a ceramic layer of any of various synthetic resins. Coatings formed by dispersing or dissolving various organic and inorganic materials may be used to improve charging characteristics and various other properties of the developing material, and said materials may be fixed to the surface of the coated carrier.
Binder type carriers may also be used. That is, the aforesaid magnetic materials having coating layers of the various synthetic resins may be used as binder resins, and various organic and inorganic materials may be added, mixed, kneaded and ground to regulate the desired particle diameter. Although commonly used carriers have mean particle diameters of 20 to 200 μm, said particle diameter may be suitably adjusted in accordance with the developing method used.
The specific examples described below are based on the embodiments of the present invention.
______________________________________Production of carrierConstituents parts by weight______________________________________Polyester resin 100(Kao K.K., NE-1110)Magnetic powder 500(Toda Kogyo, EPT-1000)Carbon black 2(Mitsubishi Kasei, MA#8)______________________________________
The aforesaid material was adequately mixed and ground in a Henschel mixer. then melted and kneaded by the use of an extrusion kneader having a cylinder part kept at 180° C. and a cylinder part kept at 170° C. The resultant blend was left cooling, the ground coarsely by the use of a feather mill, further pulverized finely with a jet mill, and classified with a classifier to obtain carrier particles having a mean particle diameter of 55 μm.
EXAMPLE 1
Five parts-by-weight carbon black (made by MA#8, Mitsubishi Kasei K. K.) and 5 pbw Supiron Black TRH (made by Hodogaya Kagaku Kogyo K. K.) were mixed and kneaded with 10 pbw styrene-acrylic copolymer resin (made by softening point: 120° C., glass transition point: 60° C.), then ground and classified to obtain the 8 μm toner A.
One part-by-weight ferrite fine particles (nickel zinc ferrite having a mean particle diameter of 15 nm was subjected to a hydrophobic process with dimethyldichlorosilane to achieve 40% hydrophobicity, electrical resistance of 6.3×10 33 Ωcm, and length-to-breadth diameter ratio of 0.9) were added to 100 pbw of the toner A, and mixed and stirred in a Henschel Mixer at 1,600 rpm for 2 minutes. Finally, the carrier produced as described in the carrier production example was added at a weight ratio (toner/carrier) of 7/93, mixed, then evaluated.
EXAMPLE 2
Developing material was produced in the same manner as described in Example 1, with the exception of the hydrophobic process of the ferrite fine particles which is described below. The developing material was then evaluated.
[Ferrite Fine Particle Hydrophobic Process]
3,3,4,4,5,5,6,6,7,7,8,8,10,10,10-heptadecafluorodecyltrimethoxysilane at 1.5 g, 0.15 g of γ-aminopropyltriethoxysilane, and 0.5 g of hexamethyldisilazane were brought into solution by 10 g of tetrahydrofuran to form a solution. Fifty grams of the ferrite fine particles of Example 1 poured into a high-speed mixer, and the aforementioned mixed solution was gradually added thereto meanwhile over a period of about 5 minutes. The material was then mixed at high speed for 10 minutes, heated at 150° C. in a thermostatic chamber, then ground to obtain hydrophobic ferrite fine particles (degree of hydrophobicity: 52%).
EXAMPLE 3
One hundred parts-by-weight of the toner A produced in Example 1, 0.5 pbw of magnetite fine particles (magnetite fine particles FB-1 (Okamura Seiyu K. K.), particle diameter: 10˜50 nm, were subjected to hydrophobic process with octyltrimethoxysilane to produce a hydrophobicity of 54%, an electrical resistance of 7.3×10 10 Ωcm, and a length/breadth diameter ratio of 0.8), and 0.1 pbw hydrophobic silica (made by Nippon Airojiru K. K., R-972) were mixed in a Henschel Mixer at a speed of 1,600 rpm for 2 minutes to produce the toner A'. The aforesaid toner A' was mixed with the carrier of the carrier production example at a weight ratio of 7/93, and the resulting developing material was evaluated.
EXAMPLE 4
A toner with constituents identical to the toner A produced in Example 1 was made, but the grinding and classification conditions were modified to produce a toner C having a mean particle diameter of 6 μm. Ferrite fine particles and hydrophobic silica were processed in the same manner as Example 1, with the exception that 0.1 pbw hydrophobic silica (R-972) was added as a post-processing agent to 100 pbw toner C. The obtained toner was mixed with the carrier of the carrier production example at a weight ratio (toner/carrier) of 7/93, and the resulting developing material was evaluated.
COMPARATIVE EXAMPLE 1
A developing material was produced in the same manner as in Example 1, with the exception that colloidal silica R-972 (made by Nippon Airojiru K. K.) was used instead of the ferrite fine particles. The obtained developing material was evaluated.
COMPARATIVE EXAMPLE 2
A developing material was produced in the same manner as in Example 1, with the exception that the ferrite fine particles used had a mean particle diameter of 200 nm. The obtained developing material was evaluated.
COMPARATIVE EXAMPLE 3
The developing material was produced in the same manner as in Example 3, with the exception that magnetite fine particles untreated by a hydrophobic process were used. The material was evaluated.
Evaluation Of Physical Properties
(1) Toner particle diameter
Toner particle diameter was measured using a laser scattering type particle size distribution measuring device SALD-1100 (Shimadzu Seisakusho). The mean particle size and size distribution were determined.
(2) Carrier particle diameter
Carrier particle diameter was measured using a Microtrack model 7995-10SRA (Nikisei K. K.). The mean particle diameter was determined.
(3) Charging amount (Q/M) and scattering
Two grams of the toners prepared in the examples and comparative examples and 28 g of the previously described carrier were poured into a polyethylene bottle (50 cc capacity) and placed in a rotating frame which was then rotated at 1,200 rpm for 5 min, 10 min, and 20 min, then changes in the amount of toner charge and the mixed state were checked. After mixing for 20 min, the amount of scattering was also measured. After the developing material was exposed for 24 hr at 35° C. and 85% humidity, the charge amount of toner and toner scattering amount were again measured.
The amount of scattering was measured using a digital particulate measuring device model P5H2 (Shibata Kagaku K. K.). A magnet roller was installed 10 cm removed from the aforesaid measuring device. Two grams of the developing material was set on top of the magnet roller, and while the magnet roller was rotated at a speed of 2,000 rpm the toner particle dust was measured by the device which displayed the count value after 1 min (cpm). The amount of scattering thus produced was evaluated in three levels, such that 300 cpm or less was ranked O, 500 cpm or less was ranked Δ, and more than 500 cpm was ranked X. The Δ rank was deemed suitable for practical application, whereas the O rank was preferable. The results of the measurements of the amount of charge and amount of scattering are shown in Table 1.
TABLE 1__________________________________________________________________________ Humidity5 min mixing 10 min mixing 20 min mixing resistance valueCharge Mix Charge Mix Charge Scatter Mix Charge ScatterμC/g state μC/g state μC/g cpm state μC/g cpm__________________________________________________________________________Ex. 1-13 good -14 good -14 Δ good -11 ΔEx. 2-14 good -15 good -16 ◯ good -15 ◯Ex. 3-14 good -15 good -15 ◯ good -14 ◯Ex. 4-18 good -17 good -17 ◯ good -16 ◯Comp. 1-13 good -15 good -16 X good -12 XComp. 2-3 *1 -7 *2 -9 X *3 -6 XComp. 3-11 good -12 good -12 Δ good -9 X__________________________________________________________________________ *1: Flow characteristics deteriorate, toner remains massed and does not mix with the carrier. *2: Toner masses are relatively smaller, but remain unchanged. *3: Toner masses are nearly absent, but toner is not uniformly dispersed in the carrier.
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The present invention relates to a developer for developing electrostatic latent images obtained by mixing toner particles comprising a binder resin and a coloring agent with fine magnetic particles treated by hydrophobic agent.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method and apparatus for performing soldering by irradiating solder or an object to be soldered with laser light.
[0003] 2. Related Background Art
[0004] A technique which performs soldering by irradiating solder set between objects with laser light is disclosed in Japanese Patent Application Laid-Open No. HEI 6-77638 (Patent Document 1), for example. The soldering technique, disclosed in Patent Document 1, guides laser light outputted from a laser light source with an optical fiber, irradiates solder set between objects with the laser light outputted from the leading end of the optical fiber, and thereby performs soldering.
SUMMARY OF THE INVENTION
[0005] The inventors have studied the prior art described above in detail, and as a result, have found problems as follows.
[0006] Namely, the prior art performing soldering by laser light irradiation cannot sufficiently reduce the spot size of laser light when converging the laser light to a soldering location. It is therefore difficult for the prior art to solder microsize electronic devices and the like arranged in a length of 0.1 mm or less, for example. In particular, needs for soldering techniques in minute areas have recently been increasing as electronic devices have become smaller.
[0007] In order to overcome the above-mentioned problems, it is an object of the present invention to provide a soldering method and apparatus of enabling the soldering in minute areas.
[0008] A soldering method according to the present invention is a method which realizes the soldering by using a fiber laser apparatus capable of minutely adjusting the spot size of outputted laser light, and performs the soldering between objects by using the fiber laser apparatus and a spatial optical system. In particular, the soldering method prepares a fiber laser apparatus, prepares a spatial optical system, controls a seed light source included in the fiber laser apparatus so as to yield desirable outputted laser light, and irradiates solder set between objects with thus obtained outputted laser light.
[0009] The fiber laser apparatus to be prepared includes an optical fiber which has a single core structure and which outputs single-mode light, and a seed light source for supplying seed light to the optical fiber. In the specification, the wording “single core structure” includes the structure that only one or more core regions are concentrically arranged like a dual core, but does not include a multi-core structure such that a plurality of core regions are dotted within a central region of an optical fiber. The spatial optical system prepared includes a collimator collimating the outputted laser light from the fiber laser apparatus, and a condenser lens converging the outputted laser light transmitted through the collimator. The seed light source included in the fiber laser apparatus is controlled such that light having a pulse width of not shorter than a microsecond or continuous light is outputted as the outputted laser light from the fiber laser apparatus. By way of the spatial optical system, the outputted laser light from the fiber laser apparatus, which is obtained by controlling the seed light source as mentioned above, is applied to the solder set between the objects.
[0010] Preferably, in the soldering method according to the present invention, the objects to be soldered are heated before irradiating the solder set between the objects with laser light. In particular, the objects are initially heated by irradiation with the outputted laser light from the fiber laser apparatus converged by the spatial optical system. Thereafter (after the objects are heated), the outputted laser light from the fiber laser apparatus, which is converged by the spatial optical system, is applied to the solder set between the objects, whereby the objects can be soldered more efficiently to each other. Namely, peripheral areas of the soldering part can be prevented from being heated unnecessarily.
[0011] The soldering method according to the present invention may comprise the step of removing an unnecessary solder part after soldering the objects. Namely, after soldering the objects, an unnecessary solder part generated at the time of soldering the objects is irradiated with light having a pulse width of a nanosecond or less outputted from one selected from the fiber laser apparatus and another fiber laser apparatus irradiates by way of the spatial optical system, whereby the unnecessary solder part can be removed.
[0012] In the soldering method according to the present invention, the spatial optical system is adjusted so as to converge the outputted laser light from the fiber laser apparatus such that the spot size of the outputted laser light, applied to the solder from the fiber laser apparatus, falls within the range of 1 μm to 100 μm.
[0013] In the soldering method according to the present invention, it is preferable that the optical fiber includes a Yb-doped optical fiber, whereas the fiber laser apparatus includes a wavelength conversion device for converting the wavelength of the output light from the optical fiber. In this case, the light whose wavelength is converted to 532 nm by the wavelength conversion device irradiates the solder by way of the spatial optical system.
[0014] In the soldering method according to the present invention, the seed light source preferably includes a semiconductor laser, whereas the fiber laser apparatus has an oscillation adjustment mechanism adjusting an oscillation condition of the semiconductor laser as a MOPA-type laser apparatus.
[0015] The soldering method according to the present invention may comprise a step of protecting a soldering part in the objects. Namely, before soldering the objects, one of the objects is bonded to a surface of a plastic sheet with an adhesive. Thereafter, in the state where the one object bonded to the plastic sheet is soldered with the other object, the objects are soldered to each other. As another protecting means, respective soldering parts in the objects are covered with a plastic sheet after soldering the objects. Thereafter, as the outputted laser light from the fiber laser apparatus, light having a pulse width of not shorter than a microsecond or continuous light irradiates the plastic sheet by way of the spatial optical system, thereby forming a plastic protective film in the soldering parts.
[0016] A laser soldering apparatus according to the present invention irradiates solder set between objects with laser light, thereby soldering the objects. In particular, the laser soldering apparatus comprises a fiber laser apparatus and a spatial optical system, whereas the fiber laser apparatus outputs light having a pulse width of not shorter than a microsecond or continuous light as output light.
[0017] The fiber laser apparatus is one outputting single-mode light as outputted laser light, and includes an optical fiber, a seed light source, and an oscillation adjustment mechanism. The optical fiber includes an amplification optical fiber having a single core structure and outputting amplified single-mode light, for example. The seed light source supplies seed light to the optical fiber. The oscillation adjustment mechanism enables both continuous and pulsed oscillations in the optical fiber.
[0018] On the other hand, the spatial optical system includes a collimator collimating the outputted laser light from the fiber laser apparatus, and a condenser lens converging the outputted laser light having transmitted through the collimator.
[0019] In the laser soldering apparatus according to the present invention, the oscillation adjustment mechanism preferably comprises a structure for enabling an oscillation of a nanosecond pulse in the optical fiber. Also, it is preferable that the fiber laser apparatus has a pulse width adjustment mechanism for adjusting the pulse width of the outputted laser light in order to regulate an oscillation condition in the optical fiber.
[0020] The present invention will be more fully understood from the detailed description given hereinbelow and the accompanying drawings, which are given by way of illustration only and are not to be considered as limiting the present invention.
[0021] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will be apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1A is a view for explaining an initial step of the soldering method according to the present invention while showing the structure of an embodiment of the laser soldering apparatus according to the present invention, whereas FIG. 1B is a plan view specifically showing an arrangement of objects to be soldered;
[0023] FIG. 2 is a view for explaining an intermediate step of the soldering method according to the present invention while showing the structure of an embodiment of the laser soldering apparatus according to the present invention;
[0024] FIG. 3 is a view for explaining the final step of the soldering method according to the present invention while showing the structure of an embodiment of the laser soldering apparatus according to the present invention;
[0025] FIG. 4 is a view showing the structure of a fiber laser apparatus employed in the laser soldering apparatus according to the present invention;
[0026] FIG. 5 is a view showing another structure of a fiber laser apparatus employed in the laser soldering apparatus according to the present invention; and
[0027] FIG. 6 is a graph showing the wavelength dependency of absorption ratio of Sn.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] In the following, embodiments of the soldering method and laser soldering according to the present invention will be explained in detail with reference to FIGS. 1A , 1 B, and 2 to 6 . In the explanation of the drawings, constituents identical to each other will be referred to with numerals identical to each other without repeating their overlapping descriptions.
[0029] FIGS. 1A , 2 , and 3 are views for sequentially explaining the steps of the soldering method according to the present invention while showing the structure of an embodiment of the laser soldering apparatus according to the present invention. FIG. 4 is a view showing the structure of a fiber laser apparatus employable in the laser soldering apparatus according to the present invention. FIGS. 1A , 2 , and 3 show not only a laser soldering apparatus 1 , but also a substrate 91 and coaxial cable center conductors 92 which are objects to be soldered, and solder 93 and a plastic 94 .
[0030] The laser soldering apparatus 1 comprises a fiber laser apparatus 10 , a guide optical fiber 20 , and a spatial optical system 30 . The spatial optical system 30 includes a collimator 21 , a beam expander 31 , and a condenser lens 32 . As shown in FIG. 4 , the fiber laser apparatus 10 comprises an optical amplifier 11 , a seed light source 12 , and an oscillation adjustment mechanism 13 . The optical amplifier 11 includes an amplification optical fiber 14 , a pumping light source 15 , and an optical coupler 16 .
[0031] The amplification optical fiber 14 is an optical device having a single core structure and outputting amplified light as single-mode light, an example of which is a Yb-doped optical fiber amplifying light having a wavelength of 1064 nm. The pumping light source 15 is an optical device outputting pumping light to be supplied to the amplification optical fiber 14 , and includes a semiconductor laser device, for example. The seed light source 12 is an optical device outputting seed light to be amplified in the amplification optical fiber 14 , and includes a semiconductor laser device, for example. The oscillation adjustment mechanism 13 drives the seed light source 12 , so as to enable both continuous and pulsed oscillations, and adjusts the pulse width in the case of pulsed oscillation (functions as a pulse width adjustment mechanism).
[0032] The pumping light outputted from the pumping light source 15 is supplied to the amplification optical fiber 14 through the optical coupler 16 . The supplied pumping light pumps elemental Yb contained in the amplification optical fiber 14 . The seed light source 12 driven by the oscillation adjustment mechanism 13 outputs seed light. The seed light is fed into the amplification optical fiber 14 through the optical coupler 16 , and is amplified in the amplification optical fiber 14 . Namely, the fiber laser apparatus 10 has a MOPA (Master Oscillator Power Amplifier) structure. The light amplified in the amplification optical fiber 14 is outputted from the fiber laser apparatus 10 as outputted laser light.
[0033] The outputted laser light from the fiber laser apparatus 10 is fed into the guide optical fiber 20 from one end thereof and propagates through the guide optical fiber 20 . The outputted laser light having propagated through the guide optical fiber 20 is collimated (outputted as parallel light into the space) by the collimator 21 provided at the other end of the guide optical fiber 20 . The parallel light outputted from the collimator 21 is expanded by the beam expander 31 in terms of the luminous flux diameter, and then is converged by the condenser lens 32 . Thus converged outputted laser light irradiates the solder 93 set between the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered.
[0034] FIG. 1B is a view showing a state of arrangements of copper patterns 91 a provided on a substrate 91 and the coaxial cable center conductors 92 arranged with intervals P, and a spot S of the outputted laser light. Specifically, the example shown in FIG. 1B illustrates a state in which the width of each copper line pattern 91 a (the width of the electrode pad part) formed on the substrate 91 is 100 μm, the diameter of each coaxial cable center conductor 92 is 60 μm, and cream solder is applied as the solder 93 between the copper patterns on the substrate 91 and the coaxial cable center conductors 92 . The laser soldering apparatus 1 scans the spot S over the substrate 91 such that the solder 93 is irradiated with the outputted laser light, so as to solder the coaxial cable center conductors 92 to the copper patterns 91 a of the substrate 91 , respectively.
[0035] At the time of soldering, the single-mode light (outputted laser light) outputted from the fiber laser apparatus 10 is light having a pulse width of a microsecond or greater or continuous light, and the outputted laser light from the spatial optical system 30 irradiates the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered or solder 93 . Since the fiber laser apparatus 10 outputs single-mode light or the luminous flux diameter of the light outputted from the fiber laser apparatus 10 is expanded by the spatial optical system 30 before the light is converged, the spot diameter of the light converged by the spatial optical system 30 can become smaller.
[0036] Suppose a case where light having a wavelength λ of 1064 nm outputted from the fiber laser apparatus 10 expands its luminous flux diameter D to 10 mm with the beam expander 31 and then is converged by the condenser lens 32 having a focal length f of 100 mm. Let a be the beam quality factor (M 2 ) of light outputted from the guide optical fiber 20 . Here, the minimal spot diameter d of the light converged by the condenser lens 32 is obtained by the expression of d=1.27·f·λ·a/D. In general, the beam quality factor a of light outputted from an optical fiber is said to be 1.
[0037] Therefore, the minimal spot diameter d of the light converged by the condenser lens 32 is about 13.5 μm. Thus, the fiber laser apparatus 10 can converge laser light to minute areas and consequently perform microsize soldering, whereby the coaxial cable center conductor 92 having a diameter of 60 μm can be soldered to the copper pattern 91 a having a width of 100 μm formed on the substrate 91 .
[0038] In general, the spot diameter D of the light incident on the condenser lens 32 is adjusted such that the spot diameter d of the light converged by the condenser lens 32 becomes 1 μm to 100 μm. When the spot diameter d of the light converged by the condenser lens 32 is less than 1 μm, the optical system is not easy to adjust, whereby the soldering operation becomes troublesome. When the spot diameter d of the light converged by the condenser lens 32 exceeds 100 μm, on the other hand, unnecessary solder parts increase. When the spot diameter d of the light converged by the condenser lens 32 falls within the range of 1 μm to 100 μm, the soldering operation becomes easy while unnecessary solder parts are less.
[0039] When a converging point of light having a pulse width of not shorter than a microsecond or continuous light is positioned at the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered or solder 93 , the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered or solder 93 can be heated without dissipating the solder 93 . In this case, the substrate 91 and coaxial cable center conductors 92 can be soldered to each other in a short time (see FIGS. 1A and 1B ).
[0040] Before soldering, the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered may be irradiated with the outputted laser light from the spatial optical system 30 . This preheats the objects to be soldered, and improves attachment of solder 93 when the solder 93 is irradiated with the outputted laser light from the spatial optical system 30 (see FIGS. 1A and 1B ).
[0041] An unnecessary solder part 93 a may occur at the time of soldering. It will be preferred in this case if light having a pulse width of a nanosecond or less outputted as outputted laser light from the fiber laser apparatus 10 (or another fiber laser apparatus) irradiates the unnecessary solder part 93 a through the spatial optical system 30 . This can favorably remove the unnecessary solder part 93 a (see FIG. 2 ).
[0042] Here, it will be preferred if the pulse width of the outputted laser light irradiating the unnecessary solder part 93 a is a nanosecond or less. When the irradiation power of irradiating outputted laser light per unit time is made greater, the unnecessary solder part 93 a is rapidly heated without a lapse of time in which heat generated by light absorption is conducted. Such ablation can easily remove the unnecessary solder part 93 a.
[0043] Light having a pulse width of a nanosecond or less can be outputted as the outputted laser light, in the case that the modulation period of a driving signal supplied to a semiconductor laser device acting as the seed light source 12 is adjusted. Light having a pulse width of a nanosecond or less can also be outputted, in the case that a pulse compressor which compresses the pulse width is provided.
[0044] It will also be preferred when the coaxial cable center conductors 92 are bonded to the surface of a plastic sheet with an adhesive, and are soldered to the substrate 91 in the state where the coaxial cable center conductors 92 bonded to the plastic sheet are in contact with the substrate 91 . Alternatively, after soldering the coaxial cable center conductors 92 and the substrate 91 to each other, the soldering parts of the coaxial cable center conductors 92 and substrate 91 may be covered with a plastic sheet 94 , and the outputted laser light (light having a pulse width of not shorter than a microsecond or continuous light) from the fiber laser apparatus 10 may irradiate the plastic sheet 94 from the upper side through the spatial optical system 30 . In this case, the plastic sheet 94 covering the soldering parts forms a protective film (see FIG. 3 ). Namely, the soldering parts in the coaxial cable center conductors 92 and substrate 91 are covered with the plastic protective film. As the plastic sheet 94 , polyacetal, polycarbonate, or polyethylene terephthalate is used favorably, for example.
[0045] FIG. 5 is a view showing another structure of the fiber laser apparatus 10 employable in the laser soldering apparatus according to the present invention. The fiber laser apparatus 10 A shown in FIG. 5 is employed in place of the fiber laser apparatus 10 ( FIG. 4 ) included in the laser soldering apparatus 1 shown in FIGS. 1A , 2 , and 3 . The fiber laser apparatus 10 A shown in FIG. 5 differs from the fiber laser apparatus 10 shown in FIG. 4 in that it further comprises a wavelength conversion device 17 .
[0046] The wavelength conversion device 17 is an optical device which inputs light having a wavelength of 1064 nm from a Yb-doped optical fiber acting as the amplification optical fiber 14 and generates light with a wavelength of 532 nm having an optical frequency which is twice that of the former light. As such a wavelength conversion device 17 , a nonlinear optical crystal such as KTP, for example, is favorably used. The light having the wavelength of 532 nm outputted from the wavelength conversion device 17 is converged on the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered or solder 93 through the guide optical fiber 20 and spatial optical system 30 .
[0047] Thus irradiating the objects (substrate 91 and coaxial cable center conductors 92 ) to be soldered or solder 93 with the light having the wavelength of 532 nm enables soldering of further smaller areas. In general, the light absorption ratio of metals is greater at the wavelength of 532 nm than at the wavelength of 1064 nm. For example, as FIG. 6 shows the wavelength dependency of absorption ratio of Sn, the light absorption ratio of Sn at the wavelength of 532 nm is several times that at the wavelength of 1064 nm. Therefore, soldering can be performed more efficiently when the light at the wavelength of 532 nm is utilized.
[0048] The soldering method and laser soldering apparatus according to the present invention enables soldering of objects having a size further smaller than before.
[0049] From the invention thus described, it will be obvious that the embodiments of the invention may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended for inclusion within the scope of the following claims.
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The present invention relates to a soldering method and the like comprising a structure for making it possible to solder microsize objects to each other. The soldering method is a method realizing the soldering by using a fiber laser apparatus capable of minutely adjusting the spot size of outputted laser light, and prepares the fiber laser apparatus and a spatial optical system before soldering the objects. The fiber laser apparatus includes an amplification optical fiber having a single core structure and outputting amplified single-mode light, and a seed light source supplying seed light to the amplification optical fiber. The spatial optical system includes a collimator collimating the outputted laser light from the fiber laser apparatus, and a condenser lens converging the outputted laser light transmitted through the collimator to solder which is set. Light having a pulse width of not shorter than a microsecond or continuous light outputted as outputted laser light from the fiber laser apparatus is applied to the solder set between objects to be soldered through the spatial optical system.
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BACKGROUND OF THE INVENTION
The invention relates to an electronic sewing machine and more particularly relates to a pattern elongation system of the sewing machine to produce a pattern of stitches enlarged or reduced in the fabric feeding direction with a constant feeding pitch such as the satin stitches. The sewing machine has an electronic memory storing stitch control data which are optionally read out to control the needle positions, so as to adjust the configuration of a pattern of stitches in a manner as mentioned.
According to the pattern elongation device of the sewing machine, the transmission mechanism from a pattern cam to the stitch forming instrumentalities is mechanically adjusted, and therefore the device is in general mechanically complex to produce various elongated patterns symmetrical or asymmetrical, and has been actually difficult to be reduced into practice. In fact, no pattern elongation device or system has been proposed in an electronic sewing machine having a memory storing the stitch control data.
SUMMARY OF THE INVENTION
According to the invention, the stitch control data are optionally read out from the electronic memory in accordance with the designations for enlarging or reducing a pattern in the fabric feeding direction. The memory stores a discriminating signal each in pair with each of the stitch control data for discriminating, in response to the enlarging or reducing designations of a pattern, whether or not each stitch control date may be employed to a single pattern or may be employed commonly to different patterns. A pattern elongation selecting part is operated to produce an elongation signal. A pulse generator is operated in synchronism with rotation of the upper drive shaft of the sewing machine to produce a timing pulse per rotation of the upper drive shaft. An oscillator is operated in relation to the timing pulse to address the memory per stitch of the pattern, thereby to scan the locations of the stitch control data. A comparator compares the elongation signal and the discriminating signals to cause the oscillator to determine the addresses for the stitches of pattern. The data of the memory may be employed commonly to different patterns so as to effectively use the function of the memory. Thus the elongation as well as the reduction of a pattern may be optionally selected by easy operation of the sewing machine.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sewing machine incorporated with the invention;
FIG. 2 is a control circuit of the invention;
FIG. 3 is representation of patterns to be produced by the invention; and
FIG. 4 is a table showing the addresses and the corresponding data of memory.
DETAILED DESCRIPTION OF THE INVENTION
In reference to FIG. 1 a sewing machine 1 has a housing 1a providing a front face thereof. A predetermined number of pattern selecting switches 2 are arranged on the front face of the sewing machine. An operating knob 3 is provided on the front face of the sewing machine at a position spaced from the pattern selecting switches 2 as shown. The operating knob 3 is pushed to make effective or ineffective an elongation mechanism of the sewing machine for elongating a selected pattern. The degree of the elongation is determined by rotation of the operating knob 3. An indicating lamp 4 is provided on the front face of the sewing machine in the neighbourhood of the operating knob 3. The lamp 4 is lighted to indicate that the elongation mechanism is effective.
In reference to FIG. 2 showing a control circuit of the invention, the pattern selecting switches 2 are specifically indicated by SW1-SW7. Those are normally opened switches each having one end grounded and the other end connected to a positive control power source Vcc through a pull-up resistor R1. If the pattern selecting switches SW1-SW7 are selectively operated to select different patterns, the other end of the operated switch becomes low level and NAND circuits NA2, NA3 produce a specific code signal to a latch circuit L1. NAND circuit NA4 produces a high level signal to a monostable multivibrator circuit MM1 when one of the switches SW1-SW7 is operated. Then the positive output Q of the monostable multivibrator circuit MM1 gives a trigger signal to the trigger terminal of the latch circuit L1 for latching the pattern code.
SW8 is a normally opened switch which is closed each time when the operating knob 3 is pushed. The switch SW8 has one end grounded through a resistor R2 to always remain low level and the other end connected to the power source Vcc to be high level when the switch SW8 is closed. The high level signal is applied to AND circuit AND1, which give the high level signal to the trigger terminal Cp of a JK-type flip-flop circuit FF1 only when a specifice bit (d3) of the outputs (d1, d2, d3) of the latch circuit L1 is high level. The flip-flop circuit FF1 has terminals J, K connected to the power source Vcc and a reset terminal R connected to the positive output Q of the monostable multivibrator circuit MM1. The flip-flop FF1 is reset when a pattern is selected by operation of one of the switches SW1-SW7 and the output Q remains low level as long as the switch is not operated subsequently. The output Q is inverted each time the switch SW8 is operated in the condition that one of the pattern selecting switches SW5, SW6, SW7 for selecting elongatable patterns SW5, SW6, SW7 is operated and therefore the output (d3) of the latch circuit L1 becomes high level.
AND circuit AND2 has one input terminal receiving a code 0 0 0 1 for nullifying the elongation mechanism of the sewing machine and automatically restoring the sewing machine to a condition for producing a standard form of the selected pattern. The AND circuit AND2, has the other input terminal receiving the output Q of the flip-flop circuit FF1 in the inverted condition, and gives the code 0 0 0 1 to a latch circuit L2 through OR circuit OR1 when the output Q is low level.
The operating knob 3 is rotated to operate a variable resistor VR so as to take out adjusted potentials U, V, W from the power source Vcc. An analog-digital converter AD converts the adjusted potential into a digital value and gives the same to one input terminal of AND circuit AND3. The AND circuit AND3 has the other input terminal connected to the output Q of the flip-flop circuit FF1 through the OR circuit OR1, and gives the code of the analog-digital converter AD to the latch circuit L2 when the output Q of the flip-flop circuit FF1 is high level, i.e. when the switch SW8 is operated to make effective the elongation mechanism.
The indicating lamp 4 in FIG. 1 is lighted when the output Q of the flip-flop circuit FF1 is high level, though such a circuit is not shown. OR circuit OR2 receives a pulse to operate a delay circuit TD1 each time a changeover is made between the positive output Q of the monostable multivibrator MM1, the output of the AND circuit AND1 and the output terminals U, V, W of the variable resistor VR, thereby to give a trigger signal to the trigger terminal Cp of the latch circuit L2. Thus the input signal is latched to the output terminals (d4)-(d7) of the latch circuit L2 through the OR circuit OR1 each time when one of the switches 2, the switch SW8 or the variable resistor VR is operated.
A counter of master-slave type C has a reset terminal R connected to the complement output Q of the monostable multivibrator circuit MM1 and the output side binary code connected to an electronic memory ROM. The counter C produces a progressive code signal each time it receives an input pulse φ at the input terminal Cp and progressively advances the addresses of the memory ROM from (o) to (m) repeatedly as shown by decimal numbers in FIG. 4. The outputs (D1)(D2)(D3) of the outputs of the memory ROM are respectively connected to the inputs of exclusive OR circuits ExOR1, ExOR2, ExOR3 each in pair with the outputs (d1)(d2)(d3) of the latch circuit L1. The exclusive OR circuits ExOR1, ExOR2, ExOR3 have the outputs respectively connected to the data terminal D of a D-type flip-flop circuit FF2 through OR circuits OR2, OR3. The flip-flop circuit FF2 has the output Q which is reset to O when the power source Vcc is applied though the circuit is not shown. The output Q is connected to the reset terminal of an astable multivibrator circuit AM.
The astable multivibrator circuit AM has a pulse output terminal φ which is connected to a delay circuit TD2 and to the input terminal Cp of the counter C. NOR circuit NOR1 has an input connected to the output of the delay circuit TD2 and another input connected to the output of a delay circuit TD3 which as an input connected to the positive output Q of the monostable multivibrator circuit MM1. The NOR circuit NOR1 has an output connected to the trigger terminal Cp of the flip-flop circuit FF2.
The outputs D4-D7 of the memory ROM are connected to the inputs of AND circuits AND4-AND7 each in pair with the outputs (d4)-(d7) of the latch circuit L2, and the outputs of these AND circuits are connected to the data terminal D of the flip-flop circuit FF2 through NOR circuit NOR2 and the OR circuit OR3.
A pulse generator SG produces a timing pulse per rotation of an upper drive shaft of the sewing machine (not shown) when a needle bar (not shown)is at a predetermined position during the vertical reciprocation thereof. The timing pulse is applied to the trigger terminal Cp of a monostable multivibrator circuit MM2, so that the flip-flop circuit FF2 having a preset terminal Ps connected to the complement output Q of the monosable multivibrator MM2 may be preset with the rising signal applied thereat.
The data to the respective addresses in the memory are partly shown in FIG. 4. The code (D3, D2, D1) in accordance with the output terminals D3, D2, D1 of the memory ROM constitutes a pattern discriminating signal for designating an address to be employed in common to a signal (d3, d2, d1) of the latch circuit L1 and the corresponding signal (D3, D2, D1) in FIG. 4. Stitch control signals Dp in FIG. 4 are employed in accordance to the designated addresses to control the stitch forming instrumentalities of the sewing machine. In this embodiment, the signals Dp are shown with the decimal numbers for controlling the needle coordinates of the sewing machine.
The code (D7, D6, D5, D4) at the output terminals D7, D6, D5, D4 of the memory ROM constitutes a discriminating signal for enlarging or reducing a stitch pattern. With the operated position of the switch SW8 and of the variable resistor VR due to the operation of the knob 3, the pattern elongation signal at the outputs (d7, d6, d5, d4) of the latch circuit L2 is compared to the signal (D7, D6, D5, D4) of the memory (ROM). If these two signals are same, this is indicated by the logic 1 and the corresponding address is designated and the corresponding stitch control signal Dp is employed. If the idenifying logic 1 represents the bits d4 and D4 of the signals, this corresponds to the selection of a pattern designating signal (input 0 0 0 1 of AND circuit AND2) for a standard pattern such as shown in FIG. 3 (A) is selected and to the reading-out of the corresponding stitch control signals. If the identifying logic 1 represents the bits d5 and D5 of the signals, this corresponds to the selection of the potential at the terminal U of the variable resistor VR and to the reading-out of the corresponding stitch control signals. As a result, a pattern is produced as shown in FIG. 3 (B), which is elongated twice of the standard pattern as shown in FIG. 3 (A). Similarly if the identifying logic 1 represents the bits d6 and D6 or d7 and D7 of the signals, this corresponds to the selection of the potential at the terminal V or W of the variable resistor VR and to the reading-out of the corresponding stitch control signals. As a result, a pattern is produced as shown in FIG. 3 (C) or in FIG. 3 (D), which is elongated three times or four times of the standard pattern as shown in FIG. 3 (A).
The memory ROM has an output terminal Dp for giving stitch control signals in the data Dp as shown in FIG. 4 to the stitch forming instrumentalities ACT of the sewing machine. The patterns shown in FIG. 3 are stitched with the fabric transported vertically in the forward direction while the needle is moved laterally. The fabric is transported with a constant feeding pitch and the needle is laterally moved from 15 at the center to maximum on both sides of the center. As shown in FIGS. 3 and 4, the center position of the needle is indicated by 15, the maximum movement of the needle in the rightward direction is indicated by O and the maximum movement of the needle in the leftward direction is indicated by 30.
According to the embodiment, the memory ROM produces the stitch control signals at the output terminal Dp thereof. It is however possible to produce calculating signals at the same output terminal for calculating out the stitch control signals.
Operation is as follows: Explanation will be made as to the formation of the pattern shown in FIG. 3 (B) which is applied with a constant feeding pitch. If the pattern selecting switch SW5 is pushed, the data (d3, d2, d1) of the latch circuit L1 becomes 1 0 0 meaning the selection of the standard pattern shown in FIG. 3 (A). In this case, the output Q of the flip-flop FF1 is low level, and therefore the data (d7, d6, d5, d4) of the latch circuit L2 becomes 0 0 0 1.
Then if the variable resistor VR is manipulated to connect the terminal U thereof to the analog-digital converter AD, and then if the switch SW8 is pushed, the output Q of the flip-flop circuit FF2 becomes high level and the data (d7, d6, d5, d4) of the latch circuit L2 becomes 0 0 1 0 in accordance to the potential at the terminal U of the variable resistor VR. Namely the logic 1 of the data (d5) designates the pattern shown in FIG. 3 (B).
With application of the control power source Vcc, the flip-flop circuit FF2 is firstly reset and the output Q has a logic 0 and the astable multivibrator circuit AM is reset. The counter C is reset by the abovementioned pushing operation of the switch SW5. The memory ROM is addressed at the address O and the data (D7-D1) becomes 0 0 0 1 0 0 0. Then the data (d3, d2, d1) and the data (D3, D2, D1) are compared. As the data are not in accord, the data input terminal of the flip-flop circuit FF2 becomes high level, and the output Q becomes high level with the continuous pulse signal of the delay circuit TD3 applied to the terminal Cp, and then the astable multivibrator circuit AM oscillates. When the address (n) is reached, the data (D7-D7) becomes 1 1 1 1 1 0 0 , and the data is compared with 0 0 1 0 1 0 0 of the data (d7-d1). As the data D5 and d5 are logic 1, the NOR circuit NOR2 becomes 0. As the data D3, D2, D1 and d3, d2, d1 are 1 0 0, the OR circuit OR2 becomes 0, and therefore the terminal D of the flip-flop circuit FF2 becomes 0 and the output Q becomes low level, and then the oscillation of the astable multivibrator circuit AM is stopped.
Thus the memory ROM, when addressed at the address (n), produces the output data 15 at the output terminal Dp to operate the stitch forming instrumentalities ACT, thereby to form the initial stitch. Although the outputs at the addresses from (O) to (n-1) are applied to the stitch forming instrumentalities ACT, such outputs will not actually operate the stitch forming instrumentalities because the addressing operation by the counter C is made at an extremely high speed.
When the upper drive shaft of the sewing machine makes one complete rotation, the timing signal of the pulse generator SG sets the flip-flop circuit FF2 and the astable multivibrator circuit AM oscillates. As the counter C advances a number 1, as shown in FIG. 4 the data D5 at the address (n+1) is logic 1 and therefore the astable multivibrator AM stops the oscillation. Then the data 16 at the output Dp of the memory ROM control the second stitch. With further rotation of the upper drive shaft of the sewing machine, the data 5 at the addresses (n+2) and (n+3) are logic 0 and therefore these addresses are passed over. When the address (n+4) is reached, the data D5 is 1 and the data 13 at the output Dp controls the third stitch. As shown in FIG. 4, the following stitches are controlled by the data of the output Dp 18, 11, 20, 9, 22, 8, 24, 6, 26, 4, 28, 2, 30, and 0.
With further advance of the addresses, the data D3, D2, D1 and the data d3, d2, d1 are not in accord and the addresses (m and O) are passed over and the address (n) is reached. Thus the initial stitch of pattern is repeatedly produced.
In FIG. 4, the data D7-D4 including a plurality of logics 1 means that the data may be employed so many times to so many patterns to be elongated. At the addresses (n+11) and (n+13) the data Dp is 21. This is because the pattern such as shown in FIG. 3 (D) designating the bit D7 with logic 1 requires the data Dp to be adjacent to each other as 10 and 21 at the addresses (n+10) and (n+11) while the pattern such as shown in FIG. 3 (C) designating the bit D6 with logic 1 requires the data Dp to be set apart as 19 and 21 at the addresses (n+12) and (n+13). Since it is impossible to backwardly trace the addresses, the data are so located for convenience sake.
If the operating knob 3 is rotated to switch over from the terminal U to the terminal V of the variable resistor VR, the data (d7-d4) of the latch circuit L2 becomes 0 1 0 0 and the pattern shown in FIG. 3 (C) is produced. If the switch SW8 is pushed by pushing operation of the knob 3, the flip-flop circuit FF1 is inverted and the data (d7-d4) becomes 0 0 0 1 and the standard pattern shown in FIG. 3 (A) is produced.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of pattern elongation systems differing from the types described above.
While the invention has been illustrated and described as embodied in a sewing machine, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A pattern elongation system in an electronic sewing machine includes a number of switches on the housing of the machine and a rotatable knob for actuating a pattern selecting circuit of the pattern elongation system. The pattern elongation system further includes a memory for storing stitch control data and a discriminating signal, a pulse generator operated in synchronism with rotation of the upper drive shaft of the machine and producing a timing pulse, an oscillator cooperating with the pulse generator to address the memory per stitch of the pattern, and a comparator which compares the elongation signal and the discriminating signals to cause the oscillator to determine the addresses for the stitches of pattern.
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RELATED APPLICATIONS
This application is a non-provisional of U.S. Provisional Application No. 61/784,080 filed Mar. 14, 2013 and incorporated herein in its entirety by this reference.
COPYRIGHT NOTICE
© 2012-2014 QS Industries Inc. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR §1.71(d).
TECHNICAL FIELD
We describe methods or means for conveying sound and/or digital information by one or more movable or fixed Remote Objects on a model railroad layout to Sound and Control Centers, Local Sound and Control Units and walk-around throttles to produce sound and operation that enhances the model train experience.
BACKGROUND OF INVENTION
One of the first methods of bidirectional communication was used by Pacific Fast Mail (PFM™) for sensing the position of a steam model train drive wheel. The wheel sensor cam would produce a short circuit condition to a high frequency signal applied to the track. The PFM sound system would detect this RF short circuit condition as the drive wheel on the model moved to different positions and apply a chuff (steam exhaust) audio signal to the track which was then applied to a speaker inside the moving locomotive. This type of bidirectional communication did not use an active signal sent from a remote object (the locomotive) but rather a condition in the locomotive that was passively polled by the RF signal sent from the control system to determine the locomotives wheel position. In passive polling communication systems, the receiver of the bidirectional information sends a signal to the remote object and looks at the condition of the sending signal for information. In active polling communication, the locomotive responds to a query from the command station and responds with an active signal sent by the remote object back to the command station.
The NMRA Digital Command Control System does have a method of bidirectional communication used in Service Mode. Service Mode is essentially a programming mode where the command station can program various behavior parameters (called Configuration Variables, CV's) into the locomotive and also read out CV values stored in the locomotives decoders using Acknowledgement pulses (called Acks). Acknowledgements are performed by the decoder affecting the load a locomotive presents to the command station to indicate a single bit response to a query. For example, the command station might query a decoder if the value of a certain CV 8-bit register is “one”. If there is no acknowledgement, the next query asks “is it 2”. If there is no Ack the next query asks, “is it 3” and so on until it gets an Ack to confirm the value. This is a slow procedure since it may require a full 256 queries before it gets an Ack. This is a passive polling method of doing bidirectional communication.
SUMMARY OF SELECTED EMBODIMENTS
Bidirectional communication may become a very important part of the communication system between remote objects on a model train track and various receivers either at the source of track power or stationary receivers that are placed at different locations on the layout or among remote objects on the track. Some of the advantages of bidirectional communication include: 1) displaying the speed of a remote object, 2) determining the simulated or actual air pressure in brake pipes, 3) the location of a remote object on a layout, 4) the internal temperature of the remote object, 5) fuel levels, 6) motor temperature (if it has a motor), 7) electronics board temperature, 8) inclination angle or grade, 9) curvature of the track, 10) distance traveled since odometer reset.
Additional advantages of bidirectional communications may include: 11) trip odometer value, 12) total distance traveled since new, 13) total time of operation since reset or new, 14) actual or simulated maintenance condition, 15) remaining simulated or actual fuel, 16) remaining simulated or actual water in a steam tender and/or steam locomotive boiler, 17) water supply for steam heaters, 18), actual or simulated traction motor current, 19) steam boiler pressure, 20) actual or real wheel slippage conditions, 21) remaining actual or simulated sand for traction, 22) open or closed condition of couplers, 23) stress of loading on drawbar, 24) the physical motion of the remote object such as bumps or side to side motion, 25) remaining smoke fluid or water in the simulated smoke or steam generator, 26) the conditions of various lights or actual or simulated appliances, 27) tractive force, 28) model's electric motor power and current, 29) track voltage, 30) digital packet reception errors, 31) bi-directional transmission errors, 32) radio communication from simulated or actual crew, 33) talk among real or simulated crew members, 34) track side actual or simulated detector reports, 35) ambient lighting conditions (such as day or night, tunnel, bad weather), 36) actual or simulated diesel notch positions, 37) simulated or actual traction motor current, 38) diesel transition setting, 39) generator voltage, 40) diesel motor RPM, 41) train accident sounds or report, 42) grade crossing alert, 43) actual or simulated prime mover operating conditions, 44) locomotive cab number, 45) locomotive train number, 46) DCC loco and consist ID numbers, 47) programming behavior settings (analog or command control), 48) remote object sounds (from sound system or from internal or external mounted microphones), 49) video signals (from internal or external mounted cameras), 50) GPS data (from local or actual global positioning systems), 51) queries and data from trackside transmitters or transceivers, 52) scheduling conditions (on-time, behind schedule, etc), 53) time check of actual or simulated time (fast-time), 54) load conditions, 55) actual or simulated Steam Cutoff setting or Johnson bar position, 56) actual or simulated conductor crewman communications, 57) actual or simulated train order verifications, 58) actual or simulated track condition reports, 59) actual or simulated dynamic brake condition and level setting, 60) routing reports (such as when a turnout is changed), 61) fuel pressure, 62) etc.
Bidirectional communication is an important part of the emerging technologies of train control where computers automatically control the speed, direction, etc. and the routing of model trains. To know where a particular locomotive is and its present status allows the computer to make the necessary decisions to properly direct different trains to their locations while preventing collisions and maintaining schedules.
FIG. 1 shows a block diagram of five common modules used in some embodiments along with multiple means of communication. The modules include a control center, 130 , a power district, 120 , for powering selected portions of the track, multiple hand held throttles, 111 and 112 , two remote module, one without sound capability, 100 , and one with sound capability, 140 . The remote objects can either be stationary or mobile on the track system.
All modules are shown connected to the standard system bus, 161 , for bidirectional data communication. Modules are each shown with RF radio link transceivers, 121 , 131 , 133 , 102 , 142 , and optional RF transceivers are shown in hand held throttles 110 , 112 . These RF radio links can be can be of many types Blue Tooth, IR, WiFi, or even hardware tethered direct links. Preferred transceivers will be bidirectional. The RF transceivers are optional and, if used, can serve the same function as the standard system bus, 161 , since the RF transceivers connect all modules together on a common communication system. The choice of including RF links may depend of the choice of scale. For instance, communication via a common bus may not be the best choice for G′ Gauge, particularly if the locomotive remote modules are powered by on-board batteries; in this case, Blue Tooth, WiFi, Infrared or other RF type links may be a better choice. For smaller gauges, RF modules may be too large to be practical. Still, RF type links may be retained between walk-around throttle control centers like 120 and 130 to provide mobility of operation around the layout.
A third addition to this communication system is a new type of bidirectional DCC which can be applied to the track and used as a general communication medium for any modules connected to the track system. Since DCC is limited in data bandwidth, a separate DCC system is added called “Q-Link” with allows accessories to be included without burdening the basic DCC system. Q-Link is designed for local accessories and may be configured separately for each power district. Q-Link, like our DCC system will be bidirectional with its own transceivers, shown as 162 , 164 , 103 and 147 .
One embodiment for Q-Link would be to make it part of a model train sectional track system with its own hidden Q-Link bus conductor. This would allow accessories like turnout switch machines, trackside signals, water towers, passenger stations, loaders and unloaders, etc. to be easily connected to any track that had access to the Q-Link bus. The use of a DCC Q-Link is preferred for many accessories that have already been designed for use with DCC commands. The added bidirectional capability should not interfere with these legacy accessories.
Another communication innovation is a method to transmit back analog sound samples from remote objects by monitoring its load applied to the track at the control center 130 or more likely by power district modules like 120 . Not only will this method retrieve sound data from one remote object but will retrieve the sum of sounds of all remote objects within the power district. The retrieved sounds can be used in track side base speakers to fill in the base components that are not sufficiently produced in the model. Also retrieved sounds can be used to create cab sounds back at the control system or for user headphones, such as 113 and 111 . This method of retrieving sound samples from remote objects, called BackWave Sound, is described later in this document.
A forth addition to this communication system is a method to locally generate commands to remote objects on a track section by modifying the local DCC track waveform. Local commands are important in model railroading to stop trains at specific locations for track side signals, passenger stations, increasing or decreasing grades, indicate specific location markers, provide data from track side detectors, etc. The method is described later in this document.
All models, 100 , 120 , 130 and 140 include a microprocessor (μP), and hardware capability designated at HW, and is shown as 109 , 165 , 167 and 168 . The hardware defines mechanical and electromechanical features under microprocessor controller for each module and can include such functions as motor controls, solenoids, lights, displays, smoke and steam generators, actuators, proximity detectors, bi-directional LED transceivers of embedded track transceivers, accelerometers, inclinometers, speed detectors, calibrated track loading under certain conditions, etc.
One of many mobile or fixed Remote Objects, 140 , includes System Data and Sound Processor, 141 , which contains stored sound and/or sound related information, long term erasable memory, and firmware for communications, sound processing and operating the Remote Object. The System Data and Sound Processor, 101 , can include actual sound data such as full or partial digital sound files, real time or pre-processed sound files, and sound information such as file length, sample rate, dynamitic range, volume scaling, etc. In addition, ancillary information relevant to sound reproduction in the model railroad environment such as the location of the remote object, speed of the object (if mobile), Identification (ID) Number, or other information about the state of the remote object is also stored in the System Data and Sound Processor, 101 .
Remote Object, 140 , also includes one or more Sound Production Channels such a, 143 and 145 , along with speakers 144 and 146 . Two or more sound reproduction channels provide considerable advantages for Remote Object sound systems. If they are part of a locomotive sound decoder, the speakers can be placed in different areas of the locomotive and/or tender to produce sound appropriate to their locations. For instance, if the model were of a prototype locomotive that had two prime movers (e.g. diesel motors) of the same motor type, separate speakers placed apart in a model could simulate independent sounds for each prime mover. Even in small scales, the separation of the two diesel motors into two independent speakers makes a signification difference in the quality of the sound. Often, models are produced where two similar prime mover sounds are both summed into one speaker channel which unfortunately sounds more like a single noisy motor. In addition, prime mover sounds can be directed into two separate coupled locomotives to reduce the cost of having both locomotives equipped with full sound systems.
Other sounds that commonly occur in different areas of a prototype locomotive, such as sounds of opening and closing a front diesel cab door, radio cab chatter from the cab, front coupler opening or closing, rear coupler opening or closing, steam generator sounds for passenger diesels at the rear of a locomotive, etc. can by simulated in the model by having the sounds emanate from different speakers. In steam locomotives, additional sound reproduction channels allow local tender sounds such as water and coal, wood or oil loading. Two or more channels can simulate moving sounds such as crewmen walking along the track and/or talking outside of a locomotive, maintenance work on different areas of the locomotive such as different diesel trucks, brakeman changing a turnout, walkie-talkie communication such as between brakeman and engineer, etc. It would, in fact, be desirable to have four separate sound channels available for the larger scales such as O′Scale and G′Scale; for instance, for diesels, speakers at each end of the locomotive for locations specific sounds of cab, couplers, radio com, passenger steam heat boiler, etc., a speaker in the roof area for horn, fans, dynamic brake sounds, etc. a speaker in the fuel tank for sounds of traction motors, bells, generators, pumps, fuel and water loading and maintenance sounds, etc.
More than one channel can also provide better sound acoustics for steam locomotive models. For instance, a small speaker could be placed in the model's boiler near the steam chest under the stack where the steam exhaust (chuff) would normally be heard and a large base speaker placed in the tender for low frequency response. Since the human ear is not as able to determine the location of low frequency sound, a listener would believe that all the chuff sounds were coming from the boiler speaker, even though this speaker is not producing the full frequency response.
Fixed Remote Objects such as environmental sound modules that are designed to produce local sound effects could also benefit from multiple sound channels. For instance, sound of a downtown city area could simulate the sounds of cars, trucks, police car with sirens moving down streets. Airport sounds could also include simulation of moving planes taking off or landing. Waterfront sound models could include simulated sounds of moving boats and seagulls. Environmental sound units would like be controlled directly through local Q-Link bus.
Remote Objects, 100 and 140 , System Data and Sound Processor, 101 and 141 , can include general purpose microprocessors or custom processors, RAM, ROM, and non-volatile memories, Analog to Digital Convertors, Digital to Analog Convertors, Firmware, power supplies, rectifiers, signal detectors, etc. Besides polyphonic sound data generation and other sound related processing, they may also control other functions in the remote object such as motor control, speed control, lighting effects, smoke generators, turnout control, communication parsing and decoding, and other functions common to model trains. Remote Objects, such as 100 and 140 , can communicate through common bus, 161 , if connected to their respective System Data and Sound Processors, such as 101 and 141 .
The Remote Objects can also include means to provide selected information via their Transceiver Means, such as 102 and 142 , to other Transceiver Means, such as 121 and 131 , which are part of Sound and Control Center, 130 , and Local Sound and Control, 120 , or Walk-around throttles such as 110 and 112 . Sound and Control Center, 130 , is one of many possible Sound and Control Centers on the layout, and Local Sound and Control, 120 , is one of many possible such units dedicated to local district power or control on the layout. One advantage of using RF or WiFi transceivers on remote objects such as model locomotives is that video can be transmitted more reliably to the control center or even directly to walk-around throttles that have display screens; this would allow viewing of images made by miniature cameras on the model locomotives. Audio could also be transmitted along with the video for both sound and sight from the point of view of the miniature engineer inside the model cab. Smart phones and tablets configured to WiFi reception and transmission can also be configured as both controlling means and video and audio display means for model trains.
Sound and Control Center, 130 , includes Sound Data and Sound Processing Means, 122 , which includes data processors, memories, firmware, etc. for parsing and decoding sound and sound related data from the Transceiver, 131 , Q-Link transceiver, 164 or bidirectional DCC signals from 129 .
Sound and Control Center, 130 , can include Layout and Control, 134 , which provides signaling and/or digital commands to the layout, 136 , to affect Remote Objects such as locomotives, turnouts, rolling stock, environment sound modules, accessories, loader and unloaders, uncouplers, layout lighting, other Sound and Control Centers, Local Sound and Control such as 120 , power blocks or power districts, and other features common to model train layouts. Computer control of trains via Personal Computers (PS) or dedicated data processes can also be part of the Sound and Control Center, 130 , and control line 161 can include common digital buses for the control of the different features and functions mentioned above.
Local Sound and Control, 120 , is similar to Sound and Control Centers such as 130 , except it is designed to provide local sound effects and control and will usually also include local Layout and Train Control, 123 . For instance, 130 may include local block control or local NMRA DCC power district control of locomotives turnouts, rolling stock, environment sound modules, accessories, loader and unloaders, uncouplers, layout lighting, and other remote objects. Local Layout and Train Control, 123 , can accept or send commands via control bus, Q-Link, 160 . Although sound control is local for 120 , sound information or commands can also be conveyed back and forth between any number of Local Sound and Control Units and Sound and Control Centers via Standard System Bus, 161 .
Both Sound and Control Centers, such as 130 , and Local Sound and Control, such as 120 , contain sound reproduction means. For the Sound and Control Center, 130 , there can be one or more sound reproduction channels such as 137 and 139 . Speakers, 138 and 140 , produce sound from Sound Production, 137 and 139 respectively. For Local Sound and Control, 120 , sound reproduction channels, 125 and 127 , power speakers, 126 and 128 respectively. The different Sound Production channels can be used to provide stereo or spatial effects or can be used to provide simulated moving sound effects. This can be useful when speakers are placed near track or other areas where a mobile Remote Object may operate. To simulate moving sound that is coordinated with the moving object, sound can be varied smoothly from one speaker to the other. Other speakers can be placed in different or more remote areas to provide echo and reverb effects. If it is necessary to simulate sound moving over a great distance on a model train layout, the sound can be moved smoothly from one Local Sound and Control unit to the next by sending sounds and commands via bus 161 .
Both Sound and Control Centers, such as 130 , and Local Sound and Control, such as 120 , may have means, 133 , for communication between any number of hand held transceiver walk-around throttles such as 110 . Walk-around throttles, such as 110 , may also contain means to reproduce sounds via a built in speaker, ear buds, or headphones, 111 . Sound and/or sound information can be conveyed by Sound and Control Center, such as 130 , to the walk-around throttle via transceivers, 133 or 131 and by Local Sound and Control units such as 120 , using transceiver, 121 . In addition, sound and/or sound information can be conveyed directly from remote objects, such as 100 or 140 , via their transceivers 102 and 142 .
Sound and sound related information can also be available for model train remote control systems that communicate directly to remote objects from fixed or hand held throttles such as the walk-around throttle, 112 . In this case, sound and/or sound information is communicated directly between throttle, 112 and remote object's, 100 , transceiver, 102 , and remote object's, 140 , transceiver, 142 . Sound can be reproduced through the Walk-around throttle built in speaker, ear buds, or headphones, 111 and/or 113 . In addition, microphones can be included as part of walk-around throttles 110 and 112 to allow users to communicate with each other or the dispatcher in large layouts.
Means of providing information to Transceiver Means, 121 and 131 , from Remote Objects, such as 100 and 140 , can include radio frequency transmission, Infrared or Visible light transmission, direct sound transmission, transmission down the layout railroad track or cables connected directly or indirectly from the remote objects to the Transceiver Means, 121 and 131 . Indirect transmission might include first conveying information to the model railroad track, through remote object's electrical connection to the track and from the track to the transceiver means, 121 and 131 , or conveyance to local receivers or detectors of one type of signal and then forward to the Transceiver means, 121 and 131 , by the same or one or more alternate transmission means. For instance, Remote Object, 140 may transfer information to remote object, 100 , through transceiver means, 103 , to a local power district controller, such as 120 , which in turn conveys information to the central control module, 130 , which sends out a global DCC signal through 136 to the layout which is received by Transceiver Means, 147 for remote object 140 . As an example, suppose the lead locomotive in a long train with mid-trail helps and pushers receives a local track side signal to stop at a red signal. The lead locomotive in turns sends a command via DCC bidirectional communication to local power district controller, 120 , which in turn tells 130 about the need for the train to stop, which then sends out a global throttle signal that applies to all locomotives in the train. This prevents any locomotive from getting having different throttle commands that can cause derailments. In addition, the lead locomotive can send back continuous information about its position and speed so the control center, 120 , that can allow 130 to update the stopping action of the train to stop where it should. If modules are equipped with RF links, these links could convey information between remote objects directly.
Both Sound and Control Centers, such as 130 , and Local Sound and Control, such as 120 , have USB inputs that can be connected to PC's and/or the internet. PC can facilitate programming behavior parameters such as NMRA CV's, downloading new sounds, operations in service mode, etc. Personal Computers can be used to program the operation of trains through the Control Center and Local Sound and Control district modules to route trains, perform basic signaling functions, automatic switching, speed control, collision avoidance, fast time, coordinated environmental sounds and lights such as night and day effects, etc. In addition, access to the internet and the availability of local cams and locomotives with on-board cameras can allow other model train enthusiasts to log on locally and control other layouts that provide this kind of service.
One advantage of some embodiments is to produce a completely integrated sound and control environment that can supply sound, and/or sound records and/or sound related information directly from Remote Objects back to Sound and Control Center (such as 130 ), Local Sound and Control Units (such as 120 ) and/or to walk-around throttles (such as 113 ), to provide bidirectional DCC information from mobile remote objects, to provide a way for local accessories to be integrated into the global control system via the Q-Link connection, to provide means for commands to be sent to mobile remote objects that venture into local areas, a way for one remote mobile device to communicate to other remote devices, particularly if they are all part of the same train, a way to track the location and speed of individual trains via their odometers and knowledge about their positions when they enter different locals and the positions of turnouts, ways to allow PC control of the entire train environment, access to layouts from users via the internet and a track system that allows easy connection to local accessories via a simple DCC system auxiliary bus like Q-Link.
In particular, sounds provided from remote objects via the DCC BackWave sound can be used to reproduce sounds or enhance sound already produced or stored by Remote Object or sound information can be used to coordinate operation and sounds produced by Remote Objects with sounds stored and produced by Sound and Control Center and/or Local Sound and Control units. For instance, the base sounds stored in Remote Objects but reproduced poorly by the Remote Object's audio system and limited acoustics can be enhanced by reproducing the base sounds by Sound and Control Centers, Local Sound and Control Units, and/or walk-around throttles where better control of lower frequency sounds are available. These sounds can be added without affecting the perception that the sounds are coming from the Remote Object since the source location of low base sounds cannot be easily detected by human sound perception.
Some embodiments disclosed herein can also be used to produce simulated sounds appropriate for moving model locomotives by transmitting from the model sound information such as the acceleration and simulated and real load, notch setting in diesels, speed, steam exhaust (chuff) triggers and cutoff settings for steam locomotives, direction, local terrain such as tunnels, cuts, open area, travel over turnouts or crossovers, grades, etc. that can all affect the modeled sound effects. In this manner, the sounds produced by the Sound and Control Centers, Local Sound and Control Units and/or walk-around throttles can be coordinated to the operation and/or sounds of the locomotives. In addition, sounds and/or sound information from many different locomotives can be used to produce combination sounds from the different locomotives in consists.
Another example is to provide sound related information or reproduce the sounds from Remote Objects to simulate sounds appropriate for the interior of a locomotive cab. This provides an enhanced and more realistic experience for the model train user that is operating the cab controls of his locomotive. Depending on the type of sounds or sound information available, the sounds can provide valuable feedback about the operation of his Remote Object such as sounds that reflect how hard a locomotive is working, how fast it is going, its surroundings, etc. Other sounds can be added by at the cab controls such as radio communications by the dispatcher or by other operators or local sounds appropriate for the current location of the Remote Object such as automobile traffic sounds, factory sounds, police sirens, crossing gate bells, barking dogs, rail fans, other passing trains, etc. and Doppler shift effects could be added as a extra features. In other words, cab sounds would not be Doppler shifted but outside sounds would be Doppler shifted according to the speed information provided by the Remote Objects. Echo and Reverb, which is difficult to produce on-board the locomotive could be reproduced via environmental stationary remote object sound objects. Since this system can determine where a locomotive or train is located and can retrieve sounds via BackWave technology, these sounds can be delayed and recombined to produce echo effects and reverb appropriate for tunnels and cuts.
The transceivers communication technologies used in different embodiments may affect the capabilities and limitations of such embodiments, for example, as summarized below.
Radio Transmission
Using Radio Frequency Transceivers such as RF, Blue Tooth, and WiFi can provide means for each Remote Objects to communicate with Sound and Control Center, Local Sound and Control Units and/or walk-around throttles. In order to prevent different Remote Objects RF transceivers from interfering with each other, it would be necessary to either have each transceiver tuned to different frequencies or develop a protocol that only allowed only one to communicate at a time. If the intention is to send continuous sound from each remote object and to have all of the different sound sources reproduced in part or in whole by the Sound and Control Center, Local Sound and Control Units and/or walk-around throttles, then it would easier if each remote object communicated on its own individual RF channel. In this case each received and detected transmissions from all Remote Objects would be applied to the Sound data and Sound Processing Means for sound processing. For instance, if there are many locomotives in a consist and each is producing sound and transmitting sound to the Local Sound and Control unit, then these sounds can be processed together and summed to provide production of all the sounds from the remote objects.
FIG. 2 shows two Remote Objects, locomotives 201 and 202 , which at least include the elements shown in FIG. 1, 100 or 140 . In the case of locomotives, 201 and 202 , the transceivers are Radio Frequency units transmitting at carriers F 1 and F 2 respectively which are received by antenna 206 , connected to Local Sound and Control unit, 204 . Local Sound and Control, 204 , transceiver, 205 , is indicated by a group of “n” individual transceivers, each tuned to a different frequency F 1 through Fn or each locomotive could use WiFi or similar modular transceivers already configured to deal with multiple transmitted data sources. The vertical double dots indicate numerous individual transceivers not shown in the transceiver group, 205 . The Local Sound and Control, 204 , is shown connected to the block or power district track, 203 . Local Layout and Control by the Local Sound and Control, 204 , can include power and/or bidirectional digital commands for operating locomotives and other Remote Objects.
In this example, Remote Object, 201 , is transmitting Sound and Sound Related Data on the F 1 frequency carrier to be received by antenna, 206 , detected by the F 1 Transceiver in the Transceiver Cluster, 207 , and applied to Sound Data and Sound Processing Means, 208 . At the same time, Remote Object, 202 , is transmitting Sound and Sound Related Data on the F 3 frequency carrier to be received by antenna, 206 , detected by the F 3 Transceiver in the Transceiver Cluster, 207 , and applied to Sound Data and Sound Processing Means, 208 , at the same time. If both locomotives are sending sound samples then these can be processed and summed by 208 and delivered for real time sound production of sounds produced in the two locomotives.
The advantage of RF transmission over sending sound samples and sound related data down the track from mobile Remote Objects like locomotives is that it avoids loss of the sound data signal when contact is lost between track and locomotive wheels or pickups. Its disadvantage is the cost and complexity of having each locomotive transmit on its own individual carrier frequency and the necessity of having multiple transceivers in the Sound and Control Centers and Local Sound and Control units. In addition, the sounds may not be restricted to a local area since RF may carry to other Local Sound and Control units in other locations. Also, since the locomotives are moving, there is unpredictable signal strength at Local Sound and Control Units or Sound and Control Centers as RF is reflected off different surfaces.
Other methods of transmitting sound and bidirectional data include light such as Infrared that can be picked up locally by LED receivers. Problems with light include some of the same problems with radio waves: 1) light can be blocked by obstacles on the layout, 2) light can be accidentally received in adjacent block receivers, 3) data must be encoded and transmitted so there is no interference from different remote objects, etc.
Sound Transceivers
Sound Transceivers made up of special microphones and speakers could transmit and receive sound and data. For instance, another way that base sounds can be enhanced from remote objects is to pick up the sounds from local microphones and amplify the diminished base sounds and reproduce them locally from stationary base speakers. While this would help fill in some of the base components, it will always be limited by how much base content can be present in the remote object speakers.
Remote object sounds and data could also be transmitted on a supersonic carrier to other stationary or remotely located microphones and detected. The remote object would need special supersonic speakers to transmit the carrier signal. However, this method also has the problem of separating the different sound sources from multiple remote objects that are picked up by other sound transceivers.
Simultaneous Sound Sources
Another way to add in missing base components from the remote object speaker is to produce simultaneous sounds from both the remote object and local sound reproduction sources using identical sound records. This way the limitations of the remote object speaker are filled in with local identical sound sources through large stationary base speakers. The one problem with this technique is to keep the simultaneous sounds in sync which will require sound control data from the remote object to trigger the same sounds in the local stationary amplifier and base speaker. For instance, if both a model steam locomotive (remote object) and a stationary sound reproduction system had identical steam exhaust records (Chuffs), a trigger to produce a chuff sound could be transmitted by the remote object to the local amplifier to trigger its chuff sound at the same time. One of the advantages to identical sound sources in the remote object and a stationary sound reproduction system is that full high fidelity sounds could be produced and modified at the control center to simulate sounds heard in the locomotive cab.
Transmission of Bidirectional Sound and Data Down the Track
Using the track to provide bi-directional data is appealing since the track system already exists on the model train layout that connects the control center to each remote or stationary object. The biggest problem with any new method of transmitting data and sound on the track system is the existing standards that already exist for model train communication. Any new data transmission techniques would preferably be an extension of and compatible with existing technologies.
The four main popular track communication technologies are: 1) Analog DC, 2) Analog AC, 3) NMRA DCC Command Control, 4) TMCC (Train Master Command Control) for AC power track systems, and 5) MTH DCS (Digital Command System). Both analog methods use variable voltage to control the speed or power delivered to locomotives and for the most part lack any kind of commonly accepted bidirectional communication. As method previously, the NMRA DCC command control uses acknowledgement pulses in their programming to determine the digital content of special decoder registers called CV or Configuration variables. There is also a proprietary bidirectional system developed by the Lenz Company for operation mode but is not available to all users. Lionel's TMCC uses radio transmission down the track to send digital commands to receivers in remote and stationary objects but does not offer any kind of bi-direction control system. MTH's DCS does offer a high frequency carrier method for transmitting both data and sound to their locomotives and a bi-directional technology for receiving data from remote and stationary objects.
The Lenz system is the most interesting since it is an extension of the NMRA system and for the most part does not interfere with normal DCC operation. Briefly, the Lenz technique reduces the track voltage to zero for brief periods as shown in FIG. 3 , which are short enough that the decoders in the locomotives remain powered from their internal power supply filter capacitors. During these zero voltage periods, called the “Gap”, 301 , the decoders transmit current pulses down the track to stationary receivers to detect digital information. No DCC commands can be transmitted to the decoder during the Gap period. Since DCC decoders have standard bridge rectifier inputs, the impedance on the track is essentially zero during these periods. The bidirectional current sensing at the command stations and the current from the decoders are so designed that voltage produced on the track do not exceed the turn on voltage for the decoder bridge rectifiers.
BRIEF DESCRIPTIONS OF THE DRAWINGS
FIG. 1 is a block diagram showing the various means of controlling, powering, sound reproduction and communicating between remote and stationary objects in model railroading.
FIG. 2 describes how radio transceivers can be used to communicate data and sound between objects in a model railroad and in particular the limitations of using these techniques.
FIG. 3 shows an example of a DCC track signal employing the Gap in the Lenz technique for bi-directional communication.
FIG. 4 shows an example of a DCC track signal using The Drop for bi-directional communication using a polling technique.
FIG. 5 shows a basic decoder with basic on-board power supply in addition to a calibrated current sink for bi-directional communication.
FIG. 6 shows a detailed example of the DCC waveform used between 14 volts peak, 601 , and 7 volts, 602 , during the Drop which maintains DCC data transmission at all times.
FIG. 7 shows an example of track bi-directional current polling data during The Drop and expanded detail of the nature of the digital current pulses.
FIG. 8 shows an example of a DCC waveform where The Drop is one sided on the DCC waveform.
FIG. 9 shows an example of a DCC waveform where The Drop occurs after each DCC bit and before the next bit with reduced DC component.
FIG. 10 shows an example of a sound decoder with basic on-board power supply in addition to a DAC current sink for bi-directional polling of digital data and bi-directional polling of sound analog sound.
FIG. 11 shows an example of the analog sound data samples from the calibrated DAC current sink for each sound data sample used in BackWave sound concept.
FIG. 12 is an example of asymmetric waveform drop on the track polling current.
FIG. 13 is an example of polling current averaging at the DCC base station or track driver.
FIG. 14 is an example of a reconstructed waveform from the polling BackWave sound data.
FIG. 15 is a best fit analog waveform from the original example of digital sound data samples.
FIG. 16 is a comparison of original digital sound data samples and the reconstructed waveforms from polling BackWave sound data samples.
FIG. 17 shows an example of the effect of a high frequency component in the original data on the polled sample data.
FIG. 18 shows the results on track polling current with averaging the original sound data over epochs of polling and its adjacent non-polled periods.
FIG. 19 compares reconstructed sound waveforms from polling of adaptive averaging of original data over epochs of polling and its adjacent non-polled periods to averaging the original sound data over the same epochs.
FIG. 20 compares reconstructed sound waveforms from averaging raw DC polling data to averaging the original sound data over the same epochs.
FIG. 21 shows a block diagram of a method for doing Adaptive Averaging in the decoder.
FIG. 22 shows how digital data can be embedded in the bidirectional analog sound waveform to provide both bi-directional digital data and BackWave sound.
FIG. 23 shows a notch Drop applied at the end of either a DCC one or zero.
FIG. 24 shows that to create a 25 uS notch in the output of our booster, the DCC with notch would be delayed from the original DCC waveform.
FIG. 25 shows the original DCC waveform and its reconstruction by the QSI Booster where the notch is on the leading edge and its concurrent problems with settling time at the beginning of the notch.
FIG. 26 is a solution to the delay problem with a notch on the back of the DCC pulse by always starting the notch 25 uSec after the start of the pulse.
FIG. 27 shows the advantage of a 25 uS delay before Dropping to the notch that provides much more evenly spaced sample times. An example shows polling a high frequency sine wave at Nyquest and noting its reconstructed polled waveform.
FIG. 28 shows the ringing and settling time when the Drop occurs on the waveform where the notch is on the back side of DCC pulse waveform.
FIG. 29 shows a block diagram of the DCC control center to generate the notched DCC waveform in FIG. 28 and detection means to measure the analog current samples and embedded digital data.
FIG. 30 shows a method for modifying the DCC waveform to generate local commands to DCC decoders within a power district.
FIG. 31 shows how amplitude modulation on the DCC waveform at each half bit can double the local command data baud rate over the normal DCC baud rate.
FIG. 32 shows another method of using The Drop at two voltage levels for both local commands and for bi-directional communication and BackWave audio.
FIG. 33 shows a method to generate the two voltage level Drop and means to detect this information in the decoder.
FIG. 34 shows notch, logic one, logic zero detection from the decoder shown in FIG. 33 .
FIG. 35 shows the effect of the decoders loss of connection to the track and how it affects the digital polling data.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Polling Bi-Directional Technology
Our polling bi-directional system for data and sound can be applied to NMRA DCC, analog DC, analog AC, and is compatible with Lionel's TMCC system. There are similarities to the Lenz system but instead of using current pulses transmitted from the decoder, we use acknowledgement pulses in the decoder for both sound and data information, which is already an accepted method for bi-directional communication by the NMRA. Instead of producing a zero voltage Gap, we produce a low voltage “Drop” during which data is detected from the remote object. It is important to note that while the Lenz bi-directional system actually transmits a digital power signal from their decoder during the Gap that is received by the command station, our polling system does not require any power to be applied to the track from the decoder to provide digital data our sound information. In other words, the Lenz system actively transmits back information from the decoder, while the present polling methods retrieves information from a passive decoder. Another distinction is that DCC data continues to be transmitted during the Drop but no DCC data is transmitted during the Gap. The Lenz Gap is shown in FIG. 3 and an example employing The Drop, 401 , is shown in FIG. 4 .
Description of Circuit and Operation
A simple basic decoder with power supply is shown in FIG. 5 to illustrate how The Drop along with calibrated current loading can be used to provide bi-directional digital data and analog sound values from the sound decoder in the model locomotive.
The circuit in FIG. 5 represents our typical on-board power supply consisting of bridge rectifier, D 1 , D 2 , D 3 and D 4 , along with large filter capacitor, C 1 , five volt regulator, C 2 filter capacitor and 3.3 volt regulator. The microprocessor, uP, and motor M load are also shown, although motor control detail is not included in order to simplify the drawing. Also not shown are track voltage detector ADC (Analog to Digital Converter) circuits for monitoring the voltage waveform of the track.
An addition current source circuit has been added consisting of a bridge rectifier, D 5 , D 6 , D 3 and D 4 and uP controlled N-FET. The full-wave rectifier bridge circuit for the N-FET circuit, and the full-wave rectifier bridge circuit for the on-board power supply, share the bottom bridge rectifier diodes, D 3 and D 4 .
When the DCC signal is applied, current is supplied to the main on-board power supply and motor and also to the FET if it is on.
When the DCC peak voltage is reduced or dropped from a high voltage, 601 , (say 14 volts) to a lower voltage, 602 , (say 7 volts), as shown in FIG. 6 , the main bridge rectifier is back biased, at least until the C 1 capacitor discharges to 7 volts. During this time the only current flowing to this circuit is through D 5 , D 6 , D 3 and D 4 Bridge and N-FET current sink and perhaps a little current flowing in the track voltage detector ADC circuits.
It is during this voltage drop period, called “The Drop” that we can accomplish bidirectional polling communication. If the FET is turned on and off at say, 1 to 2 u-Sec intervals inside The Drop, the current in the track will register this change as 1 to 2 u-Sec current pulses as shown in FIG. 7 which can be detected at the DCC base station. The choice of current pulse period at the present time is arbitrary and used here only for explanation of the concept. FIG. 7 shows the high speed current polling data packets, 701 , during The Drop as well as an expanded view, 702 , of typical current data digital pulses.
A one microsecond pulse could be a digital 1 and a two microsecond pulse could be a digital zero but this is also arbitrary. For all zeros at 2 uS each, the total byte time is less than 30 uS including 1 u-Sec delays between bits. Since a DCC digital pulse is about 56-64 us, the bit widths could be expanded and still fit within a DCC digital one.
All bridge diodes should be Schottky diodes to avoid high power consumption and the enormous diffusion capacitance of P-N diodes. Also, if the motor discharged the C 1 filter cap too quickly, we could shut the motor power off during The Drop.
Note “The Drop” could be one sided, which would reduce the polling communication rate by half but would help keep the main on-board power supply charged during one half of each DCC bit. In the case shown in FIG. 8 , The Drop, 805 , occurs after each bit. The voltage drop value is also arbitrary and only shown as 7 volts for instructional value.
This waveform would produce a distinct DC offset which would interfere with stretched zeros analog operation to control conventional locomotives in DCC analog mode. We call this an “Asymmetric Drop Waveform” since “The Drops” occur only during one polarity of the waveform.
As shown in the DCC waveform in FIG. 9 , it is also possible to drop at the end of every bit, such as 901 , and the beginning of the next bit, such as 902 ; In this case, there are two one-sided drops in a row where bidirectional communication occurs. Although this waveform still has a DC component, it is much reduced from the example in FIG. 8 . We will call this a “Symmetric Drop Waveform” since “The Drops” alternate in polarity.
BackWave Sound™
The idea of BackWave sound is to poll an analog value that is the value of the present sound sample playing to allow it to be read by the command station that is producing the track waveform. The circuit shown in FIG. 10 is the same as FIG. 5 except that sound production, 1001 , is added in addition to a calibrated current sink, 1002 , that is an analog (DAC) function of the sound sample digital value and/or digital data. For instance, if we were producing 16 bit resolution on-board sound, the current sink analog value could be calibrated up to 16 bits. As each sound sample was fetched from memory by the microprocessor for sound reproduction, the same digital value is used to set the value of calibrated analog current sink. The current measured at the command station during The Drop would be equal to the value of the analog current sink at that time.
In this circuit, the current source can be set to a new sample value as each sound sample is fetched from memory. If the calibrated analog current source is updated continuously, the calibrated analog current source might look like the graph in FIG. 11 as an example of sound analog sample data.
In this example, current flows continuously from the DCC track voltage waveform through diodes D 5 or D 6 through the calibrated analog current source and then through D 3 or D 4 to return to the DCC track voltage supply. When the DCC track voltage waveform is at The Drop potential (7 volts in this example), all DCC track current is due to the calibrated current sink. At the full peak track potential (14 volts in this example), the current from the DCC track voltage supplies the entire on-board system through diodes D 1 -D 4 , including any current needed for the motor, recharging any power supply capacitors, as well as supplying the calibrated sink current through D 4 -D 5 and D 3 -D 4 .
For the Asymmetric Drop waveform from FIG. 8 , the track voltage and current during The Drop would be determined as illustrated in FIG. 12 .
Note that the track current is not uniform during each drop. The reason is that the calibrated current source may not be synchronized to the DCC waveform. Not only is the sample rate faster for the calibrated current source in this example but the DCC waveform has an asymmetric sample rate due to the unpredictable nature of data being transmitted down the track and the fact that digital ones and zeros have different pulse widths. The notch in the track current value, 1205 , 1206 , 1207 , 1208 , etc. are due to timing misalignment with the DCC waveform.
If the current pulses could be averaged mathematically in the DCC base station, the resulting current pulses would look like FIG. 13 for this same example.
And the reconstructed analog sound waveform would look similar to the dark line, 1401 , in FIG. 14 .
Compare this to the original waveform in FIG. 15 from FIG. 11 , where the dark line, 1501 , represents a best fit reconstructed sound waveform.
FIG. 16 compares the original analog reconstructed waveform, 1501 , to the reconstructed analog waveform from the sampled sink current samples, 1401 .
The reconstructed waveform is a good match over about one half of the indicated time period. However, there are four peak values of the original reconstructed waveform in FIGS. 16 ( 1601 , 1602 , 1603 and 1604 ) where the match is quite poor between the original and the reconstructed waveform. The reason is quite apparent from the sampling times from the original DCC waveform from FIG. 8 , which is also shown in FIG. 12 . The four areas shown as 801 , 802 , 803 , and 804 are where virtually no pole current samples were made of the original waveform occurred because the DCC waveform was not in The Drop sampling period at those times. These four areas represent critical data changes that were not sampled and include in the reconstructed waveform. For instance, 801 , represents a sample time which occurred a low value in the original sample waveform 1601 . The high current value, 1602 , was not sampled at 802 . The precipitous drop, 1603 , was not sampled at 803 and the rapid rise at 1604 was likewise not sampled at 804 .
This is not surprising; it is a consequence of sampling at a lower rate than the original sample rate; data will be lost. Since our intent is to provide the best reconstruction of the original data at the new sink current sampling rate, it would be good to analyze the accuracy of the reconstructed waveform for the bandwidth corresponding to the DCC sample rate. In other words, it we assume an average sample rate based on likely occurrence of DCC ones and zeros, there will be a corresponding Nyquist frequency that provides a good estimate of the best bandwidth we can expect at our DCC sample rate. As an example, if we assume equal occurrence of DCC ones and zeros, the average sample rate is 2 samples per 300 u-Seconds or an average sample rate of 6.67 k-Samples/sec. Nyquist would be 3.33 kHz. Since DCC ones are much more common than zeros, this is a good worst case estimate for expected bandwidth for the type of “Asymmetric Drop Waveform” used in this example.
In any case, the data rate presented to the Calibrated Current Sink will need to be bandwidth limited to a sample rate that is approximately the DCC sample rate. This will ensure that high frequency components that are present in the sound records do not contribute to the lower frequency samples from the DCC sample rate. For instance, if the current source received a single high value high frequency contribution that was present during one of the DCC sample periods, it would contribute a false low frequency value at the lower DCC sample rate. As an example, consider the waveforms from FIG. 12 , where we have added a high frequency contribution to the Calibrated Current Sink, 1301 , shown in bold in FIG. 17 . The original value from FIG. 8 for this period is shown as dotted line 1302 . Since our addition to the Sink Current Waveform is symmetric, the dotted line, 1301 , represents the average value during this period.
This high frequency component is above Nyquist for the DCC average sampling rate but yet it contributes to a significant error in the sampled waveform as shown by the new value, 1303 , compared to the original value 1304 .
Because the sampled sound record data used to set the Calibrated Sink Current has terms in excess of Nyquist, this data should be resampled at a lower frequency nearer the DCC sample rate. However, the DCC sample rate is asymmetric in time and unpredictable except for its average value. What is required is a way to adapt the resampling of the sound record data to correspond to the changes in the DCC waveform sample times. In addition, we would like the sink current samples to line up to the DCC sample periods to ensure a single value for each sample. This will ensure that the reconstructed waveform at the command station will be an exact copy of the resampled sound record data.
One way to resample data is to do waveform analysis on the original sampled data to provide a best fit analog curve to provide continuous values over time. This curve can then be resample to provide a new digital record at a lower sample rate. Another simple option is to average adjacent values to lower the sample rate by a factor of 1/(number of averages taken).
One option is to time average each previous epoch from the last DCC sample read up to the start of the DCC current sample read. The data presented to the DAC current sink would be this average of the previous data. For instance, consider the thirteen Epochs shown in FIG. 18 for the example Asymmetric DCC waveform from FIG. 12 .
Each Epoch starts and stops when the polarity changes to the Drop voltage of 7 volts. It is the time average during this period that is applied to the Calibrated Current Sink for the DCC sample read.
FIG. 19 shows two curves. The dashed curve, 1901 , shows the results of averaging adjacent sound samples on the original Sound Record Samples from the second graph in FIG. 18 . This curve represents a simple resampling of the sound data at one half the original sample rate where new samples are calculated from simple averaging of adjacent original sample points. In the absence of using adaptive averaging, this might be the preferred method of providing low pass filtering and resampling to a lower sample rate to avoid inaccuracies during the DCC sampling as discussed above.
The solid curve, 1801 , shows the reconstructed waveform from DCC samples based on Adaptive Averaging of the original sound samples. The dashed curve has been moved to the right an average of 150 uSec since each sample represents data from the previous epoch and on the average is late by an amount that is based on delay contributions from DCC ones and zeros (where we have assumed equal occurrences of both ones and zeros).
FIG. 20 shows two curves. The dashed curve, 1901 , is the same as that shown in FIG. 19 and represents a simple resampling to one half the original sample rate based on simple averaging of adjacent sample periods. The solid curve, 1401 , is from FIG. 14 and is the reconstructed waveform from raw DCC sampling of the original sound records.
Comparing FIG. 19 and FIG. 20 , the reconstructed waveform from Adaptive Averaging appears to be more accurate (using root-mean-square error analysis) when using asymmetric time sampling from the example DCC waveform used in these examples.
Lost DCC Signal
Model trains do not have perfect electrical pickup. Sometimes the pickups are resistive and sometimes all connection is briefly lost. Our bidirectional method of detecting a current load is very forgiving of resistive pickups since the detected current will still have the same value even if there is some insertion loss due to voltage loss across the pickups, that is, as long the voltage Drop does not exceed the voltage compliance of the current sink.
Complete pickup loss is a different story. At reasonable speeds the loss is usually very brief (1-100 uSec). At low and very low speeds, the loss can be a few milliseconds to full loss at speeds below 1 smph. Most sound systems w/o UPS backup will have enough stored charge for only about 10 mSec. If we assume a reasonable loss of 1-2 msec in DCC track signals from time to time, this represents a loss of about 10 samples. If this behavior were common at low speeds the Nyquist bandwidth would be reduced to about 300 Hertz which is not great but probably acceptable.
The command station can make some compromise of these kinds of losses by detecting that no bidirectional samples are being received and playing recently detected sound records. One method is to play the last few milliseconds of detected and stored sounds backwards and then jumping to any new sound samples that are then detected. To ensure that the command station knows when no signal has been detected, a minimum sink current should always be present even if the sound is at its minimum value. That way, if the command station does not detect any bidirectional current at all, it would know that it is due to a loss of DCC signal at the on-board sound system and not a minimum sound value.
One advantage of Adaptive Averaging is that if the DCC signal does disappear, the averaging continues. When the DCC signal returns, a reasonable data point is then sampled.
Method for Doing Adaptive Averaging for Asymmetric Sampling:
The diagram in FIG. 21 shows the method for doing Adaptive Averaging which would be an addition to the decoder circuitry shown in FIG. 10 . The DCC signal, 2100 , is applied to the DC Edge detector, 2101 , which determines that a DCC polarity transitions has occurred or that a disconnected DCC signal has returned. The DCC signal, 2100 , is also applied to the DCC Level Detector, 2102 , that determines if the DCC signal is in The Drop. If these two conditions are met in the DCC Sample Detector, 2103 , then the Timer, 2104 , is reset and started.
The Timer then triggers the Digital Sound Sample Integrator, 2107 , to send its present average value to the Time Average Register, 2108 , which sets the value of the Digital to Analog Convertor Current Sink, 2109 , to produce a calibrated current. The Digital Sound Sample Integrator, 2107 , then immediately starts time averaging the current value of the Digital Sound Sample Register, 2106 , which contains the current value of the sound sample. As each new sound sample is produced by the Digital Sound System Digital Output, 2105 , a new sound sample value is presented to the Digital Sample Register, 2106 , to be time averaged by the Digital Sound Sample Integrator, 2107 . The Digital Sound Sample Integrator integrates over time the series of Digital Samples sent to it by the Digital Sample Register by summing the current value at each time interval. When a new DCC Sample Resets the Timer, 2104 , the total time is read by Digital Sound Sample Integrator, 2107 , which is divided into the current integrated sum value. This new value is then sent to the DAC Calibrated Current Sink and starts integrating the new values from the Digital Sound Sample Register. This process continues over and over as each new DCC Sample Detection is received.
The block diagrams in FIG. 21 are illustrative of the functions necessary to perform the detection, timing, averaging, etc. Depending on the microprocessor and its I/O capabilities, the functions shown could be produced in software.
Analog Sound Summing and Digital Data Communication
An advantage of using current polling of analog sound samples is that the current samples from all locomotives on the track are summed by the command center detector. A big advantage of using Adaptive Averaging is that the DCC Sample current is constant and does not need to be post processed at the command center to determine an average value necessary to reconstruct the waveform. This is also important if it is necessary for the command station to wait until the measurements settle before the value is accepted. Without Adaptive Averaging, the current is not ensured to be constant from any powered locomotive and there is no way to tell when the polled current is a valid indicator of the actual summed sound samples.
Another advantage of constant current is that it may be possible to combine bidirectional digital communication and analog sound sample polling. This method consists of using the calibrated DAC sink current source to produce the sum of the analog sound sample current and a fixed additional digital current value. For instance, the graph in FIG. 22 shows the current generated by the DAC when a digital word is superimposed on the analog sound sample during a 112 uSec DCC sample epoch. The fast digital signal, 2201 , is shown expanded in the bubble, 2202 .
Some advantages of this circuit are:
The locomotive does not need to supply current from its own limited power supply and filter cap for bi-directional communication. This method is compatible with DCC and can also be used in Analog without modification and would not eliminate some of the decoders that are currently incompatible with Lenz's method. This method could also be compatible with Lenz bi-directional communication as long as The Gap and The Drop did not occur at the same time. The current can be larger and more detectable. For BackWave sound, the current representing the analog sound value can be summed for each locomotive on the track. This does not appear to infringe the Lenz patent or other patents listed in his patent. This is a safer design than Lenz's method since it is not necessary to short out one of the lower bridge diodes during bi-directional communication. This technique is relatively immune to resistive track pickups on the locos since the sink current remains the same even if there are a few volts of drop across the pickups. This is particularly important for BackWave sound. One advantage of the Asymmetric waveform is that on the average there is no DC component. However, over shot periods there can be a small DC offset depending on the bit pattern.
Additional Observations:
We could have the step waveform decay to keep up with the decay of the on-board filter capacitor. Also the slant in the waveform would prevent infringing Lenz patent that claims data being transmitted only when the DCC waveform is not changing. Instead of the two disconnect diodes for the calibrated current sink, we could instead have a pass device that would shut off the main bridge so no current flows into the motor or electronics. Transmitting bi-directional acks (acknowledgement pulses) via the calibrated current sink could be done without a step in the waveform. This keeps DCC as it is but unfortunately it means that most existing decoders will not work with the BWA system. The voltage steps will allow most decoders to still be operable with BWA. Bi-directional communication can be used to talk down the cars in a train. It can selectively talk to only those locomotives and cars that have electronics. The idea is that the bi-di gets detected at the base station, which then retransmits the data via changing the steps in the waveform from one voltage to another or by increasing or decreasing the peak DCC voltage bit by bit. Each car or loco on the track will be witness to the changed waveform and hence get the data as it is generated. Instead of a separate upper bridge to power the current sink, we could simply shut off the power to the motor and on-board electronics with a pass device right after the main bridge. The only load connected would be the current sink. This would have the effect of discharging the parasitic inductance quickly since there would be large voltage drop across the pass device during the discharge. The only reason not to use this method is that other non-QSI and early QSI products would continue to provide a load to the power supply when we are trying to read bi-directional acks. The loco can know when it has failed to deliver bi-directional digital acks, since it knows when it has lost power. When this happens the loco can send out a new byte right away without having to wait for the base station to analyze the data and report back via DCC.
Another waveform that is symmetric and can have twice the bi-directional data transmission rate is shown below.
Imagine a pure DCC waveform (without notch) being applied to our Track Driver or booster, which generates the modified track waveform and reads bi-directional current sink data and/or BackWave audio samples from locomotive decoders. Our booster has no way of knowing whether it is a one or a zero. In order to create the above waveform the booster needs to buffer the digital data and then recreate the waveform which would be time delayed from the original as shown in FIG. 24 . It would need to be delayed by the period of one digital zero (100 uSec). The original waveform and its reconstruction by the QSI Booster are shown in FIG. 25 .
Another problem besides the complication of recreating the waveform is that the customer would have to give up using his other boosters; otherwise there could be a short between power districts as the conducting wheels moved over the adjacent track joints between blocks. In fact, the NMRA has a specification that the delay in a booster must not exceed 5 uS.
There are also problems if stretched zeros or Lenz bidirectional are used. A stretched zero means the delay must wait until the zero is finished before recreating it with the notch which can be a delay of 1 mSec. If we agreed to accept stretched zeros, then the minimum delay in our booster would be 1 msec. If “The Gap” is used with Lenz bidirectional, then there is about a 300 uSec period without any DCC transmission while the bi-directional data is read. During this period the Lenz DCC transmitter would be primed ready to accept bidirectional information from Lenz decoders, but the QSI Booster would be sending delayed DCC waveforms during The Gap, preventing any reception.
These problems could be eliminated if the notch were on the leading edge of the reconstructed waveform as shown in the diagram in FIG. 25 . However, this presents another problem with settling time. When the notch starts, the voltage will oscillate or ring for some time due to track inductance. The amount of time it takes to settle depends on the amount of inductance and the voltage change to the start of the notch. If the notch is at the end of the waveform, the voltage changes by ΔV but if the notch is at the beginning, the voltage changes is twice the DCC peak value less ΔV, or 2VA−ΔV. This is a much bigger value and requires a much longer settling time, making it unlikely to read the data. Lenz has a settling spec of 32 uS for “The Gap” which is generated by a voltage change of VA, the peak DCC voltage. If our ΔV is about 2 volts, and the peak voltage about 16 volts, then the corresponding settling time for a notch at the end of DCC waveform is about [2/16] *[32 uS] or about 4.0 uS. If the notch is at the beginning, the settling time is [(2*16−2)/16]*[32 uS] or about 60 uS, which exceeds our 25 uS window.
One way to solve the problem of delaying the waveform until after it is determined if each bit is a one or zero, is to start the notch 25 uS after the waveform has started regardless of its period, and then let the notch extend all the way to the end. This creates a longer notch for zeros than for ones which should not cause any problems and in fact may have some advantages.
Starting the notch 25 uS after each DCC bit starts allows the QSI Booster to meet the NMRA DCC delay spec of 5 uS. This type of waveform is shown in the diagram in FIG. 26 . The top wave is the DCC waveform applied to the booster and the second waveform is the output of the QSI Booster.
The extended notch has the additional advantage of improved sample rate for BackWave sound. The sample 25 uS windows are shown in the second diagram in FIG. 27 . The longer notch for the DCC zero bit allows us to have two 25 uS sample intervals. For illustrative purposes, if we assume the DCC digital “one” pulse is 50 uS rather than 56 uS, we can assume the time interval between sample windows is also 25 uS. This allows us to calculate the approximate sample rate of once every 50 uS or 20,000 kSamples per second. This is actually higher than our intended sample rate for our sound engine (approximately 16 kSamples) which means we could actually send full bandwidth sound via BackWave technology to our TrackDriver or district power module. A sine wave at Nyquist (8 kHz) is shown in the third figure and the sampled value (with full sample window) shown in the last figure. I think it would have been a useful addition to our recent ASIC (Application Specific Integrated Circuit) chip to include a sample-and-hold ADC output for our BackWave sound rather than to have to filter and resample the result at the TrackDriver.
Another advantage of the long sampling period possible with the extended zero Drop is that digital data can be transmitted, possibly up to a full byte. Normally, we had intended to include a nibble for each digital “one” notch. This would allow a full byte per DCC digital bit. This is shown in FIG. 28 where a nibble is shown for the top notch; the second nibble would be transmitted on the bottom notch for the same DCC “one”.
The expanded bubble, 2801 , below the track voltage waveform shows the track current during the period of our bi-directional communication period. The current is shown descending rapidly with the beginning of the notch because the power supply filter cap back biases the Quantum System bridge rectifier. There is a period of time, At D , where the track current oscillates due to the track inductance. After the oscillations die out, the current remaining is the slow audio analog current from the on-board calibrated DAC current sink. The digital current data is superimposed in parallel with its own current sink. The digital data is a series of 4 uS wide current pulses with 4 uS separations. A digital “one” is when the current sink data is present and a digital “zero” occurs when the digital sink current is zero. A similar waveform occurs on the negative notch where the second nibble occurs. The two nibbles make up a single digital word.
This technique allows us to produce specific bi-directional data in concert with the digital packet sent to an addressed locomotive. We are looking for the following kinds of information from a locomotive each time it is addressed: 1) speed (8 bits), 2) simulated brake pressure (8 bits), 3) simulated fuel (8 bits), 4) simulated water level (8 bits), 5) track voltage (8 bits), 6) real motor current (8 bits), 7) real temperature, 8) simulated diesel traction motor current, 9) trip odometer value (8 bits?), 10) cutoff value for steam locos, 11) light settings (16 bits), etc. Not all of this information is necessary during each transmission, but there is nevertheless, a great deal of information we need from each locomotive updated regularly for display on our gauge pack and for control of the individual trains.
One critical piece of information that we do need is the location of each locomotive. One way to do this is to know when a locomotive enters a power district and then to track its location by the value of the trip odometer and the positions of the turnouts. The above bi-directional communication system allows each track driver to know rapidly when a locomotive enters its district since only its bi-directional receiver gets that information when it sends its speed command. It can then send an immediate command to that locomotive to start its trip odometer to track its position.
Since bi-directional information starts only after the locomotive knows that a packet is sent to its address, we will start transmitting after the first two DCC bytes are generated for extended packet formats. This leaves from three to four bytes plus the two to three zero separators (start bits) remaining in the packet for bi-directional transmission in addition to the following idle packet of 20 DCC ones. This is a total of 44 to 52 DCC bits per extended packet or 44 to 52 bytes of bi-directional information.
If we add the extra transmission opportunities for the extended notch on zeros, we can transmit even more information. We know we will have a fixed 5-6 start zero bits for each DCC byte, plus on the average about 20 to 28 zero bits as part of the 5-6 byte commands. This provides a total of 64-80 bytes of bi-directional communication per packet. The baud rate for this would be about 64 kbits/sec assuming a average of 8 k DCC bits per second. In contrast, the Lenz system sends back five bi-directional current pulse communication bytes when the track power is reduced to zero for 300 uS after a under a command to the specified locomotive to send this information back. Since this happens only after a full placket is sent, or a average of 64 bits or once every 6.9 ms, the Lenz data rate is really only about 5.8 kbits/sec.
DCC Notch Transmitter
A block diagram of the DCC control center to generate the notched DCC waveform in FIG. 28 and detection means to measure the analog current samples and embedded digital data is in FIG. 29 .
The notch is inserted into the DCC waveform via the Voltage Drop Module, 2903 , which consists of a series of dropping diodes, a resistor for current sensing, and a FET under microprocessor control to either produce a fixed insertion loss or short circuit when the FET is activated. The Voltage Drop Module, 2903 is shown as a specific embodiment for clarity. In general, there can be other ways of producing the voltage drop needed by this module. A DCC waveform is commonly created from a fixed DC voltage source, 2902 , and an active bridge circuit, 2905 , under microprocessor control to alternate the polarity applied to the track to produce specific DCC commands. In FIG. 29 , the voltage Drop Module is in series with the DC power supply, 2902 , and the Active Bridge Circuit to produce a voltage drop under command from the microprocessor. The DC power supply waveform, 2900 , shows a constant voltage with voltage on the vertical axis versus time on the horizontal axis. The notched waveform, 2906 , shows where the notch is inserted for a DCC one versus a DCC zero; the dotted lines shows the timing marks where the notches are applied. At the same time at alternating timing locations, the microprocessor instructs the bridge rectifier to invert the waveform applied to the track to produce the notched DCC waveform, 2907 , shown at the output of Active Bridge 2905 .
The Voltage Drop Module, 2903 , also contains a sense resistor, R, to produce a voltage drop in proportion to the track current during the time the notch is applied to the waveform. The resistor is sufficiently small to generate only a percentage of the total voltage drop from the dropping diodes. The voltage drop across the resistor, R, is sensed by the current sensing module, 2904 , which may provide the functions of amplification, filtering, and analog to digital conversion to produce a signal appropriate for the microprocessor, 132 . This may include separating the analog sound samples from embedded digital data from the remote objects calibrated loading described earlier. The sampled sounds are based on current samples generated by the remote objects on the layout and since these are analog values, all the current samples from different remote objects are summed in the resistor R. This means that this total current represents the simple sum of the sound samples for all remote objects that are connected to the DCC system. After these samples are processed to produce a continuous sound output, they can be delivered to the Sound Production modules 137 , and 139 to be applied to speakers 138 and 140 . In addition to the sounds sampled from the remote objects on the layout, sounds stored in the Microprocessor, Sound Data and Sound Processing Means, 132 can be added to the recovered sounds to produce extra effects such as cab chatter, dispatcher comments, common internal cab sounds, etc. In addition, the low base sounds not reproduced well in the remote object can be applied to super low base or subwoofer speakers, perhaps located under the layout. The recovered remote object sounds can also be filtered and modified to produce the more muffled sounds for what a locomotive engineer would hear from inside the cab. The cab sounds could also be transmitted back to the user headphones, 111 , through transceiver 131 and 110 . While the user interaction is shown here as happening through a wireless interface, that user interaction could also occur manually on unit 131 . In the manual case, unit 131 and 133 would actually be part of a single unit and wireless connectivity would be absent.
The microprocessor generates the notch and polarity inverting timing for DCC command signals based on signals from the user through transceiver 133 from user walk-around throttle, from direct inputs from Train Control, 134 , or from inputs from other sources through transceiver 131 . These transceivers are shown to be radio linked but could be any kind of transceiver capable of receiving and/or transmitting digital or analog information.
Alternatives to Lenz Asymmetric Waveform Detection
Bernd Lenz has a patent for sending information to locomotives locally that is independent of the locomotive's address. Normally, any command to a locomotive has to be addressed to that locomotive or it must be a broadcast command sent to all locomotives simultaneously. It is not possible to send a local DCC command to a locomotive within an electrically isolated area since by definition, the same DCC signal is ubiquitous; it must be applied to all areas of the layout. This requirement is useful to prevent short circuits as a locomotive moves from one location to another across power districts. In addition, if the user wanted to use DCC to send a local command to a locomotive, he would need to know when that locomotive entered that specific locality and then send the command to that specific locomotive. This is doable but not very practical. So Lenz proposed a method of altering the symmetry of selected DCC bits or groups of bits to from an asymmetric waveform by selectively decreasing the voltage amplitude of DCC peak voltage by a series of diode drops. This method would allow a local transmitter to send data locally at a rate of one bit per DCC bit that could then be detected by the decoder independent of the DCC signal. A typical waveform is show in FIG. 30 where the asymmetric waveform is applied bit-by-bit.
The top waveform shows a typically DCC waveform, in this case a transmission of the byte (1,0,0,1,1,1,0,1) as indicated by the labels, 3001 , at the bottom of the top diagram. The second waveform shows the same DCC being transmitted along with Lenz's asymmetric waveform modifications. Here we have assigned a digital “0” when the waveform for a single DCC bit is asymmetric and a digital “1” when the waveform for a single DCC bit is symmetric as indicated by the labels, 3002 , at the top of the bottom diagram. Here a local digital byte (0,1,0,1,1,0,0,1) is different and independent of the example DCC byte.
The advantage of the Lenz system is detection. The problem with detecting voltage reliably is due to resistive loses along the track and in the locomotive pickups; the voltage can change abruptly due to poor pickups as the locomotive moves, particularly at slow speeds. Lenz's method looks at a measureable voltage difference between the two polarities of a DCC bit rather than specific voltage levels.
Other advantage of Lenz's method is that if a locomotive should straddle two adjacent blocks with different asymmetric waveforms, the method of using diodes to lower the voltage means that the higher voltage bit wins (sort of a wire OR) and while data may be lost, there is no short circuit.
A third advantage is that direction of the asymmetry does not matter since Lenz is only trying to detect if each DCC bit it is symmetric or not. So if a locomotive should move through a reverse loop which will flip the DCC waveform, the decoder will detect the same local data transmissions.
New Methods
A method that does not depend on the waveform asymmetry is shown in FIG. 31 . The top waveform shows a typically DCC waveform, 3101 , in this case a transmission of the byte (1,0,0,1,1,1,0,1), as indicated by the labels, 3102 , at the top of the top diagram. The second waveform shows the same DCC waveform being transmitted along with modification in amplitude. It we assign a reduction in the DCC half bit amplitude as a digital zero and unmodified amplitude as a digital one, then the asymmetric waveform transmitter has sent the following 16 bits of digital information on the above waveform (0,1,1,0,0,1,0,1,1,0,0,1,0,0,1,0), as indicated by the labels, 3103 , at the top of the top diagram.
We are proposing another method to do this that may actually be better. The idea is similar except that instead of lowering the voltage of the DCC amplitude, we would lower the voltage of the notch Drop amplitude. One advantage is that we do not have to carry the full track current for this voltage change. We can still use a series of diodes to lower the voltage but very little current is required. An example of a waveform using this method is shown in FIG. 32 . The top waveform is the same DCC signal as the top waveform in FIG. 31 . The second waveform, 3202 , shows the notched version of the standard DCC waveform with the notch amplitude determined by the digital value of the local transmission. This is generating the same 16 bits of digital information (0,1,1,0,0,1,0,1,1,0,0,1,0,0,1,0) as before in FIG. 31 , except the notch Drop magnitude is used to encode each bit. A large magnitude Drop in notch, indicated by dashed lies, 3203 and 3204 , encodes a digital 0 while a smaller magnitude Drop in the notch, indicated by dashed lies, 3205 and 3205 , encodes a digital 1, as indicated by the digital designation at each notch.
The Lenz patent actually describes a means to provide an asymmetric waveform to the track where the locomotive assigns a digital one or zero to each DCC bit depending on whether it is symmetric or asymmetric. Even though our signal is asymmetric, it is not what we detect. We look at each half bit and we are looking only at the applied voltage in the notch.
Another advantage is that this waveform does not affect the current detected for out bi-directional technology unless the low voltage level is below the voltage compliance of our current sinks.
A simple transmitter and receiver for this type of waveform is show in FIG. 33 . The on-board bi-level notch receiver, 3301 , in the locomotive is shown on the left and is an addition to the normal decoder or sound decoder, such as the examples in FIG. 5 and FIG. 10 . The local bi-level notch transmitter, 3302 , on the right shows an insertion loss block make up of four diode drops with a switch, 3303 , across the diode block under control of the microprocessor1. The insertion loss diode block is in series between the DCC signal source, 3300 , and the track connections. If the switch is closed, there is no additional voltage insertion loss. If the switch is open, there is a voltage drop of about 3 volts to the DCC signal that is applied to the local track block section. Note that the DCC signal that is applied to the local transmitter already includes volt notches. Although the switch is shown as a simple relay, back-to-back FET's with opto-isolation control is also an option.
When the Q-Link sends a command packet addressed to the local bi-level notch transmitter's uP with commands to relay to any locomotive in the local block, the transmitter will applied an addition 3 volt drop to selected notches for transmitting a digital zero or apply no additional voltage drop to selected notches for transmitting a digital one. The outgoing DCC waveform, 3304 , shows the third and fourth and the seventh and eight DCC half bits with the additional Drop in the notch. The added voltage drop is only applied to the notch and does not affect the DCC peak voltage value.
In order to ensure the transmitter applies the additional voltage drop only to the notch and not the DCC peak voltage, a rectifier and notch detector, 3305 , is included. When a notch is detected, this information is relayed to the uP, 3306 , which along the bi-level command from the Q-Link, 3307 , will serially apply the voltage drop to selected notches to transmit the bi-level notch commands to the locomotive decoder.
The receiver includes additional rectifier diodes, 3308 and 3309 , connected to the two track rails, with filter cap, 3309 , to detect the peak DCC voltage signal. A series of dropping diodes, 3310 , that applies a voltage midway between the peak DCC value and the first notch level is applied to the first comparator, 3314 . When a notch of any level occurs, the notch detector will go high. This is shown in the third diagram in FIG. 34 .
Additional diodes, 3311 , apply a second voltage reference to the Notch Level comparator, 3313 , that is half way between the two detected notch levels. If a first notch level occurs (bi-level digital one), then the detector output is high. If a second level occurs (bi-level digital zero), then the comparator goes low. The output of the comparator is shown in the fourth diagram in FIG. 34 , called “Notch Level”. To determine the bi-level digital value, the on-board microprocessor in the locomotive's decoder will detect the concurrence of the notch detection and the notch level. If both are high, then a bi-level digital “one” has occurred as shown in the fifth diagram; if the notch detection is high but the notch level is low, then a bi-level digital zero has occurred as shown in the sixth diagram.
A simple peak detector consisting of a full-wave bridge and filter capacitor is used to measure and hold the DCC peak value. A resistor, R, 3312 , is included to provide current for the dropping diodes and also to bleed the capacitor charge to allow the detector to react to changing DCC peak voltage. The RC time constant is selected to make sure the peak value will react to the variability of the DCC signal due to power losses on the layout and to variation in pickup resistance. I would guess that we do not want the DCC peak value to drop less than two diodes drops during a stretch zero time interval of 12 mSec, which could be the time a notch might exist under this unusual circumstance. Assuming a high DCC voltage of 18 volts and two diode drops of 1.44 volts, the RC time constant would be about 0.143 Seconds. The diode current needs to be about 2 mA, so R needs to be about 10K. C would be about 22 of at 35 volts.
A third comparator, 3315 , is included in the receiver to detect if the applied DCC voltage is lost. If this happens, then the on-board decoder's uP should consider all data that occurs during power loss as invalid, rather than an extended zero which is what the second bi-level comparator would mistakenly read. It should probably discard the preceding detected bit before power lost and the first bit of data after power is restored.
The low output from the third compactor, 3315 , could also be used to alert the on-board decoder's uP that that any current sink bi-directional data is also invalid. Since the current detector at the base station is also aware that the bi-directional data is not present, the on-board uP could re-sink the same digital current data until both the locomotive and the base station agree that the data is finally valid.
The loss of power also means BackWave sound is not being polled as well. It may be possible at the command station to reconstruct or provide a continuation of the low frequency sound by replaying sound stored in the base station memory or some canned sound in memory that would at least continue to provide some base effects. We should assume that the lost power could be a long as 10 ms.
The effect of a period of lost DCC signal is shown in the set of diagrams in FIG. 35 . If the lost signal is due to bad pickups on the locomotive then the DCC signal is still present on the track as shown in the top diagram, 3501 , at time interval, 3508 . The rectified DCC abruptly stops, as shown in the second diagram, 3502 , and the valid data output from the third comparator goes low as shown in the third diagram, 3503 . The notch detector, 3504 , goes high during this period since any drop from the peak DCC level looks like a notch. The notch level, 3505 , also goes low since having the rectified DCC go to zero appears to the second comparator as a second level digital signal. The effect of all this is that no bi-level digital ones are detected, 3506 , and an extended zero is falsely detected, 3507 .
It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims.
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Remote objects, which may include cars and locomotives, rolling stock and or fixed objects in a model railroad layout, convey sound and/or other digital information to a Sound and Control Centers, Local Sound and Control Units and or walk-around throttles to produce sound and operations that enhances the model train experience. Preferably, remote objects may communicate with the sound and control center by wireless means, and over separate communication channels. Sound information and related data from the separate channels can be processed, combined, enhanced or used to fetch additional sounds from memory, in order to drive at least one speaker that is separate from the remote objects. The speaker(s) may be especially advantageous to produce or enhance low frequency audio sounds coordinated with activity at the remote object(s).
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-In-Part of copending application Ser. No. 12/620,225 filed Nov. 17, 2009, which application is a Division of copending application Ser. No. 11/439,547 filed May 24, 2006, the contents of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to a hydrothermally stable alumina, its process of manufacture and its use as a desiccant. More specifically, the present invention relates to a process of treating transition aluminas with a soluble silicon inorganic compound.
The industrial activated alumina adsorbents are produced exclusively by the rapid (flash) calcination of the Bayer process derived aluminum hydroxide (Gibbsite, ATH) powder followed by wet agglomeration and thermal activation. These adsorbents exhibit X-ray diffraction patterns of transition alumina phases. They typically have high BET surface area and good adsorption properties for moisture and other contaminants. This makes them suitable for treatment of various industrial streams.
Most of the adsorption processes using activated alumina require frequent thermal regeneration to remove the adsorbed water and to render the adsorbent active for the next adsorption cycle. In the course of regeneration, the adsorbent experiences the simultaneous effect of elevated temperature, pressure and high moisture content, with hot liquid water percolating through the adsorbent bed, causing hydrothermal aging and loss of adsorption performance.
While the loss of performance over regeneration cycles is small in some desiccant applications and the adsorbent can last thousand of cycles, there are some severe applications resulting in much faster deterioration of performance, which are challenging even for the most stable alumina adsorbents.
Natural gas drying presents the most prominent example of a severe application.
Activated aluminas have been widely used for NG drying for about twenty years. However, the short lifetime caused by hydrothermal aging led to replacement of activated alumina by molecular sieves in most of the units. In spite of this, the inlet portion of the adsorbent bed still needs a protective layer of another adsorbent capable to handle the carryover of liquids and heavy hydrocarbons.
Alumina quickly loses its drying performance when used as protective layer. Hence, there is a need of a hydrothermally stable alumina that will provide both protection against heavy hydrocarbons and additional drying capacity in the equilibrium portion of the bed. It is known that activated alumina is superior to molecular sieves as desiccants at high water concentrations.
Another example of severe desiccant applications are some internally heated dryer for compressed air where a quick deterioration of cyclic adsorbent performance takes place.
In spite of the fact that the need of improvement in the hydrothermal stability of activated alumina has been acknowledged (see the article of R. Dale Woosley “Activated Alumina Desiccants” in A LUMINA C HEMICALS —S CIENCE AND T ECHNOLOGY H ANDBOOK edited by L. D. Hart, American Ceramic Society, 1990, page 241-250), there remains a lack in reported success in preparing hydrothermally stable aluminas.
U.S. Pat. No. 4,778,779 by Murrell et al. discloses a composition comprising discrete particles of bulk silica supported on the external surface of a porous gamma alumina support. Aqueous colloidal silica is claimed as a source of the silica material. Heating above 500° C. in presence of steam is required to disperse at least a portion of the silica over the alumina surface. Preparation of active cracking catalysts, not the improvement of the material stability, is the focus of the invention by Murrell et al. High temperature is needed in order for the alumina and the silica components to form an active aluminosilicate phase.
U.S. Pat. No. 4,013,590 discloses that the mechanical and thermal properties of aluminum oxide are improved through their impregnation with an organic silicon compound dissolved in an organic solvent followed by thermal treatment and controlled oxidation at 500° C. Colloidal silica does not work for this purpose and it is listed in the patent as a “negative” example.
The patent above and other literature sources deal with the BET surface area stability of alumina towards high temperature treatments. The focus of these prior art developments is to delay the alumina phase transformation in high temperature application such as catalysts for exhaust gas treatment. Besides cerium, rare-earth and alkaline-earth elements, silicon was also found to have stabilizing effect on alumina. The paper “Stabilization of Alumina toward Thermal Sintering by Silicon Addition” authored by Bernard Beguin et al., J. OF C ATALYSIS, 127, 595-604, (1991) studies the thermal stability of alumina toward sintering at 1050° to 1220° C. in presence of steam. The authors assume that the hydroxyl groups of alumina react with the silicon containing precursor.
W. R. Grace U.S. Pat. No. 5,147,836; U.S. Pat. No. 5,304,526 and U.S. Pat. No. 6,165,351 cover preparation of silica-containing bayerite alumina which is used to obtain hydrothermally stable silica “stabilized” eta alumina. The latter may be used in preparation of catalytic compositions, especially for the catalytic cracking Sodium silicate is added to the aluminum sulfate, sodium aluminate and magnesium hydroxide which are further mixed and reacted to precipitate the bayerite alumina.
Phosphorus has been also found useful for improving the thermal stability of gamma alumina with regard to sintering and phase transition to alpha alumina (see, for example, the paper from A. Stanislaus et al. “Effect of Phosphorus on the Acidity of gamma—Alumina and on the Thermal Stability of gamma-Alumina Supported Nickel-Molybdenum Hydrotreating Catalysts”, published in A PPLIED C ATALYSIS, 39, 239-253 (1988). In addition to improving the thermal stability, phosphorous alters the acidity of the source alumina.
In 1992, Alcan obtained U.S. Pat. No. 5,096,871 entitled “Alumina-Alkali Metal Aluminum Silicate Agglomerate Acid Adsorbent”. This patent does not refer to improvement of hydrothermal stability of the alumina, but describes the addition of sodium silicate and sodium aluminate in the agglomeration process of alumina powder to form an alkali metal aluminum silicate coating on the internal surfaces of alumina. This alkali metal coating provides the functionality of the agglomerate to serve as an adsorbent of acid substances.
SUMMARY OF THE INVENTION
The present invention greatly improves the hydrothermal stability of alumina desiccants and simultaneously reduces the dust formation with activated aluminas. The modified adsorbent maintains low reactivity and is still suitable for application in reactive streams.
The existing processes for manufacturing activated alumina can easily accommodate the production of the hydrothermally stable alumina described in the present invention. The additives used are inexpensive and no adverse environmental effects are expected. No heat treatment is needed as is the case in the prior art methods to prepare a thermally stable alumina carrier.
The hydrothermally stable alumina desiccants of the present invention will prolong the lifetime and improve the performance of all processes employing thermal regeneration of the adsorbent. Severe regeneration applications such as natural gas drying will especially benefit from this invention.
The transition alumina phases formed by rapid calcinations of aluminum hydroxide have high BET surface area and are very reactive toward water. While this feature is generally useful since it helps forming beads by agglomeration and allow for the fast pick up of moisture during adsorption, in long term, especially at severe conditions of thermal regeneration of the adsorbent, it causes irreversible re-hydration effects, which speed up the aging process of alumina.
It is well known that the hydrothermal aging consists of conversion of the high surface area alumina phases to crystalline Boehmite (AlOOH) which has low BET surface area and is a poor adsorbent. The formation of crystalline Boehmite can be observed with several techniques such as X-ray diffraction, infrared spectroscopy and thermal gravimetric analysis (TGA).
Activation at higher temperature increases somewhat the hydrothermal stability of alumina since it produces alumina phases, which are more stable toward re-hydration. Unfortunately, the BET surface area and the adsorption capacity decline after high temperature calcinations. On the other hand, this approach achieves only a moderate improvement of the hydrothermal stability of alumina.
The present invention provides a process of making a hydrothermally stable alumina adsorbent comprising mixing together a solution containing a silica compound with a quantity of alumina powder to produce alumina particulates, curing the alumina particulates and then activating said cured alumina particulates to produce a hydrothermally stable alumina adsorbent. In the preferred embodiment of the invention, the alumina particulates are treated with water or a colloidal silica solution.
The hydrothermally stable alumina adsorbent comprises silica containing alumina particles comprising a core, a shell and an outer surface. The core contains between about 0.4 to 4 wt-% silica wherein said silica is homogeneously distributed throughout the core and the shell extends up to 50 micrometers from the outer surface towards the core. Typically, the shell contains on average at least two times more silica than the core.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, we found that the stability of the alumina toward rehydration increases significantly by introducing silica in the course of the activated alumina manufacturing process. Surprisingly, no high temperature or activating agents are needed to achieve major improvement of the hydrothermal stability. The term “silica” as used herein refers to a variety of silicon inorganic compounds ranging from colloidal solution of silica to silicic acid or alkali metal silicates. Ullmann's E NCYCLOPEDIA OF I NDUSTRIAL C HEMISTRY , Sixth Edition, Wiley-VCH, 2003, Vol. 32, pages 411-418 lists soluble inorganic silicon compounds that are suitable for the purposes of the invention.
Inorganic silicon compound with limited solubility could be also useful for the purpose of the invention since their solubility enhances upon the presence of transition alumina that has strong affinity to silicon compounds. Thus, the transfer of discrete silicon moieties from the solid inorganic compound through the surrounding liquid towards transitional alumina could be facilitated.
One theory to explain the positive effect of the silica compound is that silica species tend to adhere to the most active sites on the alumina surface, which are prone to fast rehydration. Thus, the silica species will then “deactivate” such rehydration sites by preventing them from further reacting with water upon formation of unwanted hydroxyl compound of alumina.
Although a mere spraying of activated alumina beads with colloidal silica improves the hydrothermal stability, a very strong improvement is achieved when a soluble silica compound is admixed to the nodulizing liquid, which is used to form alumina beads in a rotating tub, for example.
The alumina particulates that are treated in this invention are powders that have a size generally in the range of about 1 to 20 microns, while the alumina beads that are eventually formed would have a formed size of about 500 to 11,200 microns, preferably from about 1,000 to 6,300 microns, corresponding to a particle size according to US Standard screen sizes from 18 to ¼″ mesh. The alumina particulates are subjected to a curing step at a temperature that can range from about 40-70° C., preferably from about 50-65° C. The duration of the curing step is for about 2-48 hours, preferably about 6 hours. It has been found that a curing step for less than 2 hours results in agglomerates being formed that have poor physical strength for use in drying natural gas.
Strong improvement of both hydrothermal stability and dustiness can be attained by forming alumina particulates in presence of silica followed by spraying of the particulates with a colloidal silica solution. The amount of silica can range from 0.1 to 8 wt-%. Addition of less that 5% silica is sufficient to produce a strong improvement in the hydrothermal stability. Normally, addition of about 2% silica is adequate for producing alumina with excellent hydrothermal stability.
The adsorbents of the present invention are a hydrothermally stable alumina adsorbent that comprises silica containing alumina particles comprising a core, a shell and an outer surface The core contains between about 0.4 to 4 wt-% silica with the silica homogeneously distributed throughout the core. The shell extends up to 50 micrometers from the outer surface towards the core and the shell contains on average at least two times more silica than the core.
The adsorbents of the present invention can be used for thermal swing process for drying and purification of gas and liquid streams. Among the most important types of gas streams that can be treated are natural gas, process gases in a variety of industrial processes such as refining and air prepurification in the air separation industry. Pressure swing adsorption processes can be operated with these adsorbents with long-term stability towards rehydration and chemical attack combined with dust free operation.
The following examples illustrate the present invention.
EXAMPLE 1
Flash calcined alumina powder A-300 manufactured by UOP, Des Plaines, Ill., was fed into a 4 feet rotating tub at a rate of 0.8 lbs/min. Water at a rate of 0.5 lb/min was also continuously supplied using a pump and nozzle assembly. Small amount of 30×40 mesh alumina seed was charged first into the nodulizer in order to initiate forming of larger alumina beads. The operation continued until about 50 lbs of material (8×14 mesh nominal particle size) were accumulated. The sample was cured upon storage in a closed container. Subsequently, about 4.5 lbs of the sample was charged into a one feet pot and rotated for about 5 minutes while sprayed with about 120 cc water. The sample was then immediately activated at 400° C. for one hour using an oven with forced air circulation. We refer to this sample as to AlWW where W designates water used in both forming and additional spraying operations.
EXAMPLE 2
The procedure described in Example 1 was used except that 4.5 lbs of alumina particulates were sprayed with a colloidal silica solution (Nalco 1130) to achieve addition of 0.8 mass-% SiO 2 calculated on an volatile free alumina basis. We refer to this sample as to AlWSi where Si stands for the silica used in the spraying operation.
EXAMPLE 3
Flash calcined alumina powder A-300 manufactured by UOP, Des Plaines, Ill., was fed into a 4 feet rotating tub at a rate of 0.8 lbs/min while a pump and nozzle assembly continuously supplied at a rate of 0.51 lbs/min a sodium silicate solution. The solution consisted of 1 part Grade 40 sodium silicate and about 8 parts water. Small amount of 30×40 mesh alumina seed was charged first into the nodulizer in order to initiate forming of larger alumina particulates. The operation continued until about 50 lbs of material were accumulated. The particle size fraction 8×14 mesh was separated and subjected to curing in a closed container. Subsequently, about 4.5 lbs of the sample was charged into a one feet pot, sprayed with about 120 cc water and activated as described in Example 1. The silica content of this sample is about 2.2 mass-% as calculated on a volatile free alumina basis. This sample is referred to as AlSiW.
EXAMPLE 4
Spherical particulates were prepared and cured as described in Example 3. Instead of water, the particulates were sprayed with a colloidal silica solution and activated as described in Example 2. This sample is referred to as AlSiSi in order to show that Si is used in both forming and final spraying stage of material preparation.
The samples were tested for hydrothermal stability in an electric pressure steam sterilizer (All American, model #25×). Six portions, five grams each, of the same sample were placed into the sterilizer and subjected to steam treatment for about 17.5 hours at 17 to 20 psi (122° to 125° C.). The samples were tested after the treatment for Boehmite formation using a FTIR method. A composite sample was prepared by merging the individual samples and BET surface area was determined using the standard method with 300° C. activation step. BET surface area was also measured on the samples before the hydrothermal treatment.
Table 1 compares all the data, including data for other commercial desiccants.
TABLE 1
BET
before
BET after
treatment
treatment
Difference
Sample
Description
m 2 /g
m 2 /g
m 2 /g
% Decrease
AlWW
Example 1
359
181
178
49.6%
AlWSi
Example 2
359
211
148
41.2%
AlSiW
Example 3
317
318
−1
−0.3%
AlSiSi
Example 4
305
321
−16
−5.2%
CA-1
Commercial
343
200
143
41.7%
alumina
CA-2
Commercial
360
200
160
44.4%
alumina
SCA
Commercial
340
264
84
24.7%
Si coated
alumina
SA
Commercial
677
512
165
24.4%
silica
alumina
Table 1 shows that introducing colloidal silica helps to increase the hydrothermal stability—compare AlWW to AlWSi sample and the SCA sample to CA-2 sample (SCA is prepared by silica coating of alumina beads). However, a strong increase of the hydrothermal; stability is observed when Si is introduced while forming particulates—Examples 3 and 4. The samples AlSiW and AlSiSi have a higher BET surface area than do the fresh samples after hydrothermal treatment.
Table 2 shows that spraying with colloidal silica is needed to reduce the dustiness of the Si nodulized alumina particulates. Nodulizing in presence of an inorganic silica compound, such as sodium silicate, followed by spraying with colloidal silica allows for strong improvements in both hydrothermal stability and dustiness.
The dustiness was measured using turbidity measurements as practiced for alumina and other adsorbents.
TABLE 2
Turbidity
Sample
Description
NTU Units
AlWW
Example 1
44.0
AlWSi
Example 2
10.6
AlSiW
Example 3
107.0
AlSiSi
Example 4
35.4
The data suggests that introducing up to 2-3% SiO 2 with the nodulizing liquid would strongly increase the hydrothermal stability of alumina. Treatment with colloidal silica to add additionally 1-2% SiO 2 is then needed since the Si nodulized material tends to be dustier than the water nodulized alumina.
Sodium silicate was used herein because it is cheap and readily available. Other silica compounds may be used.
A possible advantage of an alkali metal silicate is that it contains an alkali metal, which can “neutralize” some acid sites should active aluminosilicate form upon thermal treatment.
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The hydrothermal stability of transition aluminas used as adsorbents and catalyst carriers is improved through their treatment with a soluble silicon inorganic compound such as sodium silicate wherein the silicon compound is mixed with the alumina powder at the production stage of forming particulates by liquid addition. The silicon containing particulates are activated by heating at a temperature lower than 500° C. and treated, before or after the thermal activation, by a colloidal silica solution to produce a hydrothermally stable, low dust alumina. The total silica content of the final product is typically less than 5 mass-%.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a configurable umbrella which can be converted into different shapes having a rib assembly which includes a rigid portion and a flexible portion that provides non-uniform flex strength of the ribs.
2. Description of the Related Art
A conventional umbrella typically has a cloth covered, dome shaped canopy that is symmetrical to a central pole and is supported by ribs that are secured to the pole and radiate outward. The ribs are evenly spaced around the pole and their cantilevered outer portions are equally flexed. Each rib is exactly the same and all are operated in unison via a single slide on the pole. In operation the umbrella is opened to its functional configuration or closed for storage by collapsing the ribs against the pole.
Conventional ribs of an umbrella have the same flex strength since each rib is formed of the same material and construction. The cantilevered portion of a conventional rib is composed of one material and is constructed with uniform thickness throughout its length. Thus, the flex strength of any rib is uniform throughout its cantilevered length. Accordingly, all conventional ribs share a common curvature profile when pressure is applied along the rib length. The curvature rate peaks in the first third of the distance from the fixed end to the free end, declines almost to zero in the middle third, and the third nearest the free end is essentially straight.
An open conventional canopy holds its intended shape since each rib of the umbrella is flexed in the same manner, the canopy is symmetrical to the pole, the cantilevered portions are the same length and the canopy cover is contoured to fit the flexed ribs. When these conditions are met the restraining force of the fabric and the restoring force of the flexed ribs can be sufficiently in equilibrium throughout the canopy to hold its shape. Conventional umbrellas have the shortcoming that if any of the above-described conditions are not met the ribs will not fit the fabric contour because they will seek equilibrium outside their intended positions, and the canopy will not hold its shape.
U.S. Pat. No. 5,505,221 describes a modification to the typical dome configuration of an umbrella with off-center support. The umbrella is symmetrical along a central vertical plane rather than the pole. Ribs of differing lengths are used to form a canopy having an elongated dome. A similarly shaped umbrella is described in Italian patent number 0372882. U.S. Pat. No. 4,838,290 describes a hat shaped umbrella with asymmetric properties, having cantilevered rib portions of differing lengths.
U.S. Pat. Nos. 5,307,827 and 5,355,903 issued to one of the inventors of this disclosure describe a dual function asymmetric umbrella. The primary embodiment of these patents is an umbrella in which the configuration can be altered to form a shade for auto windshield interiors. Ribs are unevenly spaced around the pole having cantilevered portions of differing lengths. The canopy has a flattened center in order to fit against a windshield and does not have a conventional dome shape.
In the closed position all ribs of the dual function umbrella are folded against a collapsed pole. From the closed position the umbrella can be opened and latched in either of two positions, each producing a different canopy configuration. In one open position, some of the ribs are partially extended and some are fully extended causing the canopy configuration to be approximately rectangular so it can be placed against the inner surface of a vehicle windshield as a shade. In the other open position all ribs are fully extended to produce an oval canopy to function as a conventional rain umbrella. The ribs that can be either partially or fully extended are referred to as “multiple position ribs.” Their outer portion can be extended or folded by moving two slides on the pole. The other ribs are conventionally constructed and operated. The multiple position rib inner portion supports and controls the outer flexible portion using a push bar that runs the length of a girder from the pole to a piston housed at the other end of the girder. The piston is connected to the rib by a hinge. The above-described dual function umbrella has several shortcomings such as: the multiple position rib has a limited range of motion; the multiple position rib lacks the rigidity to hold a fully extended rib firmly in place; the use of multiple position ribs and conventional ribs in the same umbrella causes canopy surface unevenness; push bars used in the multiple position rib are vulnerable to damage; when the umbrella is to be used as a car shade four ribs are fully opened to extend the canopy horizontally which makes it difficult to place against the windshield if the entire upper surface of the dashboard is not flat; and the rib construction poses a sizing problem for the car shade umbrella in that one size umbrella fits a limited number of vehicles and is either too large or too small for most windshields.
Conventional rib construction causes the rib tips of umbrellas to be inflexible and therefore hazardous when the canopy is being opened or is in use. It is well known that the rib tips can cause eye and other injuries. This disadvantage has always been considered inherent to umbrellas and inescapable.
It is desirable to provide an umbrella which can be varied in shape and provide improved stability, safety and reduced vulnerability to damage.
SUMMARY OF THE INVENTION
The present invention provides a range of umbrella shapes and configurations for increasing umbrella utility and safety. The umbrella includes rib assemblies each formed of an inner support assembly attached to an outer cantilevered assembly. The inner support assembly is rigid and the outer cantilevered assembly is flexible. The cantilevered assembly can have non-uniform flex strength. The umbrella can include a plurality of multiple position ribs and single position ribs each formed of the rib assembly extending radially from a pole. The multiple position ribs can be secured in either an extended or folded position when the umbrella is in use and the remaining single position ribs are extended.
The present invention provides rib assemblies with varied cantilevered rib flex strength within a rib or from rib to rib as needed to produce equilibrium between the restoring force of the ribs and the restraining force of the umbrella's canopy cover. It has been found that in asymmetrical shaped canopies the restraining force of the cover against the flexed ribs is not uniform along the length of a rib or from rib to rib. Accordingly, the flex strength of conventional ribs is not able to hold the asymmetrical shaped canopy cover in its intended shape.
The flex strength profile of each rib of an umbrella required for canopy equilibrium is a function of the canopy cover's stretch properties and the desired shape of the canopy. The present invention includes rib assemblies including outer cantilevered portions having flex strength profiles to achieve the following configurations: umbrellas with asymmetric domes in which flex strength profile varies between ribs; flattened or spherical dome shaped umbrellas in which the required curvature of a rib is constant or increases with distance from the fixed end; and umbrellas with soft rib tips in which flex strength is reduced at the rib ends while rib to fabric equilibrium is maintained in the rest of the canopy.
Flex strength properties that change along the length of a rib are achieved by changing the cross sectional characteristics along its cantilevered length, or by using multiple materials to form the cantilevered portion. More specifically, the cantilevered rib portions can be formed of a graduated or tapered cross sectional area of a rib formed of a single material; a rib formed in at least two segments with each segment having a different cross sectional area; a rib formed in segments with each segment formed of a material of different flex strength; and a rib formed in segments with at least one segment having a different cross sectional profile, such as that of a coiled or flat spring.
The structure of a multiple position rib allows the umbrella to be capable of at least two open positions. The multiple position rib includes a two-part telescoping girder to strongly support a hinged outer cantilevered portion of the rib. The multiple position rib is controlled by a hub slide assembly moveable on the umbrella pole. Compared to the multiple position ribs described in U.S. Pat. Nos. 5,307,827, and 5,355,903, the present invention has the advantages of reducing the number of parts, holding the ribs more firmly, allowing the ribs to be controlled through a greater range of motion, and allowing the ribs to be subjected to less damage.
Conventionally, the ribs of an umbrella fold toward the pole. The folded outer portion of a rib normally points toward the pole. However if only some ribs of an umbrella are partially folded while the others remain fully extended, the canopy cover will restrict and alter the direction of the folding portions which can bend the ribs. In the present invention, the outer portion of the multiple position rib is hinged to a swiveling pivot joint to allow the rib to be partially folded while others remain fully extended.
The present invention allows the umbrella to be latched temporarily while partially open. This permits the operator to position the umbrella on a dashboard so that the single position ribs are free to open fully against the windshield. A latched partially open position also affords a person leaving a vehicle more immediate rain protection than otherwise possible.
The rib construction of the present invention also provides increased rib tip flexibility without compromising overall stability. Flexible rib ends have the advantages of the ability to compress temporarily part of the umbrella's perimeter surface area, thereby an umbrella can be opened in doorways too narrow for conventional umbrellas, the ability for allowing the user to avoid opening the umbrella in the rain; the ability of its flexible rib ends to bend on contact with the door's frame and remain clear of the door path, since if they do not encounter the door's frame they will assume their intended shape in the windshield; and the ability to flex when contacting a person or object which is especially beneficial in confined or crowded areas such as busy sidewalks for improved safety. Accordingly, the umbrella construction makes it possible for one size to fit most windshields. In addition, the umbrella has the advantage that persons seated next to one another in an open stadium can fold a portion of the umbrellas to allow the umbrellas to be used without intruding on each other.
Umbrellas are widely used as promotional items. Corporations and other organizations purchase umbrellas with their name or logo imprinted on the canopy cover and redistribute them as a means of advertising. The present invention enhances the promotional value of umbrellas because flattened canopy surface areas provide a larger viewable area for logos and other promotional art than conventionally domed surfaces. This is especially true for using the umbrella as a car shade because its flattened surface is readily and fully viewable not only when it is in use as a rain umbrella but also when it is used as a car shade.
These and other features of the invention can be further understood with reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of the umbrella of the present invention which can be used as a vehicle shade showing a cut away pole and hub slide assembly with one multiple position rib without a canopy cover. The umbrella is open and the rib is extended in an open position.
FIG. 2 is an exploded side view of a swivel joint and assembly shown in FIG. 1 .
FIG. 3A is a perspective view of the hub slide assembly shown in FIG. 1, the upper and lower sections of split hub are adjacent to one another.
FIG. 3B is a perspective view of a the hub slide assembly shown in FIG. 1, the upper and lower sections of the split hub are separated.
FIG. 3C is a perspective view of the hub slide assembly shown in FIG. 1 .
FIG. 4 is a cut away view of two hub slide leaf latches of the split hub slide when the umbrella is in a first open position.
FIG. 5 is a cross-sectional view of the umbrella when the umbrella is in a second open position wherein a multiple position rib is in a folded position.
FIG. 6 is a cross-sectional view of the umbrella shown in FIG. 1 when the umbrella is in a closed position.
FIG. 7A is a top plan view of a canopy used with FIG. 1 with all ribs extended in the first open position.
FIG. 7B is a side elevational view of the canopy shown in FIG. 7 A.
FIG. 8A is a top plan view of a canopy used with FIG. 1 in a second open position, the umbrella is open with four single position ribs extended and four multiple position ribs folded.
FIG. 8B is a side elevational view of the canopy shown in FIG. 8 A.
FIG. 9 is a side view of an alternate embodiment of this invention having a flattened dome and flexible skirt.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
During the course of this description like numbers will be used to identify like elements according to the different figures which illustrate the invention.
FIGS. 1-8 illustrate an umbrella having a flattened canopy surface with two open positions and a closed position which can be used as a modified car shade in accordance with the teachings of the present invention. The umbrella includes at least one multiple position rib and at least one single position rib. Alternately, the umbrella can be formed of all multiple position ribs. FIGS. 7A-7B show a top and side view of a first open position in which all multiple position ribs are extended. The umbrella in this position takes the form of a conventional umbrella. FIGS. 8A-8B show a top and side view of a second open position in which the single position ribs are fully extended and the multiple position ribs are partially extended. In the second open position, the single position ribs extend laterally and the multiple position ribs extend vertically. The umbrella in this form takes the form of a shade screen. The canopy can have a desired canopy shape such as a quadrilateral, rectangle or trapezoid so that the shade screen can fit readily against the inner surface of a vehicle windshield. In the closed position all ribs are folded against a pole of the umbrella.
FIG. 1 illustrates umbrella 10 comprising pole 11 and multiple position rib assembly 12 . Multiple position rib assembly 12 comprises inner support assembly 14 and outer cantilevered assembly 16 . Inner support assembly 14 has a rigid structure and outer cantilevered assembly 16 has a flexible structure. Inner support assembly 14 comprises girder rod 18 , girder sleeve 20 , control strut 22 , link hinge 24 , beam 26 , link rod 28 and swivel pivot joint 30 . Girder sleeve 20 is moveable to be telescoping with girder rod 18 . Girder sleeve 20 is slotted to receive link hinge 24 . Girder sleeve 20 is connected to control strut 22 with pivot 17 .
Link hinge 24 connects girder rod 18 to beam 26 . End 21 of link hinge 24 is pivotally connected to girder rod 18 . End 25 of beam 26 is pivotally connected to end 23 of link hinge 24 . End 25 of beam 26 is also pivotally connected to link rod 28 .
Outer cantilevered assembly 16 comprises inner rib section 34 , outer rib section 36 , rib hinge 38 and end cap 39 . End 33 of inner rib section 34 is attached to rib hinge 38 . End 35 of inner rib section 34 is attached to outer rib section 36 . Preferably, outer rib section 36 is formed of a coil spring. Upon contact with an object (not shown), outer rib section 36 bends towards pole 11 , thereby altering the shape of outer cantilevered assembly 16 and a canopy (not shown) attached thereto. After contact is terminated, outer rib section 36 returns to its original position. Inner rib section 34 can be formed of a larger cross section area than outer rib section 36 for changing the flex strength along the length of outer cantilevered assembly 16 . Alternately, the inner rib section 34 and cantilevered section 36 can be integral formed as a single tapered rib.
End cap 39 fits over end 37 of outer rib section 36 . End cap 39 can be formed of a resilient material.
Rib hinge 38 is pivotally attached to link rod 28 as shown in FIG. 2 . Rib hinge 38 is also pivotally attached with swivel pivot joint 30 to girder sleeve 20 . Swivel pivot joint 30 swivels rib hinge 38 and girder sleeve 20 .
Beam 26 is perpendicular to pole 11 when umbrella 10 is in the first open position, as shown in FIG. 1 . Since FIG. 1 excludes a canopy cover, inner support assembly 14 and outer cantilevered assembly 16 form a straight line perpendicular to pole 11 as it would prior to attaching the canopy cover. In this first open position, rib hinge 38 rests on girder sleeve 20 for rigidity to help prevent canopy inversion in high wind conditions.
Broken line 32 shown in FIG. 1 illustrates a curvature profile of outer cantilevered assembly 16 when attached to a fabric canopy cover (not shown). The rate of curvature of broken line 32 increases with distance from the secured end of outer cantilevered assembly 16 which comprises inner rib section 34 attached to rib hinge 38 . Preferably, inner rib section 34 is tapered to have a smaller width as the distance increases from rib hinge 38 for providing flex strength that decreases with distance from rib hinge 38 in order to achieve equilibrium with the restraining force of the canopy fabric. The flex strength profile of each rib of an umbrella required for canopy equilibrium is a function of the canopy cover's stretch properties and the desired shape of the canopy.
In an alternate embodiment, inner rib section 34 is formed of a different material than the material used for outer rib section 36 . Preferably, inner rib section 34 is formed of a material having greater flex strength than the material of the outer rib section 36 . For example, inner rib section 34 can be formed of a nylon material filled with glass fibers or other stiffening fillers and outer rib section 36 can be formed of unfilled nylon.
Inner support assembly 14 is coupled to fixed hub 40 and hub slide assembly 42 . End 27 of beam 26 is pivotally connected to pole 11 by fixed hub 40 . As illustrated in FIGS. 3A-3C, hub slide assembly 42 is comprised of base hub 43 , base hub shaft 44 , split hub 46 , base hub toggle lock 48 , hub separator spring 50 , sleeve 52 , and two split hub leaf latch assemblies 54 , 56 . Hub slide assembly 42 slides along the pole 11 . Split hub 46 slides along base hub shaft 44 . End 19 of girder rod 18 is pivotally connected to base hub 43 . Split hub 46 is comprised of upper section 45 and lower section 47 . Lower section 47 of split hub 46 is pivotally attached to end 31 of control strut 22 of multiple position rib assembly 12 . Sleeve 52 preferably is formed of a steel lining and provides for hub slide assembly 42 to interface with pole 11 .
Base hub toggle lock 48 secures hub slide assembly 42 at any position along pole 11 when base hub toggle lock 48 is extended horizontally. Movement of base hub toggle lock 48 upward or downward from the horizontal against base hub shaft 44 disengages hub slide assembly 42 to allow movement of hub slide assembly 42 . Hub separator spring 50 is positioned between upper section 45 of split hub 46 and base hub 43 . Hub separator spring 50 accelerates the downward movement of upper section 45 when upper section 45 is unlatched. Hub separator spring 50 compresses when upper section 45 is latched.
The position of lower section 47 of split hub 46 on base hub shaft 44 determines whether the umbrella 10 opens to either the first open position shown in FIG. 1 or the second open position shown in FIG. 5 . In the first open position, lower section 47 of split hub 46 is secured adjacent to upper section 45 of split hub 46 , as shown in FIG. 3 A. In the second open position, lower section 47 of split hub 46 is separated from upper section 45 of split hub 46 , as shown in FIG. 3 B. When lower section 47 is secured at the top of base hub shaft 44 with leaf latch 54 while the umbrella is opening umbrella 10 is placed in the first open position in which multiple position rib assemblies 12 are fully extended. When lower section 47 is not secured at the top of base hub shaft 44 , umbrella 10 is placed in the second position with multiple position rib assemblies 12 in a folded position when the umbrella 10 is opened.
Split hub leaf latch assemblies 54 and 56 are used respectively to latch and unlatch lower section 47 of split hub 46 and upper section 45 of split hub 46 . Referring to FIG. 4, each split hub leaf latch assembly 54 , 56 comprises leaf spring 60 , plunger 62 , plunger spring 64 , and latch spring 66 . Leaf spring 60 is received in cavity 67 in the slide portion 44 of base hub 43 .
Hub leaf latch assemblies 54 and 56 automatically release respectively lower section 47 and upper section 45 of split hub 46 when the base hub shaft 44 moves from upper section 70 to lower section 72 of pole 11 . Upper section 70 of pole 11 has a larger diameter D 1 than the diameter of lower section D 2 . When plunger 62 passes from the larger diameter D 1 of upper section 70 of pole 11 to the smaller diameter D 2 of lower section 72 of pole 11 , plunger 62 is pushed against lower section 72 by plunger spring 64 . Movement of plunger 62 depresses leaf spring 60 and allows split hub 46 to pass over it because plunger spring 64 overrides lighter latch spring 66 . Latch spring 66 maintains outward pressure on the leaf spring 60 . Hub leaf latch assemblies 54 and 56 can also be manually operated to release lower section 47 and upper section 45 of split hub 46 by depressing leaf spring 60 .
FIG. 5 illustrates multiple position rib assembly 12 of umbrella 10 in the second open position. Lower section 47 of split hub 46 is separated from upper section 45 of split hub 46 . Control strut 22 extends vertically. Outer cantilevered assembly 16 is folded towards pole 11 .
FIG. 6 illustrates multiple position rib assembly 12 of umbrella 10 in the closed position. Lower section 72 of pole 11 is telescoped within upper section 70 of pole 11 . In this closed position, inner support assembly 14 and outer cantilevered assembly 16 collapse to fold against pole 11 . Beam 26 is folded against upper section 72 , link rod 28 is pivoted against beam 26 . A portion of girder rod 18 and girder sleeve 20 also rest against beam 26 . Inner support assembly 14 rests against girder sleeve 20 and the control strut 22 . Button lever and pole extension release mechanism 80 locks umbrella 10 in the closed position. Hub slide assembly 42 is received in cavity 82 of handle 84 .
In operation, upward movement of the base hub 43 on pole 11 opens umbrella 10 into the first open position shown in FIG. 1 . Downward movement of the base hub 43 on pole 11 closes umbrella 10 into the closed position shown in FIG. 6 . Umbrella 10 is closed from either the first open position or the second open position by pulling split hub upper section 45 to its lowest position on base hub shaft 44 which causes base hub toggle lock 48 to unlock hub slide assembly 42 . Continuation of the downward pulling motion moves base hub 43 over pole extension latch 58 to collapse lower section 72 of pole 11 inside upper section 70 of pole 11 .
To open umbrella 10 to rain position shown in FIG. 1, the user depresses button lever and pole extension release mechanism 80 and pushes upward on lower section 47 of split hub 46 . The upward motion raises both upper section 45 and lower section 47 of split hub 46 to their highest position on the base hub shaft 44 to be engaged by leaf latch assemblies 54 , 56 . The upward motion also places hub slide assembly 42 at the top of upper section 72 of pole 11 . Hub slide assembly 42 can be secured in place by raising base hub toggle lock 48 . Opening umbrella 10 to the second open position is achieved in a similar manner except that the user pushes upward on upper section 45 of split hub 46 . Lower section 47 of split hub 46 remains near the bottom the base hub shaft 44 when upper section 45 is secured by leaf latch 56 .
In one embodiment, the flex strength of outer cantilevered assembly 16 of at least one multiple position rib assembly can be different than the flex strength of the outer cantilevered assembly 16 of any of the other rib assemblies.
FIGS. 7A and 7B illustrate umbrella 10 having multiple position rib assemblies 12 and single position rib assemblies 90 extended horizontally. Canopy cover 92 is in the first open position. Preferably, umbrella 10 includes four multiple position rib assemblies 12 and four single position rib assemblies 90 . Single position rib assemblies 90 are identical in construction to the multiple position rib assembly 12 except that pivot joint 30 does not swivel. Canopy 92 can be attached to multiple position rib assemblies 12 and single position rib assemblies 90 with canopy tie down straps 94 . Girder rods 18 of all eight preferred multi-position rib assemblies and single position rib assemblies can be attached pivotally to the base hub 43 . Upper section 45 of split hub 46 can be pivotally attached to control struts 22 of each of the four preferred single position is rib assemblies 90 . Lower section 47 of split hub 46 can be pivotally attached to control struts of each of the multiple position rib assemblies 12 .
Horizontal panel 96 of canopy cover 92 extends between each pair of single position rib assemblies 90 . Vertical panel 97 of canopy cover 92 extends between each pair of multi-position rib assemblies 12 . Corner panel 98 of canopy 92 extends between an adjacent single position rib assembly 90 and a multi-position rib assembly 12 . Center mount screw cap 99 secures canopy 92 to pole 11 .
FIGS. 8A and 8B illustrate umbrella 10 including canopy cover 92 in the second open position. Single position ribs 90 extend horizontally and the multiple position rib assemblies 12 are vertical.
When the umbrella 10 is in the second open position the outer cantilevered assembly 16 of four single position rib assemblies 90 have less curvature than in the first open position. When the multiple position rib assemblies are folded in the second open position the perimeter of canopy cover 92 is smaller than it is in the first open position, relaxing canopy 92 pressure on the four single position rib assemblies 90 causing them to flatten. Because outer rib section 36 is a flexible spring that will bend on contact with a car door's frame, umbrella 10 can fit windshields several inches narrower than the width of umbrella 10 .
FIG. 9 illustrates a soft-skirted rain umbrella. This embodiment is conventional in purpose and operation. Rib placement and symmetry are also conventional. However, conventional rib design and construction are improved by this embodiment to soften the rib ends of the umbrella. As illustrated by FIG. 9 outer dome 102 is flattened and rib curvature rate accelerates at outer cantilevered portion 104 of ribs 106 . Outer cantilevered portion 104 comprises inner section 107 , outer section 108 and end cap 110 . Inner section 107 is conventionally constructed with a uniform cross sectional profile. Outer section 108 is formed of a flexible coil spring with sufficient strength to maintain canopy 112 intended shape in use. End cap 110 can be formed of a resilient material.
It is to be understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments which can represent applications of the principles of the invention. Numerous and varied other arrangements can be readily devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention.
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The present invention relates to umbrellas having various canopy shapes which shapes can be altered during use. A multiple position rib formed of a telescoping rib girder in combination with a hub slide assembly with multiple hubs allow the umbrella to be opened to two or more functional positions. An embodiment is an umbrella that can be used as a car shade having two open canopy configurations. In a first open position, all multiple position ribs are in an extended position so that the umbrella serves as a conventional rain umbrella. In a second open position, at least one of the multiple position ribs is folded to allow the umbrella to fit inside a vehicle windshield thereby serving as a sun shade. The multiple position rib can be formed of a rigid inner support assembly and a flexible outer cantilevered assembly. Flex strength properties of the outer cantilevered assembly can be varied within a rib and between ribs to provide a stable frame for certain unconventionally shaped umbrellas, including domes with flattened centers, asymmetric rib configurations, and ribs of differing lengths. Flex strength properties of the outer cantilevered assembly can be also varied to increase the flexibility of rib ends without compromising open canopy integrity. On contact rib ends can bend down toward the pole altering the shape of the canopy perimeter. The rib ends can return to their original positions when contact is terminated.
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BACKGROUND
The invention relates to pallet systems, and in particular, pallet systems that facilitate loading and unloading, and limit the shifting of loaded items.
Pallets are used to ship loads of one or more items that are placed and secured onto pallets. Smaller items may be shipped by packaging the items into larger packaging units, which are then loaded onto the pallets. For example, to ship a large quantity of loose or fragile items such as eggs, the items may be arranged in stackable trays, and the stacked trays are loaded onto the pallet.
A pallet loaded with items is often wrapped for shipment to secure the load, sometimes using rigid end boards.
SUMMARY
In general, in one aspect, the invention features a pallet system for supporting a load of at least one tray having side supports. The pallet system includes a pallet having at least one pair of parallel guide rails raised above a top surface of the pallet, each pair of guide rails configured to be straddled by side supports of a tray.
Advantageous embodiments of the invention include one or more of the following features. The space between each pair of guide rails is substantially open. The guide rails are raised above the level of a weight bearing area of the top surface of the pallet.
The pallet system includes at least one end stop on the top surface of the pallet, each end stop positioned to limit longitudinal movement of a tray loaded on the pallet. The pallet system includes two end plates, configured to be vertically positioned at edges of the pallet at ends of the guide rails. Each end plate has an inside surface shaped to complement contours of the end surfaces of the tray. The pallet system includes end plate holders for securing the first and second end plates. In one example, the end plate holders are notches in the guide rails.
The pallet system includes a pallet base comprising a conventional pallet and a pallet cap securely fitting onto the pallet base to form the pallet, the top surface of the pallet cap forming the top surface of the pallet.
In general, in another aspect, the invention features a stacked pallet, including a pallet, having at least one pair of parallel guide rails raised above its top surface, and trays stacked in layers on the pallet, wherein each tray of the first layer has side supports straddling a pair of guide rails on the pallet.
Advantageous embodiments of the invention include one or more of the following features. The stacked pallet further includes end plates secured to the stacked trays. For example, wrapping secures the end plates to the stacked trays. Adjacent trays in the first layer of the stacked trays are laterally interlocked by the guide rails straddled by the adjacent trays. Within each layer of trays, the trays laterally interlock.
In general, in another aspect, the invention features a method of loading a pallet by providing at least one pair of raised parallel guide rails on a top surface of a pallet and forming a first layer of trays by sliding each tray onto the pallet along a pair of guide rails.
Advantageous embodiments of the invention include one or more of the following features. The method provides at least one end stop on the top surface of the pallet, wherein a tray is slid along a pair of guide rails until its front surface contacts an end stop.
The method forms a stack of trays by repeatedly sliding trays over trays already on the pallet. Trays of the stack are laterally interlocked. The method secures end plates to the stack of trays. When secured, an end plate has an inside surface facing an outside surface of the stack of trays. This inside surface is contoured to complement the outside surface of the stack of trays. Securing end plates to the stack of trays is achieved in one example by wrapping the end plates to the stack of trays.
Among the advantages of the invention are one or more of the following.
The pallet system restricts both the lateral and longitudinal movement of items loaded onto the pallet.
Vertically positioned end plates at both pallet edges at ends of the guide rails further restrict the longitudinal movement of items on the pallet. The pallet system provides enhanced stability when loaded and wrapped.
The pallet allows trays to be slid on and off, and is suitable for automated loading and unloading of the trays.
Other features and advantages of the invention will become apparent from the following description and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1. is a perspective view of a pallet system in accordance with the invention.
FIG. 2 is a perspective view of a pallet cap in accordance with the invention.
FIG. 3 is a cross-sectional view of a loaded pallet system in accordance with the invention.
FIG. 4 is a top detail view of a pallet cap in accordance with the invention.
FIG. 5 is a top view of a loaded pallet in accordance with the invention.
FIG. 6 is a cross-sectional view of a stack of end plates in accordance with the invention.
FIG. 7 is a cross-sectional view of the pallet cap of FIG. 2.
FIG. 8 is a cross-sectional view of a stack of pallet caps in accordance with the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, a pallet system based on a conventional pallet, referred to here as the pallet base 10, is fitted with a pallet cap 20 to provide a pallet in accordance with the invention. Alternatively, the pallet may be a single integrated unit. The pallet system can be used, for example, to ship trays 30 such as those described in pending U.S. Pat. No. 5,816,406, which is incorporated by reference.
FIG. 1 shows in an exploded view the relationship of elements of the pallet system. Several layers of trays are loaded onto the pallet, and the end plates 40a, 40b are respectively positioned at front and back ends of the load to help secure the load of trays 30 to each other and to the pallet, as well as to protect the ends of the trays and provide rigidity to the stack of trays. Typically, though not shown in FIG. 1, the entire load including the end plates 40a, 40b is wrapped with a film, either manually or using a machine and methods such as those described in U.S. Pat. Nos. 5,423,163 and 5,531,327.
The pallet base 10 is a conventional plastic pallet. As shown, a conventional plastic pallet typically has pockets 11 that elevate the top surface of the pallet and provide recesses 12 which allow the pallet to be handled by standard equipment such as forklifts. Because the exact shape and placement of the pallet pockets 11 may vary among pallet models and manufacturers, the pallet cap 20 has pockets 21a, 21b, 21c customized to fit within the pockets 11 of a particular pallet 10.
The pallet cap pockets 21a, 21b, 21c position the pallet cap 20 on the pallet base 10 and provide support for the weight of loads borne by the pallet cap 20. In the configurations shown in FIGS. 1 and 2, the pallet cap pocket 21a extends to the base of the pallet base pocket 11 to provide support and has ribbed walls to provide structural strength. Pallet cap pockets 21b and 21c are provided primarily for positioning the pallet cap 20 on the pallet base 10.
Referring to FIG. 2, the pallet cap 20 has raised, parallel guide rails 22, which are labelled in pairs 22a, 22b, 22c. The number of guide rails 22 may vary, depending on the size and shape of the trays to be loaded. For example, FIG. 2 shows a pallet cap 20 having three pairs of guide rails 22a, 22b, 22c, designed for a load three trays wide, as is illustrated in FIG. 1.
Referring to FIG. 3, each tray 30 has side supports 31. The pairs of guide rails, such as pair 22c, are sized and spaced so that when such a tray is loaded directly on the pallet cap 20, the tray side supports 31 closely straddle a pair of guide rails, thus constraining the lateral movement of the tray 30. The guide rails 22c help to position the tray 30, and as shown, also help to interlock adjacent trays 30. In FIG. 3, the top surface of pallet cap 20 is substantially open between the pair of guide rails 22c, which enables the open space to be used for packing items, in this case, eggs. The guide rails 22c avoid contact with the tray 30 or its load, and are raised above the level of the weight bearing surface of the pallet cap 20.
The arrangement of parallel guide rails allows trays to be loaded onto the pallet by sliding the tray over a pair of guide rails from a front end of the pallet towards a back end, along the direction of the arrow 25 of FIG. 2. The opposite action may be used to unload trays from the pallet. The motion of a tray may be stopped by optional end stops 23, which are positioned at the outer edges of each pair of guide rails 22, towards the back end of the pallet. These end stops 23 limit the longitudinal movement of the trays parallel to the guide rails 22. FIG. 4 provides a more detailed illustration of the positions of the end stops 23.
When a pallet is loaded and ready to be prepared for shipping, the end plates 40a, 40b are vertically positioned at the front and back ends of the pallet as shown in FIG. 1. End plates are vertically positioned in one or more of the notches 24 found at both ends of each guide rail 22 (FIGS. 2 and 4). The notches 24 act as end plate holders for holding the end plates in position.
End plates may provide greater stability to a stack of trays by being shaped to complement the shapes of the trays loaded onto the pallet. For example, FIG. 5 shows a top view of a pallet loaded with trays 30 shaped like those described in U.S. Ser. No. 08/673,698. The end plates 40a, 40b are shaped to complement the contour of the tray edges.
Referring to FIGS. 1 and 5, the end plates 40a, 40b at both ends of the pallet may be substantially identical or interchangeable. The end plates may be narrower than the pallet or load, as shown, and advantageously may be approximately 22 inches wide which allows them to be used with pallets and loads of different widths. For example, a pallet having an industry standard size of 40 inches by 48 inches can support layers having two rows of three trays, where the trays are egg trays of a standard size, such as is disclosed in U.S. Ser. No. 08/673,698. However, pallets of other sizes can be used, including 24 inches by 48 inches (supporting two rows of two trays) and 36 inches by 24 inches (supporting one row of three trays). The end plates 40a, 40b shown in FIGS. 1 and 5 may be used for pallets having any of these dimensions. FIG. 6 illustrates a cross-section of a stack of end plates 40. As shown, the end plates may be shaped such that they nest within one another, which saves space when they are not being used.
The components of the pallet system may be made of various materials. For example, the pallet cap and end plates may be comprised of a plastic such as polypropylene or ABS plastic.
Each component can be manufactured by a variety of methods. For example, FIG. 7 illustrates a cross-section of the pallet cap 20 shown in FIG. 2, created from a sheet of plastic having a thickness approximately in the range of 0.08-0.125 inches. The plastic sheet can be formed by methods such as thermo forming, rotomolding, and injection molding. The same thickness and methods apply to the end plates as well.
Various features of the pallet system may be customized for its intended load. For example, the pallet system exemplified in the figures is customized for supporting egg trays described in U.S. Ser. No. 08/673,698. As shown in FIG. 3, because the trays 30 carry eggs, which are fragile and have rounded bottoms, the side of the guide rails 22 likely to contact the portion of the tray 30 holding an egg have a slanted edge. At their widest point, the guide rails 22 have a width of approximately 0.5 inches, and at their highest point, have a height of approximately 0.25 inches. As shown, the guide rails 22 do not support the weight of the trays and their load. Because the trays 30 are designed to be slid into place on the pallet, end stops 23 are provided at only one end of the guide rails 22, as shown in FIG. 2. Because the trays 30 have honeycomb-shaped edges, the inside surface of the end plate is shaped to complement this surface, as shown in FIG. 5. The raised portions of the end plate have a height of approximately 0.5 inches and a width of approximately 1 inch. As shown in FIG. 6, the end plates 40 are shaped such that they are interchangeable and nest within one another, which saves space when they are not being used. FIG. 8 illustrates that the pallet cap 20 is also shaped to allow several pallet caps to be nested within one another.
Other embodiments are within the scope of the following claims. For example, the pallet may be a single integrated unit rather than a pallet cap fitting onto a conventional pallet. The sizes and positions of pallet cap pockets may vary. The length and height of guide rails, as well as the number of guide rails on a pallet may vary. The shapes and positions of the end stops may vary. For example, end stops may be implemented as a continuous rail across the pallet surface. End stops may be provided at both ends of the pallet if trays are not slid onto the pallet. End plates may have a different width, such as the full width of a pallet.
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A pallet system for supporting a load of at least one tray having side supports includes a pallet, having at least one pair of raised parallel guide rails on its top surface, each pair of guide rails configured to be straddled by side supports of a tray. The pallet may be loaded by sliding trays onto the pallet, and lateral movement of a tray loaded onto the pallet is limited by the pair of guide rails that it straddles.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2002-195955, filed Jul. 4, 2002, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a radio terminal, a communication control method and a computer program utilizing, for example, a radio connection technique “Bluetooth (trademark)”.
[0004] 2. Description of the Related Art
[0005] Recently, much attention has been paid to Bluetooth (trademark). Components needed for Bluetooth are less expensive than those needed for a radio LAN, and Bluetooth can be used anywhere in the world, utilizing the 2.4 GHz band.
[0006] In communication terminals utilizing Bluetooth, a virtual COM port (RFCOMM) is generally used for data transmission/reception. Connection via a virtual COM port (RFCOMM connections) is carried out by the following procedure.
[0007] Firstly, a device C starts to execute a Device Discovery procedure for discovering devices existing in the vicinity. In this procedure, the device C broadcasts an Inquiry message, and another device S having received this message returns, to the device C, a response message that includes its own identifier (MAC ID). Thus, the device C can know the identifiers of other devices around it.
[0008] Subsequently, the device C acquires service information (Service Record), utilizing the following procedure based on Service Discovery Protocol (SDP).
[0009] The device C establishes a connection (SDP connection) for acquiring service information with respect to a device discovered by the device discovery procedure, e.g. the device S. After that, the device C requests, to the device S, return of service information relating to a target service. Upon receiving the request, the device S returns this service information to the device C. After receiving the service information from the device S, the device C disconnects the SDP connection. This device discovery procedure and service information acquiring procedure are disclosed in, for example, Jpn. Pat. Appln. KOKAI Publication No. 2001-168881.
[0010] In the above service discovery protocol, however, only one-way transfer of service information is performed by the device S having received a return request, to the device C having made the request, but not vice versa.
[0011] After that, the device C performs a virtual COM port connection, using, as parameters, the identifier (MAC ID) of the device S obtained by the device discovery procedure, and a server channel number stored in the service information obtained from the service discovery protocol. As a result, a RFCOMM connection is established between the devices C and S for data transmission/reception.
[0012] If the device C pre-acquires a device identifier and server channel number as parameters necessary to establish a RFCOMM connection, the above-described procedure for acquiring service information can be omitted. However, in general, users cannot be expected to pre-acquire the parameters of an arbitrary communication device, therefore the above procedure is needed.
[0013] In Bluetooth, to establish an SDP connection or a RFCOMM connection, it is necessary to create a network called a “piconet”, which is formed of one master device and one or more slave devices. Between a master device and slave device that belong to same piconet, the SDP connection and the RFCOMM connection are superposed on a baseband link by a logical link (L2CAP (Logical Link Control and Adaptation Layer Protocol)).
[0014] Thus, a plurality of connections can be simultaneously established between the devices. Further, these connections can be established by either the master or slave device.
[0015] Since connections can be superposed between devices that belong to the same piconet, another connection can be easily established between devices that are communicating with each other via a certain connection. For example, when devices are accessing each other using a virtual COM port and a RFCOMM connection, an SDP connection can also be established therebetween to acquire service information, or another RFCOMM connection can be established.
[0016] However, in general use of Bluetooth, it is often impossible to create a new piconet between a device belonging to a certain piconet, and a device that does not belong to this piconet. In other words, when two devices are linked to each other, it is difficult for a third device to establish a link with one of the already-linked devices. If a link cannot be established, a connection for data transmission/reception cannot be established.
[0017] Therefore, it is difficult for the third device to establish a connection for data transmission/reception with one of those devices.
[0018] The above describes a RFCOMM connection as an example. Service information relating to a destination device is always needed to access it utilizing the Bluetooth profile. For example, in a Personal Area Network (PAN), communication is performed without a RFCOMM connection. However, service information is needed to establish a PAN.
[0019] When portable devices having a communication function are used to perform a certain function, it may be necessary to transmit information from one device to another device. In an electronic conference, for example, material prepared in the form of a file stored in each portable device is distributed to other devices, or message exchange is performed using a chat function.
[0020] However, as described above, service information relating to a destination device is needed to establish a connection for data transmission/reception. Thus, to establish a connection with an arbitrary device to freely execute communication, it is necessary for each device to pre-acquire service information relating to all the other devices.
[0021] It is difficult, however, to establish an SDP connection between a third device and first or second device when the first and second devices are linked for communication. Therefore, it is also difficult to quickly acquire service information. Further, even if an SDP connection can be established, only one-way transmission of service information is executed from the device with which a connection is established to the device that has established the connection. This is inefficient.
BRIEF SUMMARY OF THE INVENTION
[0022] Embodiments of the present invention has been developed in light of the above, and aims to provide a radio terminal capable of quickly acquiring service information necessary to establish a connection with a destination radio terminal, and a communication control method and a computer program enabling a radio terminal to perform such acquisition.
[0023] To satisfy the aim, according to a first aspect of the invention, there is provided a radio terminal corresponding to a first radio terminal associated with a second radio terminal, comprising: a first receiving unit configured to receive a first request issued from the second radio terminal; an establishing unit configured to establish, in response to the first request, a radio link with respect to the second radio terminal; a setting unit configured to set, on the radio link, a connection with the second radio terminal; a detecting unit configured to detect an event in association with the second radio terminal;
[0024] and a first transmitting unit configured to transmit, to the second radio terminal via the connection, a first request message representing that first service information concerning the second radio terminal should be transmitted to the first radio terminal, when the detecting unit detects the event.
[0025] According to a second aspect of the invention, there is provided a communication control method of setting a connection on a radio link between a first radio terminal and a second radio terminal, the communication control method comprising: detecting an event in association with the second radio terminal; transmitting, to the second radio terminal via the connection, a first request message representing that first service information concerning the second radio terminal should be transmitted to the first radio terminal, when the event is detected; and receiving the first service information.
[0026] According to a third aspect of the invention, there is provided a computer program stored in a computer readable medium provided in a first radio terminal associated with a second radio terminal, the computer program comprising: first receiving means for instructing a computer to receive a first request issued from the second radio terminal; first transmitting means for instructing a computer to transmit a second request; means for instructing a computer to establish, in response to one of the first request and the second request, a radio link with respect to the second radio terminal; means for instructing a computer to set, on the radio link, a connection with the second radio terminal; means for instructing a computer to detect an event in association with the second radio terminal; and second transmitting means for instructing a computer to transmit, to the second radio terminal via the connection, a first request message representing that first service information concerning the second radio terminal should be transmitted to the first radio terminal, when the detecting means detects the event.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0027] FIG. 1 is a block diagram illustrating a basic structure example of a radio terminal according to the embodiments of the invention;
[0028] FIG. 2 is a block diagram illustrating a configuration example of a first radio terminal used in a first embodiment of the invention;
[0029] FIG. 3 is a block diagram illustrating a configuration example of a second radio terminal used in the first embodiment of the invention;
[0030] FIG. 4 is an example of an alien-machine service information table;
[0031] FIG. 5 is an example of a non-alien-machine service information table;
[0032] FIG. 6 is a flowchart illustrating a procedure example for operating a first radio terminal used in the first embodiment of the invention;
[0033] FIG. 7 is a flowchart illustrating a procedure example for operating a second radio terminal used in the first embodiment of the invention;
[0034] FIG. 8 is a block diagram illustrating a configuration example of a third radio terminal used in the first embodiment;
[0035] FIG. 9 is a block diagram illustrating a configuration example of a radio terminal used in embodiments (2-1) to (2-3) of the invention;
[0036] FIG. 10 is a flowchart illustrating a procedure example for operating a radio terminal A used in the embodiment (2-1);
[0037] FIG. 11 is a flowchart illustrating a procedure example for operating a radio terminal B used in the embodiment (2-1);
[0038] FIG. 12 is another example of the service information table for the originator terminal;
[0039] FIG. 13 is a flowchart illustrating a procedure example for operating a radio terminal B used in the embodiment (2-2);
[0040] FIG. 14 is a flowchart illustrating a procedure example for operating a radio terminal B used in the embodiment (2-3);
[0041] FIG. 15 is a block diagram illustrating a configuration example of a radio terminal used in embodiments (3-1) to (3-3) of the invention;
[0042] FIG. 16 is a flowchart illustrating a procedure example for operating a radio terminal A used in the embodiment (3-1);
[0043] FIG. 17 is a flowchart illustrating a procedure example for operating a radio terminal B used in the embodiment (3-1);
[0044] FIG. 18 is a flowchart illustrating a procedure example for operating a radio terminal B used in the embodiment (3-2); and
[0045] FIG. 19 is a flowchart illustrating a procedure example for operating a radio terminal B used in the embodiment (3-3).
DETAILED DESCRIPTION OF THE INVENTION
[0046] Embodiments of the invention will be described with reference to the accompanying drawings.
[0047] FIG. 1 shows a basic structure example of a radio terminal according to the invention.
[0048] Reference numeral 11 denotes the stacked structure of the Bluetooth protocol, and reference numeral 12 a Bluetooth module.
[0049] The stacked structure 11 comprises a host control interface (HCI) as the lowest layer, a logical link (L2CAP) as the second lowest layer, a virtual COM port (RFCOMM) and Service Discovery Protocol (SDP) as the second highest layer, and an application layer as the highest layer. Actually, a radio terminal 1 comprises processing units corresponding to the respective layers, i.e., an HCI processing unit 11 , L2CAP layer processing unit 112 , RFCOMM processing unit 113 , SDP processing unit 114 and application layer processing unit 115 .
[0050] Further, the Bluetooth module 12 comprises a link manager (LM) 121 , link controller (LC) 122 , radio frequency circuit (RF) 123 and antenna 124 .
[0051] RFCOMM or SDP data is basically processed in the following manner.
[0052] If the radio terminal 1 is an originator or transmitter, the RFCOMM processing unit 113 or the SDP processing unit 114 generates RFCOMM data or SDP data when necessary, and the L2CAP layer processing unit 112 converts the data into a packet and supplies the packet to the Bluetooth module 12 via the HCI processing unit 111 . The Bluetooth module 12 , in turn, executes fragmentation on the packet using the link controller 122 , modulates it using the radio frequency circuit (RF) 123 , and outputs it from the antenna 124 .
[0053] On the other hand, if the radio terminal 1 is a destination or receiver, processing is performed in the order reverse to the above, with the result that a signal from the transmitter is finally received and processed by the RFCOMM processing unit 113 or the SDP processing unit 114 .
[0054] In the description below, the above-mentioned application is not always limited to one directly operated by a user via an interface, such as a graphical user interface (GUI). For example, the application may be so-called middleware that is not directly operated by a user but operates in accordance with an instruction from an application existing in an upper layer.
[0055] Descriptions will now be given of radio terminals having configurations similar to the above.
[0056] Processing units used in the radio terminals can be realized only by hardware such as semiconductor chips. Alternatively, a CPU may be installed in the radio terminals so that part or the whole processing can be realized by software. In the case of realizing the processing using software, the software may be recorded in a recording medium installed beforehand in a computer, or in a computer-readable recording medium, such as a CD-ROM, or may be acquired from a communication medium, such as the Internet.
[0057] Firstly, a first embodiment will be described.
First Embodiment
[0058] FIG. 2 shows a configuration example of a first radio terminal employed in a first embodiment. As seen from FIG. 2 , a radio terminal 2 a comprises a transmission/reception unit 21 for transmitting and receiving a request to transmit service information (service information transmission request message) or service information, to and from any other radio terminal, an alien-machine service information storage 22 for storing service information received from any other radio terminal, and a service information acquisition unit 23 for requesting any other radio terminal to transmit service information.
[0059] FIG. 3 shows a configuration example of a second radio terminal used in the first embodiment. As seen from FIG. 3 , a radio terminal 2 b comprises a transmission/reception unit 21 for transmitting and receiving a request to transmit service information transmission request or service information, to and from any other radio terminal, a non-alien-machine service information storage 24 for storing service information for the second radio terminal itself, and a service information transmission unit 25 for transmitting the service information to any other radio terminal in accordance with a request therefrom.
[0060] The configurations of FIGS. 2 and 3 correspond to the stacked structure of FIG. 1 in the following manner. The transmission/reception unit 21 corresponds to all layers not higher than the L2CAP layer in FIG. 1 (i.e., 12 , 111 , 112 ), the service information transmission unit 25 and service information acquisition unit 23 correspond to the SDP layer ( 114 ), and the non-alien-machine and alien-machine service information storages 24 and 22 correspond to the application layer ( 115 ). The element corresponding to the RFCOMM layer 113 in FIG. 1 is not referred to in this embodiment therefore not shown in FIG. 2 or 3 .
[0061] In the second radio terminal 2 b of FIG. 3 , information concerning services that the terminal 2 b itself can provide is stored as a non-alien-machine service information table in the non-alien-machine service information storage 24 . FIG. 4 shows an example of the non-alien-machine service information table. In the example of FIG. 4 , the non-alien-machine service information table stores, in relation to each other, the type and name of each service and a server channel number used for establishment of a connection for data transmission/reception.
[0062] In the first radio terminal 2 a of FIG. 2 , information concerning services provided by other radio terminals is stored as an alien-machine service information table in the alien-machine service information storage 22 . FIG. 5 shows an example of the alien-machine service information table. In the example of FIG. 5 , the alien-machine service information table stores, in relation to each other, the terminal identifier (MAC ID) of any other radio terminal, the type and name of each service provided by any other radio terminal, and a server channel number used for establishment of a connection for data transmission/reception.
[0063] The operation of the first embodiment will be described.
[0064] FIG. 6 illustrates a procedure example for operating the first radio terminal 2 a , and FIG. 7 illustrates a procedure example for operating the second radio terminal 2 b.
[0065] In the embodiment, it does not matter what type of method radio terminals use to acquire the identifier of any other radio terminal. Assuming that the first radio terminal 2 a has already acquired the identifier (MAC ID) of another radio terminal, e.g., the second radio terminal 2 b , using, for example, a known device discovery procedure, no description will be given of the procedure of acquiring the identifier.
[0066] When a link (radio link) has been established between the radio terminals 2 a and 2 b (step S 1 ), the transmission/reception unit 21 supplies the service information acquisition unit 23 with an event signal indicative of the establishment of a link. Upon receiving the event signal, the service information acquisition unit 23 supplies a service information transmission request to the radio terminal 2 b via the transmission/reception unit 21 (step S 2 ). At this time, if no SDP connection is established between the terminals 2 a and 2 b , it is done so.
[0067] Assume that the type of service as a target of request is written in the service information transmission request. A user or certain application may set the type of service, or all types of service registered in the non-alien-machine service information table may be written. Further, another method may be used.
[0068] When the transmission/reception unit 21 of the radio terminal 2 b has received the service information transmission request (step S 11 ), it transfers the request to the service information transmission unit 25 . The service information transmission unit 25 , in turn, refers to the non-alien-machine service information storage 24 , thereby determining whether or not the non-alien-machine service information table stores a service corresponding to the type of service requested by the service information transmission request. If the table stores the corresponding service, the name, server channel number, etc., of the service are acquired, thereby creating service information with the name and server channel number corresponding to the requested type of service, or service information indicating that there is no requested type of service (step S 12 ). After that, the service information transmission unit 25 transmits the service information to the radio terminal 2 a via the transmission/reception unit 21 (step S 13 ).
[0069] When the transmission/reception unit 21 of the radio terminal 2 a has received the service information (step S 3 ), it transfers the information to the service information acquisition unit 23 . The service information acquisition unit 23 stores the service information into the alien-machine service information table (step S 4 ). If the unit 21 has received service information indicating that there is no requested type of service, this information may be stored in the area of the alien-machine service information table, to which the identifier of the radio terminal 2 a and the service name and server channel number corresponding to the service type are assigned.
[0070] At the above step S 1 , it does not matter whether connection is established from the radio terminal 2 a or from the radio terminal 2 b , or for what purpose connection is established. For example, the radio terminals 2 a and 2 b may be linked for a RFCOMM connection or SDP connection. At any rate, when the radio terminals 2 a and 2 b are linked, the radio terminal 2 a attempts to acquire service information is from the radio terminal 2 b.
[0071] As previously mentioned, it may be difficult to establish the SDP connection between a certain terminal and another. It is needed to be linked in the lower layer for establishing the SDP connection. Since it is difficult to be linked in the lower layer, it may be difficult to establish the SDP connection. On the other hand, in the embodiment, an SDP connection is superposed on the already established link. Therefore, service information can be acquired quickly and reliably.
[0072] The first radio terminal 2 a shown in FIG. 2 does not have the service information transmission unit 25 or non-alien-machine service information storage 24 , while the second radio terminal 2 b shown in FIG. 3 does not have the service information acquisition unit 23 or alien-machine service information storage 22 . In other words, the first radio terminal 2 a is assumed to be a client that only enjoys services, and the second radio terminal 2 b is assumed to be a server that only provides services. However, a device may function as a server in relation to a certain service, or may function as a client in relation to another service. Another device may function as a server and client in relation to a single service. In light of this, it is desirable that a radio terminal be provided with both the structures of the first radio terminal 2 a and the second radio terminal 2 b.
[0073] FIG. 8 shows a third radio terminal 2 c provided with both the structures of the first radio terminals 2 a and the second radio terminals 2 b. By virtue of this structure, the third radio terminal 2 c can perform both the operations of the first radio terminals 2 a and second radio terminals 2 b. For example, if the third radio terminal 2 c serves as a client in relation to a certain service, it executes the operation of the first radio terminal 2 a. If it serves as a server in relation to a certain service, it executes the operation of the second radio terminal 2 b.
[0074] The embodiments (2-1) and (2-2) will now be described.
Embodiment (2-1)
[0075] FIG. 9 shows a configuration example of a radio terminal 3 according to embodiment (2-1). The radio terminal 3 comprises a transmission/reception unit 21 for transmitting and receiving a request to transmit service information transmission request or service information, to and from any other radio terminal, an alien-machine service information storage 22 for storing service information received from any other radio terminal, a service information acquisition unit 23 for requesting any other radio terminal to transmit service information, a non-alien-machine service information storage 24 for storing service information for the second radio terminal itself, a service information transmission unit 25 for transmitting the non-alien-machine service information to any other radio terminal in accordance with a request therefrom, and an application 26 .
[0076] Each part of the radio terminal 3 of FIG. 9 basically has a function similar to that of a corresponding part shown in FIG. 2, 3 or 8 . Further, the application 26 is not limited to one directly operated by a user via an interface, but includes middleware.
[0077] The configuration of FIG. 9 corresponds to the stacked structure of FIG. 1 in the following manner. The transmission/reception unit 21 corresponds to all layers not higher than the L2CAP layer in FIG. 1 (i.e., 12 , 111 , 112 ), the service information transmission unit 25 and the service information acquisition unit 23 correspond to the SDP layer ( 114 ), and the non-alien-machine 24 and the alien-machine service information storages 22 correspond to the application layer ( 115 ). The element corresponding to the RFCOMM layer 113 in FIG. 1 is not referred to in this embodiment therefore not shown in FIG. 9 .
[0078] The operation of this embodiment will be described.
[0079] A description will be given, referring, as a terminal A, to a radio terminal 3 that issues a service information transmission request to transmit service information, and referring, as a terminal B, to a radio terminal 3 that receives the service information transmission request.
[0080] FIG. 10 shows a procedure example for operating the radio terminal A used in the embodiment, and FIG. 11 shows a procedure example for operating the radio terminal B used in the embodiment.
[0081] Firstly, the application 26 of the terminal A designates the identifier of the terminal B and the type of service to be acquired, thereby requesting the service information acquisition unit 23 to acquire service information from the terminal B (step S 21 ). The service information acquisition unit 23 of the terminal A transmits the request to transmit service information corresponding to the designated service, to the terminal B via the transmission/reception unit 21 (step S 22 ). If no SDP connection is established to the radio terminal 2 b , it is superposed on the current link between the terminals. Further, when the terminals A and B are linked, an SDP connection is superposed on the link, whereas when they are not linked, they are linked before the establishment of an SDP connection.
[0082] Upon receiving the service information transmission request (step S 31 ), the transmission/reception unit 21 of the terminal B transfers it to the service information transmission unit 25 . The service information transmission unit 25 , in turn, refers to the non-alien-machine service information table in the non-alien-machine service information storage 24 , thereby determining whether or not a service corresponding to the service type requested by the service information transmission request is registered in the non-alien-machine service information table. If it is registered, its name and sever channel number, etc. are acquired, thereby creating service information containing the name and server channel number corresponding to the requested type of service, or service information indicating that there is no corresponding service (step S 32 ). After that, the service information transmission unit 25 transmits this service information to the terminal A via the transmission/reception unit 21 (step S 33 ).
[0083] Upon receiving the service information (step S 23 ), the transmission/reception unit 21 of the terminal A transfers the information to the service information acquisition unit 23 . The service information acquisition unit 23 stores the service information into the alien-machine service information table (step S 24 ).
[0084] On the other hand, in this embodiment, the service information transmission unit 25 of the terminal B supplies the application 26 with an event signal indicating that the service information transmission request from the terminal A. Upon receiving this event signal, the application 26 instructs the service information acquisition unit 23 to acquire service information from the terminal A.
[0085] After that, processing similar to (but in a reverse order) the processing executed by the terminal A to acquire service information from the terminal B is performed at the steps S 22 -S 24 and S 31 - 533 . As a result, the terminal B acquires service information from the terminal A and stores it into the alien-machine service information table (steps S 34 -S 36 and S 25 -S 27 ). However, since the application 26 of the terminal A has already instructed the service information acquisition unit 23 to acquire service information from the terminal B, it does not again issue an instruction to acquire service information from the terminal B even when it has received, from the service information transmission unit 25 , an event signal indicating that a service information transmission request has been received from the terminal B. This is only one different point.
[0086] In the procedures shown in FIGS. 10 and 11 , the service information transmission unit 25 of the terminal B generates an event signal indicative of the reception of a service information transmission request, when it has actually received the request. However, this event signal may be generated at another point in time. For example, the event signal may be generated when establishment of an SDP connection for generation of a service information transmission request is detected.
[0087] Further, in the procedure of FIG. 11 , the terminal B transmits a service information transmission request at a step S 34 after transmitting service information at a step S 33 . Alternatively, the terminal B may transmit a service information transmission request before the transmission of service information, for example, when it receives a service information transmission request from the terminal A, or when it detects establishment of an SDP connection by the terminal A. In this case, for example, transfer of service information from the terminal A to the terminal B is performed parallel to transfer of service information from the terminal B to the terminal A.
[0088] Further, it is not always necessary for a terminal to provide service information to another terminal. Terminals do not establish a connection for data transmission/reception with terminals that provide no service information. However, even such terminals that provide no service information can establish a connection for data transmission/reception with other terminals. In such terminals, the non-alien-machine service information storage 24 stores no information. If, in this state, the service information transmission unit 25 receives a service information transmission request from another terminal, it is sufficient if a message that there is no service is returned to the terminal.
[0089] In the above processing, the terminal A establishes an SDP connection with the terminal B for acquiring service information from the terminal B, and disconnects the SDP connection after finishing the acquisition of the service information from the terminal B. However, even after the completion of the acquisition of the service information, the SDP connection may be kept until the terminal B finishes acquisition of service information from the terminal A. Further, the SDP connection may be continued a period of time after the completion of the acquisition of service information from the terminal B. This can avoid a case where the terminal B delays in processing an event signal indicative of the reception of a request to transmit service information, and the connection between the terminals A and B is cut by the terminal A before the application 26 of the terminal B instructs the service information acquisition unit 23 to acquire the service information from the terminal A.
[0090] In the prior art, when the terminal A has acquired service information from the terminal B, it can establish a connection for data transmission/reception with the terminal B. In this state, however, the terminal B cannot establish a connection for data transmission/reception with the terminal A, since it does not acquire service information from the terminal A. On the other hand, in the embodiment, when the terminal A has acquired service information from the terminal B, the terminal B has simultaneously acquired service information from the terminal A.
[0091] Accordingly, the terminal A can establish a connection for data transmission/reception with the terminal B, and the terminal B can also establish a connection for data transmission/reception with the terminal A.
[0092] The radio terminal 3 of the embodiment may have the same function as that of the terminal A or B, or both of the functions.
Embodiment (2-2)
[0093] A radio terminal example according to embodiment (2-2) is the same as that of the embodiment (2-1) shown in FIG. 9 , and each part of the embodiment (2-2) has basically the same function as a corresponding part in the embodiment (2-1).
[0094] Further, operations of the terminal A of the embodiment (2-2) is basically the same as that of the terminal A of the embodiment (2-1).
[0095] In this embodiment, the points different from the embodiment (2-1) will be mainly described.
[0096] In the terminal B of the embodiment (2-2), the steps S 34 -S 36 are not executed if the terminal B has already acquired service information from the terminal A.
[0097] Specifically, as in the embodiment (2-1), when the transmission/reception unit 21 of the terminal B has received a request to transmit service information, it transfers the request to the service information transmission unit 25 , which, in turn, supplies the application 26 with an event signal indicative of the reception of the service information transmission request from the terminal A. Upon receiving this event signal, however, the application 26 determines whether or not there is service information relating to the terminal A and the same service as requested. If there is no such service information, the application 26 requests the service information acquisition unit 23 , to acquire the service information from the terminal A, as in the embodiment (2-1). On the other hand, if there is the service information, nothing is done.
[0098] If the terminal B does not execute the steps S 34 -S 36 , the terminal A accordingly does not execute the steps S 25 -S 27 .
[0099] In the above-described embodiment (2-1), upon receiving an event signal indicating that a request to transmit service information has been supplied from the terminal A, the application 26 of the terminal B always requests the terminal A to transmit service information. On the other hand, in this embodiment, if the terminal B has ever acquired service information from the terminal A, it does not request again the terminal A to transmit service information. Thus, in this embodiment, useless communication in which the same service information is acquired again and again is avoided.
[0100] However, it may not be preferable to continue to use old service information, since service information is changed if the service provided by a terminal is changed. In light of this, time information may be added to the information stored in the alien-machine service information table, which enables appropriate information updating. FIG. 12 shows such an alien-machine service information table. In this example, a field for writing the acquisition time of service information is added in the table shown in FIG. 5 .
[0101] In this case, the terminal B operates in substantially the same manner as the above, but in a different manner only when the application 26 of the terminal B receives an event signal indicating that a request to transmit service information has been received from the terminal A.
[0102] FIG. 13 shows an example of this operation.
[0103] Upon receiving the event signal (step S 41 ), the application 26 of the terminal B refers to the alien-machine service information table in the alien-machine service information storage 22 , thereby determining whether or not the table stores service information relating to the terminal A and the same service as requested in the service information transmission request from the terminal A. If the table does not store this service information (step S 42 ), the application 26 instructs the service information acquisition unit 23 to acquire the service information from the terminal A (step S 44 ). Further, if the table stores the service information (step S 42 ), the acquisition time of the service information is compared with the present time. If the service information is determined to be old from the time comparison (step S 43 ), the application 26 instructs the service information acquisition unit 23 to acquire service information from the terminal A (step S 44 ). On the other hand, if the service information is determined not to be old (step S 44 ), nothing is executed.
[0104] As a result, old service information can be appropriately updated.
[0105] The expiration time at which service information is determined old can be changed in accordance with the type of service. For example, concerning a service provided by an application that is frequently activated and terminated, or a service whose content is frequently changed during the operation of an application, the period of validity is shortened. On the other hand, concerning a service provided by a continuously activated application during the operation of a terminal, or a service whose content is not so frequently changed, the period of validity is lengthened. As a result, service information whose content is known not to be so frequently changed is not repeatedly acquired, thereby reducing the degree of useless communication.
Embodiment (2-3)
[0106] A radio terminal example according to embodiment (2-3) is similar to that of the embodiment (2-1) shown in FIG. 9 , and each part of the embodiment (2-3) has basically the same function as a corresponding part in the embodiment (2-1).
[0107] Further, operations of the terminal A of the embodiment (2-3) is basically the same as that of the terminal A of the embodiment (2-1).
[0108] In this embodiment, the points different from the embodiment (2-1) will be mainly described.
[0109] In the terminal B of the embodiment (2-3), it is determined on the basis of the type of service whether or not a request to transmit service information should be generated. If it is not necessary to acquire service information, the steps S 34 -S 36 are not executed.
[0110] Specifically, as in the embodiment (2-1), upon receiving a request to transmit service information, the transmission/reception unit 21 of the terminal B transfers the request to the service information transmission unit 25 . The service information transmission unit 25 , in turn, supplies the application 26 with an event signal indicating that the request to transmit service information has been received from the terminal A. Upon receiving the event signal, the application 26 of the embodiment (2-3) determines whether or not service information concerning the same service as requested in the service information transmission request from the terminal A should be acquired from the terminal A. If it is determined that such service information should be acquired, the application 26 instructs the service information acquisition unit 23 to acquire the service information from the terminal A, as in the embodiment. (2-1), while it is determined that such service information should not be acquired, nothing is executed.
[0111] If the terminal B does not execute the steps S 34 -S 36 , the terminal A accordingly does not execute the steps S 25 -S 27 .
[0112] At this time, the terminal B operates in a manner similar to that described in the embodiment (2-2). However, the terminal B performs a determination procedure different from that shown in FIG. 13 upon receiving an event signal indicating that the application 26 of the terminal B has received, from the terminal A, a request to transmit service information.
[0113] FIG. 14 shows an example of this procedure.
[0114] Upon receiving the event signal (step S 51 ), the application 26 of the terminal B refers to the alien-machine service information table in the alien-machine service information storage 22 , thereby determining whether or not the table stores service information relating to the terminal A and the same service as requested in the service information transmission request from the terminal A. If the table stores this service information (step S 52 ), nothing is done.
[0115] If the table does not store the service information (step S 52 ), the application 26 determines whether or not the service information relating to the same service as requested in the service information transmission request from the terminal A should be acquired from the terminal A (step S 53 ). If it is determined that the service information should be acquired, the application 26 instructs the service information acquisition unit 23 to acquire the service information from the terminal A (step S 54 ). If the service information should not be acquired (step S 53 ), nothing is done.
[0116] For electronic conferences, there is an application, such as a chat application, which enables each of the devices participating in a conference to establish a connection with any other device for data transmission/reception. Further, there is another application for use in, for example, a presentation for distributing a material, which enables only one device as a presenter to establish a connection for data transmission/reception with the other devices as an audience, i.e., which enables only one device to transmit data and treat the other devices as receivers.
[0117] In the former application, each device needs to acquire service information from the other devices, whereas in the latter application, only the device as the transmitter needs to acquire service information from the other devices, but not vice versa.
[0118] The embodiment (2-3) is useful in these two cases, since it discriminates the case where acquisition of service information from peripheral devices is needed, from the case where the acquisition is not needed, thereby enabling service information to be acquired only when necessary. As a result, no extra service information transmission and reception is performed, therefore communication lines can be used efficiently.
[0119] Embodiments (3-1) and (3-2) will be described.
Embodiment (3-1)
[0120] FIG. 15 shows a radio terminal example according to embodiment (3-1). As seen from FIG. 15 , a radio terminal 4 comprises a transmission/reception unit 21 for transmitting and receiving a request to transmit service information transmission request or service information, to and from any other radio terminal, an alien-machine service information storage 22 for storing service information received from any other radio terminal, a service information acquisition unit 23 for requesting any other radio terminal to transmit service information, a non-alien-machine service information storage 24 for storing service information for the radio terminal 4 itself, a service information transmission unit 25 for transmitting the service information to any other radio terminal in accordance with a request therefrom, an application 26 , and a connection establishing unit 27 . In short, the radio terminal 4 of this embodiment is obtained by adding the connection establishing unit 27 to the structure of the radio terminal 3 of the embodiment (2-1) shown in FIG. 9 .
[0121] Each part of the radio terminal 4 of FIG. 15 basically has a function similar to that of a corresponding part shown in FIG. 2, 3 or 8 . Further, the application 26 is not limited to one directly operated by a user via an interface, but includes middleware. The connection establishing unit 27 establishes a connection for data transmission/reception with another terminal on the basis of the information stored in the alien-machine service information storage 22 . The transmission/reception unit 21 transmits and receives a request to transmit service information transmission request or service information, to and from any other radio terminal, and establishes a connection for data transmission/reception with any other radio terminal for data transmission/reception in accordance with a request from the connection establishing unit 27 .
[0122] The configuration of FIG. 15 corresponds to the stacked structure of FIG. 1 in the following manner.
[0123] The transmission/reception unit 21 corresponds to all layers not higher than the L2CAP layer in FIG. 1 (i.e., 12 , 111 , 112 ), the service information transmission unit 25 and service information acquisition unit 23 correspond to the SDP layer ( 114 ), and the non-alien-machine 24 and alien-machine service information storages 22 correspond to the application layer ( 115 ).
[0124] The operation of this embodiment will be described.
[0125] A description will be given, referring, as a terminal A, to a radio terminal 4 that first issues a request to establish a connection for data transmission/reception, and referring, as a terminal B, to a radio terminal 4 that receives the request.
[0126] In this embodiment, assume that when the application 26 of the terminal A establishes a connection for data transmission/reception with the application 26 of the terminal B for communication, the terminal A acquires service information from the terminal B using a certain procedure, for example, the same procedure as employed in the embodiment (2-1). This is because the identifier (MAC ID) of the terminal B and the server channel number contained in the service information of the terminal B are needed for the establishment of a connection for data transmission/reception with the terminal B. However, this embodiment differs from the embodiment (2-1) in that the terminal B does not supply the terminal A with a request to transmit the service information of the terminal A when having received, from the terminal A, a request to transmit the service information of the terminal B.
[0127] FIG. 16 illustrates an operation procedure example of the terminal A in this embodiment, and FIG. 17 illustrates an operation procedure example of the terminal B in this embodiment.
[0128] Firstly, after having acquired service information from the terminal B, the application 26 of the terminal A requests the connection establishing unit 27 to establish a connection for data transmission/reception with the terminal B, using, as parameters, the identifier of the terminal B and the server channel number contained in the alien-machine service information of the terminal B (step S 61 ). The request to establish a connection for data transmission/reception may include the type of service as another parameter, in addition to the device identifier and server channel number. Upon receiving the request to establish a connection for data transmission/reception, the connection establishing unit 27 of the terminal A transfers this request to the connection establishing unit 27 of the terminal B via the transmission/reception units 21 of the terminals A and B (step S 62 ).
[0129] Upon receiving the request to establish a connection for data transmission/reception (step S 71 ), the connection establishing unit 27 of the terminal B returns a response to the request to the terminal A. (step S 72 ), thereby completing the establishment of a connection for data transmission/reception with the terminal A. At this time, the connection establishing unit 27 of the terminal B supplies the application 26 of the terminal B with an event signal indicating that a connection for data transmission/reception with the terminal A has been established.
[0130] Upon receiving the event signal, the application 26 of the terminal B requests the service information acquisition unit 23 to acquire, from the terminal A, service information concerning the type of service corresponding to the server channel number that is related to the above connection establishing request. The service information acquisition unit 23 of the terminal B supplies, via the transmission/reception unit 21 , the terminal A with a request to transmit service information containing the designated service type (step S 73 ). At this time, if no SDP connection is established with the terminal A, an SDP connection is superposed upon the already established connection with the terminal A.
[0131] Upon receiving the service information transmission request (step S 63 ), the transmission/reception unit 21 of the terminal A transfers the request to the service information transmission unit 25 . The service information transmission unit 25 , in turn, refers to the non-alien-machine service information storage 24 , thereby determining whether or not the non-alien-machine service information table stores a service corresponding to the type of service requested by the service information transmission request. If the table stores the corresponding service, the name, server channel number, etc., of the service are acquired, thereby creating service information containing the name and/or server channel number corresponding to the requested type of service, or service information indicating that there is no corresponding service (step S 64 ). After that, the service information transmission unit 25 transmits the service information to the terminal B via the transmission/reception unit 21 (step S 65 ).
[0132] Upon receiving the service information transmission request (step S 74 ), the transmission/reception unit 21 of the terminal B transfers the request to the service information acquisition unit 23 .
[0133] The service information acquisition unit 23 stores the service information into the alien-machine service information table (step S 75 ).
[0134] In the procedures shown in FIGS. 16 and 17 , the connection establishing unit 27 of the terminal B generates an event signal when the establishment of a connection for data transmission/reception has been completed. However, this event signal may be generated at another point in time. For example, it may be generated when a request to establish a connection for data transmission/reception has been received.
[0135] In the above processing, the terminal A establishes a connection for data transmission/reception with the terminal B to access the application 26 of the terminal B, and cuts the connection when communication with the application 26 of the terminal B has been completed. However, the connection may be maintained, even after the completion of communication, until the terminal B finishes acquisition of service information from the terminal A. Further, the connection may be continued a period of time after the completion of the acquisition of service information from the terminal B. This can avoid a case where the terminal B delays in processing an event signal indicative of the reception of a request to transmit service information, and the connection between the terminals A and B is cut by the terminal A before the application 26 of the terminal B instructs the service information acquisition unit 23 to acquire the service information from the terminal A.
[0136] The radio terminal 3 of the embodiment may have the same function as that of the terminal A or B, or both of the functions.
Embodiment (3-2)
[0137] The relationship between the embodiment (3-2) and the embodiment (3-1) is basically similar to that between the embodiment (2-2) and the embodiment (2-1).
[0138] A radio terminal example according to the embodiment (3-2) is similar to that of the embodiment (3-1) shown in FIG. 15 , and each part of the embodiment (3-2) has basically the same function as a corresponding part in the embodiment (3-1).
[0139] Further, operations of the terminal A of the embodiment (3-2) is basically the same as that of the embodiment (3-1).
[0140] In this embodiment, the points different from the embodiment (3-1) will be mainly described.
[0141] In the terminal B of the embodiment (3-2), if service information has already been acquired from the terminal A, steps S 73 -S 75 are not executed.
[0142] Specifically, like the embodiment (3-1), the terminal A establishes a connection for data transmission/reception with the terminal B after having acquired service information from the terminal B, and the connection establishing unit 27 of the terminal B supplies the application 26 of the terminal B with an event signal. In this embodiment, however, the application 26 refers, upon receiving the event signal, to the alien-machine service information table in the alien-machine service information storage 22 , thereby determining whether or not the table stores service information of the terminal A concerning the type of service corresponding to the server channel number that is related to a connection establishing request from the terminal A. If the table does not store the service information, the application 26 instructs the service information acquisition unit 23 to acquire service information from the terminal A. If the table already stores the service information, nothing is performed.
[0143] If the terminal B does not execute the steps S 73 -S 75 , the terminal A accordingly does not execute the steps S 63 -S 65 .
[0144] In the above-described embodiment (3-2), if the terminal B has ever acquired service information from the terminal A, it does not request again the terminal A to transmit service information, as in the embodiment (2-2). Accordingly, also in this embodiment, useless communication in which the same service information is acquired again and again is avoided.
[0145] Also in this embodiment, information can be updated using time information stored in the alien-machine service information table, as in the embodiment (2-2). In this case, the alien-machine service information table may be similar to that of the embodiment (2-2) shown in FIG. 12 .
[0146] The operation of updating information by the terminal B is substantially the same as that in the embodiment (2-2), except for the operation performed when the application 26 of the terminal B receives an event signal indicating that a connection for data transmission/reception has been established by the terminal A.
[0147] FIG. 18 illustrates a procedure example performed in this case.
[0148] Upon receiving the above-mentioned event signal (step S 81 ), the application 26 of the terminal B refers to the alien-machine service information table in the alien-machine service information storage 22 , thereby determining whether or not the table stores service information concerning the type of service corresponding to the server channel number that is related to the above-mentioned connection establishing request from the terminal A. If the table does not store this service information (step S 82 ), the application 26 instructs the service information acquisition unit 23 to acquire the service information from the terminal A (step S 84 ). Further, if the table stores the service information (step S 82 ), the acquisition time of the service information is compared with the present time. If the service information is determined to be old from the time comparison (step S 83 ), the application 26 instructs the service information acquisition unit 23 to acquire service information from the terminal A (step S 84 ). On the other hand, if the service information is determined not to be old (step S 84 ), nothing is executed.
[0149] As a result, old service information can be appropriately updated, as in the embodiment (2-2).
[0150] Further, as in the embodiment (2-2), the expiration time at which service information is determined old can be changed in accordance with the type of service. This enables useless communication to be reduced.
Embodiment (3-3)
[0151] The relationship between the embodiment (3-3) and the embodiment (3-1) is basically similar to that between the embodiment (2-3) and the embodiment (2-1).
[0152] A radio terminal example according to the embodiment (3-3) is similar to that of the embodiment (3-1) shown in FIG. 15 , and each part of the embodiment (3-3) has basically the same function as a corresponding part in the embodiment (3-1).
[0153] Further, operations of the terminal A of the embodiment (3-3) is basically the same as that of the terminal A of the embodiment (3-1).
[0154] In this embodiment, the points different from the embodiment (3-1) will be mainly described.
[0155] In the terminal B of the embodiment (3-3), it is determined from the type of service whether or not transmission of service information should be requested, and if it is not necessary to acquire service information, the steps S 73 -S 75 are not executed.
[0156] Specifically, as in the embodiment (3-1), the terminal A establishes a connection for data transmission/reception with the terminal B after having acquired service information from the terminal B, and the connection establishing unit 27 of the terminal B supplies the application 26 of the terminal B with an event signal. In this embodiment, however, the application 26 determines, upon receiving the event signal, whether or not service information concerning the type of service corresponding to the server channel number that is related to a connection establishing request from the terminal A should be acquired from the terminal A. If it is determined that the service information should be acquired, the application 26 instructs the service information acquisition unit 23 to acquire the service information from the terminal A, as in the embodiment (2-1). If it is determined that the service information should not be acquired, nothing is performed.
[0157] If the terminal B does not execute the steps S 73 -S 75 , the terminal A accordingly does not execute the steps S 63 -S 65 .
[0158] The manner of determination by the terminal B is substantially the same as in the embodiment (3-2) (e.g. FIG. 18 ), except for the operation performed when the application 26 of the terminal B receives an event signal indicating that a connection for data transmission/reception has been established by the terminal A.
[0159] FIG. 19 illustrates a procedure example performed in this case.
[0160] Upon receiving the above-mentioned event signal (step S 71 ), the application 26 of the terminal B refers to the alien-machine service information table in the alien-machine service information storage 22 , thereby determining whether or not the table stores service information concerning the type of service corresponding to the server channel number that is related to the above-mentioned connection establishing request from the terminal A. If the table stores this service information (step S 72 ), nothing is performed. If, on the other hand, the table does not store it (step S 72 ), the application 26 determines whether or not the service information concerning the type of service corresponding to the server channel number that is related to the connection establishing request from the terminal A should be acquired (step S 73 ). If it is determined that the service information should be acquired, the application 26 instructs the service information acquisition unit 23 to acquire the service information from the terminal A (step S 74 ). If it is determined that the service information should not be acquired, nothing is performed.
[0161] As in the embodiment (2-3), the case where acquisition of service information from peripheral devices is needed is discriminated from the case where the acquisition is not needed, thereby enabling service information to be acquired only when necessary. As a result, no extra service information transmission and reception is performed, therefore communication lines can be used efficiently.
[0162] As described above, the radio terminal of the embodiments can promptly acquire service information needed to establish a connection with another radio terminal.
[0163] For example, when the radio terminal of the embodiments has detected establishment of a link between itself and another radio terminal, it acquires service information from the linked radio terminal.
[0164] Thus, service information is promptly and reliably acquired.
[0165] Further, in the embodiments, when a terminal A acquires service information from a terminal B, the terminal B acquires service information from the terminal A. Thus, both the terminals A and B can promptly acquire, from each other, service information needed to establish a connection for data transmission/reception.
[0166] Furthermore, in the embodiments, when, for example, the terminal A establishes a connection for data transmission/reception with the terminal B, the terminal B acquires service information from the terminal A. Thus, the terminal B can promptly acquire the service information of the terminal A.
[0167] The flow charts of the embodiments illustrate methods and systems according to the embodiments of the invention. It will be understood that each block of the flowchart illustrations, and combinations of blocks in the flowchart illustrations, can be implemented by computer program instructions. These computer program instructions may be loaded onto a computer or other programmable apparatus to produce a machine, such that the instructions which execute on the computer or other programmable apparatus create means for implementing the functions specified in the flowchart block or blocks. These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable apparatus to function in a particular manner, such that the instruction stored in the computer-readable memory produce an article of manufacture including instruction means which implement the function specified in the flowchart block of blocks. The computer program instructions may also be loaded onto a computer or other programmable apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer programmable apparatus provide steps for implementing the functions specified in the flowchart block or blocks.
[0168] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A radio terminal corresponding to a first radio terminal associated with a second radio terminal comprises following units. A first receiving unit receives a first request issued from the second radio terminal. An establishing unit establishes, in response to the first request, a radio link with respect to the second radio terminal. A setting unit sets, on the radio link, a connection with the second radio terminal. A detecting unit detects an event in association with the second radio terminal. A first transmitting unit transmits, to the second radio terminal via the connection, a first request message representing that first service information concerning the second radio terminal should be transmitted to the first radio terminal, when the detecting unit detects the event.
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This is a division of application Ser. No. 754,521 filed July 12, 1958, now U.S. Pat. No. 4,648,775.
BACKGROUND OF THE INVENTION
The present invention relates to bodies for refuse pickup trucks and, more particularly, to an improved body incorporating a hopper, a reciprocable packer within the hopper and a refuse collection and compaction tank whose forward end opens into communication with the hopper.
Refuse pickup trucks commonly comprise a truck chassis fitted with a body that is made by a manufacturer other than the maker of the chassis. Federal and local laws impose legal limitations on the gross weight and dimensions of the fully loaded vehicle. Thus, the body builder is commonly faced with the problem of designing a refuse compactor body that will carry the largest possible legal payload within the confines of the body size and gross vehicle weight limits imposed by these laws, so that the refuse hauler will avoid the severe fines imposed on violators, especially of the weight laws.
In the past, in order to maximize the volume of refuse carried per unit of length of the refuse truck, a quadrangular cross section of tank has been commonly used, sometimes to the full width and height allowed by the law. In a variation of the rectangular cross section body, the upper outside corners of the body or tank have been beveled into a six-sided shape. Recognizing that a circular cross section is structurally more efficient than a quadrangular section, some body builders have devised cylindrical refuse compactor bodies. However, these are wasteful of the legally available height and weight and thus inefficient in terms of maximum utilization per unit length (and weight) of the truck chassis. Further, in order to withstand the substantial internal packing pressures involved the cylindrical bodies, like the square bodies, require heavy girth reinforcement at spaced intervals along the length of the body which leads to increased manufacturing expense in view of the necessity of making arcuate girth reinforcement members. Another body that has been devised tapers divergently from the front end towards the rear end while having an octagonal cross sectional configuration. This body is essentially a quadrangular body with flattened corners and because of its tapered construction is expensive to manufacture since the girth reinforcement members at spaced intervals along the length of the bodies are of unequal perimeters and the sheet metal panels defining the facets of the body are tapered.
SUMMARY OF THE INVENTION
The refuse pickup and compactor body for vehicle mounting of my invention has a tank of uniform non-tapered right section throughout its length comprising an irregular polygon, preferably of twelve sides. At spaced intervals along its length the tank is externally girth reinforced by a peripheral assembly of short straight box beam members. Each side wall of the tank comprises a purality of sheets of very high tensile steel, e.g., on the order of 100,000 p.s.i., oriented such that the direction of final rolling of the sheet extends circumferentially, each sheet being moderately bent, no more than about 60 degrees, at circumferentially spaced apart locations to provide the desired number of facets for the side walls of the tank. Adjacent circumferentially extending edges of an adjacent pair of metal sheets are spaced apart sufficiently to define a square joint overlapping a corresponding girth reinforcement for continuous seam welding of the edge of each sheet to the corresponding box beam members. The roof and floor panels of the tank comprise longitudinally extending rectangular sheets of metal. The floor and roof panels have opposite side flanges extending longitudinally, bent no more than about 15°, the bend lines being aligned with the final direction of rolling.
A bubble or clam shell door of congruent cross section configuration is hingedly connected to the rear end of the tank. A forward end of the tank opens into communication with a hopper section of the body assembly which can be either of the top loading or side loading type. In the case of a front and top loading hopper a right section therethrough is geometrically similar to the multifaceted tank except for an upper chute portion, the opposite sides of which constitute a vertically upward extension of the extreme outside opposite side walls of the hopper. The underside of the body and hopper are supported on a laterally spaced pair of longitudinally extending box beams. The polygonal cross sectional configuration of the tank and hopper are so proportioned to the spacing between the support beams that a facet of the cross sectional configuration constituting the floor of the tank and hopper is located lower than the upper face of the supporting beams. The hopper section is fitted with a packer of cross sectional configuration matingly receivable within the hopper. The packer has a solid packing face whose upper edge terminates short of the roof of the tank. A packer follower blade is hingedly connected to the upper edge of the packer and has its upper edge guided in tracks such that when the packer is in the retracted position the blade follower is erected to constitute substantially a continuation of an inclined upper edge portion of the solid packer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is side elevational view of a refuse pickup vehicle comprising a truck chassis fitted with a refuse compactor body of the front loader type embodying my invention.
FIG. 2 is a partial transverse cross section of the body and chassis of FIG. 1, taken on the line 2--2 of FIG. 1.
FIG. 3 is a partial sectional view, on the line 3--3 of FIG. 2, showing details of construction for the roof of the tank portion of the body.
FIG. 4 is a partial sectional view taken on the line 4--4 of FIG. 2, showing details of construction of the sidewall of the tank.
FIG. 5 is a sectional view, taken on the line 5--5 of FIG. 2, showing details of construction of the floor of the tank.
FIG. 6 is an enlarged view of the area 6 of FIG. 10.
FIG. 7 is a partial side elevational view of the vehicle of FIG. 1, on a larger scale, with a portion of a side wall of the hopper portion of the body cut away to show the packer blade in a retracted position.
FIG. 8 is a view like FIG. 7 but with a different portion of the hopper side wall cut away to show the packer blade in a fully extended position.
FIG. 9 is a partial transverse cross section through the hopper, taken on the line 9--9 of FIG. 7, showing details of the packer and of the hopper framing.
FIG. 10 is a partial sectional view taken on the line 10--10 of FIG. 9.
FIG. 11 is a partial elevational view of the area 11 of FIG. 10.
FIG. 12 is a sectional view on the line 12--12 of FIG. 11.
FIG. 13 is a side elevational view of the vehicle of FIG. 1 but showing the refuse body in a tilted position for evacuating a load of compacted refuse therefrom.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the invention in detail, it is to be understood that the invention is not limited in its application to the materials or details of construction and the arrangements of the components set forth in the description or illustrated in the drawings. The invention is capable of other embodiments, e.g., side loader bodies, and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purposes of description and should not be regarded as limiting.
FIG. 1 shows a complete refuse vehicle 20 comprising a truck 21 on whose chassis a refuse compactor body 22 of the front loader type is mounted. The truck 21 is illustratively fitted with a steerable front axle assembly 23 and a two-axle rear suspension 24 such as are common in the case of refuse vehicles. The frame assembly of the truck includes a laterally spaced apart longitudinally extending pair of rails 25 on which the body 22 is mounted. While the invention is not so limited, in the illustrated case the refuse body 22 is pivotally hinged adjacent its rear end and on its underside to the rear end portions of the pair of truck frame rails 25, as by a hinge means 26.
Throughout its length the body 22 is supported on its underside by a laterally spaced apart essentially parallel pair of box beams 30, both of which are hingedly interconnected at their rear ends to the chassis rails 25 by the hinge means 26. As shown in FIG. 4, the beams 30 normally rest on top of the rails 25 throughout their length. The forward end of the body 22 comprises a hopper and compactor section 31 whose upper and forward side is fitted with a protective canopy assembly 32 that extends over the cab of the truck 21. A pair of lift arm assemblies 33, of generally U-shape configuration are mounted on opposite sides of the hopper section 31. Each of these is pivotally interconnected, as at 34, to a rigid framework including the front end of the hopper and of the body support beams 30. A hydraulic cylinder mechanism 35 is interconnected between each of the lift arms 33 and a fixed location on the body 22 for synchronously pivoting the pair of lift arms 33 about their pivot axes 34. At its swingable end each lift arm 33 is fitted with a hydraulically actuable fork mechanism 36. With this lift arm arrangement a container C can be picked up at ground level from in front of the refuse vehicle and swung up and over to a position to be inverted for dumping its contents into the hopper 31, as schematically illustrated in FIG. 7.
The rear portion of the body 22 comprises a tank section 40 whose rear end is normally closed by a clam shell door 41. While not illustrated in detail it will be understood that the upper edge of the door 41 is hingedly interconnected to the top side of the tank section 40 by hinge mechanisms 42 but normally held in closed position by a latch mechanism 43 interconnecting the bottom edges of the door and tank section. As is best seen in FIG. 13 a hydraulic mechanism 44 is interconnected between the door 41 and the framing of the rear end of the tank section 40 to open and close the door. As is also shown in FIG. 13, another pair of hydraulic mechanisms 45 are interconnected between approximately the central areas of the truck chassis rails 25 and body support beams 30 for tilting the body 22 between horizontal and inclined positions in order to dump refuse out of the body after the door 41 has been opened.
The top of the body 22 is also fitted with a means to open and close the top of the hopper section 31. This means is schematically indicated in the drawings and may take the form of an essentially rectangular panel of an expanded metal screen mounted in an essentially rectangular framework, indicated generally at 50. The opposite side edges of the panel frame are guided in tracks disposed at opposite sides of the body 22. A hydraulic mechanism 51 extends longitudinally along the mid-line of the body 22 on top of the tank section 40 to reciprocate the panel 50 into and out of obturating position with respect to the top opening of the hopper section 31. While not shown, it will be seen that the panel 50 should be configured, in transverse section, to define facets complementary to the underlying facets of the top side of the tank 40.
The tank 40 is assembled from rectangular thin sheets of metal, preferably abrasion resistant steel of very high tensile strength, and a plurality of short straight lengths of stiff reinforcement members, which are preferably square steel tubing. The metal sheets define the walls of the tank while the short straight tube sections circumferentially girdle the tank wall in assemblies at longitudinally spaced apart locations along the length of the tank. The longitudinally spaced apart girth reinforcements are interconnected, otherwise than by the tank wall, solely by the longitudinally extending body support beams 30. Major portions of the sheets forming the skin are oriented with their final direction of rolling extending in a circumferential direction while the roof panel and floor panel metal sheets have their final direction of rolling oriented parallel to the long axis of the tank. As a result, the tank 40 is essentially a stiff semi-monocoque structure in which a substantial portion of the stresses to which it is imposed are absorbed by its skin. I have found that with this arrangement substantial portions of the tank floor framing found in prior art refuse bodies can be eliminated. For the same reason, spacing between the girth reinforcements can be increased, thus resulting in fewer girth reinforcements for a given length of tank body. As a result, thousands of pounds of weight otherwise devoted to providing a sufficiently rigid and durable structure can be devoted to legal payload instead, as compared to prior art structures. My invention also achieves a lower center of gravity for a refuse vehicle on which the invention is applied.
More particularly, referring to FIG. 1, the tank 40 has a front end circumferential girth reinforcement 60 and a similar rear reinforcement 61 made up of short straight lengths of 2 by 3 inch square tubing. At spaced intervals therebetween, depending upon the desired cubic capacity of the tank 40, are a plurality of similar reinforcements 63 of 2 by 2 inch tube sections. As the tank 40 is of uniform cross section from one end to the other, without any taper, it will be understood that the reinforcements 60, 61 and 63 are congruent polygonal shapes.
FIG. 2 is a typical cross section through the tank 40, the tank being symmetrical about a vertical central plane. A twelve sided prismatic body is shown as representing the optimum compromise between the greater volume of a square body and the structural efficiency of a circular body shape. The girth reinforcement 63 includes a horizontal floor brace 63a having its opposite ends welded to the spaced pair of body support beams 30 on the inside faces of the beams. A box section gusset 65 is preferably welded beneath each end of the floor brace 63a. It should be noted that the upper face of the floor brace 63a is spaced below the level of the upper faces of the beams 30. The reinforcement 63 also includes short straight pairs of braces 63 b-f as well as roof brace 63g. As illustrated, these are miter-cut and welded end to end to define the desired polygonal shape. Preferably, each of the pair of braces 63b is reinforced by an outrigger gusset 66 welded to its underside and also welded at its inner or root end to an outside face of the corresponding body support beam 30.
The wall of the tank 40 includes a floor panel 67 comprising an elongate rectangular sheet which may be of sufficient length to extend from one end to the other of the tank. The preferred material is steel sheet of about 10 to 12 guage thickness, having a tensile strength of at least 90,000 p.s.i., approximately and, preferably, about 115,000 p.s.i. The panel 67 is oriented with its direction of final rolling oriented longitudinally of tank 40. I have found that this material can be cold bent, with the grain, up to about 15° to define the desired shape of floor panel. On each of the opposite sides of the longitudinal center line of the sheet 67 it is bent upwardly at a corner 67a to define a flange portion 67b. The spacing between the bend lines 67a is such that the underside of the floor panel 67 seats on the upper face of the floor brace 63a with the inner surface of the floor panel spaced beneath the level of the upper faces of the pair of beams 30. In the given body shape the flange portions 67b of the floor panels 67a are thus bent upwardly on the order of 15° to project sidewardly beyond the outer face of the box beams 30.
The tank has a roof panel 68, preferably also preferably made of a single length of an elongate rectangular sheet of the very high tensile thin steel sheet bent 15° along a pair of longitudinal bend lines 68a to define a mirror image of the floor panel 67. In the case of both the floor panel 67 and roof panel 68 each is externally skip seam welded to the several spaced apart floor members 63a or roof braces 63g.
In the section of FIG. 2 the balance of the tank wall, in the void between sidewardly outer edges of the floor panel 67 and roof panel 68, comprises a plurality of sheets of very high tensile strength steel. Each of these sheets is oriented such that its final direction of rolling extends circumferentially and parallel to the braces comprising the girdle reinforcements 60, 61 and 63. These sheets may, if desired, be of a thinner guage, i.e., 14 guage rather than 10 or 12 guage. In either case, I have found that these sheets can be cold bent across the grain up to about 60°, without cracking, in order to achieve the desired shape.
More particuarly, the sheets comprising the side and parts of the top and bottom of the tank comprise rectangular panels 70. Each of these is bent about pairs of bend lines or corners 70a and 70b, both pairs of bend lines being symmetrically disposed on opposite sides of a transverse midline of the panel extending across the grain. In the illustrated case, the panel is bent substantially 15° at the bend lines 70a and substantially 60° at the bend lines 70b. There is thus defined in each sheet a vertically disposed central panel 70c flanked by a pair of inclined panels 70d, each of which terminates in a terminal flange portion, 70e.
As is shown in FIG. 4, circumferentially extending edges of an adjacent pair of panels 70 are fitted against an inside face of a girdle reinforcement 63 with the adjacent edges spaced apart sufficiently, e.g., on the order of one-half inch, such that each edge can be independently continuously seam welded to the inner face of the brace 63, as indicated at 71. At the same brace 63 each panel 70 can also be skip seam welded externally. In cases where a panel 70 is of sufficient width, i.e., in the longitudinal direction of the body 40, so that it spans three posts 63, the midportion of the panel 70 can be externally skip welded to the intermediate girdle reinforcement 63, as indicated at 72. As is shown in FIG. 4, abutting edges of each panel 70 and the floor panel 67 are continuously seam welded as indicated at 73, for water tightness. Abutting edges of each panel 70 and roof panel 68 are skip seam welded together as indicated at 74 in FIG. 3.
In order to provide sufficient structural support for the door 41, the girth reinforcement 61 at the rear end of the tank is made up of heavier sections of brace tubes around its perimeter. The front reinforcement 60 of the tank is likewise made up of heavier braces or tube braces. Also, as the hopper section 31 is of lesser overwall width than tank 40 in order to accomodate the lift arm mechanisms 33 within the legal width limit of the vehicle, appropriately configured gussets (not shown) are fixed in certain locations at the junction between the rear end of the hopper section 31 and the front reinforcement 60 of the tank. Referring to FIGS. 9 and 10 the framing for the floor of the hopper section includes a spaced apart series of the cross braces 63a and outrigger tubes 63b, corresponding to the parts indicated by the same numerals in FIG. 2. A box beam 80 is secured to the outer ends of the series of outrigger braces 63b extending horizontally for substantially the full length of the hopper 31. Secured to the upper face of each member 80 is a longitudinally extending guide channel 81 also extending substantially the full length of the hopper assembly. As shown in FIG. 9, each channel 81 opens inwardly and on the outside face of its web has another hopper framing box beam 82 secured thereto.
A floor panel 84 is secured to the upper face of the series of cross braces 63a in the same manner as previously described with reference to the floor panel 67 of the tank 40. As in the case of the tank, the hopper floor panel 84 is also preferably made of a very high tensile steel sheet folded along corners or bend lines 84a and defining opposite side flange portions 84b. The gap between the opposite side edge of the flange portions 84b and the adjacent guide channel 81 is filled with a sheet metal side strip 85. Each side strip 85 may be externally welded to the outrigger 63b and have its inner edge continuously seam welded to the adjacent edge of the flange portion 84b of the main floor panel.
The remaining walls of the hopper section 31 are made up of rectangular sheet metal and square tube reinforcements in a manner well understood in the art. Suffice it to say that opposite side walls of the hopper are fitted with longitudinally spaced apart series of post reinforcements 87 to define on each side of the hopper a sidewall configuration as shown in FIG. 9. The upstanding post reinforcements 87 may be horizontally reinforced by a horizontally extending cross member 88. On each side this framework is provided with sheet metal walls to define a vertically upstanding side wall 78 a lower end portion 89 that slopes inwardly at an angle corresponding to the slope of the member 63c of FIG. 2. As is well understood in the art, the upper end of the hopper section 31 is fitted with a wind shield structure 90, which is essentially a rectangular frame around the essentially rectangular upper opening into the hopper.
Fitted within the hopper section 31 for axial reciprocation longitudinally thereof is a packer 90. The packer is constructed of preferably steel plate that is internally reinforced by appropriate bracing. As viewed in the profile of FIG. 10 the packer has a rectangular base section 91 defining a substantially vertically disposed packing face 92. As is shown in FIG. 9, the packing face 92 has its bottom and opposite side edges configured to be complementary to the corresponding portions of the hopper floor and lower side walls 89 and therefore to the corresponding portions of the tank walls. On opposite sides of the base portion 90 it is fitted with a channel shaped horizontally disposed shoe 93 of channel shape cross section and each shoe is fitted on its outer face with a wear pad 94 extending longitudinally therealong. The shoes 93 project forwardly beyond the front face 92 of the packer 90 and also extend rearwardly behind the base portion 91. As is shown in FIG. 9, each shoe 93 is nestingly slidably engaged within its companion guide channel 81 whereby the packer 90 can reciprocate through essentially the full length of the hopper section 31.
An upper portion 95 of the packer extends upwardly from and slightly forwardly relative to the base portion 91 and has a rear packing face 96 sloping upwardly at an angle of substantially 30° from the face 92 of the base portion 91. As is shown in FIG. 9, gusset plates 97 and 98 are fitted on opposite sides of the rear face of the packer in planes offset from the planes of the face 92 and face 96 in order to provide internal clearance for internal parts of the packer. As shown in FIGS. 9 and 10 the packing faces 92 and 96 obturate approximately two-thirds of the cross sectional area of the tank 10. That is, the upper horizontal edge of the packer is disposed at approximately the same level as the upper bend lines 70a of the tank wall.
A piano hinge mechanism 100 is mounted along the upper edge of the packer 90 to hingedly interconnect a follower 101 thereto. The follower 101 comprises a rigid rectangular framework 102 whose rear face is covered with a rectangular sheet metal plate 103. At each of its ends adjacent a sidewall 88 of the hopper, the follower is fitted at its top with a mounting block 104 to support a roller 105 projecting sidewardly beyond the follower. As is shown in FIG. 10, each side wall of the hopper is provided along its upper edge with a roller guide channel 106 whose forward end develops into an upwardly inclined short roller guide channel 107. As shown in solid outline, when the packer 90 is in the fully retracted position adjacent the forward end of the hopper the roller 105 is confined within the short guide channel 107 to support the rear face of the follower 101 inclined at about 30° relative to the vertical to be essentially co-planar with the sloping face 96 of the packer. When the packer is fully extended as shown in phantom outline in FIG. 10 the roller 105 is pocketed in the horizontally extending guide channel 106 such that it has been inclined to about 55° relative to the vertical. As is shown in the figure, the packer is caused to reciprocate by a pair of crossed hydraulic mechanisms 108 interconnected between the packer 90 and stationary points of the framework of the hopper assembly in a manner well understood in the art.
Several important advantages follow from the packer and hopper construction just described. In some prior art constructions the packer is approximately half as high as the entrance into the refuse tank. In order to keep refuse from falling behind the packer as it is extended, a substantially horizontal follower plate is connected to the upper edge of the packer blade. When the packer blade is retracted the follower is retracted along with the blade into its own pocket, the entrance of which is surrounded with a wiper to prevent entrance of debris into the pocket. As the follower is of relatively large area and comprises a substantial structure to withstand its use, the follower and wiper combination is quite heavy. By contrast the packer and follower of my invention are relatively light in weight and accomplish a weight saving of several hundred pounds. Additionally, since the packer 90 obturates on the order of twothirds of the opening into the tank its packing efficiency is increased.
In other prior art constructions the packer substantially fully obturates and penetrates into the opening into the tank. Accordingly, substantial forces are imposed on the framing and wall structure of the tank entrance. In the arrangement of my invention, approximately the upper one-third opening into the tank is not obturated and a substantial gap exists between the upper edge of the packer 90 and roof of the tank opening. The packer 90 is shown in phantom outline in fully extended position in FIG. 10 from which it will be observed that the upper edge of the blade does not penetrate the tank opening. At the same time, a major portion of packer 90 below its upper edge fully penetrates the entrance to the tank 40 to a depth of about that of the base portion 91. In this connection, as is shown in FIG. 10, the facets 70c and lower facets 70d of the tank walls, for an axial length equal to the penetration of the packer 90, are fitted with gussetted plates 110, 111 parallel to facets 70c and d, respectively, against which opposite sides of packer 90 slide. At the same time, the follower 101 is inclined forwardly and upwardly, now at angle of about 55° from the vertical, and is effective to prevent the refuse being compacted from falling behind the blade. Further, in the fully retracted position of the packer, when the follower 101 occupies the 30° slope indicated in solid outline, the follower 101, the opposite side walls of the hopper section 31, and top front edge of the tank 40 define a relatively large entrance opening for the reception of refuse being dumped in the mode of FIG. 7.
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A refuse compactor body has a tank section of an irregular polygonal right section that is uniform from end to end. The tank wall is made of rectangular pieces of thin very high tensile strength sheet metal and externally reinforced at spaced intervals longitudinally of the tank by polygonal peripherally continuous girth reinforcements, made up of straight short sections of metal tubes, to make a semi-monocoque structure. A floor portion of the tank is recessed between the longitudinal body support beams, which are the sole body support, to provide a relatively low center of gravity when mounted on a truck chassis. A hopper section of the body has a packer that obtruates about two-thirds of the opening to the tank and is fitted at its upper edge with a follower that pivots to a shallower slope to keep refuse from falling behind the packer blade during a compaction stroke of the packer. In a fully extended position, the upper edge of the packer does not penetrate the tank entrance and so avoids excessive stresses on the tank roof at the entrance. In a retracted position of the hopper, the follower and the packer together define a sloping surface to deflect refuse towards the packing face of the packer.
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FIELD OF THE INVENTION
[0001] The invention relates to pharmaceutical compositions comprising rhein or diacerein or salts or esters or prodrugs thereof, optionally with one or more pharmaceutically acceptable excipients. The invention also relates to methods for preparing such compositions.
BACKGROUND OF THE INVENTION
[0002] Chemically, rhein is 9,10-dihydro-4,5-dihydroxy-9,10-dioxo-2-anthracene carboxylic acid having a structure of Formula I and diacerein is 4,5-bis(acetyloxy)9,10-dihydro-4,5-dihydroxy-9,10-dioxo-2-anthracenecarboxylic acid having a structure of Formula II. Diacerein is widely used in the treatment of osteoarthritis and has a unique mode of action that differentiates it from non-steroidal anti-inflammatory drugs (NSAIDs) and other conventional forms of drug therapy. Presently, diacerein capsules are available in 50 mg strength and are marketed by Negma in France under the trade name Art 50(R).
[0000]
[0003] Diacerein is practically insoluble in solvents such as water, alcohols, acetone, dichloromethane and chloroform, which are generally used in pharmaceutical preparations. Although diacerein can be administered by oral route but it cannot be completely absorbed by the digestive tract, and this incomplete absorption results in undesirable side effects such as soft stools.
[0004] In order to overcome these problems, various derivatives, pharmaceutical compositions and specific galenic forms have been proposed in the literature. For example, European patent EP 243,968 describes a diacerein potassium salt, which is water-soluble and can be used in the preparation of compositions for parenteral administration.
[0005] Several patents/applications describe pharmaceutical compositions of diacerein. For example, EP243968 describes parenteral preparations of diacerein salts.
[0006] U.S. Pat. No. 6,124,358 and European Patent No EP904060 describe pharmaceutical compositions of rhein or diacerein, wherein rhein or diacerein is co-micronized with sodium lauryl sulfate. Although it is possible to improve the bioavailability of diacerein by co-micronization, it is still desirable to develop new formulations or new compositions which are likely to further improve the bioavailability.
[0007] U.S. Pat. No. 5,149,542 (EP263083B1); U.S. Pat. No. 4,861,599 (EP 264989B1) and U.S. Pat. No. 5,275,824 (EP 446753B1) describe controlled release or delayed release compositions.
[0008] U.S. Pat. No. 5,225,192 (EP 364944B1) and U.S. Pat. No. 5,569,469 describe different poorly soluble medicaments supported on polymer substances.
[0009] U.S. Pat. No. 5,952,383 and European Patent No EP 862423B1 provide pharmaceutical compositions of diacerein, rhein and their salts along with excipients.
[0010] There are several references known in the literature which disclose use of sugar alcohols like mannitol, sorbitol etc. as fillers in the formulations or as sensory cue agents i.e which impart feeling of cooling in mouth in case of orally disintegrating tablets (WO2007080601, EP589981B1, EP906089B1, EP1109534B1, U.S. Pat. No. 6,328,994, WO2007001086, US20070196494, US20060240101, WO2006057912, US20060057199).
[0011] In general, sugar alcohols like mannitol are employed in most orally disintegrating formulations and not in conventional immediate release formulations as sensory cue agents because the orally disintegrating tablets disintegrate in mouth instead of disintegrating in gastrointestinal tract as in the case of conventional immediate release tablets.
[0012] The present invention addresses and overcomes these commonly encountered problems of low solubility, incomplete absorption and soft stools.
SUMMARY OF THE INVENTION
[0013] In one general aspect there is provided a pharmaceutical composition comprising rhein or diacerein or salts or esters or prodrugs thereof and one or more sugar alcohols.
[0014] Embodiments of the pharmaceutical composition may include one or more of the following features. For example, the diacerein may be present in admixture with a sugar alcohol. Alternatively, it may be present in the form of a complex with sugar alcohol or is adsorbed on a sugar alcohol.
[0015] The composition may further include one or more pharmaceutically acceptable excipients including fillers, binders, lubricants, sweeteners, coloring and flavoring agents, glidants, disintegrants, surfactants, and the like.
[0016] In another general aspect there is provided a pharmaceutical composition comprising rhein or diacerein or salts or esters or prodrugs thereof characterized by the crystallographic data shown in FIG. 1 .
[0017] The composition may have the X-ray diffraction peaks at angle 2 theta of 9.6 and 13.52 degrees.
[0018] In another general aspect there is provided a method of improving the solubility of rhein or diacerein or salts or esters or prodrugs thereof, wherein rhein or diacerein or salts or esters or prodrugs thereof is associated with one or more sugar alcohols.
[0019] In another general aspect there is provided a process for the preparation of a pharmaceutical composition, the process comprising spraying a solution of rhein or diacerein or salts or esters or prodrugs thereof in one or more organic solvents, optionally with one or more sugar alcohols and/or one or more pharmaceutically acceptable excipients in a flow of a fluid under supercritical pressure to form particles and collecting the particles.
[0020] Embodiments of the pharmaceutical composition may include one or more of the following features. For example, the composition may further include one or more pharmaceutically acceptable excipients including fillers, binders, lubricants, sweeteners, coloring and flavoring agents, glidants, disintegrants, surfactants, and the like.
[0021] In one general aspect there is provided a pharmaceutical composition comprising rhein or diacerein, or salts or esters or prodrugs thereof adsorbed on a pharmaceutically acceptable adsorbent.
[0022] Embodiments of the pharmaceutical composition may include one or more of the following features. For example, the composition may further include one or more pharmaceutically acceptable excipients including fillers, binders, lubricants, sweeteners, coloring and flavoring agents, glidants, disintegrants, surfactants, and the like.
[0023] In another general aspect there is provided a process for preparing a pharmaceutical composition comprising rhein or diacerein, or salts or esters or prodrugs thereof, the process comprising:
a) providing a slurry or solution of rhein or diacerein, optionally with one or more pharmaceutically acceptable excipients in one or more suitable solvents; b) adding pharmaceutically acceptable adsorbent to the slurry or solution of step a) or vice versa; and c) recovering the rhein or diacerein, or salts thereof adsorbed on a pharmaceutically acceptable adsorbent from the slurry or solution of step b) thereof.
[0027] In another general aspect there is provided a pharmaceutical composition comprising rhein or diacerein, or salts or esters or prodrugs thereof and one or more water-soluble cyclodextrins or derivatives thereof.
[0028] Embodiments of the pharmaceutical compositions may include one or more of the following features. For example, rhein or diacerein or salts or esters or prodrugs thereof can be present in admixture or a complex form with water-soluble cyclodextrins or derivatives thereof.
[0029] The composition may further include one or more pharmaceutically acceptable excipients including fillers, binders, lubricants, sweeteners, coloring and flavoring agents, glidants, disintegrants, surfactants, and the like.
[0030] In another general aspect there is provided a process for preparing a pharmaceutical composition comprising rhein or diacerein, or salts or esters or prodrugs thereof, the process comprising:
a) triturating rhein or diacerein with a suitable water soluble cyclodextrin or derivatives thereof optionally with one or more suitable solvents; and b) mixing the triturate of step a) optionally with one or more pharmaceutically acceptable excipients.
[0033] The “pharmaceutical composition” of the present invention as used herein, is meant for oral administration to mammals and refers to tablets, capsules, granules, beads, caplets, disc, pills, sachet, suspension, spheroids, minitablets, granules in a capsule, beads in a capsule, minitablets in a capsule, and the like.
[0034] The details of one or more embodiments of the inventions are set forth in the description below. Other features, objects and advantages of the inventions will be apparent from the description and claims.
DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 shows X-ray diffraction pattern of composition of the present invention
[0036] FIG. 2 shows X-ray diffraction pattern of plain diacerein
[0037] FIG. 3 shows comparative dissolution data of Art 50(R) and composition of the present invention (Examples 7, 8, 9 and 10)
DETAILED DESCRIPTION OF THE INVENTION
[0038] The inventors have discovered that when diacerein is adsorbed on a pharmaceutically acceptable adsorbent that provides large exposed surface area; it results in increased solubility of diacerein which, in turn, leads to a significant increase in percent drug release of diacerein as compared to Art 50(R) (the marketed formulation of diacerein). Art 50(R) releases about 14% of diacerein in 60 minutes, whereas pharmaceutical composition of the invention releases 100% diacerein in 45 minutes. The increased bioavailability further leads to reduction in side effects i.e. soft stools.
[0039] The inventors have also discovered that when diacerein is present along with water-soluble cyclodextrins, either as a physical mixture or in the form of any sort of a complex or any other physical or chemical association, it results in a significant increase in the solubility of diacerein and percent drug release of diacerein as compared to Art 50(R) (the marketed formulation of diacerein). Art 50(R) releases about 14% of diacerein in 60 minutes, whereas pharmaceutical composition of the present invention releases 90-100% diacerein in 60 minutes. The increased bioavailability further leads to reduction in side effects i.e. soft stools.
[0040] The inventors have further found that sugar alcohols like mannitol or sorbitol when used along with other known water insoluble drugs like fenofibrate, Irbesartan, aripiprazole, entacapone, either as a physical mixture or in the form of a complex does not result in any significant increase in solubility of these poorly soluble drugs. It was also observed that it does not make any significant difference either in solubility or percent release of these poorly soluble drugs, whether these drugs are present alone in the formulation or along with sugar alcohols.
[0041] However, the present inventors have discovered that when diacerein is present along with sugar alcohols, either as a physical mixture or in form of any sort of a complex or any other physical or chemical association, it results in a significant increase in the solubility of diacerein and percent drug release of diacerein as compared to Art 50(R) (Marketed formulation of diacerein). Art 50(R) releases about 14% of diacerein in 60 minutes, whereas pharmaceutical composition of the present invention releases about 80-100% diacerein in 60 minutes.
[0042] This significant increase in percent release of diacerein is due to dispersion of diacerein in sugar alcohol matrix leading to improved wettability, solubility, and hence increased percent release. This leads to increased bioavailability and reduction in side effects i.e. soft stools.
[0043] The inventors have further found that the diacerein-sugar alcohol composition has a different X-ray diffraction pattern as shown in FIG. 1 . X-ray diffraction pattern of plain diacerein is shown in FIG. 2 . The X-ray spectroscopic analysis of the samples obtained demonstrated the presence of a new crystallographically different entity, as shown in FIG. 1 .
[0044] The diacerein can be present in an amount relative to the sugar alcohol, such that a molar ratio between the diacerein and the sugar alcohol is from about 1:1 to about 1:10.
[0045] The diacerein-sugar alcohol composition can be prepared by various processes including anti-solvent technique, solvent evaporation, kneading, spray drying, colloidal milling, high speed mixing, and trituration.
[0046] It was also found that the diacerein-sugar alcohol composition prepared by anti-solvent method using supercritical fluid results in a significant increase in the solubility and percent release of diacerein as compared to composition which contains a mere diacerein-sugar alcohol mixture.
[0047] In one embodiment, a pharmaceutical composition can be prepared by spraying a solution of diacerein or salts thereof in one or more organic solvents in a flow of fluid under supercritical pressure to form microparticles, which are collected on a suitable sugar alcohol bed, mixed with other pharmaceutically acceptable excipients and converted into a suitable dosage form.
[0048] In another embodiment, a pharmaceutical composition can be prepared by spraying a solution of diacerein or salts thereof in an organic solvent and a suitable sugar alcohol in a flow of fluid under supercritical pressure to form microparticles, which are collected, mixed with other pharmaceutically acceptable excipients and converted into a suitable dosage form.
[0049] In yet another embodiment, a pharmaceutical composition can be prepared by triturating diacerein with a sugar alcohol; drying the triturate; mixing the dried triturate with other pharmaceutically acceptable excipients and converting the mixture into a suitable dosage form.
[0050] In still another embodiment, a pharmaceutical composition can be prepared by triturating diacerein with a sugar alcohol along with one or more surfactants; drying the triturate; mixing the dried triturate with other pharmaceutically acceptable excipients and converting the mixture into a suitable dosage form.
[0051] Suitable fluids which can be used under supercritical pressure may include carbon dioxide, water, ethane, xenon, and the like.
[0052] Suitable organic solvents used for preparing organic solution of diacerein or salts thereof are those known to a person of ordinary skill in the art and may include one or more of N-methyl-pyrrolidone, dimethylsulfoxide, dimethylacetamide, tetrahydrofuran, ketones, and the like.
[0053] Suitable sugar alcohols may include one or more of mannitol, maltitol, maltol, sorbitol, lactitol, xylitol, and the like.
[0054] Suitable surfactants which can be used may include amphoteric, non-ionic, cationic or anionic surfactants. For example, one or more of sodium lauryl sulfate, monooleate, monolaurate, monopalmitate, monostearate or another ester of polyoxyethylene sorbitane, sodium dioctylsulfosuccinate (DOSS), lecithin, stearylic alcohol, cetostearylic alcohol, cholesterol, polyoxyethylene ricin oil, polyoxyethylene fatty acid glycerides, poloxamer, cremophore RH 40, and the like
[0055] In yet another embodiment, a pharmaceutical composition can be prepared by dispersing diacerein along with pharmaceutically acceptable excipients in water and adding an adsorbent to diacerein slurry. The mixture thus obtained can be dried, blended with other pharmaceutically acceptable excipients and converted into a suitable dosage form.
[0056] In still another embodiment, a pharmaceutical composition can be prepared by dispersing diacerein along with other pharmaceutically acceptable excipients in water and spraying slurry thus obtained on to a pharmaceutically acceptable adsorbent. The mixture thus obtained can be dried, blended with other pharmaceutically acceptable excipients and converted into a suitable dosage form.
[0057] Suitable pharmaceutically acceptable adsorbents may include one or more of colloidal silicon dioxide, lactose, saccharides, calcium silicate, magnesium aluminum silicate, porous ceramics, polypropylene foams, cellulose, cellulose derivatives, polyols, starches, pre-gelatinized starches, starch derivatives, modified starches, dextrins, maltodextrins, polydextroses, dextroses, calcium carbonate, calcium phosphate, calcium sulfate, and the like.
[0058] The slurry or solution of rhein or diacerein, or salts thereof may be microfluidized through a microfluidizer in order to reduce the particle size of rhein or diacerein.
[0059] Suitable solvents which can be used in the process of the present invention include one or more of water, methanol, ethanol, butanol, isopropyl alcohol, acetone, chloroform, dimethyl acetamide (DMA), dimethyl sulfoxide (DMSO), dimethylformamide (DMF), methylene chloride, and the like.
[0060] Adsorption may be carried out by a fluidized bed processor, glatt, and spray dryer or by any other suitable coating techniques known in the art.
[0061] In general, the rhein or diacerein, or salts thereof adsorbed on a pharmaceutically acceptable adsorbent may be recovered from the suspension by any suitable means, such as removal of the solvent. The removal of the solvent can be carried out by means of drying the mixture with or without vacuum, freeze-drying, or lyophilization, and fluidized bed processor. Drying further includes evaporation and/or distillation or any other means known to a skilled artisan for removal of solvent from a mixture.
[0062] In one embodiment, a pharmaceutical composition can be prepared by triturating diacerein with a suitable cyclodextrin with one or more suitable solvents, drying the diacerein-cyclodextrin triturate, mixing the dried triturate optionally with other pharmaceutically acceptable excipients and converting the mixture into a suitable dosage form.
[0063] In another embodiment, a pharmaceutical composition of the invention can be prepared by triturating diacerein with a suitable cyclodextrin, mixing the triturate optionally with other pharmaceutically acceptable excipients and converting the mixture into a suitable dosage form.
[0064] Suitable water soluble cyclodextrin derivatives may be one or more of, β-cyclodextrin, α-cyclodextrin, γ-cyclodextrins, hydroxypropyl-α-cyclodextrin, hydroxypropyl-β-cyclodextrin, dimethyl-β-cylcodextrin, 2-hydroxyethyl-β-cyclodextrin, trimethyl-β-cyclodextrin, sulfonated cyclodextrins and the like.
[0065] The complex of diacerein and cyclodextrin may be prepared by various processes including anti-solvent technique, solvent evaporation, kneading, spray drying, colloidal milling, high speed mixing, trituration or simple mixing. The diacerein can be present in an amount relative to the cyclodextrin, such that a molar ratio between the diacerein and the cyclodextrin is from about 1:1 to 1:10.
[0066] The pharmaceutical compositions can include pharmaceutically acceptable excipients including fillers, binders, lubricants, sweeteners, coloring and flavoring agents, glidants, disintegrants, surfactants, and the like.
[0067] Suitable fillers include one or more of microcrystalline cellulose, silicified microcrystalline cellulose, mannitol, calcium phosphate, calcium sulfate, kaolin, dry starch, powdered sugar, and the like.
[0068] Suitable binders include one or more of povidone, starch, stearic acid, gums, hydroxypropylmethyl cellulose, and the like.
[0069] Suitable surfactants include one or more of sodium lauryl sulfate, monooleate, monolaurate, monopalmitate, monostearate or another ester of polyoxyethylene sorbitane, sodium dioctylsulfosuccinate (DOSS), lecithin, stearylic alcohol, cetostearylic alcohol, cholesterol, polyoxyethylene ricin oil, polyoxyethylene fatty acid glycerides, poloxamer, cremophore RH 40, and the like.
[0070] Suitable lubricants include one or more of magnesium stearate, zinc stearate, calcium stearate, stearic acid, sodium stearyl fumarate, hydrogenated vegetable oil, glyceryl behenate, and the like.
[0071] Suitable glidants include one or more of colloidal silicon dioxide, talc or cornstarch, and the like.
[0072] Suitable disintegrants include one or more of starch, croscarmellose sodium, crospovidone, sodium starch glycolate, and the like.
[0073] The coloring agents of the present invention may be selected from any FDA approved colors for oral use.
[0074] The invention is further illustrated by the following examples which are provided merely to be exemplary of the invention and do not limit the scope of the invention. Certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the invention.
[0075] The following examples are illustrative of the invention, and are not to be construed as limiting the invention.
Example 1
[0076]
[0000]
TABLE 1
S.N.
Ingredients
% w/w
Part-I
1
Diacerein
10-60
2
Microcrystalline cellulose
5-70
3
Sodium docusate
1-20
4
Sodium lauryl sulfate
1-20
5
Povidone
5-40
6
Water
q.s.
Part-II
7
Silicified microcrystalline cellulose
5-70
8
Starch
10-50
9
Croscarmellose sodium
1-15
10
Magnesium stearate
0.1-3
[0077] Procedure: Diacerein along with sodium docusate, sodium lauryl sulfate, povidone was dispersed in sufficient quantity of water to get slurry. The slurry was microfluidized through a microfluidizer and the resultant microfluidized slurry was sprayed on microcrystalline cellulose using glatt. The dried mass so obtained was sieved and blended with silicified microcrystalline cellulose, starch, croscarmellose sodium, lubricated with magnesium stearate and the lubricated blend was filled into hard gelatin capsules of a suitable size.
[0000]
TABLE 2
Dissolution data
Time
% Drug released
% Drug released
(min)
(Art 50(R))
(Example-1)
5
3
45
10
4
78
15
5
89
20
7
95
30
9
98
45
11
100
60
14
100
[0078] Table 2 provides the dissolution data for diacerein capsules prepared as per the formula given in Table 1. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example 2
[0079]
[0000]
TABLE 3
S.N.
Ingredients
% w/w
Part-I
1
Diacerein
10-60
2
Microcrystalline cellulose
5-70
3
Sodium docusate
1-20
4
Sodium lauryl sulfate
1-20
5
Povidone
5-40
6
Water
q.s.
Part-II
7
Silicified microcrystalline cellulose
5-70
8
Starch
10-50
9
Croscarmellose sodium
1-15
10
Magnesium stearate
0.1-3
[0080] Procedure: Diacerein along with sodium docusate, sodium lauryl sulfate, povidone was dispersed in a sufficient quantity of water to get slurry. Microcrystalline cellulose was added to the slurry under stirring. The wet mass thus obtained was tray dried overnight in an oven at 35-40° C. The dried mass was sieved and blended with silicified microcrystalline cellulose, starch, croscarmellose sodium, lubricated with magnesium stearate and the lubricated blend was filled into hard gelatin capsules of a suitable size.
Example 3
[0081]
[0000]
TABLE 4
S.N.
Ingredients
Qty/Caps (% w/w)
1
Diacerein
10-90
2
Hydroxy propyl beta cyclodextrin
20-65
3
Purified water
q.s.
4
Sorbitol
0.5-20
5
Crospovidone
5-40
6
Silicified microcrystalline cellulose
15-50
7
Sodium stearyl fumarate
0.5-2
[0082] Procedure: Diacerein and hydroxypropyl beta cyclodextrin were mixed and triturated with water for few minutes. Diacerein hydroxypropyl cyclodextrin complex thus formed was dried, sized to a suitable size and mixed with sorbitol, crospovidone, silicified microcrystalline cellulose and sodium stearyl fumarate. The final mixture was filled into hard gelatin capsules of a suitable size.
[0000]
TABLE 5
Dissolution data
Time
% Drug released
% Drug released
(min)
(Art 50(R))
(Example-3)
5
3
39
10
4
69
15
5
81
20
7
87
30
9
91
45
11
93
60
14
96
[0083] Table 5 provides the dissolution data for diacerein capsules prepared as per the formula given in Table 4. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 Tampon phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example 4
[0084]
[0000]
TABLE 6
S.N.
Ingredients
Qty/Caps (% w/w)
1
Diacerein
10-90
2
Hydroxy propyl beta cylodextrin
20-65
3
Purified water:isopropyl alcohol
q.s.
4
Sorbitol
0.5-20
5
Crospovidone
5-40
6
Silicified microcrystalline cellulose
15-50
7
Sodium stearyl fumarate
0.5-2
[0085] Procedure: Diacerein and hydroxypropyl beta cyclodextrin were mixed and triturated with water/isopropyl mixture for few minutes. The diacerein hydroxypropyl cyclodextrin complex thus formed was dried, sized to a suitable size and mixed with sorbitol, crospovidone, silicified microcrystalline cellulose and sodium stearyl fumarate. The final mixture was filled into hard gelatin capsules of a suitable size.
[0000]
TABLE 7
Dissolution data
Time
% Drug released
% Drug released
(min)
(Art 50(R))
(Example-4)
5
3
33
10
4
62
15
5
73
20
7
79
30
9
83
45
11
90
60
14
94
[0086] Table 7 provides the dissolution data for diacerein capsules (50 mg) prepared as per the formula given in Table 6. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 Tampon phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example 5
[0087]
[0000]
TABLE 8
S.N.
Ingredients
Qty/Caps (% w/w)
1
Diacerein
10-90
2
Hydroxy propyl beta cyclodextrin
20-65
3
Sorbitol
0.5-20
4
Crospovidone
5-40
5
Silicified microcrystalline cellulose
15-50
6
Sodium stearyl fumarate
0.5-2
[0088] Procedure: Diacerein and hydroxypropyl beta cyclodextrin were mixed and triturated for few minutes. The diacerein hydroxypropyl cyclodextrin complex thus formed was mixed with sorbitol, crospovidone, silicified microcrystalline cellulose and sodium stearyl fumarate. The final mixture was filled in to hard gelatin capsules of a suitable size.
Example 6
[0089]
[0000]
TABLE 9
S.N.
Ingredients
Qty/Tabs (% w/w)
1
Diacerein
10-90
2
Hydroxy propyl beta cyclodextrin
20-65
3
Purified water
q.s.
4
Sorbitol
0.5-20
5
Crospovidone
5-40
6
Silicified microcrystalline cellulose
15-50
7
Sodium stearyl fumarate
0.5-2
[0090] Procedure: Diacerein and hydroxypropyl beta cyclodextrin were mixed and triturated with water for few minutes. The diacerein hydroxypropyl cyclodextrin complex thus formed was dried, sized to a suitable size and mixed with sorbitol, crospovidone, silicified microcrystalline cellulose and sodium stearyl fumarate. The final mixture was compressed into tablets using a suitable tooling.
[0000]
TABLE 10
Dissolution data
Time
% drug released
% drug released
(min)
(Art 50(R))
(Example-6)
5
3
62
10
4
78
15
5
85
20
7
88
30
9
91
45
11
94
60
14
98
[0091] Table 10 provides the dissolution data for diacerein capsules (50 mg) prepared as per the formula given in Table 9. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 Tampon phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example 7
[0092]
[0000]
TABLE 11
S.N.
Ingredients
% w/w
Part I
1
Diacerein
10-90
2
Sorbitol
0.5-20
Part II
3
Microcrystalline cellulose
5-60
4
Croscarmellose sodium
1-25
5
Magnesium stearate
1-15
[0093] Procedure: Diacerein was mixed with sorbitol and triturated with minimum amount of water to form a pasty mass. The pasty mass was dried, sieved to form granules and mixed with microcrystalline cellulose, croscarmellose sodium, and magnesium stearate. The final mixture was filled into hard gelatin capsules.
[0000]
TABLE 12
Dissolution data
Time
% Drug released
% Drug released
(min)
(ART 50(R))
(Example-7)
5
3
29
10
4
53
15
5
68
20
7
76
30
9
82
45
11
89
60
14
90
[0094] Table 12 provides the dissolution data for diacerein capsules (50 mg) prepared as per the formula given in Table 11. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example 8
[0095]
[0000]
TABLE 13
S.N.
Ingredients
% w/w
Part I
1
Diacerein
10-60
2
Sorbitol
0.5-20
3
Docusate sodium
1-20
4
Sodium lauryl sulfate
1-20
Part II
5
Glycine
1-20
6
Lactose
5-40
7
Crospovidone
5-40
[0096] Procedure: Diacerein was mixed with sorbitol, sodium docusate, sodium lauryl sulfate and triturated with minimum amount of water to form a pasty mass. The pasty mass was dried, sieved to form granules and mixed with glycine, lactose and crospovidone. The final mixture was filled into hard gelatin capsules.
[0000]
TABLE 14
Dissolution data
Time
% Drug released
% Drug released
(min)
(Art 50)
(Example-8)
5
3
16
10
4
35
15
5
50
20
7
60
30
9
72
45
11
78
60
14
82
[0097] Table 14 provides the dissolution data for diacerein capsules (50 mg) prepared as per the formula given in Table 13. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example 9
[0098]
[0000]
TABLE 15
S.N.
Ingredients
% w/w
Part I
1
Diacerein
10-90
2
N-methyl pyrrolidone
qs
3
Mannitol
10-90
Part II
4
Microcrystalline cellulose
5-60
5
Croscarmellose sodium
1-25
6
Magnesium stearate
1-15
[0099] Procedure: Diacerein was dissolved in N-methylpyrrolidone and sprayed (Spray rate: 3 ml/min) in a flow of carbon dioxide (15 Kg/h) under supercritical pressure (100 bars, 40° C.) on bed of mannitol placed in a spray reactor. The particles thus formed were recovered on the bed of mannitol and mixed with microcrystalline cellulose, croscarmellose sodium, and magnesium stearate. The final mixture was filled into hard gelatin capsules.
[0000]
TABLE 16
Dissolution data
Time
% Drug released
% Drug released
(min)
(ART 50(R))
(Example-9)
5
3
27
10
4
45
15
5
60
20
7
69
30
9
82
45
11
88
60
14
95
[0100] Table 16 provides the dissolution data for diacerein capsules (50 mg) prepared as per the formula given in Table 15. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 phosphate buffer at 37° C.±0.5° C. was used as a medium.
Example-10
[0101]
[0000]
TABLE 17
S.N.
Ingredients
% w/w
Part I
1
Diacerein
10-90
2
Mannitol
10-90
3
N-methyl pyrrolidone
qs
Part II
3
Microcrystalline cellulose
5-60
4
Croscarmellose sodium
1-25
5
Magnesium stearate
1-15
[0102] Procedure: Diacerein and mannitol were dissolved in N-methylpyrrolidone and sprayed (Spray rate: 3 ml/min) in a flow of carbon dioxide (15 Kg/h) under supercritical pressure (100 bars, 40° C.) in a spray reactor. The particles thus formed were recovered and mixed with microcrystalline cellulose, croscarmellose sodium, and magnesium stearate. The final mixture was filled into hard gelatin capsules.
[0000]
TABLE 18
Dissolution data
Time
% Drug released
% Drug released
(min)
(Art 50(R))
(Example-10)
5
3
92
10
4
100
15
5
100
20
7
100
30
9
100
45
11
100
60
14
100
[0103] Table 18 provides the dissolution data for diacerein capsules prepared as per the formula given in Table 17. For determination of drug release rate, USP Type 2 Apparatus (rpm 75) was used wherein 1000 ml of pH 5.7 phosphate buffer at 37° C.±0.5° C. was used as medium. Comparative dissolution profile of Art 50(R), Example 7, 8, 9 and 10 is shown in FIG. 3 .
[0104] While the invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the invention.
|
The invention relates to pharmaceutical compositions comprising rhein or diacerein or salts or esters or prodrugs thereof, optionally with one or more pharmaceutically acceptable excipients. The invention also relates to the methods for preparing such compositions.
| 0
|
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/322,469, filed on Apr. 14, 2016 which is herein incorporated by reference in its entirety.
ACKNOWLEDGEMENTS
[0002] This invention was made with government support under grant number FA9550-15-1-0238, awarded by the U.S. Air Force. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates generally a system that can be used to measure force, distance and/or contact during robotic manipulation. More specifically, the present invention relates to a measurement system comprising a low-cost tactile sensor that combines force and distance measurements and can be retro-fitted to existing robotic grippers and hands.
BACKGROUND OF THE INVENTION
[0004] Grasping and manipulation remain hard challenges in robotics. After identifying an object's pose, a robot's end-effector needs to be controlled so that impact with the object provides a sufficient number of constraints for successful pick-up while maintaining the object's pose until all desired contact points are reached, thereby preventing the object from moving out of the end-effector's reach. There exist complementary approaches to tackle subsets of the grasping problem, ranging from relying on compliance of the gripper's material, pushing the object to exploit environmental constraints, obtaining a precise 3D model of the object and calculating an appropriate grasp, to using visual servoing to make up for uncertainty in sensing and actuation. In practice, each class of solutions addresses a very narrow range of problems and presents distinct challenges. For example, most compliant hands exclusively rely on compliance to successfully grasp an object once its pose has been determined. Touch sensors have been used to determine whether the grasp is successful, but cannot be used to improve the grasp prior to contact. Exploiting environmental constraints such as walls or a bowl has been shown to increase grasping success, but planning such a motion requires precise knowledge of the environment's geometry and would benefit from active sensing to determine whether an object has reached a desired pose. Using 3D sensing suffers from uncertainty in both sensing and actuation, making reliable grasps very difficult, regardless of the type of end-effector used. While visual servoing might help alleviate this challenge by allowing to make up for errors in sensing and actuation, it requires precise registration of an object's geometry, which is difficult in particular when the hand comes close to the object and thereby shields it from external sensors mounted on the wrist or elsewhere on the robot.
[0005] Combining compliance, planning and reactive control is a promising avenue. Using simple infrared distance sensors within a robotic gripper for reactive control during the final phase of grasping has been proposed. Similarly, reactive control can be based on finger torque, curvature or contact itself, which can be achieved by a large number of sensing modalities ranging from capacitive to resistive and optical. Commercially successful systems (that is, widely deployed) in-hand sensors however are virtually non-existing as of yet as they are difficult to manufacture and expensive. At the same time, the algorithmic foundations for reactive grasp planning are only sparsely developed, with most of the focus on the sense-plan-act model that requires precise sensing and actuation.
[0006] While there exist a myriad of both distance and pressure sensors, none of them are commercially successful as they are costly to manufacture and often impractical to use. The dominating paradigm for locating objects and determining grasp points is therefore to use external sensors such as cameras and depth sensors. These sensors do not have sufficient resolution and fail in cluttered or hard-to-reach environments, such as reaching inside a shelf.
[0007] Accordingly, it is desirable to provide a low-cost measurement system and method to measure force, distance and/or contact during robotic manipulation using commodity infrared proximity sensors.
SUMMARY
[0008] Presented herein is a measurement system comprising at least one low-cost tactile sensor embedded in elastomer that combines force and distance measurements. The proposed sensor can be simple to manufacture and easy to integrate with existing hardware. The invention also comprises a low-cost method to measure force, distance and/or contact using at least one commodity infrared proximity sensor that can be retro-fitted to existing robotic grippers and hands. The sensor can be less than 1 cm 2 and can be arranged in strips and arrays, drastically facilitating manipulation tasks in uncertain environments. The elastomer can protect the sensor, provide a rugged and low-friction surface, as well as allow performing force measurements using Hooke's law.
[0009] The sensor comprises a commodity digital infrared distance sensor that is embedded in a soft polymer, which doubles as a spring for force measurements based on Hooke's law. The strong dependence of infrared-based sensors on surface properties can be overcome by exploiting the discontinuity that the elastomer coating introduces into the sensor response.
[0010] Related methods of operation are also provided. Other apparatuses, methods, systems, features, and advantages of the force, distance and/or contact measurement system will be or become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional apparatuses, methods, systems, features, and advantages be included within this description, be within the scope of the force, distance and/or contact measurement system, and be protected by the accompanying claims.
DESCRIPTION OF THE FIGURES
[0011] FIG. 1 is a perspective view of the system for measuring force, distance and/or contact during robotic manipulation of the present application, showing at least one sensor embedded in a polymer and positioned on a robotic gripper, according to one aspect;
[0012] FIG. 2 is a schematic diagram of the system of FIG. 1 ;
[0013] FIGS. 3A-3C illustrate a process for manufacturing the system of FIG. 1 ;
[0014] FIG. 4 is a perspective view of an experimental setup to test the system of FIG. 1 ;
[0015] FIGS. 5A-5C are charts illustrating the sensor responses for different design parameters of the sensor of FIG. 1 ;
[0016] FIGS. 6A-6D are charts illustrating the sensor responses for different color targets and target distances for the sensor of FIG. 1 ;
[0017] FIG. 7A is a perspective view of the system of FIG. 1 in which the gripper is attempting to grasp a cube;
[0018] FIG. 7B is a chart illustrating the values sensed by the left and right gripper as the grippers approach the cube of FIG. 7A ;
[0019] FIG. 8 is a chart illustrating the difference between the left gripper and the right gripper in FIG. 7B ;
[0020] FIG. 9A is a chart illustrating the values sensed by the left gripper as the gripper approaches the pan of FIG. 10A , FIG. 9B illustrates raw values of the contact data for the fifth sensor of the right gripper, FIG. 9C illustrates calibration data for black cardboard, and FIG. 9D is a chart illustrating the values sensed by the right gripper as the gripper approaches the pan of FIG. 10A ;
[0021] FIGS. 10A and 10B are perspective views of the system of FIG. 1 in which the gripper is attempting to grasp a pan;
[0022] FIG. 11 is a 3D point cloud model of a cup created by date collected by the system of FIG. 1 ;
[0023] FIGS. 12A-12B are perspective views of the system of FIG. 1 in which the gripper is attempting to grasp a toy airplane;
[0024] FIGS. 13A is a chart illustrating the estimation of possible grasp location of the YCB airplane for the left finger of the system of FIG. 1 ;
[0025] FIGS. 13B is a chart illustrating the estimation of possible grasp location of the YCB airplane for the right finger of the system of FIG. 1 ; and
[0026] FIG. 14 is a perspective view of the system for measuring force, distance and/or contact during robotic manipulation of the present application, comprising a 4×8 sensor array embedded in a polymer and positioned on a robotic gripper, according to one aspect.
DESCRIPTION OF THE INVENTION
[0027] The present invention can be understood more readily by reference to the following detailed description, examples, and claims, and their previous and following description. Before the present system, devices, and/or methods are disclosed and described, it is to be understood that this invention is not limited to the specific systems, devices, and/or methods disclosed unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
[0028] The following description of the invention is provided as an enabling teaching of the invention in its best, currently known aspect. Those skilled in the relevant art will recognize that many changes can be made to the aspects described, while still obtaining the beneficial results of the present invention. It will also be apparent that some of the desired benefits of the present invention can be obtained by selecting some of the features of the present invention without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present invention are possible and can even be desirable in certain circumstances and are a part of the present invention. Thus, the following description is provided as illustrative of the principles of the present invention and not in limitation thereof.
[0029] As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “sensor” includes aspects having two or more such sensors unless the context clearly indicates otherwise.
[0030] Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[0031] As used herein, the terms “optional” or “optionally” mean that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
[0032] The application relates to systems and methods for measuring force, distance and contact during robotic manipulation. In one aspect, the system 10 comprises at least one infrared proximity sensor 12 embedded in a polymer 14 as illustrated in FIG. 1 . The at least one embedded sensor can be positioned on a conventional robotic gripper 16 and/or hand. In another aspect, the at least one infrared proximity sensor 12 can comprises a plurality or proximity sensors arranged in strips, arrays and/or other predetermined patterns embedded in a polymer and positioned on the robotic gripper. For example, the system of FIG. 1 shows two sensor arrays mounted to the parallel gripper 16 of a “Baxter” robot 18 (Rethink Robotics, Boston, Mass.), such that a first array can be mounted to a first finger of the gripper and a second array can be mounted to a second finger of the gripper. The ability to select the frequency of each sensor allows one to arrange sensors in opposite pairs, such as on a robotic gripper, without interference. The at least one sensor can provide force, distance and/or contact measurements to a processor for further manipulation and to provide feedback regarding the robotic gripper.
[0033] As used herein, the term “contact” means the event when both distance and force are zero. For example, a robot contacts an object to be manipulated when the distance from the robot to the object is zero, and when the force exerted by the robot on the object is zero.
[0034] Infrared sensors can be strongly non-linear, dependent on the surface properties of sensed objects, and sensitive to cross-talk from other sensors or infrared light in the environment. Increasing use in consumer electronics such as smart phones has led to a new generation of devices that improve cross-sensitivity by integrating sensor and emitter with digital signal processing.
[0035] In one aspect, the sensor 12 can be an integrated proximity and ambient light sensor such as, for example and without limitation, a VCNL 4010 sensor marketed by Vishay Semiconductors. This device has a relatively miniature 3.95×3.95×0.75 mm 3 package which combines an infrared emitter and PIN photodiode for proximity measurement, ambient light sensor, a signal processing IC, a 16 bit ADC, and inter-integrated-circuit (I 2 C) communication interface. The chip allows setting a large variety of parameters. For example, one parameter can be the emitter current (20 mA to 200 mA in increments of 10 mA). In another example, a parameter can be the carrier frequency in the range from 390.625 kHz-3.125 MHz in four increments. The emitter current should not be confused with the actual power consumption, which is less than 4 mA when performing 250 measurements per second at full (200 mA) power, and in the order of μA when doing 10 or less measurements per second.
[0036] In one aspect, the at least one sensor 12 can be a single embedded sensor. In other aspects, the sensor can comprise a plurality of embedded sensors arranged in an array. That is, the plurality of sensors 12 can be arranged in n x m array, where n and m can be one, two, three, four, five, six, seven, eight, none, ten or more than ten. For example, the plurality of sensors can be arranged in a 1×8 array positioned on the finger of a gripper 16 , an 8×8 array positioned on the hand of a gripper, a 20×20 array positioned on a gripper and the like. In another example, the system of FIG. 14 shows a 4×8 sensor array mounted to a Baxter robot. In this example, a second array (not shown) could be interleaved to create a dense 8×8 sensor array. In one aspect, the sensors 12 can be arranged in groups of eight using an I 2 C multiplexer (TCA9548A, Texas Instrument). This chip has a 3-bit address supporting arrays of up to 8×8 sensors. At 100 kHz / 2 C bus frequency, a single measurement can require 1470 ,μs including communication, allowing to read an 8×8 array at 10 Hz and a strip of eight at 85 Hz.
[0037] Each sensor 12 can be embedded in a polymer, such as for example and without limitation, an elastomer 14 . In one aspect, the polymer can be a transparent polymer (to infrared light) when cured. That is, the sensor can be embedded in a polymer that is transparent to the sensor 12 . In another aspect, the polymer 14 can be, for example and without limitation, polydimethylsiloxane, (“PDMS”) such as Dow Corning Sylgard 184 and the like. PDMS is a widely used silicon elastomer, whose mechanical and optical properties are known. PDMS is simple to manufacture and cheap, while providing good transparency and mechanical properties such as resistance to chemical and mechanical abrasion. The elastomer can protect the sensor and provide a rugged and low-friction surface, as well as allow performing force measurements using Hooke's law. Further, adding the elastomer introduces an infliction point in sensor response upon contact which can be detected by simple signal processing. It can therefore possible to determine contact independently of the surface properties, as well as calibrating the sensor on the fly.
[0038] The integrated infrared emitter of the sensor 12 has a peak wavelength. For example, if the sensor is a VCNL 4010, the peak wavelength can be about 890 nm. The light from the emitter passes through the PDMS in which the sensor is embedded. The emitted light can then reflected by nearby objects and received by a photo-receiver of the sensor. The amplitude and phase of the received light vary as a function of the distance to the surface, and the surface orientation, color and texture.
[0039] Due to the quadratic decay of light amplitude with distance, the sensor 12 can have its highest resolution right after its minimum range, for example 0.5 mm. It can therefore be possible to measure small variations in distance in the order of hundredths of millimeters. In one aspect, this effect can be exploited by measuring the elastic deformation that occurs when an object is pressed against the sensor. As the elastomer acts like a spring with a constant Young's modulus E, the force is given by
[0000]
F
≈
EA
d
Δ
x
(
1
)
[0000] with A the contact area over the sensor, d the width of the PDMS layer and Δx the measured deformation. Note that the sensor area can be constant and smaller than the actual contact area of typical objects. Yet, the value of F can be approximate as PDMS cannot be infinitely compressed and eventually changes its absorption properties.
[0040] Let the emitted light intensity be I 0 and the measured reflected intensity from an object be I. Let the thickness of the rubber be d and the distance to the object x. Depending on the index of refraction of the rubber material, a fraction R of the light will be reflected from the interface between rubber and air, a fraction κ will be scattered, and a fraction A will be absorbed at the target surface. Assuming that the light intensity decays quadratically with distance, the amount of returned infrared light can be approximated as
[0000]
I
x
>
0
≈
I
0
(
1
-
R
)
A
(
d
+
x
)
2
+
I
0
R
1
d
2
-
κ
I
0
.
(
2
)
[0041] The reflection at the PDMS/air interface can be calculated using the Fresnel equation, which reduces to
[0000]
R
=
n
1
-
n
2
n
1
+
n
2
2
(
3
)
[0000] for normal incidence. With the refractive index of PDMS n 1 ≈1.41 and that of air n 2 ≈1, around 2.9% of the light can get reflected from the internal surface of the PDMS as well as on the outside on the return path.
[0042] This formalism helps to better understand certain edge cases. First, when d<<x, the light intensity at the receiver is dominated by I 0 R 1/d 2 , which leads to saturation of the sensor. The width d of the PDMS therefore governs the maximum current at which the sensor can be operated and thereby the maximum attainable range. At the same time, the width governs the maximum allowable Δx and thereby the maximum force and its resolution that the sensor can measure.
[0043] Once the object touches the sensor surface, i.e. x=0, (2) reduces to a constant which is a function of material properties. After touching, the PDMS gets compressed by
[0000]
Δ
x
≈
dF
EA
,
[0000] leading to
[0000]
I
x
<
0
≈
I
0
A
(
d
-
dF
EA
)
2
-
κ
I
0
(
4
)
[0000] Note that (4) still depends on the surface reflectance A, which therefore needs to be known for accurate force measurements. As I x=0 =const and the derivative of (2) increasing when approaching zero, while the derivative of (4) decreasing, x=0 appears to be an inflection point, which possibly could be detected in recordings of I.
[0044] In one aspect, the at least one infrared sensor 12 requires few external components, such as, for example and without limitation, 3 capacitors. Encapsulation of the sensor in a polymer such as PDMS 14 can be readily accomplished by fixing the circuit board in a mold and pouring the liquid polymer in it. The elastomer then cures to form a robust and compliant rubber contact surface for grasping and manipulation. Illustrations of the process are shown in FIGS. 3A-3C .
[0045] In order to avoid air being trapped at the interface between PDMS 14 and the sensor 12 , the assembly can be degassed in a vacuum chamber, according to one aspect. The PDMS can then be cured in an oven at 70° C. for about 20 minutes. To accurately study the optical properties of amorphous PDMS, it can be useful to purify the raw materials before the mixing process to avoid extrinsic losses, e.g. by particle scattering. The base material and coupling agents can thus be filtered using a cellulose-mix-ester membrane filter having a pore size of about 0.2 μm. The entire sensor preparation process can take around 5 hours per pair.
[0046] To experimentally characterize the performance of the proposed tactile sensor 12 , the response of an individual sensor can first be characterized. Then the sensing capabilities of a complete array of sensors can be characterized by installing the array on a parallel gripper 16 . FIG. 4 shows the experimental setup to test and characterize the performance of the sensors, according to one aspect. The setup can be designed in a way which allows the testing of both an individual taxel and complete arrays in their proximity and force regions. The setup comprises a 0.15×0.13 m 2 screen that can be mounted vertically on a sliding rod with precise linear control. A digital force gauge such as a Shimpo FGV-10XY and the like can be mounted horizontally on the opposite side of the screen to measure the force exerted on the sensor 12 .
[0047] Single-point measurements at distances from 0 to 6 cm in increments of 1 cm can be recorded, as well as force from 1N to 5N in increments of 1N for current values from 40 mA to 200 mA in increments of 40 mA ( FIG. 5A ). Results show saturation of the sensor 12 for distances below about 1 cm at current values exceeding 80 mA due to Fresnel reflection inside the PDMS. At about 80 mA, the sensor can saturate at less than about 2N force, whereas a 40 mA setting can allows measurement across the range from 0 to 5N.
[0048] The thickness of PDMS 14 can have an effect on the amount of light absorbed and scattered within the PDMS material. However, the amount of light reflected back from the air-PDMS surface can remain the same regardless of the thickness of the PDMS as the amount of reflection can depend only on the refractive indexes of the material.
[0049] FIG. 5B shows the response of two sensors 12 cast in PDMS 14 with the base to curing agent in 8:1 ratio and thickness of 6 mm and 12 mm. A difference can be observed in the force reading. In one aspect, thicker PDMS can tend to allow the reading of higher force values, however thicker PDMS comes with the drawback of lessening the dynamic range, and thereby resolution, of the sensor 12 in the 0 to 5N region. As absorption within the material can be marginal, thickness does not significantly alter the proximity reading.
[0050] The mid-infrared transmission of thin PDMS film can be characterized using Fourier Transform Infrared (FT-IR) Spectrometry. The transmittance of infrared light can depend on the mixing ratio of two parts causing the composition of PDMS to change; for example, a lower mixing ratio can result in higher transmittance. Maximum transmittance of about 95% can be found between wavenumbers 2490-2231 cm −1 with mixing ratios of 8:1. To compare the results at wavenumbers 12500-10526 cm −1 (800-950 nm), three mixtures of PDMS with different mixing ratio of the base and curing agent (5:1, 10:1, and 12:1) were prepared. FIG. 5C shows the sensor proximity and force values for different mixing ratios. The Young's modulus of PDMS changes by about 35-40% where the density changes by 1% over the range of mixing ratio from 8:1 to 12:1. In one aspect, there can be a small difference in the force region among these values, and a more distinct distance measurement, in particular for 8:1 mixing ratios. As the cross-over from distance to force is at approximately the same sensor reading, 8:1 mixing ratios can provide the widest dynamic range in the force regime, but the smallest dynamic range in the distance regime.
[0051] For calibrating the relationship between the sensor 12 reading and actual distance, the sensitivity of the sensor to surface reflectance was characterized. The data for different distances across a variety of sensors for white paper was recorded. A width of 6 mm at a mixing rate of 8:1 was chosen due to the higher dynamic range in both the distance and force regime.
[0052] The intensity of light reflected from objects can be dependent on the color, pose and surface properties of the object. Five different colored target cardboard papers (red, yellow, white, gray and black, Canson, 150 gsm) were chosen. The colored cardboard papers were mounted on a screen shown in FIG. 4 which served as target objects for a distance sensor 12 coated by 6 mm PDMS at 8:1 mixing ratio.
[0053] FIGS. 6A-6D show the response of the sensor 12 to different colors. The proximity measurements can be comparatively lesser influenced by the reflective properties of the target surface than the force measurements. While brightly colored materials can give better readings than darker ones, there is not necessarily any significance difference in the sensor response to different colors, except for the black paper.
[0054] The reflectance for a variety of colors can be in the range of 0.9 (gray) to 1.0 (white), whereas black cardboard has a reflectance of 0.12. Cardboard of all colors can be more reflective than wood (0.77), brick (0.61) or concrete (0.53), but less reflective than surfaces such as polished plastic or china.
[0055] In order to obtain a relationship between sensor 12 readings and actual distance, data from fourteen different sensors and white paper was recorded. Seven sensors were soldered in a line at 10 mm spacing to a rigid PCB as illustrated in FIG. 1 . The response of two such fourteen sensor arrays was recorded at twenty-four distances ranging from 0.5 to 19 cm and 50 measurements each for 120 mA. While 120 mA leads to saturation in the force regime (when using white paper), this value allows obtaining better ranging and works with objects that are less reflecting. The data is shown in FIGS. 6A-6D .
[0056] This data was fitted with a function of the form y=ax b +c using MATLAB's curve fitting toolbox's trustregion method and bisquare weighting of outliers. The candidate function corresponds to physical intuition (with b=−2) and can be inverted to
[0000]
x
=
1
(
(
y
-
c
)
/
a
)
λ
h
(
5
)
[0000] Notice that the denominator of the above equation includes the b-th root, which yields complex values for y<c. This can be the case whenever a sensor 12 reading falls below the asymptote of the fitted curve, which can be the case for farther-away measurements. Therefore all measurements can be converted into a decibel scale using log 10 I/I ∞ , where I ∞ is the measurement obtained in plain air. With b≈−1 after fitting on the log-scale, all distance measurements remain real. The fit as well as absolute error for both the raw and PDMS-coated sensors are shown in FIG. 6C . A slightly higher absolute error for all measurements with PDMS can be observed, which initially makes objects appear closer (up to about 7 cm) and then farther apart than the raw sensor. Data follows a similar trend for distances from 10 cm to 19 cm, but are not shown as the high error at this range makes those measurements impractical to use.
[0057] As force measurement can be susceptive to surface reflectance, fits for a variety of colored papers were performed using data from FIG. 6A . Results for a subset (white, red, black) are shown in FIG. 6D . Using an equation of the form y=ax b has provided good results, with R-squared values ranging from 0.9898 (black) to 0.9953 (white).
[0058] The at least one sensor 12 can be mounted on the parallel gripper 16 of a robot, such as for example and without limitation, the Baxter robot from Rethink Robotics, which is equipped with two 7-DOF arms. The size of each finger sensor can be 80×2×1 mm ( FIG. 1 ), which is small enough to install on the stock electric parallel gripper of the robot. Two separate pairs of finger set with grasp ranges varying from 0-68 mm to 68-144 mm were manufactured. In one example, each finger set can comprise an array of eight sensors. Two fingers can be interfaced via an Arduino Uno microcontroller that polls all sixteen sensors in a round-robin fashion. The microcontroller can connect to a control computer and ROS via a USB port, which can also provide the supply voltage for the sensors. Unless otherwise noted, all objects can be chosen from the Yale-CMU-Berkeley (YCB) Object and Model set.
[0059] Proximity sensing can first be used to center a gripper 16 around an object. This can be helpful because successful grasping can require both fingers to simultaneously make contact. For example, grasping a cup at its handle induces a turning motion that needs to be counteracted by the opposite finger before the cup has turned out of the robot's grasp. Similarly, removing a block from a Jenga tower requires the gripper to create force-closure with the block while inducing a minimum amount of motion on the block itself.
[0060] FIG. 7A depicts a similar situation, in which imprecise alignment will collapse a tower of wooden blocks. The grippers 16 were closed in discrete steps and the response from the sensor was recorded. The response from the sensors on the right finger is shown in solid lines and the response from the left finger is shown in dashed lines in FIG. 7B .
[0061] Assuming the surface properties (reflectance) are the same on both sides of the object, data shown in FIG. 8 can be used to servo the end-effector to a position in which both distances are roughly equal using feedback control and inverse kinematics (Baxter SDK PyKDL).
[0062] Force sensing can be used to determine the location of incidence of an object on the gripper. FIG. 9A shows the raw measurements of all sensors 12 when grasping the handle of a YCB pan ( FIG. 10A ). The data shows which sensors made the most contact, letting us infer the approximate size of the object. Closer inspection of contact data, here the 5th sensor of the right finger, reveals that gentle pressure drives the sensor to roughly 2×104 ( FIG. 9B ), which is similar to values generated by contact with black cardboard ( FIG. 9C ). Furthermore, fitting a spline to the raw data and calculating its derivative (MATLAB spline and fnder), reveals that the sensor 12 response has an extrema close to where the black cardboard crosses from the distance to the force regime. Performing the same operation on data from the left finger suggests a material of slightly higher reflectance (the sensor maxes out at 2.4×104) with a cross-over point at a raw value of 17529. While not sufficient to determine the actual object properties, the suitability of using extrema on the sensor response (minimum, maximum, and cross-over point) to identify specific materials can be explored in the future. Indeed, the cross over point for all experiments shown in FIG. 6A for currents ranging from 40 mA to 200 mA in increments of 40 mA (25 experiments) can be detected. This suggest that the sensor response indeed follows that of equations 2-4.
[0063] Given the material parameters, in-hand proximity sensing can be used to augment, and possibly register against, conventional 3D sensing. The robot arm can be programmed to reach a specified scanning position on the table in a position shown in FIG. 10B . It can be assumed such a position can be reached using coarse visual or RGB-D data, as well as the proximity sensors themselves. The robot wrist joint can be rotated around the object in increments of 0.17 rad in the interval of [−π;π]. Using the actual encoder value at each step and converting sensor readings into centimeters using (5) yields polar coordinates of each point where the infrared light hits the object. The resulting data is shown in FIG. 11 . While noisy due to non-orthogonal incidence angles at the handle and the bottom of the cup, the fidelity of the model is sufficient to highlight the presence of the cup's handle.
[0064] A toy airplane form the YCB object set which has a highly reflecting surface was also selected. FIGS. 12A and 12B show the direction in which the robot wrist is swept across the wing to detect a possible grasp location, this time using a horizontal motion.
[0065] FIGS. 13A and 13B show the response of the sensors 12 to the toy airplane. While the distance measurements are underestimated due to the reflectance of the opposite gripper (at a distance of around 7 cm) and the airplane wing, the presence of the airplane wing is clearly discernible. As the wing starts appearing in the field of view of the sensors a decrease in distance can be seen, which reaches a maximum at the wing's center, and then gradually increases as the robot arm moves away from the wing. This can be due to the fact that the infrared emitter is better approximated by a lobe than by a ray. The symmetry of the reflected plane at the center of the wing can cause the photo receiver to receive the maximum possible reflected intensity available from the airplane wing, illustrating the limitations in lateral resolution, which would need to be compensated by an orthogonal sweep, should a more accurate 3D reconstruction be desired.
[0066] The sensor 12 of the present application has a series of design parameters comprising the choice of the material itself, its mixing ratio, its thickness, and the current at which the emitter operates. Each of these parameters can affect the sensors' range, dynamic range, and thereby resolution and accuracy. While far from exhaustive, systematic experiments presented here highlight important trends, and allow obtaining a good trade-off between ranging and force sensing capabilities.
[0067] Though roughly following the form y=ax b +c, this approximation introduces non-negligible systematic error, an effect that gets amplified by adding a PDMS layer, which introduces another constant to the denominator of (2). While better non-linear approximations could be found, e.g., using support vector machines or training a neural network, the sensor 12 an be sensitive to surface properties. For example, black paper is five times less reflecting than white paper, whereas shiny objects are more reflecting. However, most practical application of the sensor might not require calibration at all. Indeed, centering around an object only requires equalizing sensor readings, which are both monotonously increasing and continuous from infinity to 5N force.
[0068] Moreover, it can be possible for the system 10 to take measurements independently of surface reflectivity by looking at peaks in the derivative of the signal emitted from the sensor 12 .
[0069] Further, the shape of the function that relates distance/force/contact measurements to raw sensor 12 readings is of similar quality independent of the surface properties, thickness, mixing ratio, and current, with an infliction point at the contact point. Performing a firm grasp on an unknown object such as the panhandle in FIG. 10A allows recording such a curve in its entirety and might allow to infer its material properties given all other parameters of the sensor are known. For example, when squeezing the handle, the sensor 12 reading maxes out at around 2.1×104, which is slightly above the value of black paper at 120 mA (1.8×104) for 6 mm PDMS (8:1). Together with actual distance information obtained from the gripper 16 itself, it might be possible to calibrate the sensor online by performing a simple grasp, and then use this data to perform an accurate 3D reconstruction.
[0070] Squeezing an object might also provide insight for tuning the sensing current. For example, the sensor 12 current could be reduced until the sensor saturates at a value below the maximum reading, and calibration data could be obtained during a second squeeze.
[0071] Another limitation of optical proximity sensors can be their dependence on the angle of incidence. While this is not noticed with rotation symmetric objects such as those used here, scanning a rectangular object using a circular swivel motion, e.g., could cause the object to appear elliptical. As the resulting error is well quantified, contact information can be exploited to estimate the angle of a surface. Similarly, sensor-based motion planning techniques could allow complete reconstruction of a 3D object and/or registering it with information obtained by other sensors such as vision and depth.
[0072] An integrated force, distance and/or contact sensor 12 is provided that can be simple to manufacture and low-cost, yet providing a series of benefits that conventionally required much more complex sensors. As expected with infrared-based sensors, the sensor can be strongly nonlinear, highly sensitive to surface properties and has poor lateral resolution when compared with ray-based or RGBD sensors.
[0073] Nevertheless, the sensor has a wide range of use cases that facilitate grasping and manipulation ranging from contact point detection, determining grasp points, to object registration, and can possibly be improved by improved sensor models and sensor-based motion planning strategies. The necessary processing could be co-located with the sensor, allowing it to autonomously identify surface properties of an object and adapt accordingly.
[0074] Although several aspects of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that many modifications and other aspects of the invention will come to mind to which the invention pertains, having the benefit of the teaching presented in the foregoing description and associated drawings. It is thus understood that the invention is not limited to the specific aspects disclosed hereinabove, and that many modifications and other aspects are intended to be included within the scope of the appended claims. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described invention.
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A force, distance and contact measurement system comprising at least one low-cost tactile sensor embedded in elastomer and retrofitted onto existing robotic grippers is provided. The sensor is simple to manufacture and easy to integrate with existing hardware. The sensor can be arranged in strips and arrays, facilitating manipulation tasks in uncertain environments. The elastomer protects the sensor, provides a rugged and low-friction surface, and allows performing force measurements.
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BACKGROUND OF THE INVENTION
This invention relates to a rust converting and rust inhibiting composition, and more particularly, to a primer composition in the form of an aqueous suspension or aqueous emulsion, which is capable of lifting rust from steel and providing the steel with a corrosion resistant surface.
Removal and prevention of corrosion, particularly rust on steel surfaces, continue to be serious problems. At the present time, to provide corroded metal with a corrosion resistant surface, it is necessary for the metal to be cleaned by mechanical and/or chemical means before application of the primer, otherwise the corrosion continues. Further, available rust inhibiting primers have serious disadvantages.
A rust inhibiting primer composed of red lead and iron oxide, as well as a rust inhibiting primer having a fish oil base are well known. However, these primers are not adequate to protect steel from corrosion, particularly when the steel is subjected to relatively severe conditiions.
According to British Pat. No. 915,512, a nonaqueous primer with rust inhibiting properties is obtained by means of a phosphate of calcium or zinc as the rust inhibitor.
A protective coating composition is disclosed in U.S. Pat. No. 3,249,447 which contains a siccative organic coating composition and a polyvalent metal of a di-(aromatic)phosphinate.
In U.S. Pat. No. 4,064,084 a corrosion inhibiting poly(arylene sulfide) coating has been disclosed. This coating must be heated to a temperature of 500°-900° F. to effect a cure, which is an obvious disadvantage.
According to U.S. Pat. No. 4,086,182, a composition which contains a synthetic binding agent and a complexing agent for iron, which is a polymeric esterification product of an aromatic oxycarboxylic acid containing phenolic groups, is capable of converting a surface film of an oxide on iron or steel and to provide a corrosion resistant film. However, the resultant film is deep black in color and moreover, must be removed prior to the application of another coating, since it does not adhere to other paints.
An anticorrosive pigment is disclosed in U.S. Pat. No. 4,211,565 which is obtained by calcining 30 to 70 mol percent of magnesium, calcium and/or zinc oxide, 70 to 30 mol percent of iron oxide and up to 20 mol percent of chromium oxide at a temperature of 200° to 900° C.
An inexpensive, efficient and effective composition which both removes or converts active corrosion to the passive form and provides a protective film which inhibits further corrosion, even under severe conditions, and which is also compatible with other paints has not been disclosed up to the present time.
SUMMARY OF THE INVENTION
The principal object of the present invention is the provision of a composition which converts rust on the surface of a metal to an inactive or passive form and which provides a coating which inhibits further corrosion.
Another important object of the invention is the provision of a composition which lifts rust from a metal surface and which provides a protective film which inhibits corrosion, even under severe conditions.
A further important object of the invention is the provision of a composition which not only lifts rust from a metal surface and provides a coating which inhibits further corrosion, but is also compatible and adherent to other commonly used paints and primers.
A further object of this invention is the provision of a rust converting and rust inhibiting primer which is flexible, has good adhesion to steel and which is compatible with other coatings.
Still another object of this invention is the provision of a rust converting and rust inhibiting primer which dries rapidly in the air under ordinary conditions of temperature and pressure.
These and other objects of the invention are obtained by a rust converting and rust inhibiting primer which is comprised of an aqueous suspension or aqueous emulsion of an alkyd resin, about 150 to 275 parts by weight of pigment containing at least about 50 parts by weight of red oxide pigment and the remainder being extender pigment, a drying accelerator for the alkyd resin which is a salt of a polyvalent metal, in an amount of about 0.50 to 1.5 parts by weight of the polyvalent metal and about 1 to 7 parts by weight of a surfactant which is active as an oil-and-water dispersant or emulsifier, all parts by weight being based on 100 parts by weight of the alkyl resin.
DESCRIPTION OF THE INVENTION
The term "rust converting", as used herein, means that rust, i.e., iron oxide, is converted into a different form, probably a more complex structure which is not actively corrosive. Further, it is believed that the primary composition of the invention provides an absorbing action which raises the corrosion product from the substrate. This lifting is further activated or aided by the chemical reaction which converts the rust when the wet film of the primer contacts the clean metal surface. The corrosion product thus becomes part of the paint film, where it is enveloped by the resinous portion of the film and prevented from further contact with oxygen and moisture. In this way, the further formation of corrosion products, particularly rust, is prevented.
The drying resin, which is responsible for the formation of the film on the surface of the steel, is preferably a medium or long oil alkyd resin such as a soya or tall oil alkyd resin; soya-phthalic anhydride alkyds are particularly preferred.
A surfactant which is effective as an oil-and-water dispering or emulsifying agent is essential in the instant composition; nonionic surfactants including for example ethylene oxide surfactants, i.e., polyoxyethylene, ethoxylated alcohol and the like can be used, although ionic surfactants, particularly amine salts of long chain unsaturated fatty acids such as oleic, lauric and stearic acids are preferred and the triethanolamine salts are particularly preferred. The surfactant is present in the composition of the invention in an amount of about 1 to 7 parts by weight and more preferably, about 2 to 4 parts by weight per 100 parts by weight of the resin.
The composition of the invention contains a pigment in an amount of about 150 to 275 and more preferably, about 180 to 250 parts by weight per 100 parts by weight of resin. Of the pigment, at least about 50 parts by weight is red oxide pigment, i.e., Fe 2 O 3 . The maximum amount of red oxide pigment present in the composition of the invention is not critical; however, for economy, the maximum amount is preferably about 100 parts by weight and more preferably, about 65 parts by weight per 100 parts by weight of the pigment. The remainder of the pigment is extender pigment, such as calcium carbonate or silica. Other pigments such as zinc oxide and lead peroxide may also be included in the composition of the invention, in minor amounts, as a substitute for or in addition to the extender pigment. For example, zinc oxide may be used in an amount of 0.2 to 2.5 parts by weight per 100 parts by weight of the resin and lead oxide in an amount of about 1 to 3 parts by weight per 100 parts of the resin. Likewise, zinc phosphate and calcium borosilicate, which are nontoxic rust inhibitors and are helpful in increasing the length of the effectiveness of the inhibitor action may be present in the composition of the invention in amounts of about 5 to 15 parts by weight, based on 100 parts by weight of the alkyd resin.
As a drying accelerator for the alkyd resin, one or more polyvalent metal salt is included in the composition in an amount of about 0.5 to 1.5 parts by weight based on 100 parts by weight of the alkyd resin. Preferably, the drying accelerator is an oil soluble salt of at least two metals selected from cobalt, manganese, lead, zinc and zirconium.
A pigment antisettling agent usually a clay, such as BENTONE, is advantageously included in the composition of the invention in an amount of about 1 to 4 parts by weight, and more preferably, about 1.5 to 2.5 parts by weight per 100 parts by weight of the alkyd resin. Likewise, a pigment dispersion or wetting agent, known in the art, such as a soya-lecithin composition is desirably included in the composition of the invention in an amount of about 2 to 10 parts and more preferably, 4 to 8 parts by weight per 100 parts by weight of the alkyd resin.
Among other agents which may be included in the composition of the invention is a chelating or sequestering agent such as the disodium salt of ethylenediaminetetraacetic acid in an amount of about 1 to 4 parts by weight and more preferably, about 2-3 parts by weight based on 100 parts by weight of the resin.
As the vehicle for the rust-converting and rust-inhibiting primer of the invention, a mixture of water and organic solvents is preferred. The proportion of water to organic solvent in parts by weight, is about 1:4 to 1.5:1, and more preferably, about 1:2 to 1:0.8. Of the organic solvent, the major amount is a nonpolar solvent, such as naphtha or mineral spirits and a minor amount, i.e., about 2 to 25 percent and more preferably, about 5 to 16 percent of the organic solvent is a polar solvent, such as a lower alcohol, ethylene glycol, cellosolve acetate, propylene carbonate and the like. Based on 100 parts per weight of the resin, the vehicle of the primer of the invention is preferably composed of about 4 to 20 and more preferably, about 6 to 15 parts per weight of polar solvent, about 80 to 150 and more preferably about 90 to 110 parts per weight of nonpolar solvent and about 50 to 125 and more preferably about 80 to 110 parts by weight of water.
If it is desired to thin the primar, additional nonpolar solvent, such as petroleum spirits can be added without detriment.
It is a particular advantage of the invention that the primer may be applied directly to the corroded surface of the metal to be protected; it is desirable to remove any losse pieces of rust, usually dusting off of loose particles of rust, by a rag or soft brush is sufficient; cleaning by mechanical means such as a wire brush and/or chemical means before application of the primer of the invention is not necessary. The rust converting and rust inhibiting primer of the invention, which can be applied by conventional means such as brushing, rolling and spraying, is effective not only to inhibit further corrosion, but to convert adherent rust on the surface of the metal to a nonactive form and also to lift the corrosion from the surface of the metal and envelope it in the resin.
A coating of the primer composition of the invention is set, i.e., dried to the touch in about six hours, dried hard enough for recoating in twelve hours and dried throughout in sixteen hours.
Adhesion of a film of the primer of the invention to clean and corroded steel, galvanized metal and previously painted surfaces is excellent. The primer of the invention even adheres well directly to zinc-galvanized metals without prior preparation. The rust converting and rust inhibiting primer of the invention is exceedingly compatible and can be coated directly on top of a variety of coatings, and can also be overcoated with a wide variety of coatings including alkyd enamels, aluminum paint, acrylic enamels, urethanes, epoxy-polyamides, epoxy esters, two-component acrylic-polyurethane, two-component water-epoxy, high gloss moisture-cure polyurethane, linseed oil, and even specialized paints, such as bridge paint which meets federal specification TTP 651-D and bridge paint which meets New York specification 708-110.
In addition to its excellent compatibility with other coatings, fast drying and effectiveness in converting and inhibiting rust, the primer of the invention has excellent flexibility and freeze-thraw resistance. No cracking is observed when a coating of the primer of the invention is bent over a 1/4 inch mandrell through 180° and the primer of the invention can be applied at 35° F., even to damp surfaces.
The following examples further illustrate the best mode currently contemplated for carrying out the invention, but must not be construed as limiting the invention in any manner whatsoever.
EXAMPLE 1
Preparation of The Rust Converting And Rust Inhibiting Primer
A soya-alkyd resin (100 percent solids, 23-25 percent phthalic anhydride, manufactured by Cellomer) in an amount of 85 kg., 1.7 kg. of the antisettling agent, BENTONE 34, (manufactured by National Lead), 12 kg. of methanol and 2.8 kg. of soya-lecithin a pigment dispersing agent are mixed at ambient temperature of about 20°-27° C. Red oxide pigment (Fe 2 O 3 ) in an amount of 45 kg., and calcium carbonate, an extender pigment in an amount of 150 kg. are added and ground together with the initial mixture to hegman 6. A drying accelerator for the resin composed of 1.36 kg. of 12% cobalt naphthenate, 1.8 kg. of 6% manganese naphthenate and 1.8 kg. of zirconium naphthenate is added together with 91 kg. of petroleum spirits.
Water in an amount of 94.5 kg. and 2 kg. of triethanolamine oleate are combined and mixed with the ground mixture of alkyd resin and pigment.
EXAMPLE 2
Preparation of The Rust Converting And Rust Inhibiting Primer
A soya-alkyd resin (100 percent solids, 23-25 percent phthalic anhydride, manufactured by Cellomer) in an amount of 87.5 kg., 1.8 kg. of the antisettling agent, BENTONE 34, (manufactured by National Lead), 0.45 kg. of methanol and 3.6 kg. of the pigment dispersing agent, soya-lecithin, are mixed at ambient temperature of about 20°-27° C. Red oxide pigment (Fe 2 O 3 ) in an amount of 45.3 kg., calcium carbonate in an amount of 147 kg. and calcium borosilicate in an amount of 6.8 kg. are added and ground together with the initial mixture to hegman 6. As the drying accelerator for the resin, the same ingredients in the same proportion as in Example 1, but in a total amount of 3.6 kg., are added together with 88.5 kg. of petroleum spirits and cellosolve acetate in an amount of 3.6 kg. to reduce the consistency of the mixture.
Water in an amount of 91 kg., 1.8 kg. of triethanolamineoleate, 2.3 kg. of ethylene glycol and 1.8 kg. of the disodium salt of the ethylenediaminetetraacetic acid are combined and when fully dispersed are mixed with the ground mixture of alkyd resin and pigment. Zinc oxide in an amount of 0.2 kg. and lead peroxide in an amount of 1 kg. are then added to complete the composition.
EXAMPLE 3
Preparation of The Rust Converting And Rust Inhibiting Primer Composition
The same soya-alkyd resin used in Example 1 in an amount of 87.5 kg. is mixed with 1.8 kg. of BENTONE 34, manufactured by National Lead, 0.45 kg. of propylene glycol and 7.25 kg. of the soya-lecithin pigment dispersing agent at ambient temperature. Red oxide pigment in an amount of 56.7 kg., silica as an extender pigment in an amount of 147 kg. and calcium borosilicate in an amount of 11 kg., are ground together with the alkyd resin mixture to hegman 7. The mixture is then thinned by adding 88.5 kg. of petroleum spirits and 5.4 kg. of cellosolve acetate, a drying accelerator for the alkyd resin composed of cobalt naphthenate, manganese naphthenate and zirconium naphthenate in the same proportion used in Example 1, but in a total amount of 3.6 kg. is combined with the mixture.
Water in an amount of 91 kg., triethanolamine oleate in an amount of 3.2 kg., ethylene glycol in an amount of 4.5 kg. and the disodium salt of ethylenediaminetetraacetic acid in an amount of 1.8 kg. are combined and then mixed with the alkyd resin pigment mixture. Zinc oxide in an amoiunt of 1.8 kg. and 3 kg. of lead peroxide are then added to the composition.
EXAMPLE 4
Determination of Corrosion Resistance
Cold rolled, hot rolled and pickled steel panels were exposed to a salt spray atmosphere in a salt spray cabinet to produce a corrosion deposit. The corroded panels were rinsed and dried and then coated with the rust converting and rust inhibiting primer of the invention produced in accordance with Example 1.
The dry film thickness was 3.0 mils or 75 microns. The coated panels were permitted to air dry for 18 hours and were then reexposed to salt spray in accordance with ASTM B 117.
After 800 hours of exposure, the panels were examined. No evidence of corrosion deposit was found on the surface of the primer coating.
COMPARATIVE EXAMPLE A
Determination of Corrosion Resistance Using Comparative Primers
Steel panels were exposed to a salt spray atmosphere in accordance with Example 4, rinsed and dried and then coated with two primers, one complying with the requirements of Federal Specification TT-P-86 type II, which is a red lead-iron oxide primer, and one complying with Federal Specification TT-C-530B, which is fish-oil base rust inhibiting primer.
After 600 hours of exposure, the panels were examined and some corrosion deposits on the surface of the red lead-iron oxide primer were found, with several ruptures in the paint film. The same condition was found on the surface of the fish-oil based primer.
EXAMPLE 5
Determination of Corrosion Resistance Of Panels Coated With The Primer Of The Invention And Various Top Coats
Corroded and rust covered steel panels prepared as in Example 4, were coated with the primer of the invention prepared according to Example 1. After drying overnight in the air, the panels were then coated with the following top coats:
A. Exterior alkyd enamel (TT-E-489)
B. Epoxy-polyamide enamel
C. Solvent based acrylic enamel
D. Urethane base enamel (aliphatic).
The coated panels were exposed to a salt spray test (ASTM B 117) for 600 hours.
A second series of panels were prepared in the same manner and were exposed to accelerated weathering (ASTM E 42) for 300 hours.
The exposed panels were examined and the following observations were made.
Salt spray exposed panels: none of these panels showed any evidence of corrosion deposits on the enamel coat.
Weathered panels: none of the panels showed any evidence of corrosion deposit on the enamel coat.
EXAMPLE 6
Determination of Compatibility
To determine the capability of the primer of the invention to maintain adhesion with various types of top coats, the following materials were applied over the primer prepared in accordance with Example 1 after two days of air drying:
A. Alkyd enamel
B. Epoxy enamel (two-component)
C. Solvent based acrylic enamel
D. Aliphatic urethane enamel.
The coated panels were exposed to 300 hours of salt spray (ASTM B 117) and to 600 hours of accelerated weathering (ASTM E 42).
The exposed panels were then examined; none showed any evidence of rust formation either on or beneath the top coat.
None of the panels showed any loss in intercoat adhesion nor in overall adhesion to the initially rusty surface.
The weathered panels were subjected to an adhesion test, using the 25 square cross-hatch tests. None of the panels showed any loss in intercoat adhesion, nor in overall adhesion to the initially rusty surface.
EXAMPLE 7
Determination of the Form of the Iron Compound after Application of the Primer
Attempts were made by x-ray diffraction to idenify the mineral phase on the surface of the steel, as well as in the paint itself after application and drying of a coat of the primer prepared as in Example 1 and applied to a corroded steel surface as in Example 4. Examination of the x-ray scan showed the presence of hematite (Fe 2 O 3 ) on the surface as well as within the layer of primer. A portion of the iron compound was identified as ferrous oxide (FeO) with an indefinite crystal structure. Since Fe 3 O 4 is actually a coprecipitate of Fe 2 O 3 and FeO, it is assumed that both forms of the iron oxide are present.
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A rust converting and rust inhibiting primer is disclosed which comprises an aqueous suspension or aqueous emulsion of an alkyd resin, about 150 to 275 parts by weight of pigment containing at least 50 parts by weight of red iron oxide pigment, the remainder being extender pigment, a drying accelerator for said alkyd resin composed of one or more polyvalent metal salts in an amount of about 0.5 to 1.5 parts by weight of said metal and about 1 to 7 parts by weight of a surfactant active as an oil-and-water dispersant or emulsifier all parts by weight being based on 100 parts by weight of said alkyd resin. The primer is compatible with a wide variety of coatings and can be applied directly to a clean or corroded surface of a metal.
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The invention relates to a terminal head for processing a workpiece by means of a laser beam.
BACKGROUND OF THE INVENTION
A prior art terminal head has a housing and an insert, which can be inserted laterally into the housing and has a focussing optical system for focussing the laser beam.
The focussing optical system and insert are permanently connected to one another, with the result that it is virtually no longer possible to align the focussing optical system relative to the laser beam after introduction of the insert into the housing. In the case of different focal lengths of the focussing optical system, it is impossible, furthermore, to displace the position of the focal point of the system in the longitudinal direction of a laser beam in order to align the focal point of the focussing optical system relative to the tip of a nozzle which is located at the end of a housing on the side where radiation is output and through which the laser beam passes.
SUMMARY OF THE INVENTION
It is the object of the invention to develop the terminal head of the type mentioned at the beginning in such a way that a better possibility is provided for positioning the focussing optical system.
A terminal head according to the invention differs from the prior art in that the focussing optical system can be displaced relative to the insert via positioning means which are partly situated on the outwardly pointing side of the insert.
If it is necessary to replace a focussing optical system by another having the same or different optical properties, either a new insert with the desired focussing optical system can be inserted into the housing, or the old insert can be used with a new focussing optical system inserted into it. In both cases, a simple adjustment of the focussing optical system relative to the laser beam is possible. Specifically the adjusting means permits adjustment of the focussing optical system even when the insert has already been reinserted into the housing. The positioning of the focussing optical system can thus be undertaken when a laser beam is present, and can therefore be performed in a decidedly precise fashion.
The adjusting means can be designed for displacing the focussing optical system in the longitudinal direction of a laser beam in order, for example, to be able to position the focal point of the focussing optical system relative to the tip of a nozzle which is connected to the end of the housing on the side where radiation is output and through which the laser beam passes.
The adjusting means can also be designed for displacing the focussing optical system at right angles to the longitudinal direction of the laser beam, in order to make the center of the focussing optical system and the center of the beam coincide.
According to a very advantageous refinement of the invention, the insert can be positioned inside a larger opening of the housing at an axial position by means of an adaptor plate which can be connected to the housing. The adapter plate has a recess at this axial position which accommodates the insert in a fitted fashion.
If very strongly mutually deviating focal lengths of the focussing optical system are required because of a desired type of material to be processed or because of prescribed thicknesses of material to be processed, the focal lengths must be arranged at axial positions in the housing which are situated far removed from one another if the focal point of the focussing optical system is to retain its original position relative to the end of the housing on the side where radiation is output or relative to the nozzle.
For this purpose, a relatively large opening is located in the housing which permits positioning of the insert at different axial positions of the housing. In order to be able to fix the insert at one such axial position, provision is made of an adaptor plate which covers the housing opening and has precisely at this axial position a recess for accommodating the insert. If the insert is to be positioned at a different axial position, use must be made of a different adaptor plate which is equipped with a recess present at this axial position.
The respective adaptor plates which cover the housing opening can be attached to the housing by clamping screws, for example, just like the insert seated in the recess, in the last-mentioned case the clamping screws being present on the adaptor plate.
According to a refinement of the invention, the adjusting means for displacing the focussing optical system in the longitudinal direction of the laser beam includes a rotatable adjusting ring situated coaxially with the longitudinal direction of the laser beam. This adjusting ring projects forward over a portion of its circumference through the front plate of the insert, with the result that it can be operated even if the insert is inserted into the housing. By rotating the adjusting ring, it is therefore possible to displace the focussing optical system in the longitudinal direction of the laser beam.
The adjusting ring is advantageously permanently connected to an adjusting cylinder which has an external thread onto which a cylindrical lens is threaded which is secured against rotation and supports the focussing optical system. Thus, upon rotation of the adjusting cylinder via the adjusting ring the cylindrical lens holder is moved to and fro in the longitudinal direction of the laser beam, depending on the direction in which the adjusting ring is rotated.
According to a very advantageous development of the invention, the adjusting cylinder has axial through channels, the axial through channels opening into a coaxial annular channel which is present in the adjusting cylinder and faces the focussing optical system. This annular channel is connected via an annular restrictor to a space present above the focussing optical system, with the result that compressed air fed via the through channels can expand because of the annular restrictor and effectively cool the focussing optical system situated below it.
According to a refinement of the invention, the cylindrical lens holder can be displaced in a fitted fashion in a guide sleeve on which the adjusting ring is supported. In this case, the adjusting ring rests on the surface of the guide sleeve on the side where radiation is input. It is held there free from play in the axial direction of the guide sleeve.
According to a further advantageous refinement of the invention, the guide sleeve is mounted in a fixed axial position on the rear of a front plate of the insert so as to be capable of pivoting about a spindle which extends at a spacing parallel to the longitudinal direction of the laser beam. It is possible in this arrangement for this spindle to be permanently connected to the guide sleeve and guided in a laterally fitted fashion between limbs which project from the rear of the front plate. Consequently, on the one hand it is possible to pivot the guide sleeve, and with it the focussing optical system, about the spindle. On the other hand, it is also possible to displace the guide sleeve at right angles to the longitudinal direction of the laser beam, since the spindle can also be displaced between the limbs, which extend parallel to one another and have a mutual spacing which corresponds to the diameter of the spindle.
Furthermore, according to an advantageous development of the invention the guide sleeve is drawn against the rear of the front plate with the aid of springs. The springs may be guided around the guide sleeve, for example, and fastened with their ends to the rear of the front plate.
The adjusting means for the planar displacement of the focussing optical system can then project through the front plate, and may comprise screws. There are preferably present two screws which lie in the plane at an angle relative to one another, which are respectively aligned with the centre of the laser beam. Accommodated between the screws is the spindle about which the guide sleeve can pivot.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitative of the present invention, and wherein:
FIG. 1 shows a view of the front of a terminal head according to the invention including an insert;
FIG. 2 shows a top view of the terminal head according to FIG. 1;
FIG. 3 shows an axial section of the terminal head; and
FIG. 4 shows a top view of the insert according to FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows the front of the terminal head according to the invention, which is provided with the reference numeral 1. This terminal head 1 includes a housing 2 which is sealed above and below by covers 3 and 4. As may be seen from FIG. 2, the upper cover 3 has a central opening 5 through which a laser beam (not represented) enters into the terminal head 1. The cover 3 is fastened to the housing 2 by screws 6. Fastened to the underside of the cover 4 is a nozzle electrode 7 which carries at its tip a sensor electrode 8 with the aid of which a spacing between the terminal head I and the workpiece to be processed can be measured in a capacitive way. In this case, the laser beam passing through the terminal head 1 traverses the nozzle 7 and the sensor electrode 8 in order to impinge on the workpiece. Applied to the nozzle electrode 8 is a sensor potential which is fed via an electrical connection 9 with a coaxial connector 10. In this arrangement, the terminal head 1 is at earth potential, screen potential or a DC potential which can be used to detect a collision. Further, feed lines for cooling or cutting gases are located on top or at the sides of the terminal head I and will not be explained further here.
As may be seen from FIG. 1, there is located on the front of the housing 2 an opening 11 which is of rectangular construction and extends over the entire height of the housing 2. This opening 11 is sealed tight by an adaptor plate 12 which, for its part, is permanently screwed to the housing 2 with the aid of clamping screws 13 and 14. The clamping screws 13 and 14 project through the adaptor plate 12 and are screwed into side walls of the housing 2.
Located in the lower region of the adaptor plate 12 is a recess 15 through which an insert 16 is inserted in a fitted and sealing fashion into the housing 2. This insert 16 has a front plate 17 which is seated in a fitted fashion in the recess 15. In this arrangement, the insert 16 is secured against falling out of the housing 2 by the clamping screw 13. In order to prevent the insert 16 from being pushed too far into the housing 2, there are present on the front plate 17 further positioning screws 18 and 19 which are screwed into the front plate 9 and strike against the front of the adaptor plate 12 with their head.
As will be described, the insert 16 includes a focussing optical system and can be positioned as required at different heights or axial positions in the housing 2. This requires the use of an adaptor plate 12 which has a corresponding recess 15 at the desired axial position.
Located on the front of the front plate 17 of insert 16 is a handle 20 with the aid of which the insert 16 can be extracted from the housing 2. Furthermore, an adjusting ring 21, which is situated coaxially with the longitudinal direction of a laser beam and can be rotated by hand in one direction or the other, is accessible via the front plate 17. The adjusting ring 21 has a kurled area on its outer circumferential surface for this purpose. Moreover, adjusting screws 22 and 23 which serve the purpose of planar adjustment of the focussing optical system which is borne by the insert are screwed into the front plate 17. By rotating one or both adjusting screws 22, 23, the focussing optical system can be displaced in a plane at right angles to the longitudinal direction of the laser beam. A window 24 in the front plate 17 is used to read off the height of the focussing optical system which, for this purpose, can be provided with a suitable marking. A scale (not represented) can be located at the window 24.
FIGS. 3 and 4 respectively show the insert in axial section and top view. Identical elements to those in FIGS. 1 and 2 are provided in this case with identical reference numerals.
In accordance with FIG. 3, the front plate 17 has on its rear two projections 25 and 26 which are essentially of U-shaped construction and have two limbs which extend parallel to one another and whose opening points away from the front plate 17. These projections 25 and 26 can be connected in one piece with the front plate 17. One is located on the upper end of the front plate, the other being located on the lower end of the front plate. A pin 27 or 28 is respectively guided between two limbs of a respective projection 25, 26. The spacing of the two limbs, extending parallel to one another, of a respective projection 25, 26 corresponds in this case to the diameter of the pin 27, 28 respectively guided between the limbs. The pins 27, 28 can thus be displaced between the limbs, but can also rotate, specifically about their longitudinal axis.
The projections 25, 26, or limbs respectively engage in horizontal slits 29, 30, which are located in a portion of the circumferential wall of a guide sleeve 31. The pins 27, 28 pass vertically through these horizontal slits 29, 30, the pins 27, 28 themselves being permanently inserted in the respectively top and bottom wall region of the guide sleeve 31. The centre line of the guide sleeve 31 is provided in FIG. 3 with the reference numeral 32. This centre line 32 extends in the longitudinal direction of the laser beam, it thus being the case that the laser beam should be situated coaxially with the centre line 32. The pins 27, 28 extend parallel to the centre line 32, while the respective limbs of the projections 25, 26, and also the slits 29, 30, are respectively situated at right angles to the centre line 32. In this arrangement, the limbs of the projections 25, 26 are guided in the horizontal slits 29, 30 free from play when seen in the vertical direction, that is to say any direction parallel to the centre line 32. The guide sleeve 31 therefore cannot be displaced in the longitudinal direction of the centre line 32. Rather, the guide sleeve 31 can be displaced only in a plane at right angles to the centre line 32, or can be rotated about the pins 27, 28.
The guide sleeve 31 is drawn against the rear wall of the front plate 17 with the aid of springs 33. The springs 33 are laid in this arrangement around the guide sleeve 31 and fastened with their ends to pins 34 which are located inside a web 35 which is fastened to the rear of the front plate 17. Only one of these webs 35 is to be seen in FIG. 3, while the second of the webs 35 can be seen at the bottom of FIG. 4. The ends of the springs 33 are inserted into slits 36 inside the webs 35, the pins 34 being situated inside these slits 36. The pins 34 are not represented in FIG. 4, for the sake of clarity.
With the aid of the adjusting screws 22, 23 already mentioned, the guide sleeve 31 can now be displaced in a plane at right angles to the centre line 32 against the force of the springs 33. In this process, the pins 27 and 28 can likewise be displaced in the region between the respective limbs of the projections 25, 26, or can rotate about their longitudinal axis. In the top view in FIG. 4, the pin 27 is to be seen below which and coaxially with which the pin 28 is situated. The adjusting screws 22, 23 project obliquely through the front plate 17 and are screwed in threaded through bores which are located in the front plate 17. The adjusting screws 22, 23 can, for example, be grub screws, and are aligned such that they extend at 45° relative to one another and are aligned essentially with the centre of the guide sleeve 31. They strike with their front positioning surfaces against the circumferential wall of the guide sleeve 31.
The guide sleeve 31 is of cylindrical internal construction and accommodates in a fitted fashion a cylindrical lens holder 37 which can be displaced in the longitudinal direction of the guide sleeve 31. This lens holder 37 is secured against rotation, for which purpose it has on its outer circumference an axial slit 38 into which a radial securing element 39 engages, for example a grub screw which is screwed into a threaded bore inside the circumferential wall of the guide sleeve 31.
The lens holder 37 itself is likewise designed in a hollow cylindrical fashion and accommodates a focussing optical system 40 in its lower part. This focussing optical system 40 can include one or more lenses and is inserted from below into a correspondingly enlarged opening in the lens holder 37. On the circumferential side, the focussing optical system 40 rests on a corresponding shoulder 41 of the lens holder 37. In order to secure the focussing optical system 40 in the lens holder 37, it is possible to screw into the latter a securing ring 42 which is situated coaxially with the centre line 32 and via its end face presses the focussing optical system 40 against the shoulder 41. The focussing optical system 40 can also have additional spacer rings 43 for the purpose of positioning lenses.
The focussing optical system 40 can be displaced with the lens holder 37 in the longitudinal direction of the centre line 32, since the axial slit 38, into which the securing element 39 engages, permits such a displacement. In order to achieve this, the lens holder 37 is provided in its upper hollow cylindrical region with an internal thread 44 into which an adjusting cylinder 46 is screwed via an external thread 45. The external thread 45 is located on the outer circumferential surface of the adjusting cylinder 46. On its upper end or end on the side where radiation is input, this adjusting cylinder 46 has a horizontal flange 47 with which it is connected in one piece. This horizontal flange 47 rests on the end face of the guide sleeve 31 on the side where radiation is input and is connected on its external circumferential rim with the adjusting ring 21 situated coaxially with it. On its lower side, this adjusting ring has an inwardly pointing projection 48 by means of which it grips a circumferential flange 49 of the guide sleeve 31 from behind. It is achieved in this way that the adjusting ring 21 and adjusting cylinder 46 and horizontal flange 47 cannot move in the axial direction of the guide sleeve 31. For reasons of process engineering, the adjusting ring 21 and horizontal flange 47 are screwed to one another, following which they are permanently connected to one another, for example by means of securing pins or bonding. Elements 46, 47 and 21 thus form one part.
If the adjusting ring 21 is rotated, it drives the adjusting cylinder 46 correspondingly via the horizontal flange 47, which because of the engagement of the parts 47 and 45 leads to an axial displacement of the lens holder 37. Depending on the direction of rotation of the adjusting ring 21, the lens holder 37 and, with it, the focussing optical system 40 is displaced upwards or downwards. The adjusting ring 21 does not in this case touch the front plate 17 and can therefore be displaced relative to the latter, specifically with the displacement of the guide sleeve 31 via the adjusting screws 22, 23.
Located in the upper region of the adjusting cylinder 46, that is to say on its end face on the side where radiation is input, is a circumferential channel 50 which is situated coaxially with the centre line 32 and into which a pressurised, gaseous cooling medium is introduced. This circumferential channel 50 is connected to axial channels 51 which are located in the wall of the adjusting cylinder and open into an annular channel 53 which is located in the end of the adjusting cylinder 46 in the side where radiation is output. This annular channel 53 is also coaxial with the centre line 32. It is open in the direction of the centre line 32 and tapers in the direction of the end of the adjusting cylinder 46 on the side where radiation is output. Screwed into this end of the adjusting cylinder 46 is a sleeve 54 whose external wall region closes the annular channel 53 as far as possible in the radial direction, a small annular gap forming a restrictor remaining only in the axial direction. The pressurised gaseous medium then exits through this annular restrictor from the annular channel 53, in which case it expands and cools in order to then impinge on the surface of the focussing optical system 40 on the side where radiation is input. The focussing optical system 40 can be effectively cooled in this way.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A terminal head for processing a workpiece using a laser beam includes a housing into which an insert including a focusing optical system is laterally inserted. The terminal head includes a positioning device accessible from outside of the housing for displacing the focusing optical system relative to the insert. The adjusting device may displace the focusing optical system in a longitudinal direction of a laser beam and at right angles to the longitudinal direction of the laser beam. This arrangement allows the focusing optical system to be readily changed and properly adjusted within the housing.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a hydraulic anti-lock braking system for a two-wheeler and to a method for controlling a hydraulic anti-lock braking system.
[0003] 2. Description of the Related Art
[0004] A bicycle anti-lock braking system is able to increase the safety of the bicyclist and the other road users. For example, bicycle anti-lock braking systems which control the braking force mechanically with the aid of cables are known.
[0005] The growing market of electrically driven bicycles (so-called e-bikes) and the associated constant availability of electrical energy on the bicycle offer new possibilities for active bicyclist protection. The electric motor assistance of the bicyclist additionally, in principle, increases the average speed, and moreover also allows less experienced bicyclists to achieve destinations at higher altitudes.
[0006] In the motorcycle field, anti-lock braking systems are known which operate analogously to motor vehicle anti-lock braking systems using a return principle. The brake fluid is delivered from the brake back in the direction of the brake lever with the aid of a pump and a motor.
BRIEF SUMMARY OF THE INVENTION
[0007] It is the object of the present invention to provide an energy-saving anti-lock braking system for a two-wheeler which has a simple design and is low-maintenance.
[0008] One aspect of the present invention relates to a hydraulic anti-lock braking system for a two-wheeler, for example for an e-bike or a moped.
[0009] According to one specific embodiment of the present invention, the anti-lock braking system includes an inlet valve for connecting and disconnecting a hydraulic connection between a brake actuating device and a wheel brake; an accumulator or intermediate accumulator for accommodating brake fluid from the hydraulic connection between the inlet valve and the wheel brake; and an outlet valve for connecting and disconnecting the accumulator to and from the wheel brake.
[0010] The brake actuating device, which is attached to the handlebar of the two-wheeler, for example, may include a brake lever, which may be used to increase a pressure in a piston. The piston may be connected via a hydraulic connection to a wheel brake, in which a brake cylinder presses brake shoes against a brake disk or a wheel rim as a result of the hydraulic pressure, for example. An inlet valve is situated in the hydraulic connection (which may include one or multiple hydraulic lines) and may be used to prevent a pressure on the wheel brake from being increased further with the aid of the brake actuating device. The pressure on the wheel brake may be reduced via an outlet valve by being able to discharge brake fluid into an accumulator via the opened outlet valve. The accumulator may provide a variable volume, for example with the aid of a piston in a cylinder.
[0011] The accumulator is designed to return brake fluid into the hydraulic connection between the inlet valve and the wheel brake, for example by reducing its variable volume. For example, the accumulator may be emptied again by pushing back the piston.
[0012] In general, the accumulator may temporarily store the pressure present during filling and use it to automatically empty itself again.
[0013] The brake fluid is thus not delivered into the hydraulic connection between the brake actuating device and the inlet valve, but is returned to where it was withdrawn from the hydraulic connection. In this way, additional lines may be dispensed with.
[0014] A hydraulic anti-lock braking system may result in the advantages of shorter response times and lower maintenance compared to a cable-based mechanical anti-lock braking system. Moreover, a hydraulic anti-lock braking system may be adapted to existing hydraulic brakes.
[0015] Compared to an anti-lock braking system using the return principle, less electrical energy is required since only the valves have to be switched. This may result in a lower box volume and a lower weight. Since a pump having an associated motor may be dispensed with, lower costs may result.
[0016] The inlet valve, the outlet valve, and the accumulator may be combined to form a shared regulating module, which provides a shared housing for these components, the housing having ports and terminals for hydraulic and electrical lines, for example. A control circuit board having an electronic control device may also be situated in the regulating module.
[0017] According to one specific embodiment of the present invention, the accumulator includes a spring element which is tensioned when the accumulator is filled, so that the spring element automatically empties the accumulator when the pressure in the accumulator drops. For example, the spring element may be a mechanical spring element, such as a helical spring or a leaf spring. The spring element may also be an elastically compressible body or a gas volume.
[0018] According to one specific embodiment of the present invention, the inlet valve is an electrical inlet valve, which closes when energized, for example. As long as the inlet valve is not supplied with electric current, it is (completely) open, and brake fluid is able to flow unimpaired between the brake actuating device and the wheel brake. When it is supplied with electric current, the inlet valve closes (completely), and the hydraulic connection between the brake actuating device and the wheel brake is interrupted.
[0019] According to one specific embodiment of the present invention, the outlet valve is an electrical outlet valve, which opens when energized, for example. As long as the outlet valve is not supplied with electric current, it is (completely) closed, and brake fluid is not able to flow out of or to the accumulator. When it is supplied with electric current, the outlet valve opens (completely), and (depending on the pressure gradient) brake fluid is able to flow out of the accumulator into the hydraulic connection, or out of the hydraulic connection into the accumulator.
[0020] According to one specific embodiment of the present invention, the hydraulic anti-lock braking system further includes an electronic control device, which is designed to activate the inlet valve and the outlet valve and to open and close them as a function of an ascertained locked state of one wheel of the two-wheeler. When the wheel does not lock up, the two valves may remain non-energized. If the wheel locks up, initially the inlet valve may be closed, and if needed the outlet valve may be opened.
[0021] According to one specific embodiment of the present invention, the control device is designed to receive signals from a position sensor of the brake actuating device and/or from a hydraulic pressure sensor in the hydraulic connection. These signals may be used to ascertain whether a rider of the two-wheeler intends to brake. For example, the rider may actuate a brake lever of the brake actuating device and change its position, which is then detected by the position sensor. As a result, a pressure of the brake fluid in the hydraulic connection increases, which is detectable by the pressure sensor.
[0022] According to one specific embodiment of the present invention, the control device is designed to receive signals from a rotational speed sensor on a wheel and, based thereon, determine a locked state of the wheel of the two-wheeler. The rotational speed sensor may be used to ascertain a wheel circumferential speed. If the same deviates from a reference speed of the two-wheeler, this indicates the locking of the wheel.
[0023] According to one specific embodiment of the present invention, the control device is designed to output signals to a signal lamp, which indicate whether the control device has identified a locked state. For example, the signal lamp may be switched off when the wheel does not lock up, and it may flash when the wheel locks up.
[0024] According to one specific embodiment of the present invention, the inlet valve, the outlet valve, and the accumulator are connected to a first hydraulic brake circuit for a first wheel of the two-wheeler. The two-wheeler may have separate brake circuits for the two wheels. The hydraulic anti-lock braking system may include a second inlet valve, a second outlet valve, and a second accumulator, which are connected to a second hydraulic brake circuit for a second wheel of the two-wheeler. The hydraulic anti-lock braking system may be used for the front wheel and/or the rear wheel. When it is used for both wheels, two independent regulating modules, or also one shared regulating module, may be used.
[0025] It is possible for the hydraulic anti-lock braking system to have an autonomous power supply unit (independently of a power supply unit of the two-wheeler). This power supply unit may be situated in the housing of the regulating module. The hydraulic anti-lock braking system may also be used in powered two-wheelers, which have an autonomous power supply unit directly in the hydraulic regulating module or outside thereof.
[0026] A further aspect of the present invention relates to a two-wheeler having a hydraulic anti-lock braking system, as it is described above and below. In addition to electrically driven two-wheelers, the anti-lock braking system may also be used in powered two-wheelers having an internal combustion engine, in particular for lightly powered two-wheelers, for example up to a maximum speed of 40 km/h (such as motorized bicycles or mopeds).
[0027] A further aspect of the present invention relates to a method for controlling a hydraulic anti-lock braking system for a two-wheeler. The method may be carried out using an anti-lock braking system as it is described above and below. For example, the method may be carried out by an electronic control device.
[0028] According to one specific embodiment of the present invention, the method includes the following steps: ascertaining whether a wheel of the two-wheeler locks up after a pressure was built by a rider, with the aid of a brake actuating device, in a hydraulic connection which connects the brake actuating device and a wheel brake for the wheel; closing an inlet valve to disconnect the hydraulic connection when the wheel locks up; ascertaining whether the wheel of the two-wheeler locked up when the inlet valve was closed; opening an outlet valve to accommodate brake fluid in an accumulator from the hydraulic connection between the inlet valve and the wheel brake; and keeping the outlet valve open to return brake fluid into the hydraulic connection between the inlet valve and the wheel brake with the aid of the accumulator after the rider has released the brake actuating device.
[0029] For example, based on the signals of the position sensor on the brake actuating device, the control device may identify that the rider has started to brake. It is also possible for the control device to ascertain this based on the signals of an alternative or additional pressure sensor, which ascertains the pressure in the hydraulic line between the brake actuating device and the inlet valve, for example.
[0030] Based on the signals of a rotational speed sensor, the control device is then able to ascertain whether or not the wheel is locking up. If the wheel locks up, the control device closes the inlet valve (at least partially), so that the pressure on the wheel brake is not able to rise, and thus the braking force also does not increase further.
[0031] If the wheel should still be locked up after the inlet valve has been closed, the control device may open the outlet valve (at least partially), and brake fluid may flow from the wheel brake into the accumulator, so that the pressure on the wheel brake decreases, and thus also the braking force is reduced. If the accumulator is full, the rider may further increase the braking force and thus trigger an intentional locking of the wheel.
[0032] A spring element may be situated in the accumulator, for example, which is contracted when the accumulator is filled and thus absorbs energy. This energy, which was effectively introduced into the system with the aid of the brake actuating device, for example by the rider, may be used to empty the accumulator again.
[0033] After the rider has released the brake actuating device, which may also be ascertained again by the control device with the aid of the position sensor and/or the pressure sensor, the outlet valve remains open until the accumulator has been emptied again, for example with the aid of the spring element.
[0034] It shall be understood that features of the method, as described above and below, may also be features of the anti-lock braking system, and vice versa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 shows a schematic diagram of an anti-lock braking system according to one specific embodiment of the present invention.
[0036] FIG. 2 shows a schematic diagram of an anti-lock braking system according to a further specific embodiment of the present invention.
[0037] FIG. 3 shows a schematic diagram of a control device of an anti-lock braking system according to one specific embodiment of the present invention.
[0038] FIG. 4 shows a schematic diagram of a control device of an anti-lock braking system according to a further specific embodiment of the present invention.
[0039] FIG. 5 shows a diagram of a chronological progression of speeds and brake pressure, which explains a method for controlling a hydraulic anti-lock braking system according to one specific embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0040] Identical or similar parts are denoted by the same reference numerals.
[0041] FIG. 1 shows a two-wheeler 10 having a hydraulic anti-lock braking system 12 , which is designed to reduce a locking of the front wheel 14 of the two-wheeler.
[0042] The hydraulic components of anti-lock braking system 12 include a brake actuating device 16 , which is connected via a first hydraulic line 18 to a regulating module 20 , which is connected via a second hydraulic line 22 to a wheel brake 24 . Wheel brake 24 includes a wheel brake cylinder, which presses brake shoes of the wheel brake against a brake disk or a wheel rim as a result of the hydraulic pressure.
[0043] Brake actuating device 16 includes a brake lever 26 , a piston 28 having a seal 30 , and optionally a reservoir 32 for brake fluid.
[0044] Regulating module 20 , which together with electrical components may be attached in a housing 34 to two-wheeler 10 , includes an inlet valve 36 , an outlet valve 38 , and an accumulator 40 .
[0045] Inlet valve 36 is switched between first line 18 and second line 22 and connects or disconnects hydraulic connection 42 , which is formed of two lines 18 and 22 between brake actuating device 16 and wheel brake 24 . Inlet valve 36 may include a check valve, be open when de-energized, have filters on both sides and/or have a through-flow from both sides.
[0046] Outlet valve 38 is hydraulically connected to second line 22 and accumulator 40 , i.e., is connected to hydraulic connection 42 between inlet valve 36 and wheel brake 24 . Outlet valve 38 may be closed when de-energized, have filters on both sides and/or have a through-flow from both sides.
[0047] Accumulator 40 or intermediate accumulator 40 for brake fluid includes a spring element 44 , for example a return spring 44 , which tensions a piston 46 against the pressure of the brake fluid in line 22 .
[0048] Brake actuating device 16 may [include] a path sensor 48 or a position sensor 48 , which may be used to ascertain the instantaneous position of lever 26 . Based on the position of lever 26 , it is also possible to derive a pressure in first hydraulic line 18 and/or in hydraulic connection 42 . As an alternative or in addition, it is also possible to use an internal hydraulic pressure sensor 50 or an external hydraulic pressure sensor 52 to ascertain the pressure in first hydraulic line 18 and/or in hydraulic connection 42 , and based thereon optionally to derive the position of lever 26 .
[0049] Internal hydraulic pressure sensor 50 may be an integral part of regulating module 20 . External hydraulic pressure sensor 52 may be situated outside control module 20 .
[0050] A rotational speed sensor 54 is attached to wheel 14 of two-wheeler 10 and may be used to ascertain the instantaneous rotational speed or the wheel circumferential speed of wheel 14 . Rotational speed sensor 54 may include a toothed disk, which may be designed together with the brake disk, but alternatively may also be present as a separate part.
[0051] In addition to brake actuating device 16 , a signal lamp 56 may be attached to the handlebar of two-wheeler 10 , the signal lamp, as is described below, indicating to the rider of two-wheeler 10 when a control device of regulating module 20 identifies a locking of wheel 14 .
[0052] When the rider of two-wheeler 10 actuates lever 26 , a volume 58 (in a cylinder) is reduced by piston 30 , so that brake fluid flows into first line 18 and from there (if inlet valve 36 is open) reaches second line 22 and wheel brake 24 . When wheel brake 24 brakes wheel 14 , the pressure in the lines increases. As is further described below, inlet valve 36 may be closed and outlet valve 38 may be opened when wheel 14 locks up. The pressurized brake fluid from second line 22 may then reach accumulator 40 . A volume 60 (in a cylinder) is increased by the brake fluid displacing piston 46 against the force of spring element 44 . In this way, the pressure on wheel brake 24 may be reduced, even though the rider actuates lever 26 .
[0053] FIG. 2 shows a two-wheeler 10 having a hydraulic anti-lock braking system, which includes two brake circuits. The brake circuit for front wheel 14 is designed identically to the brake circuit shown in FIG. 1 .
[0054] A further brake circuit for a rear wheel 62 may also be identical to the brake circuit shown in FIG. 1 . The two brake circuits may be implemented with independent regulating modules 20 , or with one shared control module (in a shared housing 34 ), for regulating wheel 14 and/or rear wheel 62 .
[0055] FIG. 3 shows further electrical control components of hydraulic anti-lock braking system 12 . As is shown in FIG. 3 , regulating module 20 may include an electronic control device 64 , which may include a logic circuit on a printed circuit board 66 , for example having a processor.
[0056] Regulating module 20 may include terminals 68 for signal lamp 56 , rotational speed sensor 54 , position sensor 48 , and a power supply unit 65 (such as a battery of the two-wheeler). An autonomous power supply unit for regulating module 20 may be provided via an additional (internal) button cell.
[0057] Terminals 68 for regulating module 20 include supply pins and signal pins (plugs having external contacts) for ground (GND) for position sensor 48 , voltage supply (U+) for position sensor 48 and for the signal from position sensor 48 , and ground (U BAT2− ) for signal lamp 56 and voltage supply (U BAT2+ ) for signal lamp 56 .
[0058] An electrical connection or line from brake actuating device 16 to regulating module 20 may be connected to these terminals 68 .
[0059] Terminals 68 for regulating module 20 further include supply pins and signal pins (plugs having external contacts), ground (GND) for rotational speed sensor 54 , voltage supply (U+) for rotational speed sensor 54 and for the signal from rotational speed sensor 54 . An electrical connection or line from rotational speed sensor 54 on wheel 14 to regulating module 20 may be connected to these terminals 68 .
[0060] The regulating module further includes a terminal 68 for the ground (GN) of regulating module 20 and for power supply unit 65 .
[0061] Printed circuit board 66 is moreover connected to inlet valve 36 and outlet valve 38 via internal lines in regulating module 20 .
[0062] FIG. 4 shows an alternative specific embodiment for an electronic control device 64 , in which regulating module 20 includes an internal pressure sensor 50 . As an alternative or in addition, control device 64 may include a terminal 68 for an external pressure sensor 52 .
[0063] FIG. 5 shows a diagram in which speeds V are plotted against time t in an upper portion. The upper portion shows velocity 70 of two-wheeler 10 , a reference speed 72 calculated by control device 64 , and a wheel circumferential speed 74 , which is ascertained by control device 64 based on the signal of rotational speed sensor 54 .
[0064] Brake pressure 76 and fill volume 78 of accumulator 40 are plotted against time t in the lower portion. The upper portion and the lower portion show synchronous curves 70 , 72 , 74 , 76 , and 78 .
[0065] The braking process shown in FIG. 5 begins by the rider actuating brake actuating device 16 (or lever 26 ) and building pressure in hydraulic connection 42 (point in time 100 ). Wheel brake 24 is thereby activated, and speed 70 of two-wheeler 10 is reduced.
[0066] With the aid of rotational speed sensor 54 , control device 64 ascertains whether or not wheel 14 of the two-wheeler locks up. For this purpose, control device 64 calculates wheel circumferential speed 74 based on the signal of rotational speed sensor 54 , and reference speed 74 based on the signal of position sensor 58 and/or the signal of pressure sensors 50 , 52 . The locked state of wheel 14 may be ascertained by comparing reference speed 74 to wheel circumferential speed 74 .
[0067] During a braking process, during which wheel 14 continues to rotate or does not lock up (for example between point in time 100 and point in time 102 ), wheel circumferential speed 74 matches calculated reference speed 72 , and inlet valve 36 and outlet valve 28 are not energized. Inlet valve 36 is then open, and outlet valve 28 is then closed. The speed is reduced as a result of the brake pressure in wheel brake 24 . Since no locking of wheel 14 was ascertained, signal lamp 56 does not flash between points in time 100 and 102 .
[0068] If the rider releases brake actuating device 16 , the braking process is completed at this point. This may then be detected via position sensor 48 , for example, and processed in regulating module 20 .
[0069] When wheel 14 locks up, for example due to the high pressure or the low friction, control device 64 initially closes inlet valve 36 to disconnect hydraulic connection 42 (point in time 102 ). Signal lamp 56 flashes and visually indicates the regulation to the rider. The slip increases and the brake pressure is maintained between points in time 102 and 103 .
[0070] When wheel 14 then continues to rotate (differently from the case shown) and wheel circumferential speed 74 again matches calculated reference speed 72 , inlet valve 36 is no longer energized and opens again. Signal lamp 56 stops flashing and visually indicates to the rider that the regulation has ended.
[0071] Even when inlet valve 36 is closed, the control device continues to ascertain whether wheel 14 of two-wheeler 12 locks up. If wheel 14 is still locked up after some time (point in time 103 ), or wheel circumferential speed 74 does not yet match reference speed 72 of wheel 14 , control device 64 opens outlet valve 48 to accommodate brake fluid in accumulator 40 from hydraulic connection 42 between inlet valve 36 and wheel brake 24 . A pressure reduction takes place in wheel brake 24 , and brake fluid from the brake circuit is accommodated in accumulator 40 . Fill volume 78 of accumulator 40 increases.
[0072] A pressure reduction thus takes place in wheel brake 24 between points in time 103 and 104 .
[0073] At point in time 104 , control device 64 closes outlet valve 38 again. Since the inlet valve is still closed, the pressure is maintained. Wheel 14 accelerates again between points in time 104 and 196 .
[0074] When wheel circumferential speed 74 again approaches reference speed 72 , control device 64 may briefly open inlet valve 36 to enable a pressure buildup on wheel brake 24 . This may be carried out in a gradual pressure buildup, for example as shown between points in time 106 and 108 .
[0075] A renewed pressure reduction is shown between points in time 108 and 110 , during which volume 60 of accumulator 40 is filled completely up to a maximal volume 80 . Since wheel 14 locks up again, even though inlet valve 36 is closed, control device 64 opens outlet valve 38 again. The regulation continues until volume 60 in accumulator 40 has been completely filled.
[0076] The hydraulic circuit is designed in such a way that volume 58 in brake actuating device 16 is greater than volume 60 in accumulator 40 . It is thus ensured that braking continues to be possible with a completely filled accumulator 40 after a pressure reduction. Wheel 14 may then lock up when a corresponding rider input and friction (for example in the event of ice or stone chips) occur.
[0077] The pressure is then maintained between points in time 110 and 112 , and the braking process is ended after the rider has released brake actuating device 16 .
[0078] After the rider has released brake actuating device 16 (point in time 112 ), control device 64 keeps outlet valve 48 open in order to return brake fluid into hydraulic connection 42 between inlet valve 36 and wheel brake 24 . Accumulator 40 accomplishes this automatically with the aid of spring element 44 tensioned by the pressure. The spring force of accumulator 40 pushes the volume accommodated during the regulation back into the brake circuit via energized outlet valve 38 . Accumulator 40 is completely emptied between points in time 114 and 166 , during which the pressure in the hydraulic line has dropped below the pressure in accumulator 40 . The level in optionally present brake fluid container 32 rises.
[0079] In the event of a fault, for example when the rechargeable battery or power supply unit 65 , control device 64 and/or regulating module 20 (a valve 26 , 38 , for example) is/are defective, signal lamp 56 is permanently illuminated and indicates to the rider that one of the above-described defects has occurred.
[0080] In addition, it shall be pointed out that “including” does not exclude other elements or steps, and that “a” or “an” does not exclude a plurality. It shall moreover be pointed out that features or steps which were described with reference to one of the above-mentioned exemplary embodiments may also be used in combination with other features or steps of other above-described exemplary embodiments. Reference numerals in the claims shall not be regarded as limiting.
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A hydraulic anti-lock braking system for a two-wheel vehicle includes: an inlet valve for connecting and disconnecting a hydraulic connection between a brake actuating device and a wheel brake; an accumulator for accommodating brake fluid from the hydraulic connection between the inlet valve and the wheel brake; and an outlet valve for connecting and disconnecting the accumulator to and from the wheel brake. The accumulator is designed to return brake fluid into the hydraulic connection between the inlet valve and the wheel brake.
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[0001] This application is a continuation of U.S. application No. 10/141,644, filed on May 6, 2002, which is a continuation-in-part of U.S. application Ser. No. 09/968,566, filed on Sep. 29, 2001, which is a continuation of U.S. application Ser. No. 09/870,227, filed on May 30, 2001, now U.S. Pat. No. 6,340,098, which is a continuation of U.S. application Ser. No. 09/568,926, filed on Feb. 13, 2001, now U.S. Pat. No. 6,269,975, which is a continuing prosecution application of U.S. application Ser. No. 09/568,926, filed on May 10, 2000, now abandoned, which is a divisional of U.S. application Ser. No. 09/224,607, filed on Dec. 31, 1998, now U.S. Pat. No. 6,098,843, which is a continuation of U.S. application Ser. No. 09/222,003, filed on Dec. 30, 1998, now abandoned. This application incorporates by reference each application and each patent listed above.
BACKGROUND
[0002] The present invention relates generally to systems and methods for mixing and/or delivering of liquid chemical(s), and more particularly, to systems and methods for mixing and delivering liquid chemicals in precise amounts using logic devices and multi-reservoir load cell assemblies.
[0003] The present invention has many applications, but may be explained by considering the problem of how to deliver photoresist to silicon wafers for exposure of the photoresist in the process of photolithography. To form the precise images required, the photoresist must be delivered in precise amounts on demand, be free of bubbles, and be of precise uniform thickness on the usable part of the wafer. The conventional systems have problems as discussed below.
[0004] As shown in FIG. 1, a representative conventional photoresist delivery system includes supply containers 100 , 102 , typically bottles, which supply photoresist to a single-reservoir 104 by line 117 , which is connected to supply lines 106 , 108 monitored by bubble sensors 110 , 112 and controlled by valves V 1 and V 2 . The bottom of the reservoir is connected to a photoresist output line 114 to a track tool (not shown), which dispenses photoresist on the wafer. The space above the photoresist in the reservoir 104 is connected to a gas line 118 which, based on position of a three-way valve V 3 , either supplies nitrogen gas to the reservoir 104 from a nitrogen manifold line 126 , regulated by needle valve 1 , or produces a vacuum in the reservoir 104 . To sense the level of the photoresist in the reservoir 104 , the system employs an array of capacitive sensors 122 arranged vertically on the walls of the reservoir 104 . A two-way valve V 4 , located between the nitrogen gas manifold and the inlet of a vacuum ejector 124 , supplies or cuts off flow of nitrogen to the vacuum ejector 124 .
[0005] The photoresist delivery system must be “on-line” at all times so the track tool can dispense the photoresist as required. Many of the photoresist delivery systems attempt to use the reservoir to provide an on-line supply of photoresist to the track tool, but the photoresist delivery system must still refill the reservoir on a regular basis, which is dependent on timely replacement of empty supply containers. Otherwise, the track tool will still fail to deliver the photoresist when demanded.
[0006] During dispense mode, when the track tool withdraws photoresist from the reservoir 104 , the valve V 3 permits the nitrogen to flow from the nitrogen manifold to the reservoir 104 to produce a nitrogen blanket over the photoresist to reduce contamination and to prevent a vacuum from forming as the photoresist level drops in the reservoir. Once the photoresist in the reservoir 104 reaches a sufficiently low level the system controller (not shown) initiates refill mode, where a set of problems arise.
[0007] During refill mode, the valve V 4 is activated so that nitrogen flows from the manifold line 126 to the vacuum ejector 124 , which produces a low pressure line 170 thereby producing a low pressure space above the photoresist in the reservoir 104 . The bubble sensors 110 , 112 monitor for bubbles in the supply lines 106 , 108 , presumed to develop when the supply containers 100 , 102 , become empty. If, for example, the bubble sensor 110 detects a bubble, the controller turns off the valve V 1 to supply container 100 and the valve V 2 opens to supply container 102 to continue refilling the reservoir 104 . However, bubbles in the supply line 106 may not mean supply container 100 is empty. Thus, not all of the photoresist in supply container 100 may be used before the system switches to the supply container 102 for photoresist. Thus, although the conventional system is intended to allow multiple supply containers to replenish the reservoir when needed, the system may indicate that a supply container is empty and needs to be replaced before necessary.
[0008] If the supply container 100 becomes empty and the operator fails to replace it and the system continues to operate until the supply container 102 also becomes empty, the reservoir 104 will reach a critical low level condition. If this continues, bubbles may be arise due to photoresist's high susceptibility to bubbles; if a bubble, however minute, enters the photoresist delivered to the wafer, an imperfect image may be formed in the photolithography process.
[0009] Further, if the pump of the track tool, connected downstream of the chemical output line 114 , turns on when the reservoir is refilling, the pump will experience negative pressure from the vacuum in the single-reservoir pulling against the pump. Several things can happen if this persists: the lack of photoresist delivered to the track tool may send a false signal that the supply containers are empty, the pump can fail to deliver photoresist to its own internal chambers, lose its prime and ability to adequately dispense photoresist, and the pump can even overheat and burn out. The result of each scenario will be the track tool receives insufficient or even no photoresist, known as a “missed shot,” which impacts the yield of the track tool.
[0010] The present invention also may be explained by considering the problems associated with mixing and delivering slurry for chemical mechanical polishing (CMP). In semiconductor manufacturing, a slurry distribution system (SDS) delivers CMP slurry to the polisher. For example, Handbook of Semiconductor Manufacturing Technology (2000), which is incorporated by reference, describes delivery of CMP slurries to a polisher and shows an arrangement for a SDS at page 431 . In some applications, the SDS needs to mix the components of the slurry in a mix tank. During mixing and handling of the slurry, the SDS must not damage the slurry by subjecting it to too much shear, which may cause aggregation, or too little shear, which may cause settling. A pump may transfer the slurry to a distribution tank when required by the process tool. The SDS should handle a variety of chemistries because a CMP slurry formulation is often tailored to each process. The SDS should introduce precise of amounts of the slurry components into a mix tank so that the slurry mixture is known. At times, there also needs to be a precise flow rate to the process tool and/or delivery at low flow rates. At low flow rates sometime microbubbles form in the dispense lines, which prevents slurry delivery. It would be desirable to clear lines without shut down of the SDS. Of course, reliability for flawlessly daily manufacturing and delivery of the slurry is also desired, as well as ease of regular maintenance to avoid varying slurry composition that may affect process results.
[0011] Flow meters are commonly used to control the flow rates of chemicals. Flow meters are usually only accurate to within 2-3% of the desired flow rate, and are also susceptible to changes due to input pressure. Second, some chemicals will cause the flow meter to plug up and allow no flow, i.e. slurries. Another method for controlling flow is to use a “push” gas to pressurize a reservoir, and then adjust the push gas pressure to adjust the flow rate. This method also will not allow accurate flow rates, due to the potential of the push gas pressure changing, and the flow rate varying as the level within the reservoir changes.
[0012] The present invention addresses these problems as well as avoids waste of chemicals, provides a friendly user interface depicting the amount of chemicals remaining in the supply containers, and reduces system capital and operating costs. If, for example, the amount of chemical in the supply containers cannot be seen, the present invention permits the interface to be provided at a distance by conventional computer network capabilities and the electronics provided.
SUMMARY OF THE INVENTION
[0013] The present invention relates to systems using controllers or logic devices and multi-reservoir load cell assemblies for precision mixing and/or delivery of liquid chemicals. It also relates to methods of delivering liquid chemicals from supply sources to processes such that the present invention accurately accounts and adjusts for the dynamic supply and use of the liquid chemical to meet process requirements. Finally, the present invention provides multi-reservoir load cell assemblies for monitoring, regulating, and analyzing the liquid supply available to a process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 illustrates a chemical delivery system using a single-reservoir and bubble sensors on the supply lines leading to the single-reservoir.
[0015] [0015]FIG. 2A is a front cross-section of a first embodiment of the multi-reservoir load cell assembly of the present invention.
[0016] [0016]FIG. 2B is a top view of the first embodiment of the multi-reservoir load cell assembly.
[0017] [0017]FIG. 3, a piping and instrument diagram, illustrates embodiments of the chemical delivery system including the multi-reservoir load cell assemblies of FIGS. 2 A- 2 B or 4 A- 4 B.
[0018] [0018]FIG. 4A is a front cross-section of a second embodiment of the multi-reservoir load cell assembly.
[0019] [0019]FIG. 4B is a side cross-section of the second embodiment of the multi-reservoir load cell assembly.
[0020] [0020]FIG. 5A is a front cross-section of a third and sixth embodiment of the multi-reservoir load cell assembly.
[0021] [0021]FIG. 5B is a side cross-section of the third and sixth embodiment of the multi-reservoir load cell assembly.
[0022] [0022]FIG. 6, a piping and instrument diagram, illustrates embodiments of the chemical delivery system including the multi-reservoir load cell assemblies of FIGS. 5 A- 5 B or 11 A- 11 B.
[0023] [0023]FIG. 7A is a front cross-section of a fourth embodiment of the multi-reservoir load cell assembly.
[0024] [0024]FIG. 7B is a side cross-section of the fourth embodiment of the multi-reservoir load cell assembly.
[0025] [0025]FIG. 8, a piping and instrument diagram, illustrates an embodiment of the chemical delivery system including the multi-reservoir load cell assembly of FIGS. 7 A- 7 B.
[0026] [0026]FIG. 9A is a front cross-section of a fifth embodiment of the multi-reservoir load cell assembly.
[0027] [0027]FIG. 9B is a side cross-section of the fifth embodiment of the multi-reservoir load cell assembly.
[0028] [0028]FIG. 10, a piping and instrument diagram, illustrates an embodiment of the chemical delivery system including the multi-reservoir load cell assembly of FIGS. 9 A- 9 B.
[0029] [0029]FIG. 11A is a front cross-section of a seventh embodiment of the multi-reservoir load cell assembly.
[0030] [0030]FIG. 11B is a side cross-section of the seventh embodiment of the multi-reservoir load cell assembly.
[0031] [0031]FIG. 12, a piping and instrument diagram, illustrates an embodiment of the chemical mix and delivery system.
[0032] [0032]FIG. 13, a flow chart, illustrates a flow rate control system using the diminishing weight of liquid in at least one of the reservoirs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] In the first embodiment, the present invention includes a multi-reservoir load cell assembly 200 as shown in FIGS. 2 A- 2 B. The assembly 200 can be part of the system shown in FIG. 3, and can replace the problematic single-reservoir 104 and bubble sensors 110 , 112 of FIG. 1.
[0034] In this embodiment, the assembly 200 , constructed of Teflon, SST, polypropylene or any chemical compatible material, includes an upper compartment 202 , a main reservoir 206 , and a buffer reservoir 208 , all in an outer housing 212 . The buffer reservoir 208 is sealed from the main reservoir 206 by a separator 209 , and an o-ring seal 211 seals the perimeter of the separator 209 to the outer housing 212 . The separator 209 uses a center conical hole 250 that allows an internal sealing shaft 204 to form a liquid and gas-tight seal with the separator 209 . The separator 209 forms a liquid and gas-tight seal to the pneumatic tube 215 with an o-ring seal 210 . The main reservoir 206 contains a middle sleeve 214 that forms a rigid separation between the separator 209 and the reservoir cap 205 . O-ring 203 seals the perimeter of the reservoir cap 205 seals against the internal surface of the outer housing 212 . The reservoir cap 205 seals against the internal sealing shaft 204 , the chemical input tube 217 , and the pneumatic tubes 215 and 218 with a set of o-ring seals 207 , 220 , 222 , and 224 (hidden, but location shown in FIG. 2B), respectively. Mounted to the reservoir cap 205 is a spacer 244 , which also mounts to the pneumatic cylinder 226 . The reservoir cap 205 is held in position by the upper sleeve 233 and the middle sleeve 214 . The outer Teflon reservoir top 201 is bolted to the outer housing 212 and forms a mechanical hard stop for the upper sleeve 233 and the pneumatic cylinder 226 . Pneumatic airlines for the pneumatic cylinder 226 penetrate the outer Teflon reservoir top 201 through the clearance hole 260 .
[0035] It should be clear that the present invention is not limited to the delivery of CMP slurries or photoresist on silicon wafers. For example, although the invention shows advantages over the conventional system in this environment, the systems of the present invention can deliver other liquid chemicals for other types of processes. Because the novelty of the present invention extends beyond the nature of the chemical being delivered, the following description refers to the delivery of chemicals to avoid a misunderstanding regarding the scope of the invention.
[0036] As shown in FIG. 3, the multi-reservoir load cell assembly 200 shown in FIGS. 2 A- 2 B is suspended on and weighed by a load cell 412 , preferably such as a Scaime load cell model no. F60X10C610E and a programmable logic controller (PLC) 330 , preferably such as the Mitsubishi FX2N, a computer, or another conventional logic device determines the volume of the chemical in the assembly 200 from the load cell weight and the specific gravity of the chemical. For brevity, we will refer to that logic device as a PLC. As chemical from line 217 is drawn into the main reservoir 206 , the load cell 412 outputs a small mV analog signal 324 proportional to the weight on the load cell 412 . In one embodiment, an ATX-1000 signal amplifier 326 boosts the small signal 324 to the 4-20 millivolt range and sends it to an analog-to-digital converter 328 , such as the Mitsubishi FX2N4-AD, and the output digital signal 332 is sent to the PLC 330 . The PLC 330 can be rapidly programmed by conventional ladder logic. During withdrawal of the chemical, the weight of the assembly 200 decreases until the software set point of the PLC 330 is reached.
[0037] As further shown in FIG. 3, the PLC 330 may control valves V 1 -V 5 using 24 DC Volt solenoid actuated valves, and activate them by an output card such as the Mitsubishi FX2N. Each solenoid valve, when opened, allows pressurized gas from regulator 2 such as a VeriFlow self-relieving regulator, to the pneumatically operated valves V 1 -V 5 to open or close the valves. The sequence of operation of the first embodiment is programmed in the PLC 330 so the components shown in FIGS. 2 A- 2 B and 3 work as described below.
[0038] Once the chemical drops to a certain level, the PLC 330 triggers the system shown in FIG. 3 to begin an automatic refill sequence using the multi-reservoir load cell assembly 200 of FIGS. 2 A- 2 B as follows:
[0039] a) A blanket of preferably low pressure, e.g., one psi inert gas is continuously supplied by the regulator 1 , such as a Veriflow self-relieving regulator, to the main reservoir 206 by the pneumatic tube 218 .
[0040] b) The pneumatic cylinder 226 lifts the internal sealing shaft 204 , thereby sealing the buffer reservoir 208 from the main reservoir 206 .
[0041] c) Once the buffer reservoir 208 is sealed, the main reservoir 206 is evacuated to a vacuum of approximately 28 inches of mercury. As shown in FIGS. 2 A- 2 B, the pneumatic tube 218 from the main reservoir 206 connects to the output side of a three-way valve V 4 . Valve V 4 is actuated so that the tube 218 communicates with the line 316 connected to the vacuum ejector 324 as shown in FIG. 3. The vacuum ejector 324 is powered by compressed gas, which is directed to it by the two-way valve V 5 . Once valve V 5 is on, it allows compressed gas to pass through and the vacuum ejector 324 develops about 28 inches of mercury (vacuum) through the line 316 communicating with the main reservoir 206 .
[0042] d) The vacuum is isolated from the buffer reservoir 208 , which has an inert gas slight blanket above it and continues to supply chemical to the process or tool without exposing the chemical being delivered to the tool to negative pressure or a difference in pressure.
[0043] e) The vacuum generated in the main reservoir 206 creates a low pressure chemical line that is connected to the valves V 1 and V 2 . Assuming that valve V 2 opens, the low pressure line 217 causes chemical from the supply container 102 to flow into the main reservoir 206 . During this period of time the main reservoir 206 refills with chemical until a determined full level is achieved.
[0044] f) The full level is determined by use of the load cell 412 and weight calculations performed by the PLC 330 . For example, one preferred embodiment uses a buffer reservoir 208 with a volume capacity of 439 cubic centimeters (cc) and a main reservoir 206 with a capacity of 695 cc. Using the specific gravity of the chemical, the PLC 330 calculates the volume that the chemical occupies. The PLC 330 then begins a refill sequence once the chemical volume reaches or falls below 439 cc. The refill stops once the chemical volume reaches 695 cc. This sequence allows nearly all of the 439 cc of the chemical in the buffer reservoir 208 to be consumed while refilling the main reservoir 206 with the 695 cc of chemical and prevents overflow of the main reservoir 206 or complete evacuation of chemical from the buffer reservoir 208 .
[0045] g) Once the main reservoir 206 has refilled, the valve V 5 is turned off, thereby stopping gas flow to and vacuum generation by the vacuum ejector 324 . The three-way valve V 4 is then switched so that the inert gas line 218 communicates with the main reservoir 206 and an inert gas blanket is again formed over the chemical in the main reservoir 206 at the same pressure as the buffer reservoir 208 , since both lines 218 , 215 receive gas from the same inert gas manifold 318 (see FIG. 3). Also, the valve V 2 is closed which now isolates the supply container 102 from the main reservoir 206 .
[0046] After the main reservoir 206 is full of chemical with an inert gas blanket above, the internal sealing shaft 204 is lowered and allows chemical from the main reservoir 206 to flow into the buffer reservoir 208 . Eventually, the buffer reservoir 208 completely fills along with a majority of the main reservoir 206 . The pneumatic tube 215 connecting the buffer reservoir 208 fills with chemical until the chemical in the tube 215 reaches the same level as the main reservoir 206 , because the pressures in both reservoirs are identical. The internal sealing shaft 204 remains open until it is determined, to once again, refill the main reservoir 206 .
[0047] Because the first embodiment uses load cells instead of bubble sensors for determining the amount of chemical in the supply containers, the present invention provides a number of very useful features. One can accurately determine in real-time the chemical remaining in the supply containers. If the supply containers are full when connected to the system, the PLC can easily calculate the chemical removed (and added to the multi-reservoir load cell assembly) and how much chemical remains in the supply containers. This information can be used to provide a graphical representation of the remaining amount of chemical in the containers. A second feature is that the PLC can determine precisely when a supply container is completely empty by monitoring the weight gain within the system. If the weight of the reservoir does not increase during a refill sequence then the supply container is inferred to be empty. This causes the valve for the supply container to be closed and the next supply container to be brought on line. A related third feature is the load cell technology provides the ability to accurately forecast and identify the trends in chemical usage. Since the exact amount of chemical is measured coming into the reservoir the information can be easily electronically stored and manipulated and transmitted.
[0048] A second embodiment of the multi-reservoir load cell assembly 400 shown in FIGS. 4 A- 4 B, includes a buffer reservoir 408 , fastened and sealed by the o-rings 411 to the bottom cap 410 . The output chemical flows through tube connection 401 . Connected to the buffer reservoir 408 are a pneumatic tube 415 , a chemical valve 407 , a load cell separator 413 , and the load cell 412 . The load cell 412 is securely bolted to the buffer reservoir 408 and the other side is securely bolted to a rigid member (not shown) not part of the multi-reservoir load cell assembly 400 . The outer sleeve 404 slips around the buffer reservoir 408 and rests against the bottom cap 410 . The outer sleeve 404 is machined to allow the load cell 412 to pass through it unencumbered. End 405 of the valve 407 connects to the main reservoir 406 and the other end 409 connects to buffer reservoir 408 . The main reservoir 406 is encapsulated and sealed, by o-rings in the upper cap 403 . The upper cap 403 incorporates a stepped edge along its periphery to secure the outer sleeve 404 to it. Pneumatic line 418 and chemical input line 417 are secured to the upper cap 403 . The outer sleeve 404 provides the mechanical strength for the separate reservoirs 406 and 408 .
[0049] The multi-reservoir load cell assembly shown in FIGS. 4 A- 4 B, and used in the system of FIG. 3, is similar to the first embodiment with the following notable differences:
[0050] a) Valve 407 provides control of the fluid path between the main reservoir 406 and the buffer reservoir 408 .
[0051] b) The outer sleeve 404 provides the mechanical support to form the rigid assembly that supports the main reservoir 406 as well as the buffer reservoir 408 .
[0052] A third embodiment of the multi-reservoir load cell assembly shown in FIGS. 5 A- 5 B, employs two reservoirs 506 , 508 spaced apart from each other but connected by a flexible fluid line 516 . The third embodiment uses many of the previous components shown in FIGS. 4 A- 4 B, except: (i) it does not use an outer sleeve 404 ; (ii) the buffer reservoir 508 is not mechanically suspended from the main reservoir 506 ; and (iii) the load cell spacer 513 and the load cell 512 are fastened to the bottom of the main reservoir 506 .
[0053] The third embodiment operates like the second embodiment except the load cell 512 only measures the volume of chemical in the main reservoir tank 506 as shown in FIGS. 5 A- 5 B and 6 . The advantage of the third embodiment is the precise amount of chemical brought into the main reservoir 506 is always known and the PLC does not have to infer the amount of chemical that was removed from the buffer reservoir 508 during a refill operation. The third embodiment can be used in the system of FIG. 6 with the control system (i.e., PLC, A/D, signal amplifier, etc.) of FIG. 3. Note, in the application, the lead digit of the part numbers generally indicates which drawing shows the details of the part, while the trailing digits indicate that the part is like other parts with the same trailing digits. Thus, the buffer reservoir 206 and the buffer reservoir 306 are similar in function, and found in FIG. 2A and FIG. 3A, respectively.
[0054] A fourth embodiment of the multi-reservoir load cell assembly 700 shown in FIGS. 7 A- 7 B, employs the same components as the third embodiment, however, a second load cell 722 is attached to the buffer reservoir 708 . The assembly 700 is preferably used with the system of FIG. 8 with the control system of FIG. 3 with additional components for the second load cell.
[0055] The fourth embodiment of the multi-reservoir load cell assembly 700 shown in FIGS. 7 A- 7 B, operates much like the second embodiment except that the load cell 712 only measures the chemical in the main reservoir 706 and the load cell 722 only measures the chemical in the buffer reservoir 708 . The advantage here is the buffer reservoir 708 is constantly monitored so if the downstream process or tool suddenly consumes large amounts of chemical during a refill cycle, the system can stop the refill cycle short to bring chemical into the buffer reservoir 708 from the main reservoir 706 to prevent the complete evacuation of chemical from the buffer reservoir 708 .
[0056] A fifth embodiment of the multi-reservoir load cell assembly 900 shown in FIGS. 9 A- 9 B uses the same components as the third embodiment, except the load cell 912 is attached to the buffer reservoir 908 instead of the main reservoir 906 . The fifth embodiment is preferably used in the system depicted in FIG. 10 with the control system (i.e., PLC, A/D, signal amplifier, etc.) shown in FIG. 3.
[0057] Functionally, the fifth embodiment of the multi-reservoir load cell assembly 900 operates the same as the second embodiment, the only difference is the load cell 912 only weighs the chemical in the buffer reservoir 908 .
[0058] As the process or tool consumes the chemical, the weight of the buffer reservoir 908 remains constant until the main reservoir 906 also becomes empty. Then the weight in the buffer reservoir 908 will start to decrease, indicating that the main reservoir 906 needs to be refilled. At this point the main reservoir 906 is refilled for a calculated period of time. During this sequence the buffer reservoir 908 decreases until the main reservoir 906 has been refilled and the valve 907 has been reopened between the two reservoirs 906 , 908 .
[0059] A sixth embodiment uses the same components of third embodiment shown in FIGS. 5 A- 5 B. The only notable difference is that the inert gas blanket (see FIG. 6) of approximately one psi is increased to approximately 80 psi (more or less depending on the type of chemical). The increased inert gas pressure enables the sixth embodiment to use pressure to dispense the chemical at a constant output pressure, which remains unaffected even during the refill cycle. This method would allow very precise non-pulsed output flow of the chemical. This may be a highly critical feature in an ultra high purity application that pumps the chemical through a filter bank. Any pulsation of the chemical can cause particles to be dislodged from the filter bank into the ultra-pure chemical output flow.
[0060] A seventh embodiment uses the same components as the third embodiment with additional components shown in FIGS. 11 A- 11 B, including a main reservoir 1106 , a buffer reservoir 1108 , a second chemical input line 1119 added to the main reservoir 1106 through the valve 1122 , a valve 1123 added to the chemical input line 1117 , and a stir motor 1120 and an impeller assembly 1121 .
[0061] Functionally, the seventh embodiment operates the same as the third embodiment with the added capability of mixing two chemicals in precise proportions before transferring the mixture to the buffer reservoir 1108 . The chemical can be drawn into the main reservoir 1106 through open valve 1123 and the chemical input line 1117 and weighed by the load cell 1112 . When the proper amount has been drawn into the main reservoir 1106 , the valve 1123 is closed and the valve 1122 is opened to allow the second chemical to enter the main reservoir 1106 . When the proper amount has been drawn into the main reservoir 1106 , the valve 1122 is closed and the chemicals are blended via the stir motor 1120 and impeller assembly 1121 . The stirring of the chemicals can be initiated at any time during the above sequence. Once the mixing is complete, the valve 1107 opens to allow the chemical to transfer to the buffer reservoir 1108 , which is also connected to gas line 1115 . This is an ideal way to mix time sensitive chemistries and maintain a constant, non-pulsed output of the blended chemicals.
[0062] [0062]FIG. 12, a piping and instrument diagram, illustrates an embodiment of a chemical mixing and delivery system. For clarity we will discuss how the system can be used to mix components together into CMP slurry, but the system can be used to mix other chemicals. FIG. 12 contains many parts, so to avoid clutter we use double-digit part numbers rather than four-digit as the leading and trailing digit convention would require as discussed at page 13 .
[0063] The system includes a main reservoir 69 with DI water lines supplying DI water through a gross fill valve 41 and a flow control valve 43 , and a fine fill valve 42 . In an embodiment, the gross fill valve is a {fraction (3/8)}-inch valve, and the fine fill valve is a {fraction (1/4)}-inch valve. As discussed in connection with FIG. 3, the PLC may control valves using 24 DC Volt solenoid actuated valves, and activate them by an output card such as the Mitsubishi FX2N. Each solenoid valve, when opened, allows pressurized gas from regulator such as a VeriFlow self-relieving regulator, to the pneumatically operated to open or close the valves. These actuators will be referred to in the specification, but will not be shown in FIG. 12 to reduce clutter.
[0064] In an embodiment, the PLC sends a signal to such an actuator to open the gross fill valve 41 permitting water to rapidly begin to fill the main reservoir 69 . When the main reservoir 69 contains almost sufficient water, the PLC provides another signal to an actuator to close the gross fill valve 41 and to intermittently open and close the fine fill valve 42 , so called “chatter” the valve. This permits the system to add the precise balance of DI water required for the mixture. Of course, this gross fill and fine fill arrangement can be used for any component but is most useful if there is a major amount of that component in the final mixture. The flow control valve 43 is a manual or automatic controlled valve that compensates for the different water pressures available at a given facility.
[0065] The DI water recirculates through a bypass 40 then back to the DI return. If the velocity of the water recirculating is kept above some level such as seven feet/sec, it will reduce or eliminate bacteria formation. The purpose of the DI water is to dilute Chem A, which represents slurry. The slurry passes through a fine fill valve 44 to the main reservoir 69 , through a bypass 53 and recirculates to the Chem A return, which reduces the settling of abrasives suspended in the Chem A.
[0066] Chemicals B-D represent other components used in small amounts such as stabilizers, surfactants, and pad conditioners supplied through fine fill valves 46 - 48 into the main reservoir 69 . The PLC sends control signals to admit Chem A through Chem D sequentially so that the load cells 12 and 13 of the main reservoir 69 can weigh each component accurately. The two load cells shown in FIG. 12 may permit higher accuracy than one load cell, but the number of load cells is not essential to the invention. The PLC also sends control signals to the engage the main mixer motor 20 , which rotates the shaft 24 and impeller 21 , which stirs the components into CMP slurry. Process requirements will define the best time period and rpm for the impeller 21 . The impeller 21 will continuously stir certain CMP slurry formulations.
[0067] As shown at the top of FIG. 12, an inert gas supply provides inert gas through a regulator, a safety pressure relief valve 33 , and a check valve 35 to an inert gas humidifier. For some CMP slurries nitrogen is preferred, but other chemicals require other gases. One of ordinary skill will know what inert gas is suitable for a given CMP formulation. For brevity we will discuss the inert gas as being nitrogen, which is bubbled through a tube in the DI water to humidify the nitrogen. This reduces the caking of the CMP slurry mixture inside the main and buffer reservoirs. The humidified nitrogen is supplied through the main reservoir pressure regulator 51 , an inlet pressure valve 50 , and to the main reservoir 69 . The vent valve 49 is a safety valve, which is normally open (NO) when not actuated. As known, the set of check valves 16 , 35 , 37 , 39 , 76 , 86 ,and 99 prevent backflow on the associated lines.
[0068] The main reservoir 69 transfers the mixed CMP slurry to buffer reservoir(s). In one embodiment, the main reservoir 69 holds two liters so that it can effectively service each of two buffer reservoirs 71 , 92 , holding one liter each. The transfer of the CMP slurry passes through a main reservoir outlet valve 58 , through a line, then to a buffer reservoir inlet valve 60 . Likewise, the main reservoir 69 transfers the CMP slurry initially through a main reservoir outlet valve 57 , through a line, then to a buffer reservoir inlet valve 97 . The process tool determines when the buffer reservoirs 71 and 92 deliver the CMP slurry through dispense lines 1 and 2 . Manual valves 84 and 85 are associated with the dispense lines 1 and 2 lines for safety.
[0069] Buffer reservoirs 71 and 92 each include a proportional valve block, which will be used by the PLC to control the pressure in each buffer reservoir. The PLC sends control signals to the proportional valve block to maintain the pressure in the buffer reservoirs that is necessary to achieve a desired flow rate of CMP slurry from the buffer reservoirs. For example, the pressure transducer, PT in FIG. 12, reads the pressure in the buffer reservoir 71 and sends a signal indicative of that pressure to the PLC. Based on the measured pressure and the pressure set point, the PLC will send signals to the proportional valve block to either open a buffer control inlet valve 80 to increase the buffer reservoir pressure 71 or open a buffer control outlet valve 81 to decrease the buffer reservoir pressure 71 . Likewise, the pressure transducer of buffer reservoir 92 reads the pressure and sends signals to the proportional valve block to maintain the pressure necessary for a desired flow rate of CMP slurry from the buffer reservoir 92 . Based on the PLC signals, the proportional valve block will either open a buffer control inlet valve 56 to increase or open buffer control outlet valve 52 to decrease the pressure of the buffer reservoir 92 . The buffer reservoir 92 also includes an optional buffer manifold 90 , which can be used as a mounting surface to connect multiple buffer outlet valves, but is not required for a single buffer outlet valve 87 as illustrated. The buffer reservoir 71 is shown with a buffer manifold 72 , which is also not required for a single buffer outlet valve 73 .
[0070] A pinch valve is located downstream of the buffer outlet valve 73 , and another downstream of buffer outlet valve 87 . FIG. 12 shows one suitable control arrangement for the pinch valve of buffer reservoir 71 , which can be used for other buffer reservoirs such as the buffer reservoir 92 . In this arrangement, the PLC connects to an air actuator 78 , which controls the flow rate of clean dry air (CDA) passing through a pressure regulator 79 . Although not depicted in FIG. 12, it should be evident that the same communication channels, clean dry air source, and CDA lines can be used as one embodiment for the control of the pinch valve of the buffer reservoir 92 . The signal amplifier 77 , the A/D converter, and the load cells shown in FIG. 12 can be the same parts and have the same operation described in the earlier embodiments. The mixer motor 93 rotates shaft 94 and impeller 95 in the buffer reservoir 92 , and the mixer motor 71 rotates shaft 65 and impeller 66 in the buffer reservoir 71 . The buffer reservoirs 71 and 92 include buffer reservoir vent valves 62 and 53 , which are normally open to release pressure when not in service as safety features.
[0071] The parts described can be obtained from the following vendors. Partek, A Division of Parker Corporation located in Tucson, Ariz. can provide suitable gross fill valves, part no. PV36346-01, fine fill valves, part no. PV106324-00, valve manifolds 70 , 72 , and 90 , part no. CASY1449, and check valves part number CV1666. Another suitable PLC is the Mitsubishi AG05-SEU3M. A suitable proportional valve block is part no. PA237 manufactured and/or sold by Proportion Aire, Inc. located in McCordsville, Ind. A suitable inert gas humidifier part no. 43002SR01, and pinch valve, part no. PV-SL-.25, are manufactured and/or sold by Asahi America located in Malden, Mass.
[0072] In operation, the chemical mix and delivery system has different modes. The initial mode is a fill or refill sequence where the system adds and mixes together the components in the main reservoir 69 . In one embodiment, the fill or refill sequence can be implemented as follows:
[0073] 1. The PLC sends control signals to open the DI line and Chem A-D lines to supply components to the main reservoir 69 . Although not the only arrangement, it is preferred to admit these chemical components sequentially to the main reservoir 69 so that the load cells 12 and 13 directly indicate the weight of each component in the final mixture.
[0074] 2. The PLC sends control signals to an actuator to shut off the inlet pressure valve 50 which would otherwise admit nitrogen to the main reservoir 69 and to open the normally open vent valve 49 so any residual gases can vent from the main reservoir 69 .
[0075] 3. The PLC sends control signals to start the mixer motor 20 . In one embodiment, the mixer motor 20 starts when the impeller 21 is covered with DI water or Chem A, but the time is process dependent and not part of the invention. It could start before, during, or after the time Chem A-D and DI water enter the main reservoir 69 .
[0076] 4. The PLC sends control signals to an actuator to open the inlet pressure valve 50 to increase the nitrogen pressure to a sufficient pressure, e.g., 20 psig, determined by the flow rate and process requirements.
[0077] The PLC or logic device(s) will also send control signals to prepare the inert gas humidifier for service as follows:
[0078] 1. The PLC sends control signals to an actuator to close the DI drain valve 36 , which is normally open, of the inert gas humidifier.
[0079] 2. The PLC sends control signals to open the DI inlet valve 38 so that DI water begins to fill the inert gas humidifier.
[0080] 3. The HI sensor associated with the inert gas humidifier will subsequently detect a high DI water level and send signals to the PLC to send control signals to close the DI inlet valve 38 . Separately, the HI HI sensor functions to send an alarm signal if the DI water fills beyond the operational level.
[0081] 4. The PLC sends control signals to an actuator to open the valve 34 , which admits nitrogen to bubble up through the DI water to humidify the nitrogen that flows from the inert gas humidifier. The valve 34 is either all the way open or all the way closed. It is normally closed (NC) so that when the system is powered down, that is, out of operation, valve 34 closes preventing introduction of the inert gas, e.g., nitrogen into the inert gas humidifier.
[0082] 5. The inert gas humidifier feeds the nitrogen through the lines up to the inlet pressure valve 50 and the buffer inlet control valves 56 and 80 . It should be noted that the pressure supplied through the inlet pressure valve 50 is used to pressure the CMP slurry out of the main reservoir 69 at the desired flow rate.
[0083] The system transfers the CMP slurry mixed from the main reservoir to the buffer reservoir as follows:
[0084] 1. The PLC sends a signal to open main reservoir dispense valve 58 and to open buffer reservoir inlet valve 60 .
[0085] 2. The PLC also sends signals to control the proportional valve block to maintain the desired pressure in the buffer reservoir(s), that is, the set point stored in the PLC. In one embodiment, the set point pressure may be 5-12 psig when the pressure of the main reservoir 69 is held at 20 psig. In one example, a pressure transducer labeled PT in FIG. 12 provides the pressure in the buffer reservoir 71 and the buffer control outlet valve 81 opens if the pressure is too high or the buffer control inlet valve 80 opens if the pressure is too low compared to the set point for buffer reservoir 71 .
[0086] 3. The mixer motor 93 or 64 of the buffer reservoir 92 or 71 stirs the components into a mixture. Again, the start time and time period and rpm depend on the process.
[0087] In one embodiment, the process tool, for example, polisher, triggers when the dispense valve outlet 87 and 73 of respectively the buffer reservoir 92 and 71 open and close.
[0088] The load cells 91 and 96 of the buffer reservoir 92 send signals to the PLC, which will be used to control the main reservoir outlet valve 57 and the buffer inlet valve 97 for transfer of CMP slurry between the main reservoir 69 and the buffer reservoir 92 . The buffer reservoir 71 operates by a similar arrangement as shown in FIG. 12.
[0089] The load cells 12 and 13 associated with the main reservoir 69 will indicate when to add new components to make another batch of CMP slurry. The main reservoir dispense valves 57 and 58 are closed when the components are added to the main reservoir 69 so that the load cells 12 and 13 accurately indicate the weight of each component added to the main reservoir 69 .
[0090] To clean and/or flush out the main reservoir 69 , the PLC can send control signals to close the main reservoir dispense valve 58 , open the gross fill valve 41 to admit DI water, open the main reservoir dispense valve 57 , close the buffer reservoir inlet valve 97 , open the main reservoir drain valve 99 so that the DI water passes from the main reservoir 69 bypassing the buffer reservoir 92 . A similar sequence can be used with the buffer reservoir 71 .
[0091] To clean and/or flush out the buffer reservoir 92 , the DI water can pass through opened main reservoir dispense valve 57 , opened buffer reservoir inlet valve 97 , and closed main reservoir outlet valve 89 . The buffer reservoir 71 can be cleaned and/or flushed by a similar arrangement as shown in FIG. 12.
[0092] In another embodiment, a fixed orifice pinch valve can be employed in cases where ultra-low flow rates are unattainable due to the properties of the mechanical components and the physical attributes of the mediums being dispensed. This pinch valve uses a flexible flow path that is compressed to a determined set point to create a fixed orifice. This will allow the desired restriction in the flow path necessary to increase or maintain a pressure for the “push” to control very low flow rates. The pinch valve can be actuated to open the flexible flow path to its maximum orifice to allow full flow during a flush sequence and then return to the desired determined set point. For example, a {fraction (1/4)}-inch valve with a {fraction (1/4)}-inch orifice controls the push pressure to the buffer reservoir to dispense the chemical. The output valve for the fluid is also {fraction (1/4)}-inch. As the flow rate decreases the pressure required to push also decreases. In the case of ultra-low flow rate the inherent properties of the valves controlling the push pressure limit the repeatability of the precise volume of gas required to push. By installing the fixed orifice pinch valve and increasing the restriction on the dispense flow path, the push pressure can operate at higher levels resulting in precise repeatable control of ultra-low flow rates.
[0093] A PLC and/or operator can adjust the pinch valve's minimum and wide-open orifice size. The wide-open orifice setting can be used to clear obstructions in dispense lines. Turning the pinch valve wide-open is referred to as burping the line. This feature is important for CMP slurries because microbubbles form during low flow rates. The PLC can control the pinch valve so that pressure builds up to permit ultra-low flow rates and burped after a process cycle to clear any obstructions. The time period of the burp may be short such as 0.5 seconds and performed after delivery of the CMP slurry. A typical process only requires delivery of CMP slurry for up to 1.5 minutes and microbubbles may not appear in some CMP slurries for about 5 minutes so post-process burping may suffice. If not, the dispense lines can be burped more frequently without unduly affecting the flow rate over a given process cycle.
[0094] [0094]FIG. 13 illustrates the functional blocks of the PLC that will be associated with one embodiment of the flow rate control system, which uses the diminishing weight of CMP slurry or other chemical mixture in at least one buffer reservoir. The load cells constantly monitor the weight of the CMP slurry and generate analog signals indicative of the weight of the CMP slurry in the buffer reservoir. An A/D converter converts those analog signals into digital format then sends them to the PLC. The PLC stores the specific gravity of each component to calculate component volumes. In parallel or serially with this activity, the user inputs through a keyboard, keypad, or touch screen a desired volumetric flow rate such as 200 ml/min. The PLC can convert the flow rate to rate per second. Next, the PLC directs that the buffer inlet pressure valves open to apply pressure to the buffer reservoir to produce the desired flow. The PLC monitors the declining weight in a time period and compares the current flow rate to the desired flow rate. If the flow rate is too low, the PLC sends signals to the proportional valve block to increase pressure, and if the flow rate is too high, the PLC sends signals to the proportional valve block to decrease the pressure. If the volumetric flow rate is within a predetermined tolerance, the PLC send signals to the proportional valve block that neither increase nor decrease the pressure to the buffer reservoir.
[0095] In other words, a “push” gas is supplied to the buffer reservoir by either a proportional control valve or valves and pressure is monitored via a pressure transducer or transmitter. The desired flow rate is entered, and a calculation is performed to determine the required weight loss from the reservoir during the course of a certain period of time. The PLC causes a signal to be sent to the proportional valve to adjust the push gas pressure, to adjust the weight loss within the reservoir to meet the flow rate requirements. The weight loss can be monitored over the course of time varying from 0.1 seconds to 60 seconds (or higher) depending on the accuracy of the flow rate required. For example, a flow rate of 180 milliliters per minute equals a flow rate of three milliliters per second. The PLC monitors the weight change within each buffer reservoir. If the weight loss is less than three milliliters per second, the pressure is increased. If the weight loss within the buffer reservoir is greater than three milliliters per second, the pressure is decreased. To achieve greater accuracy, the time frame can be shortened to the weight loss achieved during the course of 12 second, or even as low as 0.1 second or lower. The determining factor may be the resolution of the load cells associated with the buffer reservoir. If the load cell is able to resolve 0.1 gram, tighter controls can be implemented.
[0096] This embodiment requires no additional components to control flow. Since no additional devices are used, the problems of plugging are eliminated. Because the pressure to the reservoir is controlled by the PLC, varying input pressures are accounted for and proper adjustments are made to keep the flow at the desired rate. The PLC can be used to determine the average pressure utilized to maintain the proper flow rate. Once the level within the buffer reservoir reaches a point to where it needs to be refilled, the average pressure can be utilized to maintain the flow rate while the buffer reservoir is refilling. The volume level is also monitored real time, which alleviates any requirement for additional components to detect level. The buffer reservoir will dispense chemical as required to satisfy a request command transmitted from the process tool. The volume level is replenished when a low volume set point is triggered as the declining weight is monitored. In like manner the volume being replenished is stopped when a high set point is triggered as the increase in weight is monitored.
[0097] The present invention provides at least the following benefits. The output chemical can be maintained at a constant pressure. A process tool never experiences a low-pressure chemical line that could prevent a dispense sequence from occurring; therefore the yield of the tool is increased. A multitude of containers and sizes can be connected to the reservoir system as chemical supply containers. If the fluid volume of the supply containers is known before they are connected, the computer can calculate very accurately the amount of chemical that has been removed from the container and therefore present the information to a display for a visual, real time indication of the remaining amount of chemical. The graphical interface communicates to the operator at a “glance” the condition of the supply containers. The load cells can determine when the supply container is completely empty since there will not be a continued weight increase during a refill sequence. This indicates the supply container is empty and that another container should be brought on line. In one embodiment, data logging of chemical usage can be provided since the chemical in the reservoir(s) is continuously and accurately weighed by load cell(s) which give an input signal to the PLC or other logic device which outputs real time, accurate information as to the amount of chemical available in the reservoir. The load cell is an inherently safe sensing device since failure is indicated by an abnormally large reading or an immediate zero reading, both of which cause the PLC or other logic device to trigger an alarm. The invention can also prevent bubbles that occur during a supply container switching operation from passing through to the output chemical line, can provide constant, non-varying pressure dispense with multiple supply containers, can refill itself by vacuum or by pumping liquid to refill the reservoir or refill with different chemicals at precise ratios and mix them before transferring the mixture to the buffer reservoir, which may be important for time dependent, very reactive chemistries.
[0098] The invention can provide precise flow control of fluids, chemistries, and compound mixtures utilizing pressure reservoirs fitted with valves, tubing, weight sensors (load cells), and a control system. The invention can also monitor and control volumetric level replenishment utilizing pressure reservoirs fitted with valves, tubing, weight sensors, and a control system. The invention can also replace the commonly used methodologies to control precise flow, such as manually set throttle valves and flow meters. The invention when fitted with the pinch valve can control very precise low flow rate.
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The present invention relates to chemical delivery systems and methods for delivery of liquid chemicals. In one embodiment, the present invention relates to systems having multi-reservoir load cell assemblies for delivering chemicals used in the semiconductor industry. In one embodiment, the present invention provides a multi-reservoir load cell assembly, including a controller, a buffer reservoir, a main reservoir, one or more load cells, coupled to the assembly and to the controller, operable to weigh the liquid in the reservoir(s), a plurality of supply lines, each supply line having a valve and connecting one of the supply containers to the main reservoir, and a gas and vacuum sources for withdrawing the liquid from the assembly when demanded by the controller and for refilling the assembly from the supply containers.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is application is a Continuation of U.S. patent application Ser. No. 11/391,203, filed Mar. 29, 2006, which is incorporated herein by reference in its entirety.
BACKGROUND OF INVENTION
[0002] The present invention relates to an apparatus and a method for processing an image.
[0003] In recent years, printing apparatuses have been spreading that can easily print images captured by a digital camera or the like. Recently, with the spread of digital cameras, printing apparatuses including a slot into which a memory card can be inserted or alternatively high resolution printing apparatuses including an interface for connection to a digital camera are commercially available. In such printing apparatuses, their print engines are of an ink jet type or sublimation type, and achieve high resolution printing.
[0004] Meanwhile, in the images captured by a digital camera, for example, the exposure value can be inappropriate or alternatively color fogging occurs owing to the camera's own characteristics or the like. Thus, techniques for correcting these are disclosed in, for example, Japanese Patent Publication No. 2000-165647A.
[0005] Meanwhile, the correction described above is preferred to be performed in accordance with the kind of a captured object (e.g., scenery and person). Nevertheless, the technique disclosed in the above publication has a problem that correction in accordance with the captured object cannot be performed.
[0006] Further, in recent years, so-called stand-alone printers have been commercially available, to which no personal computer is connected and in which the printing apparatus itself is composed of an image data reader and an image processor, so that the printing apparatus can perform image printing independently. In such stand-alone printers, the processing speed of the central processing unit is slower than in personal computers. This causes a problem that a long time is necessary before the start of printing when complicated correction processing is performed in accordance with the captured object.
SUMMARY OF THE INVENTION
[0007] It is therefore an object of the present invention to provide an apparatus and a method capable of performing optimal correction in accordance with the captured object in a short time.
[0008] In order to achieve the above object, according to the invention, there is provided a method of processing image data, comprising:
[0009] providing a template representative of an image of a human face;
[0010] rotating at least one of the template and the image data to adjust a relative angle between an original orientation of the template and an original orientation of the image data, so as to exclude an angle range including 180 degrees;
[0011] examining a matching between a part of the image data and the template to identify a region in the image data containing an image of a human face; and
[0012] correcting the image data in accordance with a condition of the image of the human face.
[0013] The relative angle may fall within a range from −135 degrees to +135 degrees.
[0014] The method may further comprise:
[0015] detecting angle information contained in the image data and indicative of an orientation of an image capturing device when an image in the image data is captured; and
[0016] determining the relative angle based on the angle information.
[0017] The relative angle may be determined in accordance with a positional relationship between a skin color region and black color region which are contained in the image data.
[0018] According to the invention, there is also provided a program product comprising a program operable to cause a computer to execute the above method.
[0019] According to the invention, there is also provided an image processor, adapted to process image data, comprising:
[0020] a storage, storing a template representative of an image of a human face;
[0021] a rotator, operable to at least one of the template and the image data to adjust a relative angle between an original orientation of the template and an original orientation of the image data, so as to exclude an angle range including 180 degrees;
[0022] a matching executer, operable to examine a matching between a part of the image data and the template to identify a region in the image data containing an image of a human face; and
[0023] a corrector, operable to correct the image data in accordance with a condition of the image of the human face.
[0024] According to the invention, there is also provided a printing apparatus comprising:
[0025] the above image processor; and
[0026] a printing head, operable to print the corrected image data on a printing medium.
[0027] According to the invention, there is also provided a method of processing image data, comprising:
[0028] extracting a partial region from the image data;
[0029] providing a template representative of an image of a human face;
[0030] examining a matching between the partial region and the template to determine whether the partial region contains an image of a human face; and
[0031] correcting the image data in accordance with a condition of the image of the human face.
[0032] The partial region may be located in a central region of the image data.
[0033] The method may further comprise enlarging the partial region.
[0034] The method may further comprise reducing a data size of the partial region.
[0035] According to the invention, there is also provided a program product comprising a program operable to cause a computer to execute the above method.
[0036] According to the invention, there is also provided an image processor, adapted to process image data, comprising:
[0037] an extractor, operable to extract a partial region from the image data;
[0038] a storage, storing a template representative of an image of a human face;
[0039] a matching executor, operable to examine a matching between the partial region and the template to determine whether the partial region contains an image of a human face; and
[0040] a corrector, operable to correct the image data in accordance with a condition of the image of the human face.
[0041] According to the invention, there is also provided a printing apparatus comprising:
[0042] the above image processor; and
[0043] a printing head, operable to print the corrected image data on a printing medium.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:
[0045] FIG. 1 is a perspective view of a printing apparatus according to a first embodiment of the invention;
[0046] FIG. 2 is a block diagram showing a control system of the printing apparatus of FIG. 1 ;
[0047] FIG. 3 is a block diagram showing a control system of a digital camera shown in FIG. 1 ;
[0048] FIG. 4A shows face templates used in matching processing is performed in the printing apparatus of FIG. 1 ;
[0049] FIG. 4B shows one of the face templates to which mosaic processing is performed;
[0050] FIGS. 5A and 5B are diagrams for explaining the matching processing;
[0051] FIGS. 6A through 7A show a relationship of an attitude of the digital camera and a direction of a captured image;
[0052] FIG. 7B is a diagram for explaining rotation of image data performed in the matching processing;
[0053] FIG. 8 is a flowchart showing processing performed in the printing apparatus of FIG. 1 ;
[0054] FIG. 9 is a diagram showing the configuration of an image file used in the processing of FIG. 8 ;
[0055] FIG. 10 shows a table used in the processing in FIG. 8 ;
[0056] FIG. 11 is a flowchart showing processing for identifying an image orientation shown in FIG. 8 ;
[0057] FIG. 12 is a flowchart showing processing for identifying a face in an image shown in FIG. 8 ;
[0058] FIG. 13 is a flowchart showing processing of face matching shown in FIG. 12 ;
[0059] FIG. 14 is a perspective view of a printing apparatus according to a second embodiment of the invention;
[0060] FIG. 15 is a block diagram showing a control system of the printing apparatus of FIG. 14 ;
[0061] FIG. 16 is a flowchart showing processing performed in a printing apparatus according to a third embodiment of the invention;
[0062] FIG. 17 is a flowchart showing image enlargement processing shown in FIG. 16 ;
[0063] FIGS. 18A and 18B are diagrams for explaining the image enlargement processing; and
[0064] FIGS. 19A and 19B are diagrams for explaining a modified example of the image enlargement processing.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0065] Embodiments of the invention will be described below in detail with reference to the accompanying drawings.
[0066] As shown in FIG. 1 , an ink jet type printing apparatus 11 according to a first embodiment of the invention comprises: a casing 12 ; a sheet feeding unit 13 for feeding rolled sheet R and a cut sheet (not shown); and a printing section for performing printing onto the rolled sheet R or the cut sheet.
[0067] The box-shaped casing 12 has a control panel 15 at a right side of the upper face. The control panel 15 is equipped with: an LCD (Liquid Crystal Display) 17 ; and input buttons 18 . The LCD 17 displays the menu function, the contents of operation, the status of operation, the contents of error, and the like of the printing apparatus 11 . The input button 18 is pushed when menu selection or the like is performed in the printing apparatus 11 . Further, using the LCD 17 and the input buttons 18 described here, various kinds of operations can be performed like cutting position adjustment.
[0068] The casing 12 has an ejection port 12 a at a lower part of the front face so that rolled sheet R or a cut sheet having undergone printing is ejected through this port. Further, a card slot 21 is provided at a front right side of the casing 12 , while, for example, a memory card M for recording image data captured by a digital camera 30 or the like is accommodated in this slot in a freely removable manner.
[0069] The sheet feeding unit 13 is provided at the rear face side of the casing 12 , and has a holder 22 fixed to the casing 12 and a rotary shaft 23 . Then, the termination end of the rolled sheet R is connected to and wound around the rotary shaft 23 . In this state, the rotary shaft 23 is rotatably supported on the holder 22 . Then, when a user pinches both ends of the rotary shaft 23 and then rotates the rotary shaft 23 in a normal or reverse direction, the rolled sheet R is fed forward from or rolled up to the sheet feeding unit 13 .
[0070] As shown in FIG. 2 , a control system of the printing apparatus includes a CPU (Central Processing Unit) 50 , a ROM (Read Only Memory) 51 , a RAM (Random Access Memory) 52 , an EEPROM (Electrically Erasable and Programmable ROM) 53 , a GP (Graphic Processor) 54 , an interface 55 , a bus 56 , the LCD 17 , the input buttons 18 , the card slot 21 , a card interface circuit 60 , a printer engine controller 62 , a sheet feeding motor 63 , a sheet feeding roller 64 , a carriage motor 65 , a driving belt 66 , a carriage 67 , a printing head 68 , and a RAM 69 .
[0071] Here, the CPU 50 executes various kinds of arithmetic processing according to programs stored in the ROM 51 and the EEPROM 53 and, at the same time, controls various sections of the apparatus including the sheet feeding motor 63 and the carriage motor 65 .
[0072] The ROM 51 is a semiconductor memory for storing various kinds of programs executed by the CPU 50 and various kinds of data. The RAM 52 is a semiconductor memory for temporarily storing programs and data to be executed by the CPU 50 .
[0073] The EEPROM 53 is a semiconductor memory for storing predetermined data such as arithmetic processing results of the CPU 50 and thereby holding the data even after the printing apparatus is deactivated.
[0074] The GP 54 executes display processing on the basis of a display command provided from the CPU 50 , and then provides and displays the obtained image data on the LCD 17 .
[0075] The interface 55 is a unit for appropriately converting the form of representation of the data when information is transferred between the input buttons 18 , the card interface circuit 60 , and the printer engine controller 62 .
[0076] The bus 56 is signal lines for interconnecting the CPU 50 , the ROM 51 , the RAM 52 , the EEPROM 53 , the GP 54 , and the interface 55 , and thereby realizing the transfer of information between these units.
[0077] As described above, the input button 18 is operated when menu selection or the like is performed. As described above, the memory card M is a non-volatile memory for storing image data captured by a digital camera 30 .
[0078] As described above, the card slot 21 is provided at a front right side of the casing 12 of the printing apparatus 11 , while the memory card M is inserted into this portion. The card interface circuit 60 is an interface for writing or reading information to or from the memory card M.
[0079] The printer engine controller 62 is a control unit for controlling the sheet feeding motor 63 , the carriage motor 65 , and the printing head 68 . The sheet feeding motor 63 rotates the sheet feeding roller 64 and thereby moves the cut sheet or the rolled sheet R (referred collectively as a printing sheet) in the secondary scanning direction. The sheet feeding roller 64 is composed of a cylindrical member, and moves the cut sheet or the rolled sheet R in the secondary scanning direction.
[0080] The carriage motor 65 provides a driving force to the driving belt 66 one end of which is fixed to the carriage 67 , and thereby realizes reciprocating motion of the carriage 67 in the primary scanning direction. The printing head 68 is provided with a plurality of nozzles formed in a face opposing the printing sheet, and thereby ejects ink from a plurality of the nozzles so as to record information onto the printing sheet.
[0081] As shown in FIG. 3 , the digital camera 30 includes a CPU 31 , a ROM 32 , a RAM 33 , a CCD (Charge Coupled Device) 34 , an optical system 35 , a GP 36 , an LCD 37 , an interface 38 , a bus 39 , operation buttons 40 , a card interface 41 , a card slot 42 , a memory card M, and a gyro sensor 43 . Here, explanations for components similar to those shown in FIG. 2 will be omitted.
[0082] The CCD 34 converts an optical image of an object captured through the optical system 35 , into a corresponding electric signal and then outputs the signal. The optical system 35 is composed of a plurality of lenses and an actuator. Then, a plurality of the lenses focus the optical image of the captured object onto a light receiving surface of the CCD 34 , while the actuator adjusts the focusing and the like. The gyro sensor 43 generates and outputs a signal indicating the angle (angle relative to the horizontal plane) of the camera body at the time that the object is captured by the digital camera 30 . In the digital camera 30 , information indicating the angle of the camera at the time of image capturing can be appended to the image data, in the form of exif (Exchangeable Image File Format) information described later.
[0083] In this embodiment, when a person's face is contained in image data to be printed by the printing apparatus 11 , the image data is corrected in accordance with the state of the pixels constituting the face so that an optimal printing state may be acquired.
[0084] Meanwhile, an example of a method of determining whether a face is contained in image data is to perform matching processing on the image data using a template of a face. In this method, since the size and the orientation of an image contained in the image data are not fixed, templates (the first through the fifth templates) of a plurality of sizes are prepared as shown in FIG. 4A . Then, as shown in FIGS. 5A and 5B , matching processing with each template is performed, for example, from the upper left corner of the image data to the lower right corner, so that it is determined whether a face corresponding to a template is contained. In the matching processing, as shown in FIG. 4B , mosaic processing is performed on the template so that influence of the features of an individual person is eliminated.
[0085] Meanwhile, when a person is captured by the digital camera 30 , the attitude of the digital camera 30 can be changed at the time of image capturing as shown in FIGS. 6A to 6C . FIG. 6A shows an ordinary case, while FIG. 6B shows a case that the camera is rotated counterclockwise by 90 degrees viewed from the front. FIG. 6C shows a case that the camera is rotated clockwise by 90 degrees viewed from the front. In these cases, the face contained in the image is in an upright state in FIG. 6A , in a state rotated counterclockwise by 90 degrees in FIG. 6B , and in a state rotated clockwise by 90 degrees in FIG. 6C . Thus, in these cases, when detection processing for a face is executed using the template of upright orientation as shown in FIGS. 4A and 4B , the face in the state of FIGS. 6B and 6C cannot be detected.
[0086] Thus, the image data is rotated stepwise throughout 360 degrees. Then, at each stage, scanning is performed as shown in FIGS. 5A and 5B , so that the face can be detected regardless of the image capturing angle (attitude of the digital camera).
[0087] Nevertheless, the rotation of the image throughout 360 degrees and the detection using a plurality of templates as shown in FIGS. 4A and 4B cause an increase in the processing cost. Here, the situation is not expected that image capturing is performed in a state that the digital camera 30 is rotated by 180 degrees as shown in FIG. 7A . Thus, in this embodiment, such a state is excluded from the target of processing so that the processing is accelerated. Specifically, as shown in FIG. 7B , the image data is rotated stepwise (e.g., at a step of +5 degrees) in the range of +135 through −135 degrees. Then, the processing of detecting a face is performed at each stage. As a result, in the case shown in FIG. 6B , the image becomes upright when rotated by −90 degrees. Further, in the case shown in FIG. 6C , the face is detected in the upright orientation when rotated by +90 degrees. In the cases of FIGS. 6B and 6C , the face is detected when rotated by −90 degrees and +90 degrees, respectively. However, by taking into consideration the cases that the captured object is tilted and that the digital camera 30 is tilted, the rotation is performed in the range of −135 through +135 degrees including a margin. As such, in this embodiment, the inverted state shown in FIG. 7A and its neighboring states are excluded from the target of processing, so that processing speed is improved.
[0088] When the processing shown in FIG. 8 is started, the following steps are executed. This processing is implemented when a program stored in the ROM 51 is read and executed in a case that printing of at least one predetermined image is instructed after a memory card M is inserted into the card slot 21 .
[0089] Step S 10 : The CPU 50 acquires from the memory card M an image file to be printed, then executes Huffman decompression, and thereby acquires quantized DCT (Discrete Cosine Transform) coefficients. As shown in FIG. 9 , the image file 70 is composed of header information 71 , a table 72 , and compressed data 73 . Here, the header information 71 includes, for example, exif information 71 a (described later in detail) as well as information such as the filename, the compression method, the image size, and the density unit. The table 72 is composed, for example, of a quantization table, an entropy coding table, and the like. The compressed data 73 is composed of image data compressed by the JPEG (Joint Photographic Coding Experts Group) method. The CPU 50 acquires the entropy coding table from the table 72 of the image file 70 shown in FIG. 9 , and then decodes the DC coefficients and the AC coefficients of the Y (brightness) component, the Cr (color difference component), and the Cb (color difference component) contained in the compressed data 73 in each block. At that time, the decoding is performed on an MCU basis which is the minimum coding unit.
[0090] Step S 11 : The CPU 50 performs inverse quantization of the quantized DCT coefficients obtained at step S 10 . Specifically, the CPU 50 acquires the quantization table from the table 72 of the image file 70 shown in FIG. 9 , then multiplies by the acquired values the quantized DCT coefficients obtained at step S 10 , and thereby obtains DCT coefficients.
[0091] Step S 12 : The CPU 50 caches information necessary for rotating the image, for example, into the RAM 52 . Specifically, when an image compressed by the JPEG method is to be rotated, Huffman enlargement must once be performed on each of the DC component and the AC component of an MCU. Here, as for the DC component, since Huffman coding is performed on the difference between adjacent DC component values, the correlation between adjacent MCUs poses a problem. Further, as for the AC component, the data length of each MCU becomes variable owing to the Huffman coding. Thus, it becomes unclear which data piece in the bit stream of JPEG data indicates the AC component value of the MCU. This poses a problem. Thus, in the processing of step S 12 , the value of the DC component and the address of the AC component of each MCU is acquired and cached, so that rotating processing is allowed.
[0092] Step S 13 : The CPU 50 performs inverse DCT operation on the DCT coefficients obtained at step S 11 , and thereby acquires the original pixel values.
[0093] Step S 14 : The CPU 50 converts the image of the YCC color coordinates system obtained by the processing of step S 13 into an image of the RGB (Red Green Blue) color coordinates system and an image of the HSB (Hue Saturation Brightness) color coordinates system.
[0094] Step S 15 : The CPU 50 stores and retains into the RAM 52 each of the YCC, RGB, and HSB images obtained by the processing of steps S 13 and S 14 . At that time, the images may be stored into the RAM 52 after pixel skipping at a predetermined ratio is performed in order to reduce the amount of data.
[0095] Step S 16 : The CPU 50 calculates a histogram for each component of the YCC, RGB, and HSB images stored into the RAM 52 at step S 15 . Specifically, as for the RGB image, a histogram is calculated for each of the R, G, and B images. As a result, distribution of each component constituting the image is obtained.
[0096] Step S 17 : The CPU 50 determines whether the processing has been completed for all MCUs. In the case of being completed, the CPU 50 goes to step S 18 . Otherwise, the CPU 50 returns to step S 10 and thereby repeats the same processing.
[0097] Step S 18 : The CPU 50 executes the processing of identifying the image orientation. When the attitude of the digital camera 30 (output data of the gyro sensor 43 ) at the time of image capturing is recorded in the exif information 71 a of the image file 70 , this information is extracted. Here, as a special case, when the top and bottom of the image data is reversed (in the state shown in FIG. 7A ), the situation that the top and bottom is reversed is detected by referencing to the positional relationship of a skin color region and a black region, so that the top and bottom of the image data is reversed back. Details will be described later with reference to FIG. 11 .
[0098] Step S 19 : The CPU 50 executes the processing of identifying a face contained in the image data. In this processing, for the purpose of determining whether a face image is contained in the image data, the image data is rotated as shown in FIG. 7B so that a region having a high correlation with the templates shown in FIGS. 4A and 4B is identified as a region (referred to as a “face region,” hereinafter) where a face image is contained. Here, the size of the contained face image varies depending on the distance between the captured object and the digital camera. Further, a plurality of captured objects can be contained in some cases. Thus, the detection of a face image is performed using a plurality of templates of different sizes. Further, the processing is repeated until face regions for ten persons are found. Here, as for each identified face region, the coordinates of the center part or alternatively the coordinates of the upper left corner are stored into the RAM 52 . Details will be described later with reference to FIGS. 12 and 13 .
[0099] Step S 20 : When a face image has been identified in the processing of step S 19 , the CPU 50 goes to step S 21 . Otherwise, the CPU 50 goes to step S 22 .
[0100] Step S 21 : The CPU 50 acquires the color of face skin from the face region identified at step S 19 . Specifically, a predetermined pixel constituting the face region is extracted, so that each value for R, G, and B is acquired. At that time, a plurality of pixels may be extracted so that the average or the median may be calculated. Then, these values may be used. Here, when a plurality of face regions have been identified, the color of face skin is acquired from each face region. Then, for example, the median or the average is calculated.
[0101] Step S 22 : The CPU 50 calculates correction parameters such that the color of face skin acquired at step S 21 should become a normal color of face skin. Specifically, when balance of R, G, and B deviates slightly from an appropriate value, the occurrence of color fogging is determined. Then, a correction parameter for each of R, G, and B is calculated in order to achieve correction into the normal value. Further, when the total value of R, G, and B deviates, inappropriate exposure is determined. Then, a correction parameter for each of R, G, and B is calculated in order to correct the exposure appropriately. Here, when no face has been identified at step S 19 , correction parameters are calculated, for example, on the basis of the color of the sky.
[0102] Here, the color of face skin depends on the individual race and the light source. Thus, referring to the table (see FIG. 10 ) stored in the ROM 51 , appropriate correction parameters are calculated from the acquired R, G, and B. In the example of FIG. 10 , the first through the third skin colors are listed. The first skin color is whitish. The second skin color is yellowish. The third skin color is blackish. In FIG. 10 , for each of the first through the third skin colors, value ranges for each of R, G, and B are listed for the cases that the sunlight, a fluorescent lamp, and an incandescent lamp are used as the light source. In the processing of step S 22 , pixels are sampled from a plurality of points of the face region. Then, the average or the median of each of the R, G, and B values of the sampled pixels is calculated and then compared with the table shown in FIG. 10 . Thus, the type of skin color of the target face and the type of light source are identified. Then, correction parameters are calculated such that the average of each of the R, G, and B values of the pixels should become the center value (appropriate value) in the table shown in FIG. 10 .
[0103] Here, when a plurality of face regions have been identified, a plurality of points are sampled from each face region. Then, the average or the median of the pixels is calculated for each of a plurality of the acquired persons. Then, correction parameters are calculated on the basis of these values.
[0104] Step S 23 : The CPU 50 resets a file pointer indicating the position of the target of decompression in the image file to be printed, and thereby returns the processing position to the beginning of the image file.
[0105] Step S 24 : The CPU 50 performs Huffman decompression onto the image data of one MCU line cached in the RAM 52 , and thereby obtains quantized DCT coefficients. Here, when the image is rotated, the one MCU line indicates an MCU group of one line in the vertical direction of the image. When the image is not rotated, the one MCU line indicates an MCU group of one line in the horizontal direction of the image.
[0106] Step S 25 : The CPU 50 performs inverse quantization of the quantized DCT coefficients obtained by the processing of step 24 .
[0107] Step S 26 : The CPU 50 performs inverse DCT operation on the DCT coefficients obtained at step S 25 , and thereby acquires the original data.
[0108] Step S 27 : The CPU 50 converts into an image of the RGB color coordinates system of the image of the YCC color coordinates system obtained by the processing of step S 26 .
[0109] Step S 28 : The CPU 50 performs correction processing on each pixel constituting the image of the RGB color coordinates system obtained at step S 27 . Specifically, the correction parameters calculated at step S 22 are applied onto each pixel, so that color fogging is canceled while exposure is corrected appropriately. For example, when red is too intense owing to color fogging, for example, the processing of multiplying each pixel value by a value of “0.9” is performed such that the distribution in the histogram of R should move toward the origin.
[0110] Step S 29 : The CPU 50 provides the image data obtained as a result of correction processing to a band buffer (not shown) of the printer engine controller 62 , and thereby causes the controller to execute print processing. In response to this, the printer engine controller 62 controls and causes the recording head 68 to eject ink corresponding to the image data, then drives the carriage motor 65 so as to move the recording head 68 in the primary scanning direction, and then drives the sheet feeding motor 63 so as to cause motion in the secondary scanning direction. As such, an image is printed.
[0111] Step S 30 : The CPU 50 updates the image data cached in the RAM 52 , as preparation for the next processing.
[0112] Step S 31 : The CPU 50 determines whether the processing is to be terminated. When the processing is not to be terminated, the CPU 50 returns to step S 24 and then repeats the same processing. Otherwise, the CPU 50 terminates the processing.
[0113] Details of the processing of step S 18 of FIG. 8 are described below with reference to FIG. 11 .
[0114] Step S 40 : When exif information 71 a is contained in the image file 70 , the CPU 50 acquires the exif information 71 a.
[0115] Step S 41 : When image orientation information is contained in the exif information 71 a , the CPU 50 acquires the information. Here, the image orientation information is information indicating the attitude of the digital camera (e.g., an angle relative to the horizontal plane) at the time of image capturing. For example, in the case of the digital camera 30 shown in FIG. 3 , data outputted from the gyro sensor 43 at the time of image capturing of the image is stored into the exif information 71 a.
[0116] Step S 42 : The CPU 50 determines whether image orientation information has been acquired at step S 41 . In the case of having been acquired, the CPU 50 returns to the original processing. Otherwise, the CPU 50 goes to step S 43 .
[0117] Step S 43 : Referring to FIG. 10 , the CPU 50 detects a skin color region corresponding to a person's face in the image data.
[0118] Step S 44 : The CPU 50 detects black regions corresponding to the eyes and the mouth in the image data.
[0119] Step S 45 : On the basis of the positional relationship of the black regions and the skin color region obtained from the detection results of steps S 43 and S 44 , when a triangle formed by joining the black regions is oriented such that one vertex is located at a top position (that is, a base line formed by joining the eyes is located downward), the CPU 50 determines that the image has been captured in a state that the top and bottom has been reversed as shown in FIG. 7A . Thus, the CPU 50 goes to step S 46 . Otherwise, the CPU 50 returns to the original processing.
[0120] Step S 46 : The CPU 50 executes the processing of reversing back the top and bottom of the image data captured in a state that the top and bottom is reversed as shown in FIG. 7A .
[0121] Details of the face matching of step S 19 shown in FIG. 9 are described below with reference to FIG. 12 .
[0122] Step S 50 : When image orientation information has been acquired at step S 41 , the CPU 50 goes to step S 51 . Otherwise, the CPU 50 goes to step S 52 .
[0123] Step S 51 : The CPU 50 executes the processing of rotating the image data by the angle indicated by the orientation information. Here, for example, an image of QVGA (Quarter Video Graphics Array) size obtained by reducing the original image by pixel skipping at a predetermined ratio is used as the image to be rotated (the image used for detecting the presence or absence of a face). Here, the kinds of image data employable as the target of processing include a Y (brightness) component image. That is, in the search whether a face region is contained in the image data, similarity is determined with the template consisted of density information. Thus, the Y component image (i.e., brightness information which is similar to the density information) is adopted as image data to be subjected to the face matching.
[0124] Step S 52 : The CPU 50 executes the face matching shown in FIG. 13 . Details of this processing are described later.
[0125] Step S 53 : The CPU 50 executes the processing of rotating the image data by −135 degrees. Here, the image data to be rotated is an image of QVGA size obtained by reducing the original image by pixel skipping at a predetermined ratio, similar to the above-mentioned step S 51 . Further, the kind of employed image data is a Y (brightness) component image.
[0126] Step S 54 : The CPU 50 executes the face matching shown in FIG. 13 . Details of this processing are described later.
[0127] Step S 55 : It is determined whether a face has been identified in the processing of step S 54 . In the case of being identified, the CPU 50 returns to the original processing. Otherwise, the CPU 50 goes to step S 56 .
[0128] Step S 56 : The CPU 50 executes the processing of rotating the image data by +5 degrees, then returns to step S 54 , and thereby repeats the same processing.
[0129] Step S 57 : The CPU 50 determines whether the image data has been rotated by +135 degrees. In the case of having been rotated, the CPU 50 returns to the original processing. Otherwise, the CPU 50 returns to step S 54 and thereby repeats the same processing.
[0130] In the above-mentioned processing, the image data is rotated from −135 degrees to the +135 degrees at a step of 5 degrees as shown in FIG. 7B . Then, a face is identified at each angle.
[0131] Details of the face matching of step S 52 shown in FIG. 12 are described below with reference to FIG. 13 .
[0132] Step S 60 : The CPU 50 initializes into a value “1” a variable n for specifying a template, and then initializes into a value “0” each of variables x and y for specifying the scanning position of the template.
[0133] Step S 61 : The CPU 50 selects from the ROM 51 the n-th template (described later in detail) specified by the variable n. In the first processing cycle, the value “1” is set up in the variable n. Thus, the first template is selected. As shown in FIG. 4A , each template is an image containing characteristic points (such as the eyes, the nose, and the mouth) of a face. The size is decreasing in the order from the first template to the fifth template. Here, when the image of the template is at a high resolution, accuracy degrades in the matching processing owing to the features of the face of an individual person. Thus, as shown in FIG. 4B , mosaic processing is performed on the template so that the influence of the features of an individual person is suppressed.
[0134] Step S 62 : The CPU 50 extracts from the image data a region of a size corresponding to the template selected at step S 61 , by setting up x and y at the upper left corner. In the following description, the image data extracted as described here is referred to as extracted image data. In the present example, the coordinates (x,y)=(0,0), while the first template is selected. Thus, a region an upper left corner of which is specified by (x,y)=(0,0) and having the same size as the first template is extracted as extracted image data. When the image is tilted by rotation, the image data is extracted at a range that no part of the extracted image data is lost.
[0135] Step S 63 : The CPU 50 executes matching processing between the template selected at step S 61 and the extracted image data extracted at step S 62 . An example of the matching method is to add up and accumulate the square of the difference between the extracted image data and the template in each pixel and then determine a high similarity (that is, a face is contained) when the accumulated value is smaller than a predetermined threshold. In place of this method, for example, a neural network may be employed. In this case, for example, a neural network of a three-layered structure is employed that includes an input layer, an intermediate layer, and an output layer. Then, learning is performed by inputting the image of the template to the input layer, for example, by shifting the position or the like. After that, the matching processing may be performed using the neural network in which sufficient learning has been performed.
[0136] Alternatively, instead of the neural network, the matching processing may be performed, for example, using a genetic algorithm. For example, as a parameter at the time of overlaying a template on the original image, the kind n of template and the x- and the y-coordinates of the upper left corner are defined. Then, the chromosome of each individual may be determined on the basis of these parameters. Then, the evolution of the group of individuals may be traced by considering the matching rate as the degree of adaptation of the individuals. Then, the optimal individual may be adopted as the final result of matching processing.
[0137] Step S 64 : On the basis of the result of the processing of step S 63 , the CPU 50 determines whether a face is contained in the extracted image data extracted at step S 62 . In the case of being contained, the CPU 50 goes to step S 65 . Otherwise, the CPU 50 goes to step S 66 . For example, in the case of the matching processing where the square of the above-mentioned difference is calculated, when the accumulated value is smaller than the predetermined threshold, it is determined that a face is contained.
[0138] Step S 65 : The CPU 50 stores into the RAM 52 the coordinates of the center of a region determined as containing a face. In the calculation of the center coordinates, the length corresponding to half the size of the presently selected template is added to each of the x- and the y-coordinates.
[0139] Step S 66 : The CPU 50 determines whether faces of ten persons have been detected in total in the processing until then. When faces of ten persons have been detected, the CPU 50 terminates this processing and then returns to the original processing. Otherwise, the CPU 50 goes to step S 67 . For example, when faces of three persons have been detected using the first template while faces of seven persons have been detected using the third template, the CPU 50 terminates this processing and then returns to the original processing.
[0140] Step S 67 : The CPU 50 determines whether the region from which extracted image data is to be extracted has reached the right edge of the image data. In the case of having been reached, the CPU 50 goes to step S 69 . Otherwise, the CPU 50 goes to step S 68 . That is, in this embodiment, as shown in FIG. 5A , image data of the size corresponding to the template is extracted from the image data, while this extraction is repeated in the order shown in FIG. 5B . At that time, when the region of image extraction reaches the right edge, the CPU 50 goes to step S 69 .
[0141] Step S 68 : The CPU 50 adds Δx to the x-coordinate of the upper left corner. Here, Δx is determined into an optimal value depending on the size of the selected template. For example, when the size of the template is small, the value of Δx is set small. When the size is large, the value of Δx is increased.
[0142] Step S 69 : The CPU 50 adds Δy to the y-coordinate of the upper left corner. Here, Δy is determined depending on the size of the template similar to the above-mentioned case of Δx.
[0143] Step S 70 : The CPU 50 sets up the x-coordinate of the upper left corner to be “0.” As a result, the region of image extraction returns to the left edge of the image.
[0144] Step S 71 : The CPU 50 determines whether the processing has been completed for the entire region by using a predetermined template. In the case of being completed, the CPU 50 goes to step S 72 . Otherwise, the CPU 50 returns to step S 62 and thereby repeats the same processing.
[0145] Step S 72 : The CPU 50 sets up a value “0” into each of x and y. As a result, the region of image extraction is reset into the upper left corner of the image data.
[0146] Step S 73 : The CPU 50 increments by “1” the variable n for selecting a template. In the present example, since a value “1” had been set up in the variable n, the value of the variable n becomes “2” after this processing. As a result, the second template is selected in the processing of step S 61 .
[0147] Step S 74 : The CPU 50 determines whether the value of the variable n is greater than the total number N of templates. In the case of being greater, the CPU 50 terminates the processing. In the present example, N=5 as shown in FIG. 4 . Thus, when n>5, the CPU 50 terminates this processing and then returns to the original processing. Otherwise, the CPU 50 returns to step S 61 and thereby repeats the same processing.
[0148] As described above, according to this embodiment, when determining whether a face region is contained is performed by rotating the image data, the top-and-bottom inverted angle and its adjacent angles are excluded from the target of processing, so that processing speed is improved.
[0149] The first embodiment has been described by adopting a stand-alone type printing apparatus as an example. However, the present invention is applicable also to an ordinary printing apparatus (a printing apparatus of a type used in a state connected to a personal computer). Further, the present invention is applicable also to a so-called hybrid type printing apparatus in which a scanner apparatus, a printing apparatus, and a copying apparatus are integrated as shown in FIG. 14 . Such a hybrid type printing apparatus will be described as a second embodiment of the invention. Components similar to those in the first embodiment will be designated by the same reference numerals and repetitive explanations for those will be omitted.
[0150] As shown in FIGS. 14 and 15 , a hybrid type printing apparatus 211 is equipped with: a casing 212 ; a sheet feeding unit 213 for feeding a cut sheet; a scanner section 230 for reading an image printed on a sheet medium or the like; and a printing section (not shown) for performing printing onto the cut sheet.
[0151] The box-shaped casing 212 has the scanner section 230 at the upper part thereof. An LCD 217 and input buttons 218 for various kinds of operations are provided at a center part of the front face. Similar to the casing 12 of the first embodiment, the LCD 217 displays the menu function, the contents of operation, the status of operation, the contents of error, and the like of the printing apparatus 211 . The input button 218 is pushed when menu selection or the like is performed in the printing apparatus 211 .
[0152] The casing 212 has an ejection port 212 a at a lower part of the front face, so that a printed cut sheet is ejected through this port. Further, a card slot 221 is provided at a front right side of the casing 212 , while, for example, a memory card M for storing image data captured by a digital camera or the like is accommodated in this slot in a freely removable manner.
[0153] The sheet feeding unit 213 is provided at the rear side of the casing 212 , and stocks cut sheets so as to feed one sheet at a time into the printing apparatus 211 in a case of being necessary.
[0154] The input buttons 218 include buttons for controlling the scanner function and the copying function. The scanner section 230 is composed of: an optical system and an imaging system for reading an image printed on a sheet medium; and a controller for controlling these systems. Then, under the control of the CPU 50 , the scanner section 230 reads the image printed on the sheet medium, then converts the image into corresponding image data, and then outputs the data.
[0155] In this hybrid type printing apparatus 211 , when the above-mentioned processing is performed on image data read from the memory card M or alternatively image data read from the digital camera, correction can be performed in accordance with the face contained in the image.
[0156] In this embodiment, the correction processing can be performed in accordance with the face contained not only in an image read in from the memory card M, but also in that read in by the scanner section 230 . Nevertheless, in this case, the orientation of placing an original image is not limited. Thus, for example, the image data could be read in a state that the top and bottom is reversed as shown in FIG. 7A . Thus, the face detection for the image data read in from the memory card M may be performed by rotating the image in the range of −135 through +135 degrees as described above. In contrast, the face detection for the image data read in from the scanner section 230 may be performed by rotating the image throughout 360 degrees including the state that the top and bottom is reversed.
[0157] In the above embodiments, the image data to be processed is rotated in the range of −135 through +135 degrees. However, another angle range may be employed. For example, the range of −120 through +120 degrees may be employed. In short, any angle range may be employed as long as the range includes the range of −90 through +90 degrees plus a certain amount of margin.
[0158] In the above embodiments, the range where the image is to be rotated is fixed. However, the habit of the image capturing person may be learned so that the range may be set up appropriately. For example, when the angles of FIGS. 6A and 6B are used most frequently whereas the angles of FIGS. 6C and 7A are not used, for example, the rotation may be performed in the range of −135 through +45 degrees. Alternatively, when a narrow range of camera inclination is used owing to the habit of the image capturing person, an appropriate range of rotation (e.g., the range of −100 through +100 degrees) in place of the range of −135 through +135 degrees may be adopted on the basis of learning.
[0159] In the above embodiments, the image data itself is rotated. However, the image data may be fixed while the template may be rotated. In this case, since the data amount is less in the template, the amount of processing necessary for the rotation is reduced, and thereby improves processing speed. Further, even when the image data is rotated, the entire image data need not be rotated. That is, a part of data may be extracted from the image data, so that the extracted image data may solely be rotated. In this case, when a range slightly larger than the template (a range that surrounds the rotated template) is extracted, the face detection processing can be executed normally, and still the amount of processing of data necessary for the rotation is reduced.
[0160] In the above embodiments, the face region is identified by increasing the rotation angle of the image data at a step of +5 degrees. However, the face region may be identified with increasing the rotation angle at a step of another value (e.g., +2 degrees) or alternatively with reducing the rotation angle. Further, the angle increment need not be fixed. That is, the angle increment may be reduced (e.g., +3 degrees) for angle ranges having high probability of presence of a face region (e.g., 0 degree, +90 degrees, −90 degrees, and their adjacent angle ranges). In contrast, the angle increment may be increased (e.g., +10 degrees) for the other angle ranges.
[0161] In the above embodiments, templates corresponding to a face directed frontward is employed. However, for example, templates corresponding to faces directed upward, downward, rightward, and leftward may be employed. In this case, a plurality of templates of intermediate states between the frontward face and the upward, downward, rightward, and leftward faces may be prepared so that matching processing may be executed with each template. In this case, even when the captured person is directed in a direction other than the frontward direction, the probability that the face is appropriately recognized is improved.
[0162] In the above embodiments, the entire range of the image data is subjected to the detection processing. However, for example, learning concerning a range having a high possibility of the presence of a person's face may be performed on the basis of the habit of the image capturing person. Then, a range including the high possibility range may be extracted so that the above-mentioned processing may be performed. This method allows a face to be found at minimum cost.
[0163] In the above embodiments, mosaic processing is performed on the template. However, mosaic processing may also be performed on the image data.
[0164] In the above embodiments, face detection is performed using the Y image of the image of the YCC color coordinates system. However, for example, a monochrome grayscale image may be generated from the image of the RGB color coordinates system. Then, face detection may be performed using the monochrome image.
[0165] In the above embodiments, the processing is terminated at the time that ten persons have been detected regardless of the size of their faces. However, for example, a small face can be considered as having low importance. Then, the processing may be terminated when a predetermined number of large faces have been found out. This configuration improves processing speed. Further, a number may be set up for each face size. Then, the processing may be terminated when the predetermined number of faces have been detected, for example, one face with the first template and two faces with the second template. In this case, when a large face considered as a main captured object is detected, the processing can be terminated rapidly. This reduces the processing time.
[0166] In the above embodiments, face detection is performed in the order shown in FIG. 5B . However, for example, the detection may be started at the screen center having a highest probability of containing a face, and then may be performed in a spiral manner toward the outer sides. At that time, the movement step for the extraction region may be set small in the center part of the screen, while the movement step may be increased gradually for outer sides. In this case, the detection processing can be executed at step sizes in accordance with the probability of the presence of a face. Further, when this modification is implemented together with the above-mentioned modification that the processing is terminated when large faces have been found, processing speed can be improved.
[0167] Next, a third embodiment of the invention will be described. Components similar to those in the first embodiment will be designated by the similar reference numerals and repetitive explanations for those will be omitted.
[0168] In this embodiment, as shown in FIG. 16 , at step S 118 , the CPU 50 executes the processing of enlarging of the center part of the image obtained by the processing of step S 13 . When the main captured object is a person, a person's image is located at the center part of the image in many cases. Further, when a person's image is located at a position other than the center part, the person is not a main captured object in many cases. Thus, when the center part is extracted from the image, the data amount is reduced so that processing speed is improved. Further, when the enlarging processing is performed, the portions such as the eyes and the mouth serving as the targets of face identification of step S 19 are enlarged. Further, by virtue of the enlargement, the pixel values are averaged out so that noise components are reduced. This improves accuracy in the face identification.
[0169] Details of the processing of step S 118 of FIG. 16 will be described below with reference to FIG. 17 .
[0170] Step S 140 : Using the processing of step S 15 , the CPU 50 executes the processing of size reduction of the image data retained in the RAM 52 , by pixel skipping at a predetermined ratio. Here, for example, an image of QVGA (Quarter Video Graphics Array) size obtained by reducing the original image by pixel skipping at a predetermined ratio is used as the image to be rotated (the image used for detecting the presence or absence of a face). Here, the kinds of image data employable as the target of processing include a Y (brightness) component image. That is, in the search whether a face region is contained in the image data, similarity is determined with the template consisted of density information. Thus, the Y component image (i.e., brightness information which is similar to the density information) is adopted as image data to be subjected to the face matching.
[0171] Step S 141 : The CPU 50 executes the processing of enlarging into a predetermined size the image data obtained by the pixel skipping at step S 140 . For example, as shown in FIG. 18A , the image data indicated by a solid line is enlarged into a region indicated by a dashed line which is larger than the original image by d 1 pixels (e.g., 10 pixels) in the up and down directions and d 2 pixels (e.g., 10 pixels) in the right and left directions. Here, employable methods of enlarging processing include nearest neighbor interpolation, bilinear interpolation, bicubic interpolation, and linear interpolation.
[0172] Step S 142 : The CPU 50 executes the processing of extracting image data of the original size from the image data enlarged at step S 141 , and then returns to the original processing. For example, as shown in FIG. 18B , image data of the original size is extracted from the image data enlarged at step S 141 .
[0173] In this embodiment, a region in the center part is extracted after the enlargement of the image. However, after the extraction of a region in the center part of the image, the extracted region may be enlarged. For example, after a region indicated by a dashed line is extracted from the image as shown in FIG. 19A , the extracted region is enlarged as shown in FIG. 19B . In this case, the area of a region subjected to the enlargement processing that requires a processing cost can be reduced. This improves processing speed in comparison with the case of FIGS. 18A and 18B .
[0174] With the above configurations, a region in the center part of the image data is extracted, and then the presence or absence of a face is determined. Thus, image data subjected to the processing is narrowed down. This improves processing speed. Further, a captured person is located near the center of the image in many cases. Furthermore, a person located at a position other than the center is not the main captured object in many cases. This permits efficient narrowing down of the possibility of the target of processing.
[0175] Further, the target image is enlarged after the reduction by pixel skipping. Thus, noise contained in the image is removed, so that accuracy is improved in the face matching. Further, since the original image is enlarged, elements such as the eyes, the mouth, and the nose serving as characteristic parts can easily be found out.
[0176] In a case where the above processing is performed in the printing apparatus 210 shown in FIGS. 14 and 15 , the correction processing can be performed in accordance with the face contained not only in an image read in from the memory card M, but also in that read in by the scanner section 230 . That is, for example, when a photograph or the like is placed and scanned on the scanner section 230 , the image is read in and converted into image data. Then, when processing similar to that of the above-mentioned case is performed on the image data, correction processing can be executed in accordance with the color of face skin of a person.
[0177] In this embodiment, the region from which image data is extracted is fixed. However, learning may be performed on the basis of the past processing so that an optimal range may be set up. Specifically, a portion having a high probability of the presence of a face in the image data may be identified on the basis of the past data. Then, the region may be set up such that the portion should be included. This method allows a face to be found at minimum cost.
[0178] In this embodiment, a region to be extracted in the center part is set up in an approximately rectangular shape. However, a region of another shape may be extracted. For example, the shape may be a trapezoid, a triangle, or a circle.
[0179] In this embodiment, a region in the center part is enlarged or reduced. However, recognition processing may be performed without enlargement or reduction by using the intact image of the extracted region. Further, reduction and enlargement may be repeated several times so that noise components may be reduced. This improves recognition accuracy. Further, the processing of detecting whether a face is contained may be performed after mosaic processing is performed on the extracted image.
[0180] In this embodiment, linear interpolation is employed as the method of enlarging the extracted image data. However, another processing method may be employed in the enlargement processing. Employable methods include the nearest neighbor method in which the color of an image constituting point located at the nearest position from the interpolation point is adopted intact as the color of the interpolation point, the bilinear method in which the weighted average of the color values of the four image constituting points surrounding the interpolation point is adopted as the color of the interpolation point, and the bicubic method in which the result of interpolation by the cubic spline method concerning the 4×4=16 image constituting points surrounding the interpolation point is adopted as the color of the interpolation point.
[0181] In the above embodiments, the processing shown in FIGS. 8 , 11 - 13 , 16 and 17 are executed by the printing apparatus 11 or the printing apparatus 211 . However, for example, the processing may be executed by a host computer connected to the printing apparatus 11 or the printing apparatus 211 .
[0182] The processing can be executed by a computer. In this case, a program is provided to describe the content of a processing that the printing apparatus executes. A computer executes the program whereby the processing is performed in the computer. The program, which describes the content of the processing, can be recorded in a recording medium, which can be read by a computer. A recording medium, which can be read by a computer, includes a magnetic recording system, an optical disk, a magneto-optical recording medium, a semiconductor memory, etc. The magnetic recording system includes a hard disk drive (HDD), a floppy disk (FD), a magnetic tape, etc. The optical disk includes a DVD, a DVD-RAM, a CD-ROM, a CD-R/RW (Rewritable), etc. The magneto-optical recording medium includes an MO (magneto-Optical disk), etc.
[0183] In case of distribution of programs, portable recording media, such as DVD, CD-ROM, etc., with the programs recorded are sold. Also, programs are stored in a storage device of a server computer, and the programs can be transferred to other computers from the server computer.
[0184] A computer that executes programs stores in its own storage device programs recorded in a portable recording medium, or programs transferred from the server computer. The computer reads the programs from its own storage device to execute a processing according to the programs. In addition, the computer can read the programs directly from a portable recording medium to execute a processing according to the programs. Also, the computer can also execute a processing sequentially according to the received programs each time a program is transferred from the server computer.
[0185] Although the present invention has been shown and described with reference to specific preferred embodiments, various changes and modifications will be apparent to those skilled in the art from the teachings herein. Such changes and modifications as are obvious are deemed to come within the spirit, scope and contemplation of the invention as defined in the appended claims.
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A template representative of an image of a human face is provided. At least one of the template and image data is rotated to adjust a relative angle between an original orientation of the template and an original orientation of the image data, so as to exclude an angle range including 180 degrees. It is examined a matching between a part of the image data and the template to identify a region in the image data containing an image of a human face. The image data is corrected in accordance with a condition of the image of the human face.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 10/612,745, filed Jul. 2, 2003, the entire contents of which are expressly incorporated herein by reference.
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
The present invention relates generally to circulation systems which cause fluid to flow through various system components for the purposes of clarifying, heating, purifying and returning the fluid back to the original body of fluid, and more particularly, to a pool skimmer system which cause water to flow through a basket to remove debris floating on the surface of a pool and to return the water back to the pool.
In the context of swimming pools, the water in the pool is filtered through a circulation system to filter debris from the water. In particular, the circulation system has a reservoir attached adjacent to the pool. The reservoir and the pool are attached to each other through an inlet. Water is filled into the pool to a level above the inlet such that the water from the pool passes through the inlet into the reservoir. In this regard, the inlet is partially submerged under the surface of the water in the pool, and the level of the water in the pool is equal to the level of the water in the reservoir. The reservoir is connected to a pump which draws water from the pool side of the inlet to the reservoir side of the inlet. The reservoir additionally has a filter which traps any debris floating on the surface of the water and in the water. When the circulation system is deactivated, the debris trapped in the filter is trapped in the reservoir by a rotatable weir which is located at the inlet and only rotates toward the reservoir. In this regard, the weir allows passage of water and debris from the pool to the reservoir but not from the reservoir to the pool.
The filter discussed above requires regular cleaning. For this purpose, an access opening is provided directly above the filter. The access opening is formed in a deck which surrounds the pool. Multiple techniques are employed in the prior art to cover the access opening. An example of a cover is disclosed in U.S. Pat. No. 6,393,771 ('771 Patent) which is expressly incorporated herein by reference. Briefly, the '771 Patent discloses a cover comprising a frame and a cap member. The deck is modified with an opening sized and configured to receive the frame, and the cap member is sized and configured in conjunction with the frame to be removeably engagable therefrom.
In the context of swimming pools, the above described circulation system is typical of circulation systems in current use. To trap debris floating on the surface of the pool water, the circulation system requires that the pump be extraordinarily powerful such that debris floating on the pool water are drawn toward and pass through the inlet. Unfortunately, debris is drawn toward but does not pass through the inlet. Instead, the debris floating on the water of the pool collects on both sides of the inlet. Accordingly, there is a need for an improved skimmer system.
BRIEF SUMMARY OF THE INVENTION
The present invention alleviates the deficiencies in the prior art. In accordance with the present invention, there is provided a skimmer system attached to a tank having fluid therein. The system comprises a reservoir, an inlet, a filter, a reservoir pump and a weir. The fluid in the tank defines a tank fluid surface, and the fluid in the reservoir defines a reservoir fluid surface. The reservoir receives fluid from the tank via the inlet, and the tank receives fluid from the reservoir via the reservoir pump. The level of the reservoir fluid surface is maintained below the level of the tank fluid surface when the skimmer system is turned on such that fluid in the tank and debris floating in the tank fluid is funneled into the skimmer system, debris is trapped by the filter, and only the fluid but not the debris is returned to the tank.
The inlet defines an inlet edge and an inlet surface. The inlet edge is located below the level of the tank fluid surface, and the inlet surface declines away from the tank to transfer the fluid from the tank to the reservoir. The reservoir pump transfers fluid from the reservoir to the tank. The filter is positioned between the inlet and the reservoir to retain particulate/debris therein.
The weir defines a weir edge which may be positioned above the inlet surface. The weir edge may be parallel to and substantially below the level of the tank fluid surface to allow particulate/debris in the fluid to pass under the weir when the reservoir pump is activated and to prevent particulate/debris in the fluid from passing under the weir from the reservoir side to the tank side of the inlet when the reservoir pump is deactivated.
The inlet edge may be set about one inch below the level of the tank fluid surface. An opening of the inlet is defined by the inlet edge and a height. The inlet edge may be about twenty four inches, and the height may be about four inches. The inlet surface may have a decline angle of about 20 degrees. Although the inlet surface is shown as a flat surface, it is also contemplated within the scope of the present invention that the inlet surface may have other configurations such as stair-stepped, (See FIG. 14 ), convex (See FIG. 15 ) or concave as long as the fluid from the tank may flow into the area above the filter.
The level of the tank fluid surface may be equal to the level of the reservoir fluid surface when the skimmer system is not on (i.e., reservoir pump is not activated). At this moment, the rate of fluid transfer through the inlet from the tank to the reservoir and through the reservoir pump from the reservoir to the tank may be equal to zero. Once the reservoir pump is activated (i.e., the skimmer system is turned on), the level of the reservoir fluid surface may begin to decrease in relation to the level of the tank fluid surface. Eventually, for a pump which transfers fluid from the reservoir to the tank at a constant rate, the fluid transfer rate of the fluid through the inlet will equal the fluid transfer rate of the fluid through the reservoir pump, and a steady state condition will occur. Preferably, the level of the reservoir fluid surface is about three inches below the level of the tank fluid surface at the steady state condition.
Over time, as the skimmer system operates at this steady state condition, fluid may evaporate thereby decreasing the level of the reservoir fluid surface. If fluid continues to evaporate out of the tank and reservoir, and the level of the reservoir fluid surface reaches the entrance of the reservoir pump, then air will be pumped through the pump (i.e., dry pump condition) which is not desirable. To prevent the dry pump condition, a fluid level regulator, which is in communication with an inlet fluid valve (see FIG. 1 ), may activate and deactivate the inlet fluid valve to replenish the tank and reservoir with fluid as fluid evaporates from the tank and reservoir. The inlet fluid valve is connected to an outside fluid source which when opened fills the tank and reservoir with fluid. The fluid level regulator may be attached to the reservoir and may monitor the level of the reservoir fluid surface such that the inlet fluid valve is opened when the level of the reservoir fluid surface is too low (i.e., more than about three inches below the level of the tank fluid surface) and is closed when the reservoir has been filled with a sufficient amount of fluid (i.e., the level of the reservoir fluid surface is about three inches below the level of the tank fluid surface). For example, the fluid level regulator may open the inlet fluid valve when the level of the reservoir fluid surface is greater than about four inches below the level of the tank fluid surface. As the fluid fills the reservoir, the level of the reservoir fluid surface will rise. The inlet fluid valve may remain open until the fluid level regulator senses that the level of the reservoir fluid surface is about three inches below the level of the tank fluid surface.
Alternatively, the fluid level regulator may monitor the level of the reservoir fluid surface and control (i.e., activate or deactivate) the reservoir pump to maintain the level of the reservoir fluid surface approximately three inches below the level of the tank fluid surface. In this alternative embodiment, a fluid transfer rate of the reservoir pump may be greater than a fluid transfer rate of the inlet. The fluid level regulator activates the reservoir pump when fluid level regulator senses that the level of the reservoir fluid surface is about three inches or less below the level of the tank fluid surface and deactivates the reservoir pump when fluid level regulator senses that the level of the reservoir fluid surface is greater than about three inches below the level of the tank fluid surface. The reservoir pump may cycle between the activated and deactivated states when the skimmer system is turned on.
In a further alternative embodiment, the reservoir pump which may have a fluid transfer rate greater than a fluid transfer rate of the inlet may be activated for a set period of time to drain the reservoir and deactivated to allow the reservoir to refill. The reservoir pump may cycle between the activated and deactivated states when the skimmer system is turned on.
The skimmer system may further comprise a conical tray with an aperture at the center thereof. The tray may be positioned above the reservoir. The aperture may be sized and configured to receive and removeably secure the filter. The tray is located at a level below the inlet surface so as to receive the fluid transferred through the inlet.
The reservoir may have a cubular or a cylindrical configuration. The reservoir may have a capacity of about 12 to 16 cubic feet. In relation to the cylindrical configuration, the reservoir may have a diameter of about 30 inches. In relation to the cubular configuration, the reservoir may have a base dimension of thirty inches by thirty inches.
The skimmer system may further comprise an overflow valve attached to the reservoir one inch above the inlet edge to drain fluid from the reservoir when the level of the reservoir fluid surface is greater than one inch above the inlet edge.
The skimmer system may further comprise a cover which may be positioned above the filter for closing a utility access opening formed in a fabricated surface surrounding the tank to service the filter. The access opening may extend through the fabricated surface having an exposed appearance. The cover may comprise a cap member engagable within the opening. The cap member may have a top cavity adapted to receive a selected material. The cap member may further have at least one hand/finger engagable grip for lifting the cap member and the selected material placed in the top cavity from the opening. The cap member with the material disposed within the top cavity provides an exposed surface having an appearance substantially identical to the exposed appearance of the fabricated surface.
The cap member may have two hand/finger engagable grips which are a pair of hollow tubes having holes extending to a flared bottom cavity for gripping the cap member with human fingers. The two hand/finger engagable grips may be formed opposite each other and aligned with a center of gravity of the cap member and the selected material placed in the top cavity.
The cap member may have a bottom plate, a lateral wall, and a plurality of support posts. The bottom plate and the lateral wall define the top cavity, and the plurality of support posts may be disposed within top cavity wherein each post is attached to both the bottom plate and the lateral wall.
The selected material may be castable, dirt or other material having an appearance identical or substantially similar to the exposed appearance of the fabricated surface. The cap member may additionally have at least one hole for draining moisture from the material placed within the top cavity of the cap member. In particular, the drain hole may be an aperture through the bottom plate.
In another embodiment of the present invention, an access assembly for constructing a covered access opening is provided. The access opening extends through a fabricated surface having an exposed appearance. The assembly comprises a frame and a cap member. The frame may have may have a side support for lining an access opening through the fabricated surface. The frame may also have a bottom support wherein the side support and the bottom support are sized and configured to receive the cap member. The cap member may have a top cavity adapted to receive a selected material. The cap member may further have at least one hand/finger engageable grip for lifting the cap member and the material placed in the cavity of the cap member from the opening. The hand/finger engagable grip(s) may be formed at a periphery of the cap member.
Preferably, the cap member may have two hand/finger engageable grips which are a pair of hollow tubes. The hollow tubes may have holes extending through the cap member to a flared bottom cavity for gripping the cap member with human fingers. The two hand/finger engagable grips may be formed opposite each other and aligned with a center of gravity of the cap member and the selected material placed in the top cavity.
In another embodiment of the present invention, an access assembly may comprise a cap member and a frame. The frame may have a side support for lining an access opening through the fabricated surface and a bottom support wherein the side support and the bottom support are sized and configured to receive the cap member.
The cap member and the frame may collectively define a hollow tube with a flared bottom cavity for receiving a finger of a human hand to lift the cap member out of the frame. The cap member may have formed about its periphery at least one recess which extends from the top of the cap member to the flared bottom cavity. A top view of the recess may have a semi circular configuration. The flared bottom cavity may be formed at the bottom of the cap member such that a finger may lift the cap member out of the frame.
In another embodiment of the present invention, an access assembly may comprise a cap member and a frame similar to the above mentioned access assemblies. Moreover, the cap member and the frame may collectively define the hollow tubes or hand/finger engageable grip(s). In particular, a flared bottom cavity may be formed about a periphery of the cap member. A side support of the frame may be recessed to provide access to the flared bottom cavity when the cap member is received by the frame.
When the cap member is inserted into the frame, the flared bottom cavity may not be aligned to the recess found in the side support. As such, the cap member may be rotated until the recess is aligned to the flared bottom cavity such that a person may lift the cap member out of the frame by inserting his/her fingers into the recess and grasping the flared bottom cavity.
A plurality of flared bottom cavities may be formed on the cap member. Similarly, a plurality of recesses may be formed in the side support of the frame. The plurality of flared bottom cavities may be formed about the cap member in a corresponding manner to the recesses formed in the side support of the frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a front elevational view of a skimmer system attached to a tank and a cover/access assembly;
FIG. 2 is a cross sectional view of the skimmer system illustrated in FIG. 1 ;
FIG. 3 is a top view of a fabricated surface and a first embodiment of a cover/access assembly shown in FIG. 2 ;
FIG. 4 is a side elevational view of an inlet illustrated in FIG. 2 ;
FIG. 5 is an exploded view of the first embodiment of the cover/access assembly shown in FIG. 2 ;
FIG. 6 is a top view of a cap member illustrated in FIG. 5 ;
FIG. 7 is a front cross sectional view of the cover illustrated in FIGS. 5 and 6 ;
FIG. 8 is an exploded view of a second embodiment of a cover/access assembly;
FIG. 9 is a top view of a cap member illustrated in FIG. 8 ;
FIG. 10 is a front cross sectional view of the cover illustrated in FIGS. 8 and 9 ;
FIG. 11 is an exploded view of a third embodiment of a cover/access assembly;
FIG. 12 is a top view of a cap member and a frame illustrated in FIG. 11 ;
FIG. 13 is a front cross sectional view of the cover illustrated in FIGS. 11 and 12 ;
FIG. 14 illustrates a front elevational view of a skimmer system attached to a tank wherein the inlet surface has a stair stepped configuration;
FIG. 15 illustrates a front elevational view of a skimmer system attached to a tank wherein the inlet surface has a concave configuration; and
FIG. 16 illustrates a front elevational view of a skimmer system attached to a tank wherein the fluid level regulator activates and controls the reservoir pump.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1–13 are for the purpose of illustrating the preferred embodiments of the present invention, and not for the purpose of limiting the present invention. The following discussion of the preferred embodiments of the present invention will describe the preferred embodiments in the context of residential and commercial pools. However, the present invention is not limited to residential and commercial pools. Rather, they may be expanded into other uses. For example, the preferred embodiment of the present invention may be applicable to water, oil or other fluidic tanks.
The residential or commercial pool may be a permanently installed pool, in-ground pool, above-ground-pool or an on-ground pool. For purposes of this discussion, the pool which contains the body of water shall be referred to as the tank 10 , and the water within the pool shall be referred to as the fluid 12 , as shown in FIG. 1 . The area beside the tank 10 is the fabricated surface 14 . The fluid 12 when filled into the tank 10 defines a tank fluid surface 16 . The level of the tank fluid surface 16 changes over time due to evaporation or user intervention. Typically, the tank 10 will have an open top. The tank has an inlet fluid valve 17 (see FIG. 1 ) which may be turned on automatically through a remote controller or manually through user intervention. The inlet fluid valve 17 fills the tank 10 with fluid from an outside source to raise the level of the tank fluid surface 16 . The rate at which the fluid 12 is filled into the tank 10 defines a fluid transfer rate of the inlet fluid valve 17 . The fluid transfer rate is the amount of fluid 12 that is transferred between two points per a unit of time. For example, the fluid transfer rate of the inlet fluid valve 17 is the amount of fluid 12 that may be transferred from the outside source into the tank 10 per a unit measurement of time.
FIG. 1 illustrates the skimmer system 18 . The skimmer system 18 may comprise a reservoir 20 , inlet 22 , reservoir pump 24 , filter 26 a , weir 28 and a fluid level regulator 29 . The skimmer system 18 may be incorporated into the circulation system of the tank 10 .
The reservoir 20 may be generally located adjacent to the tank 10 , and is generally located below the level of the tank fluid surface 16 when the tank 10 is full, as shown in FIG. 1 . When the reservoir 20 is filled with fluid, the fluid defines a reservoir fluid surface 31 . The reservoir 20 may have a capacity to hold approximately 12 to 16 cubic feet of fluid 12 . The reservoir 20 may have a cylindrical configuration or a cubular configuration. In relation to the cylindrical reservoir 20 , the diameter of the cylindrical reservoir 20 may be approximately thirty inches, and the height 30 of the cylindrical reservoir 20 may be approximately thirty four inches measured from the bottom of the reservoir 20 to the top of the fabricated surface 14 . In relation to the cubular reservoir, the base of the reservoir 20 may have a dimension of about thirty inches by thirty inches, and the height 30 of the cubular reservoir may be about thirty four inches measured from the bottom of the reservoir to the top of the fabricated surface 14 .
Referring to FIG. 2 , a tray 32 may be attached to the reservoir 20 at its upper portion. The tray 32 may have an inverted conical configuration. The center of the tray 32 may have an aperture.
The filter 26 a may be attached to tray 32 . In particular, the filter 26 a may be attached to the tray 32 at the aperture. The aperture of the tray 32 may be sized and configured to receive and removeably secure the filter 26 a to the tray. The filter 26 may be a standard pool basket, a wire mesh filter, a permanent medium filter, diatomaceous earth filter, cartridge filter or vacuum filter. For example, as shown in FIG. 2 , the filter 26 a is a standard pool basket.
The fluid level regulator 29 may be attached to reservoir 20 to regulate the level of the reservoir fluid surface 31 by activating and deactivating an inlet fluid valve 17 based on a sensed level of the level of the reservoir fluid surface. As shown in FIG. 1 , the fluid level regulator 29 may be in communication with the inlet fluid valve 17 . The fluid level regulator 29 monitors and regulates the level of the reservoir fluid surface 31 to be sufficiently below the level of the tank fluid surface 16 . For example, the fluid level regulator 29 regulates the level of the reservoir fluid surface 31 to be about three inches below the level of the tank fluid surface 16 . The fluid level regulator 29 may be a ballcock such as a float-arm ball type or a float-cup type. The fluid level regulator 29 may have an up position and a down position. The up position may deactivate the inlet fluid valve 17 , and the down position may activate the inlet fluid valve 17 .
An overflow valve 34 may be attached to the reservoir 20 , as shown in FIGS. 1 and 2 . The overflow valve 34 may have an opened and closed position wherein the fluid 12 exits the reservoir 20 or is retained within the reservoir 20 , respectively. The overflow valve 34 may be a spigot which may be automatically or manually controlled between the opened and closed positions. The overflow valve 34 drains the fluid from the tank 10 and reservoir 20 when the levels of the tank and reservoir fluid surface 16 , 31 are too high.
Referring to FIGS. 1 , 2 and 4 , an inlet 22 may be attached to the reservoir 20 . As shown in FIG. 4 , the inlet defines an opening 36 . The opening 36 has a width 38 and a height 40 . The inlet 22 further defines an inlet edge 42 . The width 38 of the edge 42 (i.e., the opening) may be about twenty four inches. The height 40 of the opening may be about four inches. The inlet edge 42 may be located approximately one inch below the level of the tank fluid surface 16 , as shown in FIG. 2 . When the tank 10 is empty, the inlet fluid valve 17 may be turned on until the level of the tank fluid surface 16 is approximately one inch above the inlet edge 42 . Additionally, the overflow valve 34 may be attached to the reservoir 20 at about one inch above the inlet edge 42 . Accordingly, if the levels of the tank fluid surface 16 and the reservoir fluid surface 31 are more than one inch above the inlet edge 52 , then the fluid 12 may be drained out through the overflow valve 34 to maintain the tank and reservoir fluid surface to be one inch above the inlet edge 42 .
The inlet edge 42 may be connected to an inlet surface 44 , as shown in FIGS. 2 and 3 . The inlet surface 44 declines away from the inlet edge 42 . The rate of declination of the inlet surface 44 may be about alpha (e.g., twenty degrees, etc.). (See FIG. 2 ). For example, the horizontal component of the inlet surface 44 is about eight inches, and the vertical component of the inlet surface 44 is about three inches. Although inlet surface 44 is shown as being a generally flat surface, it is also contemplated that the inlet surface 44 may have any configuration (e.g., stair-step, curved, etc.; See FIGS. 14 and 15 ) as long as a terminal edge 45 (see FIG. 2 ) of the inlet surface 44 is lower than the inlet edge 42 such that the fluid 12 may cascade downward into the reservoir 20 .
The inlet 22 and the reservoir 20 may be positioned relative to each other such that the inlet 22 directs the fluid 12 onto the tray 32 and eventually through the filter 26 a and into the reservoir 20 . The tray 32 may be located below and adjacent the inlet surface 44 such that as fluid 12 initially fills the tank 10 , the level of the tank fluid surface is raised above the inlet edge 42 and the fluid 12 of the tank 10 begins to spill into the reservoir 20 through the inlet 22 due to pressure on the tank side and gravity on the reservoir side of the inlet 22 . The rate at which the fluid 12 is drawn through the inlet 22 defines the fluid transfer rate of the inlet 22 . The fluid transfer rate of the inlet 22 is a function of the distance at which the inlet edge 42 is located below the tank fluid surface 16 , the width 38 of the inlet edge 42 , and the viscosity of the fluid 12 . The fluid 12 in the tank 10 is considered to be the influent side of the inlet 22 , and the fluid 12 in the reservoir 20 is considered to be the effluent side of the inlet 22 .
The weir 28 may be located above the inlet surface 44 , as shown in FIG. 2 . The weir 28 may be a square plate which extends across the whole width 38 (see FIG. 4 ) of the inlet opening 36 . The weir 28 may be attached to the fabricated surface 14 and extend downward toward the inlet surface 44 . The weir 28 may extend substantially below the level of the tank fluid surface 16 . The weir 28 may extend toward but does not touch the inlet surface 44 so as to allow particulates/debris within the fluid 12 and on the tank fluid surface 16 to pass under the weir 28 when fluid 12 is being transferred from the tank 10 to the reservoir 20 . In the context of pools, by way of example and not limitation, the particulates may be leaves and dead insects. The particulates may pass under the weir 28 due to the force of the fluid 12 being transferred from the tank 10 to the reservoir 20 . The weir 28 may be fixedly attached to the fabricated surface 14 . Alternatively, the weir 28 may be rotatably attached to the fabricated surface 14 . In particular, the weir 28 may rotate only toward the reservoir 20 . The normal position of the weir 28 may be vertical, as shown in FIG. 2 .
As stated above, the fluid level regulator 29 monitors and regulates the level of the reservoir fluid surface 31 to be sufficiently below the level of the tank fluid surface 16 . In this regard, the level of the reservoir fluid surface 31 is sufficiently below the level of the tank fluid surface 16 as long as the fluid 12 in the tank 10 and the particulates in the fluid 12 are able to pass through the inlet opening 36 and under the weir 28 .
Attached to the bottom of the reservoir 20 are at least one and preferably two tubes 46 which drain the reservoir 20 of fluid 12 , as shown in FIGS. 1 and 2 . Each tube 46 may have a two inch diameter. The tubes 46 may subsequently be attached to the reservoir pump 24 (see FIG. 1 ). When the reservoir pump 24 is activated, the reservoir pump 24 may transfer fluid 12 from the reservoir 20 to the tank 10 . The reservoir pump 24 defines a fluid transfer rate which defines the rate at which the fluid 12 is transferred from the reservoir 20 to the tank 10 . In this regard, the fluid 12 in the tank 10 is considered to be the effluent side of the reservoir pump 24 , and the fluid 12 in the reservoir 20 is considered to be the influent side of the reservoir pump 24 . The reservoir pump 24 may subsequently be connected to a filter 26 b (see FIG. 1 ). The filter 26 b may subsequently be connected to the tank 10 .
The fluid transfer rate of the reservoir pump 24 may preferably be constant, or in the alternative, variable. In the context of pools, the fluid transfer rate of the reservoir pump 24 and the capacity of the reservoir 20 to contain fluid 12 are sized in relation to each other such that the reservoir pump 24 does not pump air.
In relation to reservoir pumps 24 having a constant fluid transfer rate, the fluid transfer rate of the reservoir pump 24 may be equal to the fluid transfer rate of the inlet 22 when the level of the reservoir fluid surface 31 is sufficiently below the level of the tank fluid surface 16 . When the tank 10 and reservoir is filled with fluid 12 and the reservoir pump 24 is initially activated, then the level of the tank fluid surface 16 will rise which causes the fluid transfer rate of the inlet 22 to rise until the fluid transfer rate from the tank 10 to the reservoir 20 through the inlet 22 is equal to the fluid transfer rate from the reservoir 20 to the tank 10 via the reservoir pump 24 . The pump 24 and the inlet 22 eventually reaches a steady state condition in which the level of the tank fluid surface 16 is above the level of the reservoir fluid surface 31 a set distance such as about three inches. The reservoir pump 24 may be sized in relation to the fluid transfer rate of the inlet 22 such that the level of the reservoir fluid surface 31 is sufficiently below the level of the tank fluid surface at the steady state condition. For example, the reservoir pump 24 may be sized such that the level of the reservoir fluid surface 31 is about three inches below the level of the tank fluid surface 16 at the steady state condition.
In relation to reservoir pumps 24 having variable fluid transfer rates, the fluid level regulator 29 varies the fluid transfer rate of the reservoir pump 24 as a function of the level of the reservoir fluid surface 31 . The fluid level regulator 29 varies the fluid transfer rate of the reservoir pump 24 such that the level of the reservoir fluid surface 31 is sufficiently below the level of the tank fluid surface. For example, the fluid level regulator 29 varies the fluid transfer rate of the reservoir pump 24 such that the level of the reservoir fluid surface 31 is about three inches below the level of the tank fluid surface 16 .
A general operation of the above described components will be discussed. When the tank 10 is empty, the inlet fluid valve 17 is activated such that fluid 12 may fill the tank 10 . The inlet fluid valve 17 is maintained in the opened position such that the fluid 12 fills the tank 10 till the level of the tank fluid surface 16 is about one inch above the inlet edge 42 . At this time, the level of the tank fluid surface 16 is equal to the level of the reservoir fluid surface 31 .
The skimmer system 18 is activated thereby turning the reservoir pump 24 on such that fluid from the reservoir 20 is being pumped from the reservoir 20 into the tank 10 , lowering the level of the reservoir fluid surface 31 , and slightly increasing the level of the tank fluid surface in relation to each other. As the reservoir pump 24 transfers fluid from the reservoir 20 to the tank 10 , the fluid transfer rate of the inlet 22 increases until the fluid transfer rate of the inlet 22 is equal to the fluid transfer rate of the reservoir pump 24 . Preferably, this steady state condition is reached when the level of the reservoir fluid surface 31 is approximately three inches below the level of the tank fluid surface 16 .
As skimmer system 18 operates at this steady state condition, due to evaporation, the level of the reservoir fluid surface 31 may drop close to the opening of the tubes 46 connected to the reservoir pump 24 thereby producing a possible dry pump situation which is undesirable. To mitigate against the dry pump situation, the fluid level regulator 29 monitors the level of the reservoir fluid surface 16 . If the level of the reservoir fluid surface 16 is too low (i.e., more than about three inches below the level of the tank fluid surface), then the fluid level regulator 29 may activate the inlet fluid valve 17 to fill the tank 10 and reservoir 20 with fluid. For example, if the fluid level regulator 29 senses that the level of the reservoir fluid level 31 is more than four inches below the level of the tank fluid surface 16 then the inlet fluid valve 17 may be activated thereby filling the tank 10 and reservoir 20 . This raises the level of the reservoir fluid surface 31 . The inlet fluid valve 17 may be activated until the level of the reservoir fluid surface 31 is about three inches below the level of the tank fluid surface 16 .
In an alternate embodiment, the skimmer system 18 is initially activated and the fluid level regulator 29 monitors that the level of the reservoir fluid surface 31 is at the same level as the level of the tank fluid surface thereby activating the reservoir pump 24 to drain the reservoir 20 . (See FIG. 16 ). The level of the reservoir fluid surface 31 is reduced and the level of the tank fluid surface 16 is increased while the reservoir pump 24 is active because the fluid transfer rate of the reservoir pump 24 is greater than the fluid transfer rate of the inlet 22 . If the reservoir pump 24 is maintained in the active state and the fluid transfer rate of the inlet 22 is less than the fluid transfer rate of the reservoir pump 24 , then the reservoir pump 24 will eventually transfer all of the fluid 12 from the reservoir 20 to the tank 10 creating a dry pump situation. To mitigate against the dry pump situation, the fluid level regulator 29 deactivates the reservoir pump 24 when the fluid level regulator 29 reaches the down position. In this alternative embodiment, the fluid level regulator 29 does not deactivate the reservoir pump 24 until the down position has been reached (i.e., when the level of the reservoir fluid surface approaches the entrance of the tubes 46 ) even though the level of the reservoir fluid surface 31 is more than three inches below the level of the tank fluid surface 16 .
When the fluid level regulator 29 is in the down position, the reservoir pump 24 may be deactivated. Now, the fluid transfer rate of the inlet 22 is greater than the fluid transfer rate of the deactivated reservoir pump 24 thereby filling the reservoir 20 with fluid 12 . The reservoir pump 24 will be maintained in the deactivated state until the fluid level regulator 29 indicates that the level of the reservoir fluid surface 31 is about three inches below the level of the tank fluid surface 16 .
When the skimmer system 18 is activated, preferably, the inlet fluid valve 17 is cyclically activated and deactivated due to fluid evaporation or the reservoir pump 24 cycles between the active and deactivated state based on the level of the reservoir fluid surface 31 . Additionally, particulates which float on the tank fluid surface 16 (i.e., particulates which have a lower density than the fluid) are drawn into the inlet 22 and trapped by the filter 26 a . Additionally, particulates which float within the fluid 12 (i.e., particulates which have about the same density as the fluid) in the tank 10 are drawn into the inlet 22 and trapped by the filter 26 a . Additionally, other fluid treatment components may be added to the skimmer system 18 such as a clarifier, heater and purifier.
When the skimmer system 18 is deactivated, the inlet 22 continues to draw fluid 12 from the tank 10 to the reservoir 20 until the levels of the tank fluid surface 16 and reservoir fluid surface 31 are equal. At this point, the particulates which have a lower density than the fluid 12 may not pass under the weir 28 from the reservoir 20 to the tank 10 because the weir extends from the fabricated surface 14 to below the level of the tank fluid surface 16 . In this regard, the weir 28 extends substantially below the level of the tank fluid surface 16 as long as the particulates having a lower density than the fluid 12 cannot be transferred from the reservoir 20 to the tank 10 when the skimmer system 18 is deactivated.
One tank 10 may have multiple skimmer systems 18 attached thereto. For example, a plurality of skimmer systems 18 may be located equidistant around the circumference of the tank 10 . When multiple skimmer systems 18 are attached to one tank 10 , then the tubes 46 used to drain each reservoir 20 may be interconnected to a single reservoir pump 24 .
The filter 26 a needs to be cleaned out on a regular basis. As such, an access opening may be formed in the fabricated surface 14 above the filter 26 a , as shown in FIGS. 1 and 2 . The access opening may be formed directly above the filter 26 a which is secured to the tray 32 of the reservoir 20 . Referring to FIGS. 2 , 5 , 8 and 11 , a cover 68 a, b, c for closing the access opening is illustrated. The cover 68 a, b, c includes a cap member 70 a, b, c engageable within the access opening of the fabricated surface 14 . The cover 68 a, b, c is suitable for covering the access opening formed by the fabricated surface 14 , however, the access opening is preferably formed with a frame 72 a, b, c having an opening 74 a, b, c disposed within the plane of the fabricated surface 14 . To facilitate engagement of the cap member 70 a, b, c, the frame 72 a, b, c can be provided with a bottom support/rim 76 a, b, c sized to engage a bottom plate 78 a, b, c of the cap member 70 a, b, c. The cap member 70 a, b, c and frame 72 a, b, c can be constructed from any material having sufficient stiffness and durability, such as metal, fiberglass, plastic, ceramic, wood, etc.
As shown in FIGS. 5–13 , the cap member 70 a, b, c has a substantially full top cavity 80 a, b, c (see FIGS. 7 , 10 and 13 ) for receiving a selected material 82 (see FIG. 3 ). The material 82 within the cavity 80 a, b, c may be selected to provide an exposed surface 84 (see FIG. 3 ) having an appearance substantially identical with the exposed appearance of the fabricated surface 14 . Additionally, when the selected material 82 is identical to the material of the fabricated surface 14 , the exposed surface 84 and fabricated surface 14 will have compatible functional properties as well, such as respective coefficients of friction and coefficients of expansion. While a homogenous material 82 is shown in FIG. 3 , it is, of course, to be understood that non-homogenous materials such as stone and mortar or tile and grout can also be placed within the cavity 80 a, b, c to provide an exposed surface 84 having a substantially identical appearance with a similarly non-homogenous fabricated surface. It is also to be understood, of course, that a person can select a material 82 to provide an exposed surface 84 with an appearance which is merely compatible with the appearance of the fabricated surface 14 . For example, the user may prefer a material which completes a pattern in the overall landscape, or which creates a readily visible marker.
The cap member 70 a, b, c may be provided with a plurality of drain holes 86 a, b, c for draining moisture from the material 82 placed within the top cavity 80 a, b, c, and a plurality of support posts 88 a, b, c attached to the bottom plate 78 a, b, c and lateral wall 90 a, b, c for stiffening the lateral wall 90 a, b, c and anchoring the material 82 within the top cavity 80 a, b, c . Although two drain holes 86 a, b, c and four support posts 88 a, b, c are shown in FIGS. 5–6 , 8 – 9 and 11 – 12 , it is, of course, recognized that the cap member 70 a, b, c can be provided with one or more drain holes 86 a, b, c or support posts 88 a, b, c.
Referring now to FIGS. 5–7 , a first embodiment of the cap member 70 a may also be provided with hollow finger grip tubes 92 a having holes 96 a extending through the material 82 to a flared bottom cavity 94 a (see FIG. 7 ). The tubes 92 a , and more particularly, the flared bottom cavity 94 a may have a grip surface 98 a (see FIG. 7 ) to provide a finger hold for lifting the cap member 70 a and material 82 from the access opening.
Referring now to FIGS. 8–10 , a second embodiment of the cap member 70 b and frame 72 b may be provided which collectively form hollow finger grip tubes 92 b (see FIG. 10 ) having holes 96 b (see FIG. 10 ) extending through the material 82 to a flared bottom cavity 94 b . The tubes 92 b , and more particularly, the flared bottom cavity 94 b may have a grip surface 98 b (see FIG. 10 ) to provide a finger hold for lifting the cap member 70 b and material 82 from the access opening.
The holes 96 b as well as the flared bottom cavity 94 b are defined by both the cap member 70 b and the frame 72 b . More particularly, the hole 96 b may be defined by the lateral wall 90 b of the cap member 70 b and the side support 104 b (see FIG. 8 ) of the frame 72 b . As shown in FIG. 9 , the lateral wall 90 b may have at least one recess 106 . The recess 106 when viewed from the top may have a semi circular configuration. The recess defines the inner periphery of the hole 96 b . The outer periphery of the hole 96 b may be defined by the side support 104 b of the frame 72 b.
The flared bottom cavity may also be defined by the lateral wall 90 b and the side support 104 b . The inner periphery of the flared bottom cavity 94 b may be an undercut formed in relation to the hole 96 b , as shown in FIG. 10 . The outer periphery of the flared bottom cavity 94 b may be defined by the side support 104 b of the frame 72 b.
Referring now to FIGS. 11–13 , a third embodiment of the cap member 70 c and frame 72 c may be provided which also collectively form hollow finger grip tubes 92 c (see FIG. 13 ) having holes 96 c (see FIG. 13 ) extending through the material 82 to a flared bottom cavity 94 c . The tubes 92 c , and more particularly, the flared bottom cavity 94 c may have a grip surface 98 c (see FIG. 10 ) to provide a finger hold for lifting the cap member 70 c and material 82 from the access opening.
The holes 96 c as well as the flared bottom cavity 94 c may be collectively defined by both the cap member 70 c and the frame 72 c . More particularly, the hole 96 c may be defined by the lateral wall 90 c of the cap member 70 c and the side support 104 c (see FIG. 11 ) of the frame 72 c . As shown in FIG. 12 , the side support 104 c of the frame 72 c may have at least one recess 108 . The recess 108 when viewed from the top may have a semi circular configuration. The recess defines the outer periphery of the hole 96 c . The inner periphery of the hole 96 c may be defined by the lateral wall 90 c of the cap member 70 c.
The flared bottom cavity 74 c may also be defined by the lateral wall 90 c and the side support 104 c . The inner periphery of the flared bottom cavity 94 c may be an undercut formed at the periphery of the cap member 70 c . The outer periphery of the flared bottom cavity 94 c may be defined by the side support 104 c of the frame 72 c.
In all three embodiments of the cap member 70 a, b, c and frame 72 a, b, c, the cap member 70 a, b, c may have at least one hollow finger grip tubes 92 a, b, c . Preferably, the cap member 70 a, b, c has two hollow finger grip tubes 92 a, b, c. Each hollow finger grip tube 92 a, b, c may be located at distal ends or opposed sides of the cap member 70 a, b, c . The hollow finger grip tubes 92 a, b, c may be placed equidistantly from the center of gravity 99 a, b, c (see FIG. 6 , 9 and 12 ) of the cap member 70 a, b, c after being filled with the material 82 . In other words, a line connecting the two grip tubes 92 a, b, c will cross substantially close to the center of gravity 99 a, b, c of the cap member 70 a, b, c filled with material 82 . The line crosses substantially close to the center of gravity 99 a, b, c of the cap member 70 a, b, c as long as the human hand, finger or other picking device may lift the cap member 70 a, b, c from the access opening. Referring now only to the first embodiment (see FIGS. 5–7 ) and the second embodiment (see FIGS. 8–10 ), the tubes 92 a, b from a top view may have a circular configuration or a semicircular configuration (see FIGS. 6 and 9 ). The circular portions of the semicircularly configured tubes 92 a, b may be directed toward the center of gravity 99 a, b of the cap member 70 a, b . Referring now only to the third embodiment (see FIGS. 11–13 ), the tube 92 c from a top view may also have a semi circular configuration (see FIG. 12 . However, the circular portions of the semicircularly configured tube 92 c may be directed away the center of gravity 99 c of the cap member 70 c.
In use, the cap member 70 is placed within the frame 72 as shown in FIG. 2 . Depending on the materials selected to construct the cover 68 and fabricated surface 14 , it may be advantageous to wrap a self-adhering tape around the outer peripheral wall 102 a, b, c (see FIGS. 5 , 8 , 11 ) of the cap member 70 a, b, c prior to inserting the cap member 70 a, b, c in the frame 72 a, b, c . When so applied, the self-adhering tape prevents material from bonding to the cap member 70 a, b, c and additionally minimizes the amount of excess material which may enter the gap between the frame 72 a, b, c and cap member 70 a, b, c.
Once the cap member 70 a, b, c is engaged within the frame 72 a, b, c , the assembly is placed within the intended plane of the fabricated surface as shown in FIG. 2 . The assembly is then positioned and leveled so the cap member 70 a, b, c will ultimately seat in a substantially level and flush position with the fabricated surface 14 . To obtain a level and flush position with the fabricated surface, it may be necessary to countersink the frame 72 a, b, c into the base 101 (see FIG. 2 ) upon which the fabricated surface 14 will be constructed. The correct orientation for the frame 72 a, b, c and cap member 70 a, b, c can also be verified with a level placed across the cap member 70 a, b, c.
After the assembly is correctly positioned, the fabricated surface 14 is installed around the frame 72 a, b, c, and a material 82 is placed within the top cavity 80 a, b, c of the cap member 70 a, b, c . The exposed surface 84 of the material 82 typically must be smoothed and leveled so the cover 68 a, b, c will seat in a level and flush position with the surrounding fabricated surface 14 .
Once the material 82 has sufficiently stabilized within the cavity 80 a, b, c , the cover 68 a, b, c is removed from the frame 72 a, b, c, the tape (if applied) is removed from the cap member 70 a, b, c , and any excess material is cleaned from the frame 72 a, b, c and the cap member 70 a, b, c . The time required for stabilization will depend on the selected material 82 , however, persons skilled in the art will recognize that the cover 68 a, b, c typically should not be removed from the frame 72 a, b, c until it is certain that the material 82 will remain in the cavity 80 a, b, c of the cap member 70 a, b, c and that the exposed surface 84 remain smoothed and level. The cap member 70 a, b, c is then reinserted within the frame 72 a, b, c for final placement until access is required.
In this manner, access is provided for critical utilities disposed underneath the cover 68 a, b, c such as for cleaning the filter 26 a . In addition, the cover 68 a, b, c can be constructed from a material 82 which provides an exposed surface 84 having an appearance substantially identical with the fabricated surface 14 . Moreover, the functional properties of the exposed surface 84 will also be compatible with those of the fabricated surface 14 if the cover 68 a, b, c is constructed from the same material as the fabricated surface 14 . Furthermore, the cover 68 a, b, c is custom fabricated to better match with the great variety of different fabricated surfaces. While it is recognized that an illustrative and presently preferred embodiment of the invention has been described in detail herein, it is likewise to be understood that the inventive concepts may be otherwise embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.
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A skimmer system is provided which includes a reservoir, an inlet, a reservoir pump and a weir. The skimmer system may be attached to a tank having fluid therein. The fluid in the tank defines a tank fluid surface, and the fluid in the reservoir defines a reservoir fluid surface. The reservoir receives fluid from the tank via the inlet, and the tank receives fluid from the reservoir via the reservoir pump. When the skimmer system is activated, the level of the reservoir fluid surface may be maintained below the level of the tank fluid surface. The inlet edge is located below the level of the tank fluid surface. The inlet surface may decline away from the tank to direct the fluid from the tank to the reservoir. The filter is positioned between the inlet and the reservoir to retain particulate within the fluid. The weir defines a weir edge. The weir edge may be parallel to and substantially below the level of the tank fluid surface to allow particulate in the fluid to pass under the weir when the reservoir pump is activated and to prevent particulate in the fluid from passing under the weir when the reservoir pump is deactivated. The filter may be serviced through an access opening formed in a fabricated surface above the filter and covered by a cover.
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REFERENCE TO RELATED PATENTS AND PATENT APPLICATION
The subject matter of this patent application is related to that of the commonly-owned U.S. Pat. Nos. 3,950,733; 4,044,243; 4,254,474 and 4,326,259, all to Cooper et al., and to the patent application Ser. No. 775,144 of Copper et al., for "Parallel, Multi-Unit, Adaptive, Nonlinear Pattern Class Separator and Identifier," all of which are incorporated herein by reference.
1. Field of the Invention
This invention relates to adaptive information processing systems. More particularly, it relates to self-organizing input-output devices which function to separate and identify classes of patterns including those that are not linearly separable.
2. Background of the Invention
The above-referenced patents and patent application to Cooper et al. disclose methods and apparatus (systems) that can learn to classify "patterns" or real world "events" even when representations of the same are not linearly separable. The patterns or events are detected by some data acquisition device and encoded into a set of measurements or features the results of which are represented by the signal S, comprised of individual signals s 1 , s 2 , . . . s k . The signal S could be, for example, a signal coming from a camera registering a scene (pattern), or the output of a microphone detecting some sound (pattern), or from a data base representing events, historical records, etc. (abstract patterns).
In a system comprising a Nestor® Adaptive Module as described in these patents, all input signals S (which are themselves referred to herein as "patterns") belonging to the same class should elicit the same final response from the system. For example, in an application such as character recognition, any version of a handdrawn "2" seen by the system should result in an output signal which causes the character font member for "2" to be displayed on some output device, video screen, printout, etc.
A system of this type is an extremely powerful pattern class separator and identifier. The system can be trained by a learning procedure which does not require the operator to specify the (possibly) complex geography of the pattern class in the multidimensional pattern space in which the input event is represented. In such a system the input event S is preprocessed into an intermediate signal F representing only certain prescribed features of the original pattern. Subjecting the input signal S (representing the pattern) to this preprocessing step--referred to herein as encoding--should preserve enough information to permit patterns to be distinguished from each other. Information irrelevant for learning one class may be important to distinguish some other class. For this reason, it may be difficult to choose a single preprocessing strategy that removes all irrelevant information without jeopardizing the ability to distinguish some classes.
The above-referenced patent application Ser. No. 755,144 for "Parallel, Multi-Unit, Adaptive, Nonlinear Pattern Class Separator and Identifier" describes a multi-unit Nestor System® which can be regarded as a way of linking together a number of Nestor Adaptive Modules. Each component Nestor Module can be considered as a complete unit, including its own preprocessing and encoding procedures. A pattern is identified by the response it produces among these component units. Each unit has its own encoding procedures, different from that of any other. A unit's encoding procedures define its code space. It is sensitive to certain types of information in the input signal. The particular set of features it registers may give it a special aptitude for learning some types of pattern classes, but not others. To the extent that a class is well separated from all others in the pattern space of a given unit and to the extent that it is not widely distributed throughout that space, then that unit will have a natural "aptitude" for learning this class. At the same time, learning other pattern classes may require pooling the resources of several component units, none of which alone has sufficient discriminating skills, by virtue of its preprocessing and encoding properties, to distinguish these classes. In this case the system identifies an example of such a class by correlating the responses of a set of units.
The multi-unit Nestor System disclosed in the above patent application is organized to first attempt separation of pattern classes within individual code spaces and secondly, for those classes for which that is not possible, to subsequently correlate the responses of multiple units to produce an identification. Such a system works best when, within the pattern spaces of the various events, class distributions are largely (but not necessarily wholly) non-overlapping. For the non-overlapping regions of the various class territories, effective mapping of the areas ("covering" with "influence fields" of Nestor Adaptive Module "prototypes") can be rapidly achieved by showing the system a suitable training set of patterns that is a representative sample of the classes in question. Those portions of a class territory that overlap with some other class (or classes) must still be properly mapped out ("covered"). This territory must be mapped out for each of the classes laying claim to it in the pattern space. If this is done and the pattern spaces of the various units in the multi-unit system are sufficiently different from one another (ideally, but not necessarily, orthogonal) then the overlapping class regions of one pattern space will not be reproduced in some other. (Two pattern spaces are orthogonal if, for any event, its representation in one space is completely uncorrelated with its representation in the other space.) Accordingly, correlation of unit responses from multiple units will serve to identify the pattern. As an example of multi-unit correlation, consider a two unit system in which Unit 1 (U 1 ) had degenerate class territories for classes A and B while Unit 2 (U 2 ) had degenerate regions for B and C. An example of a class B pattern would result in the "confused" responses A or B from U 1 and B or C from U 2 , which could be correlated to produce the identification B.
When, within the various unit pattern spaces, class regions are largely overlapping rather than largely separated, the multi-unit Nestor System disclosed in the above referenced patent application will eventually learn to separate the classes but may require long training times and large numbers of prototypes. This is due to the fact that in some cases the act of separating class territories results in their being covered by many prototypes, each of which maps out an amount of the class region that is small relative to the size of the total class territory. This results in long training times for the system to achieve robust performance on the problem.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide a pattern class separator and identifier which can separate and identify classes of patterns having a wide variety of salient features.
Another object of the present invention is to provide a pattern class separator and identifier which can separate and identify classes of patterns which may have only small and subtle differences between them.
Still another object of the present invention is to provide a specific software-implemented embodiment of the present invention which is capable of achieving the objects stated immediately above.
These objects, as well as further objects of the present invention that will become apparent from the discussion that follows, are achieved, according to the present invention, by providing a pattern classification and identification system comprised of (a) a plurality of classification units, connected in parallel and which receive an input signal S, representing each pattern, and (b) a class selection device (CSD), responsive to the output signals produced by the classification units, for producing a single output response R representing the class of each respective pattern.
The classification units include both "generalizers" and "separators" which store "generalizer prototypes" and "separator prototypes," respectively. The system operates to compare each input pattern, first to the generalizer prototypes to determine whether such pattern falls within the region of influence of at least one generalizer prototype. If a unique and certain response to a particular input pattern cannot be produced by such comparison, the system compares such input pattern with the separator prototypes to determine whether the input pattern falls within a region of influence of at least one of these separator prototypes.
The system, according to the present invention, is a modification of the multi-unit Nestor System disclosed in the above-referenced patent application Ser. No. 775,144. This system is called "GENSEP" for "generalizer/separator." In the GENSEP system, the individual units train first to develop mappings that cover the class territories with prototypes called generalizers. Generalizer prototypes are not explicitly configured to achieve separation of classes in the code space of a unit. Rather, the system correlates the multi-unit responses of firing generalizers to achieve class separation. Another class of prototypes, called separators, develop in the system to effect class separation based upon feature subsets of the generalizer coding units.
Because the system is not attempting separation in the generalizer coding units, class coverings develop more rapidly, more robustly and with fewer numbers of prototypes. This improves the system's ability to produce identifications through the correlations of different units' responses, provided the units are not identical in terms of the feature measurements they apply to characterize the input event. When correlations among units cannot resolve a pattern class, then appeal is made to the separator prototypes that carry a subset of the input information that may serve to distinguish one class from another. Very often, enough "generalizing" units can be defined so that the response derived from correlating all such units can reduce the number of tentative classifications to two or at worst three. (This has been observed for online character recognition for the Western alphanumeric characters.) Then it is a simple matter of extracting from the generalizing units the appropriate separating feature along which pattern distinctions can reliably be made. In GENSEP we introduce a mechanism for committing separator prototypes that embody class distinctive features. In fact, a number of such separator prototypes are defined and training selects separators that are most effective for the kinds of class separation required. The separating prototypes can be viewed as implementing "rules" for disambiguating confusions; the system learns to formulate these rules as required. In this way the separator prototypes can distinguish classes of patterns which may have only small and subtle differences between them.
For a full understanding of the present invention, reference should now be made to the following detailed description of the preferred embodiments of the invention and to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a parallel, multi-unit, adaptive pattern classification system using inter-unit class correlations and an intra-unit class separator methodology according to the present invention.
FIG. 2 (comprised of FIGS. 2a and 2b) is a flow diagram depicting an algorithm for a software system (Nestor System®) implementing the adaptive pattern classification system of FIG. 1 according to a first preferred embodiment of the present invention.
FIG. 3 is a flow diagram depicting an algorithm for a software system (Nestor System®) implementing the adaptive pattern classification system of FIG. 1 according to a second preferred embodiment of the present invention.
FIG. 4 is a flow diagram depicting an algorithm for producing the output response in the adaptive pattern classification system of FIG. 1.
FIG. 5 (comprised of FIGS. 5a and 5b) is a flow diagram depicting the system training mechanism for modifying the memory in the classification units of the adaptive pattern classification system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention and its preferred embodiments will now be described with reference to FIGS. 1-5 of the drawings.
A. System Organization Units and Prototypes
In a preferred embodiment of the GENSEP system according to the present invention, as illustrated in FIG. 1, each classification unit U includes both (1) a pattern feature encoding device, responsive to the input signal S, for producing an intermediate signal F representative of the features contained in the pattern, and (2) a pattern classifier response to the signal F, for producing an output signal R representative of the respective class of the pattern, as identified by the features encoded by the feature encoding device.
Each classification unit U i sees an input S (the output of the data acquisition device, or devices, characterizing the input event) and can apply a "code" to the signal to extract from it a set of values F 1 . . . F k . As in the Nestor Adaptive Module as disclosed in the above-referenced patents, the unit operates to compare the incoming pattern vector F to a set of prototypes P j , j=1. . . N. This produces an output classification R which is indicative of the prototype or prototypes (if any) that respond to or match the pattern vector F. As each Nestor Adaptive Module is trained, it develops a unique set of prototypes for classification of incoming patterns.
Two types of prototypes develop during training in the Nestor Adaptive Modules of a GENSEP system: generalizer prototypes and separator prototypes. Generalizer prototypes are committed to the memory assigned to a particular unit in order to cover class territories as represented in that unit's coding space. Separator prototypes are committed between certain pairs of generalizer prototypes in order to separate class confusions that can be discriminated on the basis of appeal to a small subset of information in the code space of the given unit.
Thus two types of mechanisms are available for class separation in the GENSEP system. Initial discriminations are made on the basis of correlating the responses of many different units, which responses are the result of activity (firing) among generalizers only in the units. Further class discrimination is made by appealing to the classes represented among firing separator prototypes in each unit. These mechanisms allow the system to train rapidly to make appropriate generalizations about a class of patterns and to further refine its ability to distinguish that class of patterns from all others either by correlating large numbers of feature measurements or by defining precise individual feature values for discrimination.
B. Memory
B1. The "Prototype"
As described in the U.S. Pat. No. 4,326,259, memory in a Nestor System is composed of "prototypes." Each prototype has some number of input lines and one output pathway through which it communicates with other elements in the system. There are two different types of prototypes in the system: generalizer prototypes and separator prototypes.
B2. Generalizer Prototypes
Each generalizer prototype has associated with it a set of weighting factors (one for each input line), the prototype vector, P, and a threshold θ, governing whether it is "on" or "off" (firing or not firing) in response to an input pattern. The threshold defines a "region of influence" for the prototype. The region of influence is the set of all input events which will cause the prototype to o fire. This threshold may be modifiable. If modifiable, it is adjusted so as to gradually increase the size of the prototype region of influence, but it is typically not beyond some fixed percentage of the dimensionality of the code space (ranging approximately from 5 percent to 50 percent). Each generalizer prototype has a class, C, associated with it. Finally, each generalizer prototype belongs to a particular unit in the system. The unit is specified by an index u. Thus, the data set defining a generalizer prototype consists of [P; θ g ; C; u].
B3. Separator Prototypes
Like a generalizer prototype, each separator prototype has associated with it a set of weighting factors (one for each input line), the prototype vector, S, and a threshold θ s , partially governing whether it is "on" or "off" in response to an input pattern. As with generalizer prototypes, this threshold defines a "region of influence" for the separator. This threshold is modifiable and adjusted by the system in such a way as to decrease the size of the influence field of the separator. Separators whose influence field is below some minimum size are considered phase II (P2) separators; those above the minimum are called phase I (P1) separators. This distinction between the two types of separators lies primarily in the extent to which they can influence the classification of the pattern within a given unit of the system.
Additionally, each separator is associated with a pair of generalizers, (i, j). More than one separator may be associated with the same generalizer pair. Each separator has associated with it an index, k, specifying a portion of the code values of the pattern space holding the generalizer prototypes with which it is associated. In particular, if a given code space represents the pattern event in terms of measurements F 1 . . . F m , then the index associated with a separator will be some number k on the interval (l, m).
Finally, each separator has a class associated with it. Unlike the class association of a generalizer, the association of a class with a separator is a negation. In particular, if a generalizer prototype for class C fires in response to an input event, the system will tend towards the assignment of class C to the pattern. However, if a separator for class C fires in response to the pattern, the system will tend not to assign C as an identification of the pattern. Briefly, if a generalizer for C fires, it says "C"; if a separator for C fires, it is saying "not C."
Thus, the set of data defining a separator can be listed as [i;, j; k; S, θ s ;C].
C. Comparing a Pattern with Prototypes
Presented below is the procedure, according to the present invention, for comparing a pattern with a prototype in system memory. Since generalizer and separator prototypes have different properties, the procedures for comparing a pattern with a generalizer and a separator prototype are discussed separately. These procedures determine whether or not the prototype in question will fire in response to the pattern.
C1. Pattern--Generalizer Comparison
An input pattern appears to a generalizer prototype as a set of signals occurring on its N input lines. The operation of comparing a pattern and a generalizer prototype can take any of several forms depending on whether the input signals to the prototype are binary or continuous valued. Either type of signal can be processed. For brevity we review here only the procedure for pattern-generalizer comparison for the case of binary valued signals arriving on the N input lines of the generalizer. In this case the prototype weighting factor assigned to that line is itself a binary number. The total prototype activity is a count of the number of input lines on which the bit value of the pattern signal, f j does not match the bit value of the weighting vector, P j . ##EQU1## This total number of unmatched bits is compared against the prototype threshold. If the unmatched bit count is less than the threshold, the generalizer fires; if it is greater than or equal to the threshold, the prototype is silent. Thus, ##EQU2##
As has been noted in above-referenced patent application, the operations of comparing a pattern with a set of prototypes can occur in parallel; that is to say, the comparison of a pattern with each prototype can occur simultaneously. Additionally, in the comparison of a pattern with a given prototype, the operation performed on a given input line (bit comparison for binary valued inputs or multiplication for continuous valued signals) can be performed simultaneously on all input lines. This rich parallelism is an inherent feature of the Nestor System.
C2. Pattern--Separator Comparison
To review, the data structure of a separator is S=[i, j; k; S, θ s ; C]. Pattern processing by separator prototypes is similar to that by generalizers. A set of signals occurring at the M input lines of the separator prototype are compared with the separator weighting factor values, an unmatched bit count is determined and tested against the separator theshold. However, the generalizers with which the separator is paired and the feature index k further define the operation of the separator on the pattern. For clarity, we assume that the feature values [F 1 . . . F k ] defining the code vector for the pattern in the unit are the continuous, real-valued representation and that the binary equivalent of this, the set [B i ], i=1, . . . M is the information appearing at the input lines of the generalizer. Then the feature index, k, associated with the separator specifies a member of the continuous-valued set F. The binary equivalent of F k will appear as input to the separator S. Specifically, let B be a binary mapping that converts F.sub. k to a binary valued vector (b 1 . . . b m ). Then the separator unmatched sign count is determined as ##EQU3## Finally, for a separator to fire, the following conditions must hold:
(1) d<θ s (separator threshold condition)
(2) P i is firing (associated generalizer prototypes are firing)
(3) P j is firing
Note that both generalizers paired with the separator in question must be firing for the separator to fire.
D. Determining the System Response
D1. Unit Response to a Pattern
The response of a unit to an incoming pattern consists of the classes associated with its firing prototypes. In particular, those classes are organized into two lists, the generalizer class list and the separator class list. Obviously, due to the conditions required for separator firing, if the generalizer class list of a given unit is empty, the separator class list for that unit will be empty as well.
D2. System Response to the Pattern
The system response to an incoming pattern is determined by the Class Selection Mechanism (CSM) as a function of the output class lists (from both generalizers and separators) of the system units. The CSM can evaluate the contents of the class lists of all units in a variety of ways as a function of unit priority. Two preferred embodiments of the class selection mechanism are illustrated in FIGS. 2 and 3, respectively.
As in the multi-unit system described in the abovereferenced patent application, units in the GENSEP system can be arranged hierarchically, according to priority. Unit priorities are numbers that take on integer values 1, 2, 3, etc. A unit of priority n is said to operate at level n in the system. In determining the system response, the CSM considers the output of each unit in order of decreasing priority. (The highest priority is 1.) At each unit, the CSM updates a system vote count for each class and checks to determine if any particular class has satisfied the system identification criterion to allow for an unambiguous response. A typical system identification criterion defines the winning class as the class with the largest number of votes, as long as its vote count exceeds some minimum vote count (NUMWIN) and so long as the difference between the vote count of this class and that of the "runner-up" class exceeds some pre-set minimum difference (WINDIF).
The CSM can update the system vote count in different ways. In one method, the CSM polls the system units twice, in each case starting with the highest priority unit and moving through the units in order of descending priority. In the first polling, the CSM updates the system vote count on the basis of the generalizer class list. If a winning class has not been found by the time all the generalizer class lists of the lowest priority units have been polled, then the CSM initiates a second polling of the units. It begins by thresholding the system class list and throwing out all those classes below some specified minimum vote count. Then, beginning with the highest priority units, the CSM updates the system vote count as a function of the classes in the separator class lists for these units. In general, the appearance of a class in the separator class list causes the system vote count for that class to be decremented by 1. Again, after a unit's separator class list has been used to update the system vote count, if a winning class has not been found, then the unit of next lowest priority is processed.
In another embodiment of the system, shown in FIG. 3, the CSM polls each unit only once. The system vote count is updated as a function of the net number of votes for a class given the composition of both the generalizer and the separator class lists for the given unit. For example, the appearance of a class in the generalizer class list would increment its system vote count by 1; the appearance of a class in the separator class list would reduce its vote by 1. In such an embodiment, the system tends to rely less upon correlations between unit responses as a means of distinguishing classes and more on the internal discriminating ability of individual coding units at the level of single feature distinctions.
D3. Types of System Response
As in the multi-unit Nestor System described in the above-referenced patent application, the GENSEP system offers, as a final output, a system class list (CLASSL) and a response type (SYSRSP). The CSM assembles the class list from the winning class (if it exists) or from all the classes that are tied for the largest vote count (or alternatively, all the classes with vote count above some preset minimum listed in CLASSL in descending vote order). If there is a unique winning class, then the response type is "Identified" (SYSRSP="I"). If there is no winning class but there is a set of classes in CLASSL, then the response type is "Confused" (SYSRSP="C"). The set of classes appearing in CLASSL is called the "confusion set." If no classes appear in CLASSL (no prototypes fired in any of the coding units), then the response type is "Unidentified" (SYSRSP="u"). A flow chart of this algorithm for producing the outputs CLASSL AND SYSRSP is shown in FIG. 4.
E. Training the System
Training the GENSEP system requires a specification of the true identity of the pattern, the output response of the system and the representations of the input pattern. The mechanisms of training are (1) the commitment of new generalizer prototypes; (2) the adjustment (enlargement) of generalizer prototype influence fields; (3) the commitment of separator prototypes and (4) the adjustment (reduction) of separator prototype influence fields. The object of training is to effect an internal change in the system such that, if the pattern were to be immediately represented to the system, the system's response would be, if not to correctly classify the pattern, at least to produce a confusion set that would include the correct classification. Training is orchestrated by the System Training Mechanism (STM) illustrated in FIG. 5.
During training, patterns unidentifiable by correlation among the responses of different coding units will cause separators to be committed to memory. This occurs in an effort to find some feature or combination of features that will be useful to distinguish among the classes in question. The system may commit a host of candidate separators; those that are of no reliable predictive value will be trained out to phase II status, playing essentially no role in future system responses. The strategy can be likened to the system postulating a number of hypotheses and eliminating from use all those that prove incorrect.
E1. Reducing Incorrect Separator Influence Fields
Assume that the class of an input pattern is x. The first action of the STM is to reduce the influence fields of all firing separator prototypes whose class association is x. (Recall that, by firing, these separators are in effect saying "not x.") These separators may be firing in any of the system units. Part of the firing condition for separators is d<θ s , where d is the unmatched sign distance between a particular feature of the input pattern and the separator prototype in question. To silence the prototype, we change θ s to θ' s , where θ' s =d. Thus d<θ' s is no longer true, and the separator no longer fires.
E2. Commitment of Generalizer Prototypes
Once all incorrect separator prototypes have been silenced through threshold reduction, the STM activates the CSM, initiating the polling of system units in order to recompose the system response. The CSM is controlled by the STM in the following way (see FIG. 5). If a unit is polled and its generalizer class list does not contain the correct class of the input pattern, then the training mechanism commits a new prototype for this class based upon the code vector for the pattern in this unit. This prototype commitment procedure is the same as that described in the above-referenced patent application, with the exception being that the influence field is fixed at some pre-set size, generally a percentage of the dimensionality of the code space. (In previous systems the initial influence field size was a function of distance to prototypes for different classes.) Otherwise, as in previous prototype commitment procedures, the code vector of the pattern becomes the prototype vector and the class of the pattern becomes the class of the prototype.
E3. Enlargement of Generalizer Influence Fields
In some embodiments of the system, generalizer influence fields are enlarged in response to an input pattern. If the System Training Mechanism polls a unit whose generalizer class list includes the correct class, then some of the correct class generalizer prototypes may be candidates for influence field expansion. In particular, we define the growth ring of a prototype to be all those points whose unmatched sign distance with the prototype d r , obeys the following inequality:
γθ.sub.g <D.sub.r <θ.sub.g
where θ g is the threshold defining the influence field of the generalizer, and γ is some real number on the interval (0, 1). (A typical value for γ is on the interval [0.80, 0.90].
Consider the set of firing generalizers in a unit whose class matches the category of the pattern. If there is at least one prototype whose influence field contains the pattern but whose growth ring does not, then no prototypes for that class will be enlarged, regardless of whether the pattern falls within their growth rings or not. On the other hand, if there exists no correct class prototype that contains the pattern in its influence field but not in its growth ring, then all the correct class prototypes whose growth rings contain the pattern are expanded. All will have their influence fields expanded so that the pattern falls just outside the growth ring (but within the influence field) of each of them. In particular, if initially for the i th firing generalizer: ##EQU4## Thus, if the pattern were to be immediately represented, none of these generalizer prototypes would have their influence fields further enlarged.
E4. Commitment of Separator Prototypes
If, after recomposing the system response based upon firing generalizer prototypes, the system is still confused, then the System Training Mechanism attempts to commit separator prototypes between pairs of generalizers from the same unit whose classes are represented in the system confusion set. Each such pair is constituted from a firing generalizer for the correct class and a firing generalizer for some other class in the system confusion set. When the STM is attempting separator commitment for such a "correct-class, opposite-class" pair, it attempts to commit a pair of separators for each feature in the generalizer prototype vector pair. (Recall that a prototype vector has the same structure as the intermediate signal F (the pattern code vector) produced by a unit. F is organized into a set of signals F 1 . . . F k each of which is regarded as a "feature.") If the two classes of the generalizers in question are A and B, then the STM is attempting to commit for each feature in the generalizer code vectors, a pair of separators, one for "not A" and one for "not B."
Assume that in the unit in question an input pattern of class α represented by F=(F 1 . . . F k ) Let P(α)=(P(α) 1 . . . P(α) k ) and P(β)=(P(β) 1 . . . P(β) k ) be two firing generalizers for classes α and β. Further, assume that both α and β are represented in the system confusion set. Let d b (P(α) j P(β) j ) represent the binary distance between the j th feature values for P(α) and P(β). The binary distance between real-valued features P(α) j and P(β) j is computed by first converting each feature into its binary equivalent and subsequently performing an unmatched sign count on the resulting binary representations. A pair of separator prototypes is committed for the j th feature if the binary distance between P(α) j and P(β) j exceeds some minimum amount, θ s . θ s is the threshold for separator commitment. Thus if d b (P(α) j ,P(β ) j )>θ s , and no separators currently exist for this feature and this generalizer pair, then the System Training Mechanism commits a new pair of separators to system memory. Refer to them as the m th and n th separators (where n=m+1). If the m th separator is for "not α" then it is defined as ##EQU5##
The System Training Mechanism uses a variety of mechanisms to select the subset of correct-class/opposite-class firing generalizers for which separator commitment is to be attempted. Let the correct class of the pattern be C 0 . Let [C i ], i=1 . . . N be the set of incorrect classes that are represented in the confusion set. Associated with C i is a set of firing generalizers [P j (C i )], j=1 . . . G i . G i is the total number of firing generalizers for class C i . The sets ##EQU6## form the set of all possible correct-class/opposite-class generalizers for which separator commitment is possible. In one preferred embodiment of the system, the STM attempts commitment of separators for all such generalizer pairs. In another preferred embodiment of the system, the STM attempts commitment for one member only of each of the P jk (O,i) sets. It identifies for each set, the closest-opposed generalizer pair member (i.e., the generalizer pair with the smallest inter-prototype vector distance) and attempts separator commitment only for this generalizer pair in that set. This embodiment is preferred in those situations where the number of separators committed is to be minimized.
F. Example Problem
The GENSEP system has special utility in those pattern recognition applications where class territories in a given pattern space are largely overlapping. In such cases there is much more territory in the pattern space to be covered by P2 prototypes. Consider the problem as depicted below: ##STR1## There, classes A and B are degenerate in one region; C and D in another. In the systems described in the above-referenced patent application, some P1 prototypes would initially be committed for the various classes and eventually so reduced in size as to become P2 prototypes. Before this happens, however, their presence as P1's would limit the size of the influence fields of additional P2's committed to the problem. (P2 prototypes in these previously described systems are committed with an initial influence field no larger than the distance to the nearest opposite class P1.) Since P2 prototypes with, on the average, small sized influence fields are being used, it will take longer for the system to completely cover the classes with prototype influence fields. Additionally, it is likely that P2 prototypes near the border of the A-B, C-D regions will have a significant amount of their influence fields lying in both class regions. This would severely compromise the ability of the system to do any class separation in this space.
In a GENSEP system, however, more effective coverage is achieved because the size of the generalizer prototypes being committed for the classes is not restricted in any way by the locations of existing prototypes. As a result, comparatively fewer prototypes are needed to cover the space and this covering can develop very rapidly (assuming a distribution of input training patterns that captures the overall statistics of the problem as reflected in the shapes of the pattern class territories.)
The additional advantage offered by GENSEP is that separators can develop to take advantage of whatever separability is possible in the space. In particular, separators will develop for the x feature component in the code vector to separate A from C, and A from D; and, as well, B from C and B from D. In the previously described systems, the only mechanism available for separation within this unit would be P1 prototypes. As has been noted, to the extent that class territories are largely overlapping (as opposed to partially overlapping) the number of P1 prototypes that survive is greatly reduced.
There has thus been shown and described a novel parallel, multi-unit, adaptive pattern classification system which fulfills all the objects and advantages sought therefor. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art after considering this specification and the accompanying drawings which disclose preferred embodiments thereof. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are intended to be covered by the claims which follow.
APPENDIX
Glossary of Terms
Class: A conceptual definition of a group of patterns which elicits the same response from a pattern class separator and identifier. All vector signals S representing patterns within this group will produce the identical output response R. A Nestor adaptive module does not have any preset or preconceived classes before it is trained.
Classification Unit: One of a number of conceptually (or physically) separate units of the system. These units operate in parallel, or in sequence, and each comprise both an encoding portion and a classification portion. The encoding portion transforms the vector signal S into an encoded vector signal F; the classification portion attempts to translate the vector signal F into a unique output response R identifying the class of the input pattern represented by the vector signal S. Each classification unit is designated by its own hierarchy level or "priority" within the system.
Confusion Zone: An area in multi-dimensional pattern space associated with more than one pattern class. Typically, such areas are covered with at least two overlapping layers of phase 2 prototypes, each layer being associated with a different class. In some cases, these zones may also be covered by overlapping influence fields of phase 1 prototypes for different classes.
Correlation: The selection of the correct class from among several output responses of a number of Nestor adaptive modules, each of which has been presented with an encoded vector signal F representing the same input pattern.
Encode: A transformation of an incoming vector signal S, representing an input pattern, into an encoded vector signal F, using a code "c." The transformation depends upon the presence or absence of particular features in the pattern. The purpose of the transformation is to eliminate irrelevant information contained in the signal S.
Event: A real world occurrence which may be detected and represented by a vector signal S. For example, the event may be a visual pattern, detectable by a camera, or a sound pattern, detectable by a microphone. The term "event" may be used synonymously with "pattern."
Influence Field of a Prototype: A variable-sized region or territory in the multi-dimensional pattern space centered on a prototype. Upon presentation, an input pattern that falls within this territory will cause the prototype to fire.
Neighbor Search: A search within a Nestor adaptive module for neighboring prototypes within a certain distance, in the multi-dimensional pattern space, from the point representing an input pattern.
Nestor Adaptive Module: A device or method disclosed and claimed in one or more of the following U.S. Pat. Nos.: 3,950,733; 4,044,243; 4,254,474 and 4,326,259.
Pattern: A particular set of data, resulting from a real world "event" and represented by a vector signal S, which is to be classified by a pattern class separator and identifier. Although each pattern presented to the pattern class separator and identifier may be at least slightly different from every other pattern previously presented, it can be grouped into one of an arbitrary number of classes.
Pattern Signal: A vector signal S comprised of individual scalar signals s 1 , s 2 . . . s k , which represents an input pattern to a pattern class separator and identifier.
Phase 1 Prototype: A type of prototype which, when "fired," will direct the response of a Nestor adaptive module and cause a particular output response to occur.
Phase 2 Prototype: A type of prototype which, when "fired," can only indicate that an incoming pattern may fall within a designated one of a number of classes.
Prototype: A prototypical representation of a pattern as stored in a Nestor adaptive module memory. Each prototype is defined in memory by (1) a vector in the multi-dimensional pattern space; (2) a "region of influence" within the pattern space; (3) a particular pattern class with which the prototype is associated; and (4) a label specifying the phase of the prototype.
Prototype "Commitment": The establishment of a new prototype (either phase 1 or phase 2 prototype) in a Nestor Adaptive Module in association with, and as a result of the presentation of, an input pattern. Upon presentation, during training, every input pattern will either fall within the influence field of an existing prototype, or cause the formation of a new prototype.
To "Fire" a Prototype : A prototype is said to "fire" when an input pattern, represented by a vector signal S, falls within the influence field of that prototype. This causes the Nestor adaptive module, in which the prototype resides, to produce an output response.
System Level: A collection of classification units having the same priority.
Vote Counting: A correlation technique which is used when an input pattern falls within a "confusion zone" in the multi-dimensional pattern space.
System Expressions: The following expressions are defined:
______________________________________NUM.sub.-- UNIT = number of units in systemFPAT(u), u = 1 . . . NUM.sub.-- UNIT= array of pattern code vectorsSYS.sub.-- VOTE.sub.-- CNT.sub.-- LST= System Vote Count List -a list of votes, indexed on patternclassFIR.sub.-- GEN.sub.-- LST(u), u = 1 . . . NUM.sub.-- UNIT= list of firing generalizers for agiven unitFIR.sub.-- GEN.sub.-- CLASS.sub.-- LST(u), u = 1 . . . NUM.sub.-- UNIT= list of classes associated withfiring generalizers for agiven unitFIR.sub.-- SEP.sub.-- LST(u), u = 1 . . . NUM.sub.-- UNIT= list of firing separators for agiven unitFIR.sub.-- SEP.sub.-- CLASS.sub.-- LST(u), u = 1 . . . NUM.sub.-- UNIT= list of classes associated withfiring separators for a given unit______________________________________
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A system is disclosed for separating and identifying classes of patterns or events which are not necessarily linearly separable. The patterns are represented by an input signal S. The system comprises (1) a plurality of classification units, connected in parallel to receive the input signal S and (2) a class selection device, responsive to the output signals produced by the classification units, for producing a single output response R representing the class of each respective pattern. At least some of the pattern classification units include generalizer units having a memory for storing a number of generalizer "prototypes" and a comparator for comparing the vector location of an input pattern with each of the generalizer prototypes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to electronic systems and more particularly to a system and method for utilizing tracking to identify reactions to content.
2. Description of the Related Art
In electronic systems, particularly entertainment and gaming systems, a user typically controls the behavior or actions of at least one character in a game program. The users' perspective, as determined by the camera angle, varies depending on a variety of factors, including hardware restrictions, such as the processing power of the system. In games with two-dimensional graphics, typical user perspectives include a top-down view (or “helicopter” view), where the user views the game from a third-person perspective, and a side-scrolling view, where the user views the characters from a third-person perspective as they move across the screen from left to right. These perspectives require lower levels of detail, and thus, require lower processing power from the processing units of the system.
In games with three-dimensional graphics, typical user views include a fixed 3D view, where the objects in the foreground are updated in real time against a static background, and the perspective of the user remains fixed, a first-person view (i.e., the user views the game from the perspective of a game character), and third-person view, where the user views the game character from a distance away from the game character, such as above or behind the character. The views depend on the sophistication of the camera system of a game. Three types of camera systems are typically used: a fixed camera system, a tracking camera system that follows the game character, and an interactive camera system that allows the user to control the camera angle.
Although the three-dimensional perspectives are more realistic for the user, they require more processing power, and, thus, the level of detail in rendering can suffer as a result of the drain in processing power to create the three-dimensional view.
Therefore, there is a need for a system and method for improving the balance between providing rendering detail and conservation of processing power by tracking where the user focuses his attention during game play.
SUMMARY OF THE CLAIMED INVENTION
Embodiments of the present invention provide methods and systems for attention-based rendering on an entertainment system are provided. A tracking device captures tracking data associated with a user. The tracking data is utilized to determine that the user reacted to at least one area displayed on a display device connected to the entertainment system. A processor communicates the determination to a graphics processing unit and instructs it to alter the processing power used for rendering graphics in the area of the display device. If the user is paying attention to the area, the processing power is increased, which in turn increases the detail and fidelity of the graphics and/or increases the speed with which objects within the area are updated. If the user is not paying attention to the area, processing power is diverted from the area, resulting in decreased detail and fidelity of the graphics and/or decreased updating speed of the objects within the area.
Various embodiments of the present invention include methods for attention-based rendering on an entertainment system. Such methods may include receiving tracking data from at least one user by a tracking device, wherein the tracking data is captured in response to a reaction of the user to at least one area displayed on a display device. The tracking data is sent by way of the tracking device to a processor. The processor executes instructions stored in memory, wherein execution of the instructions by a processor utilizes the tracking data to determine that the user reacted to the at least one area and communicates to a graphics processing unit to alter processing power used for rendering graphics. A further embodiment includes the steps of receiving a selection by the user indicating a preference for initiating a power-saving mode, storing the selection in memory, and initiating a power-saving mode when the tracking data indicates a lack of attention to the display device by the user.
Further embodiments include systems for attention-based rendering. Such systems may include a memory and a display device connected to an entertainment system. A tracking device captures tracking data associated with a user. A processor executes instructions stored in memory, wherein execution of the instructions by the processor utilizes the tracking data to determine that the user reacted to the at least one area displayed on the display device and communicates to a graphics processing unit to alter processing power used for rendering graphics.
Some embodiments of the present invention further include computer-readable storage media having embodied thereon programs executable by processors to perform methods for attention-based rendering.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an exemplary electronic entertainment system;
FIG. 2 is a flowchart of method steps for utilizing tracking to identify reactions to content.
FIG. 3A is a screenshot of an exemplary entertainment system environment showing a standard level of detail.
FIG. 3B is a screenshot of an exemplary entertainment system environment showing a low level of detail in areas in which a user is not focusing attention.
FIG. 3C is a screenshot of an exemplary entertainment system environment showing a high level of detail in areas in which a user is focusing attention.
DETAILED DESCRIPTION
FIG. 1 is a block diagram of an exemplary electronic entertainment system 100 . The entertainment system 100 includes a main memory 102 , a central processing unit (CPU) 104 , at least one vector unit 106 , a graphics processing unit 108 , an input/output (I/O) processor 110 , an I/O processor memory 112 , a controller interface 114 , a memory card 116 , a Universal Serial Bus (USB) interface 118 , and an IEEE 1394 interface 120 , an auxiliary (AUX) interface 122 for connecting a tracking device 124 , although other bus standards and interfaces may be utilized. The entertainment system 100 further includes an operating system read-only memory (OS ROM) 126 , a sound processing unit 128 , an optical disc control unit 130 , and a hard disc drive 132 , which are connected via a bus 134 to the I/O processor 110 . The entertainment system 100 further includes at least one tracking device 124 .
The tracking device 124 may be a camera, which includes eye-tracking capabilities. The camera may be integrated into or attached as a peripheral device to entertainment system 100 . In typical eye-tracking devices, infrared non-collimated light is reflected from the eye and sensed by a camera or optical sensor. The information is then analyzed to extract eye rotation from changes in reflections. Camera-based trackers focus on one or both eyes and records their movement as the viewer looks at some type of stimulus. Camera-based eye trackers use the center of the pupil and light to create corneal reflections (CRs). The vector between the pupil center and the CR can be used to compute the point of regard on surface or the gaze direction. A simple calibration procedure of the viewer is usually needed before using the eye tracker.
Alternatively, more sensitive trackers use reflections from the front of the cornea and that back of the lens of the eye as features to track over time. Even more sensitive trackers image features from inside the eye, including retinal blood vessels, and follow these features as the eye rotates.
Most eye tracking devices use a sampling rate of at least 30 Hz, although 50/60 Hz is most common. Some tracking devises run as high as 1250 Hz, which is needed to capture detail of very rapid eye movement.
A range camera may instead be used with the present invention to capture gestures made by the user and is capable of facial recognition. A range camera is typically used to capture and interpret specific gestures, which allows a hands-free control of an entertainment system. This technology may use an infrared projector, a camera, a depth sensor, and a microchip to track the movement of objects and individuals in three dimension. This system employs a variant of image-based three-dimensional reconstruction.
The tracking device 124 may include a microphone integrated into or attached as a peripheral device to entertainment system 100 that captures voice data. The microphone may conduct acoustic source localization and/or ambient noise suppression.
Alternatively, tracking device 124 may be the controller of the entertainment system. The controller may use a combination of built-in accelerometers and infrared detection to sense its position in 3D space when pointed at the LEDs in a sensor nearby, attached to, or integrated into the console of the entertainment system. This design allows users to control a game with physical gestures as well as button-presses. The controller connects to the console using wireless technology that allows data exchange over short distances (e.g., 30 feet). The controller may additionally include a “rumble” feature (i.e., a shaking of the controller during certain points in the game) and/or an internal speaker.
The controller may additionally or alternatively be designed to capture biometric readings using sensors in the remote to record data including, for example, skin moisture, heart rhythm, and muscle movement.
Preferably, the entertainment system 100 is an electronic gaming console. Alternatively, the entertainment system 100 may be implemented as a general-purpose computer, a set-top box, or a hand-held gaming device. Further, similar entertainment systems may contain more or less operating components.
The CPU 104 , the vector unit 106 , the graphics processing unit 108 , and the I/O processor 110 communicate via a system bus 136 . Further, the CPU 104 communicates with the main memory 102 via a dedicated bus 138 , while the vector unit 106 and the graphics processing unit 108 may communicate through a dedicated bus 140 . The CPU 104 executes programs stored in the OS ROM 126 and the main memory 102 . The main memory 102 may contain pre-stored programs and programs transferred through the I/O Processor 110 from a CD-ROM, DVD-ROM, or other optical disc (not shown) using the optical disc control unit 132 . The I/O processor 110 primarily controls data exchanges between the various devices of the entertainment system 100 including the CPU 104 , the vector unit 106 , the graphics processing unit 108 , and the controller interface 114 .
The graphics processing unit 108 executes graphics instructions received from the CPU 104 and the vector unit 106 to produce images for display on a display device (not shown). For example, the vector unit 106 may transform objects from three-dimensional coordinates to two-dimensional coordinates, and send the two-dimensional coordinates to the graphics processing unit 108 . Furthermore, the sound processing unit 130 executes instructions to produce sound signals that are outputted to an audio device such as speakers (not shown).
A user of the entertainment system 100 provides instructions via the controller interface 114 to the CPU 104 . For example, the user may instruct the CPU 104 to store certain game information on the memory card 116 or instruct a character in a game to perform some specified action.
Other devices may be connected to the entertainment system 100 via the USB interface 118 , the IEEE 1394 interface 120 , and the AUX interface 122 . Specifically, a tracking device 124 , including a camera or a sensor may be connected to the entertainment system 100 via the AUX interface 122 , while a controller may be connected via the USB interface 118 .
FIG. 2 is an exemplary flowchart 200 for utilizing tracking to identify user reactions to content. In step 202 , tracking data is received from the at least one user by the tracking device that is captured in response to a reaction of a user to at least one area displayed on the display device. The tracking data may be based on any type of tracking methodology, including but not limited to gesture-based tracking using a sensor and a range camera or a controller containing an accelerometer and infrared detection, eye tracking using a specialized camera or optical sensor using infrared light, audio-based tracking using an audio sensor or a microphone, and/or biometric tracking using a controller containing biometric sensors. In step 204 , the tracking data is sent by the tracking device to the CPU 104 ( FIG. 1 ).
In step 206 , the CPU 104 executes a software module stored in main memory 102 ( FIG. 1 ) with instructions to utilize the tracking data to determine the reaction of the user to the at least one area displayed on the display device. The software module may be custom-made for different game titles, or it may be native to the gaming platform. Alternatively, the software module may have different tracking functionalities for different types of interfaces (e.g., audio tracking, video tracking, or gesture tracking). The software module may also be installed into main memory 102 by way of a digital data storage device (e.g., an optical disc) being inserted into entertainment system 100 using optical disc control unit 132 . The reaction may be a visual reaction, determined by, for example, movement of the eyes of the user toward or away from the area. The visual reaction may be captured by an integrated or peripheral camera connected to entertainment system 100 . Alternatively, the reaction may be an emotional reaction by the user. An emotional reaction may include, for example and limited to, a vocal reaction by the user captured by a microphone, or a biometric reaction captured by the controller interface 114 ( FIG. 1 ). An emotional reaction may occur, for example, when a user is surprised by an event occurring within the game (e.g., the user shouts or exclaims), or when a user is frightened or anxious because his game character is in danger (e.g., the user sweats or his pulse increases).
In step 208 , when the user reaction indicates that the user is focusing his attention on the area of the display on the display device, the CPU 104 communicates with the main memory 102 ( FIG. 1 ) and instructs the graphics processing unit 108 (FIG. 1 ) to increase processing power to render greater detail and fidelity in that area and/or to increase the speed with which objects within the area are updated in real-time.
Alternatively, in step 210 , when the user reaction indicates that the user is not focusing his attention on the area of the display, the CPU 104 communicates with the main memory 102 and instructs the graphics processing unit 108 ( FIG. 1 ) to decrease processing power to render detail and fidelity in that area and/or to decrease the speed with which objects within the area are updated in real-time.
Thus, greater processing power is diverted to areas of the display on the display device where the user is focusing most of his attention. For example, when a special effect is displayed on the display device, the user is likely to focus attention on the area of the screen in which the special effect is occurring. Meanwhile, areas of the display that the user is not focusing on (e.g., when these areas are only in the peripheral vision of user), less detail is needed and, therefore, less processing power is needed for rendering graphics. This allows the entertainment system to conserve processing power in areas that are not the focus of the attention of the user, and improve the graphical details of areas on which the user is currently focusing.
In another embodiment of the present invention, at step 212 , the user may optionally select a power-saving preference in a preference module. The CPU 104 ( FIG. 1 ) executes the preference module and instructs it to receive the selection by the user and store it in main memory 102 ( FIG. 1 ) of the entertainment system 100 . When selected, the power-saving preference initiates, at step 214 , a power-saving mode when the tracking data indicates a lack of attention to the display device by a user. The power-saving mode may include, for example and not by way of limitation, initiation of a screen saver on the display device. Alternatively, the power-saving mode may require the entertainment system 100 to shut down.
FIGS. 3A-3C illustrate exemplary screenshots of entertainment system environments with varying levels of detail based on user focus.
Referring now to FIG. 3A , a screenshot of an exemplary entertainment system environment 300 showing a standard level of detail is shown, which may occur in a game on an entertainment system that does not employ a tracking device. In this environment, no additional detail is added or diminished because no processing power has been diverted to a certain area of the screen based on the attention of the user.
FIG. 3B is a screenshot of environment 300 , showing a low level of detail in areas in which a user is not focusing attention. The focus area 310 is identified by the tracking device as the area on which the user is focusing. Focus area 310 has a normal level of detail, such as that shown in FIG. 3A . The remainder of the environment 300 has diminished detail because processing power has been diverted from these areas, which are likely only visible in the peripheral vision of the user. Therefore, a lower level of rendering is necessary.
FIG. 3C is a screenshot of environment 300 showing a high level of detail in areas in which a user is focusing attention. Focus area 310 has a higher level of detail because the processing power has been diverted from the remainder of the screen because the tracking device has recognized that the user is focusing attention only on focus area 310 . An event, such as the vehicle crash visible in focus area 310 , is one example of an event in a gaming environment that may draw the attention of the user to a particular area of a screen. Thus, a higher level of rendering is necessary in an area such as focus area 310 to improve the gaming experience for the user.
The invention has been described above with reference to specific embodiments. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The foregoing description and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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Methods and systems for attention-based rendering on an entertainment system are provided. A tracking device captures data associated with a user, which is used to determine that a user has reacted (e.g., visually or emotionally) to a particular part of the screen. The processing power is increased in this part of the screen, which increases detail and fidelity of the graphics and/or updating speed. The processing power in the areas of the screen that the user is not paying attention to is decreased and diverted from those areas, resulting in decreased detail and fidelity of the graphics and/or decreased updating speed.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/241,590 filed Sep. 11, 2009, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] The present invention relates, generally, to an electric motor for use with a hybrid vehicle, and more specifically, to an electric motor that can be combined with other motors to power a vehicle.
BACKGROUND
[0003] Advancements in technology and the growing concern for environmentally efficient vehicles have led to the use of alternate fuel and power sources for vehicles. Electric vehicles or hybrid electric vehicles use electro mechanical devices (motors) to power the vehicle. In order to provide the required torque and power to operate the vehicle the motor must be designed to operate over a broad operating range. When a motor is chosen to act for an all purpose function, such as driving a vehicle, the motor needs to have the capacity for all load conditions, including the capacity to meet the maximum torque and power demands of the vehicle.
[0004] However, vehicles do not require peak torque and power at all times of operation. During normal operating conditions there is excess torque and power available from the motor. Additionally, motors, like any power source, have certain efficiency ranges in which they achieve their optimal performance. Sizing the motor to provide the capacity for all load conditions results in an over-sized motor that must bear the inefficiency when not operating at the optimum range. Inefficiencies of the over-sized motor are most apparent when operating at low speed. At low operating speed the forces to overcome the mass of the rotor contributes to great inefficiencies. Another inefficiency from an oversized motor is, the centrifugal forces required to start and stop the motor requires excess power and depletes the available energy more than necessary.
[0005] Additionally, vehicles are available in a variety of sizes and weights which results in additional variety in the motor capacity required among various vehicles. Therefore, the larger vehicles must default to larger and unique motors. The cost to design, manufacture and carry inventory on the variety of motors required results in cost inefficiencies as well.
SUMMARY
[0006] A vehicle comprises a plurality of motors that are operatively connected with one another. The plurality of motors is operable to power the vehicle individually and in combination with one another. Each of the plurality of motors are generally identical to one another. Alternatively, the plurality of motors is operable to power the vehicle individually and in combination with one another such that each of the plurality of motors primarily operates in a predetermined efficiency range.
[0007] A method of powering a vehicle comprises operatively connecting a plurality of motors with one another and powering the vehicle with the plurality of motors individually and in combination with one another to primarily operate each of the plurality of motors within a predetermined efficiency range.
[0008] The above features and advantages, and other features and advantages of the present invention will be readily apparent from the following detailed description of the preferred embodiments and best modes for carrying out the present invention when taken in connection with the accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic illustration of an electric vehicle having a first embodiment of a stackable motor of the present invention;
[0010] FIG. 2 is a schematic illustration of an electric vehicle having a second embodiment of the stackable motor of the present invention;
[0011] FIG. 3 is a schematic graph of the stackable motor output for the second embodiment of the vehicle shown in FIG. 2 ;
[0012] FIG. 4 is a schematic illustration of a third embodiment of the stackable motor for the vehicle of FIG. 1 ; and
[0013] FIG. 5 is a schematic illustration of a fourth embodiment of the stackable motor for the vehicle of FIG. 1 .
DETAILED DESCRIPTION
[0014] Referring to the Figures, wherein like reference numbers refer to the same or similar components throughout the several views, FIG. 1 schematically illustrates a vehicle 10 including at least one motor 12 , and a transmission 14 . The vehicle 10 may be any vehicle that utilizes an electric motor to provide the vehicle with drive, such as an electric vehicle, a hybrid electric vehicle, or a fuel cell vehicle. Therefore, in addition to the at least one motor 12 the vehicle 10 may also include an internal combustion engine 16 .
[0015] In the embodiment shown there is a first motor 12 A and a second motor 12 B. The first motor 12 A and the second motor 12 B are the same size and capacity as one another. The first motor 12 A and the second motor 12 B are operatively connected to one another to drive the transmission 14 . In the embodiment shown the first motor 12 A and the second motor 12 B are coupled to one another. In this manner, the first motor 12 A and the second motor 12 B are stackable to provide the capacity required for the vehicle 10 while primarily operating within the efficiency ranges for the first motor 12 A and the second motor 12 B. Therefore, one large electric motor may be replaced by multiple smaller motors 12 . The first motor 12 A and the second motor 12 B may be any type of electromechanical device to provide power, such as an induction motor, permanent magnet machine, A/C or D/C motors, etc.
[0016] The first motor 12 A and the second motor 12 B may be coupled together directly, through clutches or a solid shaft connection, or indirectly, such as a serpentine belt. Direct coupling of the first motor 12 A to the second motor 12 B would provide an efficient arrangement with few losses. Indirect coupling may provide a more flexible arrangement for packaging the first motor 12 A and the second motor 12 B within the vehicle 10 . One skilled in the art would be able to select the manner of coupling most suited for a particular vehicle 10 . Any number of generally identical motors, 12 may be combined or stacked to provide the capacity required by the vehicle 10 .
[0017] The first motor 12 A acts as the primary motor and operates to drive the transmission 14 while the vehicle 10 is operating at steady speeds. The second motor 12 B acts as an additional power source and engages to drive the transmission 14 when additional operating loads are placed on the motors 12 , such as during accelerations of the vehicle 10 . The second motor 12 B would engage any time the operating loads exceed the capacity of the first motor 12 A. Alternatively, the second motor 12 B may be engaged prior to the capacity of the first motor 12 A and at any time when the first motor 12 A begins to operate outside of the desired efficiency range. In this manner the first motor 12 A and the second motor 12 B may both operate within their efficiency range for greater periods of time and the overall vehicle 10 efficiency will be increased.
[0018] In the above embodiment, the first motor 12 A is the primary motor for the vehicle 10 and the second motor 12 B is used to provide additional power and torque when required by the vehicle 10 . Alternatively, the second motor 12 B may be the primary motor and the first motor 12 A may be used to provide additional power and torque. Additionally, the first motor 12 A and the second motor 12 B may alternately be the primary motor and the other would provide the additional power and torque. In this manner, even overall wear on both the first motor 12 A and the second motor 12 B may be maintained.
[0019] Further, the primary motor 12 A or 12 B and the additional motor 12 B or 12 A may be engaged or disengaged to maintain operation within the efficiency ranges. The primary motor 12 A or 12 B and the additional motor 12 B or 12 A may also engage or disengage in cooperation with the shift strategy of the transmission 14 to maintain maximum efficiency of the vehicle 10 . In this manner, nontraditional shift strategies of the transmission 14 may be utilized in combination with the motors 12 to increase the efficiency of the vehicle 10 .
[0020] Additionally, the first motor 12 A or the second motor 12 B may act as the primary motor in case of mechanical trouble of the other motor 12 A-B. In this instance the primary motor 12 A-B would not be able to meet the full capacity of the vehicle 10 . However, the vehicle 10 would operate in a restricted or limp-home mode but would allow the vehicle 10 operator to reach their destination.
[0021] FIGS. 2-3 illustrate a second embodiment of the vehicle 110 including at least one motor 112 , and a transmission 114 . The vehicle 110 may be an electric vehicle or a hybrid electric vehicle 110 . Therefore, in addition to the at least one motor 112 the vehicle 110 may also include an internal combustion engine 116 .
[0022] In the embodiment shown, there are four motors, 112 A, 112 B, 112 C, 112 D to drive the vehicle 110 . As explained above any number of motors, 112 may be combined to provide the capacity required by the vehicle 110 . In this manner one large electric motor may be replaced by multiple smaller motors 112 .
[0023] The first through fourth motors 112 A-D are operatively connected to one another and may be coupled together by directly, through clutches, or indirectly, such as by a serpentine belt. Direct coupling of the first through fourth motors 112 A-D would provide an efficient arrangement with few losses. Indirect coupling may provide a more flexible arrangement for packaging the first through fourth motors 112 A-D within the vehicle 10 . One skilled in the art would be able to select the manner of coupling most suited for a particular vehicle 110 .
[0024] One of the motors 112 may be designated as the primary motor 112 A and the other motors 112 B-D may provide additional power and torque as required by the vehicle 110 . When the capacity of the first motor 112 A is exceeded or when the first motor 112 A begins to operate outside the efficiency range, the additional motors 112 B-D may be engaged. The additional motors 112 B-D may each provide the same amount of additional power and torque. Alternatively, the additional motors 112 B-D may be engaged in an incremental manner. For example, the second motor 112 B may be engaged to assist the first motor 112 A when the capacity of the first motor 112 A is exceeded or when the first motor 112 A begins to operate outside the efficiency range. When the capacity of the first motor 112 A and the second motor 112 B are exceeded or when the first motor 112 A and the second motor 112 B begin to operate outside the efficiency ranges, then the third motor 112 C may be engaged. Likewise, the fourth motor 112 D would engage when the capacity/efficiency of the first through third motors 112 A-C are exceeded. Similar to the embodiment explained above, the motor 112 A-D which acts as the primary power source for the vehicle 10 may alternate among the first through fourth motors 112 A-D to maintain even overall wear on the first through fourth motors 112 A-D.
[0025] Additionally, any one of the first through fourth motors 112 A-D may act as the primary motor in case of mechanical trouble of one of the other motors 112 A-D. For example, if the first motor 112 A is acting as the primary motor and incurs mechanical trouble the second motor 112 B may then be used as the primary motor and the first motor may be disengaged until the mechanical trouble can be corrected. In the instance of trouble for any of the motors 112 A-D then the motor 112 A-D chosen to be the primary motor and the additional operating motors 112 A-D would not be able to meet the full capacity of the vehicle 110 . However, the vehicle 110 would operate in a restricted or limp-home mode but would allow the vehicle 110 operator to reach their destination.
[0026] FIG. 3 is a graph which illustrates how the output of the first through fourth motors 112 A-D may be combined to allow the first through fourth motors 112 A-D to primarily operate within their efficiency ranges while combining to provide the capacity required by the vehicle 110 . Phase 0 indicates the output of the first motor 112 A. Phase 1 indicates the output of the second motor 112 B as operating along with the first motor 112 A such that the torque output is increased. Phase 3 indicates the output of the motors when the first through third motors 112 A-C are operating together and Phase four indicates the output of all the motors 112 A-D operating at the same time. The efficiency range for the motors 112 A-D is indicated at area 120 . By adding the outputs of the motors 112 A-D together each of the motors 112 A-D each motor 112 A-D can continue to operate within the efficiency range 120 while providing an increase in the total output torque.
[0027] FIG. 4 schematically illustrates a third embodiment of a vehicle 210 having a first motor 212 A and a second motor 212 B. The first motor 212 A and the second motor 212 B are coupled directly together. Direct coupling of the first motor 12 A to the second motor 12 B provides an efficient arrangement with few losses. The first motor 212 A has a first input member 222 A and a first output member 224 A. Likewise, the second motor 212 B has a second input member 222 B and a second output member 224 B. The first output member 224 B is connected to the second input member 224 A. In the embodiment shown, the first and second input members 222 A and 222 B are female input shafts and the first and second output members 224 A and 224 B are male output shaft. However, any arrangement of input members 222 A-B and output members 224 A-B that would mate together may be utilized.
[0028] The first motor 212 A and the second motor 212 B are identical and have the same input members 222 A-B and output members 224 A-B. Additional motors (not shown) may be connected to the first and second motors 212 A-B and would have the same input members and output members. Therefore, any number of motors 212 may be connected in any order as required to provide the capacity of the vehicle 210 .
[0029] In the embodiment shown in FIG. 4 , the second motor 212 B is connected to the transmission 214 and acts as the primary motor to drive the vehicle 210 while operating at steady speeds. The first motor 212 A acts as an additional power source and engages to drive the vehicle 210 when additional operating loads are placed on the motors 212 A-B, such as during accelerations of the vehicle 110 . The first motor 212 A would engage any time the operating loads exceed the capacity of the second motor 212 B. Alternatively the first motor 212 A may be engaged prior to reaching the capacity of the second motor 212 B and at any time when the second motor 212 B begins to operate outside of the desired efficiency range. In this manner, the first motor 212 A and the second motor 212 B may both operate within their efficiency range for greater periods of time and the overall vehicle 210 efficiency will be increased.
[0030] In the above embodiment, the second motor 212 B is the primary motor for the vehicle 210 and the first motor 212 A is used to provide additional power and torque when required by the vehicle 10 . Alternatively, the first motor 212 A may be the primary motor and the second motor 212 B may be used to provide additional power and torque. Additionally, the first motor 212 A and the second motor 212 B may alternately be the primary motor and the other would provide the additional power and torque. In this manner, even overall wear on both the first motor 212 A and the second motor 212 B may be maintained. The first motor 212 A has a first rotor 226 A and the second motor 212 B has a second motor 226 B. Due to the direct connection between the first motor 212 A and the second motor 212 B the rotor 226 A or 226 B of the additional motor 212 A or 212 B would continue to rotate while the primary motor 212 B or 212 A operates even though the additional motor 212 A or 212 B is not operating.
[0031] Additionally, either the first motor 212 A or the second motor 212 B may act as the primary motor if case of mechanical trouble of the other motor 212 A-B. In this instance the primary motor 212 B or A would not be able to meet the full capacity of the vehicle 210 . However, the vehicle 210 would operate in a restricted or limp-home mode but would allow the vehicle 210 operator to reach their destination.
[0032] FIG. 5 schematically illustrates a fourth embodiment of a vehicle 310 having a first motor 312 A and a second motor 312 B. The first motor 312 A has a first input member 322 A and a first output member 324 A. Likewise, the second motor 312 B has a second input member 322 B and a second output member 324 B.
[0033] The first motor 312 A is connected to the second motor 312 B through a first clutch 328 A. That is, the first clutch 328 A has a first clutch input member 330 A and a first clutch output member 330 B. The first motor output member 324 A is connected to the first clutch input member 330 A and the first clutch output member 332 A is connected to the second motor input member 322 B.
[0034] The second motor 312 B is connected to a transmission 314 for the vehicle 310 through a second clutch 328 B. That is, the second clutch 328 B has a second clutch input member 330 B and a second clutch output member 332 B. The second motor output member 324 B is connected to the second clutch input member 330 B and the second clutch output member 332 B is connected to the transmission 314 .
[0035] The first motor 312 A, the second motor 312 B, the first clutch 328 A and the second clutch 328 B are generally identical and each have the same input members 322 A-B, 330 A-B and output members 324 A-B, 332 A-B as one another. Additional motors and clutches (not shown) may be connected to the first and second motors 312 A-B and the first and second clutches 328 A-B and would have the same input members and output members. Therefore, any number of motors 312 may be connected through the clutches 328 A-B as required to provide the capacity required by the vehicle 310 .
[0036] In the embodiment shown, the first and second motor input members 322 A and 322 B are female input members and the first and second motor output members 324 A and 324 B are male output members. Likewise, the first and second clutch input members 330 A-B are female input members and the first and second clutch output members 332 A-B are male output members. However, any arrangement of input members 322 A-B, 330 A-B and output members 324 A-B, 332 A-B may be utilized which would allow the first and second motors 312 A-B to be connected through the first and second clutches 328 A-B
[0037] In the embodiment shown, the second motor 312 B is connected through the second clutch 328 B to the transmission 314 and acts as the primary motor and to drive the vehicle 310 is operating at steady speeds. The first motor 312 A acts as an additional power source and engages to drive the vehicle 310 when additional operating loads are placed on the motors 312 A-B, such as during accelerations of the vehicle 110 . The first motor 312 A would engage any time the operating loads exceed the capacity of the second motor 312 B. Alternatively, the first motor 312 A may be engaged prior to reaching the capacity of the second motor 312 B and at any time when the second motor 312 B begins to operate outside of the desired efficiency range. In this manner, the first motor 312 A and the second motor 312 B may both operate within their efficiency range for greater periods of time and the overall vehicle 310 efficiency will be increased.
[0038] The first motor 312 A has a first rotor 326 A and the second motor 312 B has a second motor 326 B. The first rotor 326 A does not rotate when the second motor 312 B is operating and the first motor 312 A is not operating. This is due to the first motor 312 A and the second motor 312 B being connected through the clutch 328 A which can be disengaged when the first motor 312 A is not operating.
[0039] Additionally, the first motor 312 A or the second motor 312 B may act as the primary motor if case of mechanical trouble of the other motor 312 A or 312 B. In this instance the primary motor 312 B or 312 A would not be able to meet the full capacity of the vehicle 310 . However, the vehicle 310 would operate in a restricted or limp-home mode but would allow the vehicle 310 operator to reach their destination.
[0040] In the embodiment described above the motors 12 , 112 , 212 , 312 are described as being generally identical to one another. That is, the motors 12 , 112 , 212 , 312 have the same general size, capacity and preferably configuration of one another. Alternatively, this may mean for a particular vehicle 10 , 110 , 210 , 310 configuration the motors 12 , 112 , 212 , 312 of that vehicle 10 are able to be used interchangeably with one another.
[0041] While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
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A vehicle comprises a plurality of motors operatively connected with one another. The vehicle is powered with the plurality of motors individually and in combination with one another to primarily operate each of the plurality of motors within a predetermine efficiency range.
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FIELD OF THE INVENTION
The present invention relates to a shutter for closing over a window, door or other opening of a building, for protecting the window, door or opening during extreme temperature conditions, as can occur during fires, in particular bushfires. The invention has been developed particularly in relation to the protection of windows and it will therefore be convenient to describe the invention in that context. However, it will be appreciated that the invention has wider application to doors or other openings, such as chimneys, flues or air vents.
BACKGROUND OF THE INVENTION
Windows, doors or other openings in buildings form parts of the building structure which can fail during extreme temperature conditions and which thereafter allow entry into the building of flames and embers, and of oxygen which fuel the flames and embers. Once a fire is established within a building, it is difficult to save the building from complete destruction. Accordingly, it is recognised that protection of windows, doors and other openings in a building is important in order to protect buildings against destruction by fire.
Windows can be protected by shutters which typically are positioned to form a cover over the external side of the window. Shutters exist already to close over a window and certain shutters have been developed for protection of windows in bushfire conditions. However, shutters of which the applicant is aware typically are aluminium roller shutters and a disadvantage with these shutters is that the melting temperature of aluminium can be lower than the temperature to which the shutter is exposed during a bushfire, so that the aluminium shutter could melt in such extreme temperature conditions. For that reason, recent amendments in Australia to building standards require shutters used for protection in bushfire conditions to continue to operate in a protective manner in temperatures exceeding the melting point of aluminium, i.e. in temperatures beyond 700° C.
Some existing shutters have been constructed in steel, which has a higher melting temperature than aluminium and so does not suffer the same drawbacks as aluminium. However, these shutters do not prevent transmission of radiant heat from the external or fire side of the shutter to the internal or non-fireside, and because of that radiant heat transmission, it is often the case that the window frame or the glass of the window fails even though the shutter is in a position covering the window. These forms of shutters also have sealing issues and therefore can leave gaps between the shutter and the surrounds of the window and this allows ingress of embers and oxygen.
There are also flame and smoke control ‘curtain’ type products, typically used in indoor environments to prevent the spread of fire from one area of a building to another. These products however have limited benefit when applied externally over windows or doors, as they can be deflected or shifted by wind, or if hit by flying embers and other debris for example, causing the glass of the window to break or allowing ember and heat access to the frame of the window or door. Such curtain type products are also not primarily designed for deflecting the heat, so that they can allow the cavity between the curtain and the window or door to get excessively hot and thus cause the window glass or window or door frame to fail.
Some curtain fabrics exist that do have fire retardant or heat reflective properties, but these fabrics are not necessarily capable of long term external use. In addition, they can also present difficulties for mounting, so that prohibitively expensive and difficult mounting arrangements are required.
Accordingly, applicant is not aware of a shutter which operates successfully under extreme temperature conditions as can occur during some extreme bushfire events. The applicant has therefore developed a new and unique shutter which aims to overcome or at least alleviate some of the disadvantages with shutters of the prior art.
SUMMARY OF THE INVENTION
According to the present invention there is provided a shutter comprising:
an outer sheet of generally square or rectangular shape,
a non-combustible insulating panel of generally the same shape as the outer sheet, and
a frame,
the panel being positioned between the outer sheet and the frame so that the outer sheet overlies a first broad face of the panel and the frame is attached adjacent to a second broad face of the panel which is opposite the first face,
the outer sheet having a melting point of greater than or equal to about 840° C., the panel being operable to retard heat transmission from the first face thereof adjacent to the outer sheet to the second face opposite the first face, so that when the first face is exposed to a temperature of 730° C. for a period of 15 minutes, the temperature at the second face does not exceed 250° C.,
each of the outer sheet and the panel being secured to the frame and the frame being substantially resistant to distortion up to a temperature of about 250° C.
A shutter of the above kind advantageously can protect a window, door or other opening from both direct flame and from radiant heat, thereby increasing the likelihood of the window, door or other opening surviving extreme temperature conditions. Moreover, the shutter can limit the progression of heat through the window, door or other opening, so that occupants of a building which is subject to an extreme temperature condition, for example a bushfire, can be subject to reduced temperature within the building than would otherwise be the case if the shutter was not fitted to the window, door or other opening. Still further, a shutter according to the invention can be made to have a aesthetically pleasing appearance despite its required construction, which is important given that the shutter is an external fitting which is on view at all times.
The outer sheet of a shutter according to the invention can be of any suitable material, although a metal outer sheet is considered at this stage to be most appropriate, in particular a steel sheet. Testing to date has employed successfully a 0.5 mm “Colourbond” steel sheet.
Other materials suitable for adoption for the outer sheet could be employed subject to satisfying the requirement of providing a resistance to melting up to 840° C. Such materials could include metals or fabrics having suitable fire resistance. In the testing to date, a 0.5 mm “Colourbond” steel sheet has provided a non-combustible layer which has resisted melting at temperatures of up to 840° C. Advantageously, such a steel sheet has also provided a suitable barrier against penetration of flame and oxygen to the internal side of the shutter. In addition, that material also is cost effective compared to other materials that could be employed.
The non-combustible insulating panel can also be manufactured from any suitable material, but in testing to date, a suitable panel has been found to comprise a 13 mm thick plasterboard which is supplied by Lafarge Plasterboard Ltd under the product name “Firestop”. However, it is envisaged that various other materials could satisfy the requirements of the insulating panel of the invention, for example fibrous materials or foam materials, and it is expected that panel thicknesses of between 10 to 16 mm could be employed. Panels of greater or lesser thickness could be employed, but greater thickness panels could increase the bulk of the shutter beyond acceptable levels, while panels of reduced thickness could require more expensive materials that increase the cost of the shutter prohibitively.
The outer sheet overlies the insulating panel and each of the outer sheet and the insulating panel are attached to or supported by the frame. In some forms of the invention, the outer sheet and the insulating panel can be fixed together and in one arrangement, an adhesive is employed for that purpose. In some forms of the invention, the adhesive can be selected to fail at a certain upper temperature, with the outer sheet then being supported by the frame when adhesive failure takes place. The benefit of selecting an adhesive which will fail at a particular temperature is to allow expansion of the outer sheet during an extreme temperature event. By this mechanism, the adhesive fails which then allows the outer sheet to expand under the extreme temperature, but the outer sheet is maintained in position, albeit less precisely, by the frame. Thus, while allowance is made for some shifting or movement of the outer sheet, that movement is not sufficient to expose the insulating panel to direct flame, and the outer sheet thus continues to perform the function of providing a barrier against flame and oxygen penetration through the shutter. Accordingly, while the aesthetic appearance of the shutter might deteriorate upon failure of the adhesive, the structural integrity of the shutter remains intact and the shutter continues to form an effective barrier and temperature retarder, protecting the window, door or opening over which the shutter has been placed.
Many suitable adhesives are likely to be available which meet the requirements for fixing the outer sheet and panel in the shutter and for failing at a selected temperature if required. In testing conducted to date, a construction adhesive, Selleys Silicone 401 industrial engineering adhesive sealer, has been successfully employed, having a 205° C. failure temperature.
Screws can be employed for various fastening requirements. For example, screws can be employed for fastening the outer sheet and the panel to the frame, whereby the screws extend through the outer sheet and the panel and into engagement with the frame. However, it is preferred to minimise the number of screws used because during an extreme temperature event such as a bushfire, heat can be conducted through a screw which projects from the external side of the shutter through to the internal side of the shutter. This conduction can raise the temperature to which the window is exposed and thus excessive conduction can detract from the performance of the shutter and potentially lead to window failure. Additionally, where the screws are fixed to the frame, conduction through the screws can result in heating of the frame and excessive heating can distort the frame and again, detract from the performance of the shutter. Accordingly, by minimising the number of screws which are employed, heat transmission of this kind is minimised and the likelihood of window failure or of frame distortion occurring is likewise minimised.
For further fixing of the outer sheet and the panel, the frame can include or define a lip or flange, or a channel, within which edge regions of the outer sheet can be captured or located. In this arrangement, edge regions of the outer sheet can be adhesively fixed to the lip, flange or channel, or fixed by suitable fasteners, such as rivets, or they can simply be positioned within the lip, flange or channel. The panel can also be adhesively fixed to the frame, or it can be fixed to the frame by suitable fasteners, or both. The panel can also be positioned within the lip, flange or channel in the same manner as the outer sheet. The lip, flange or channel can extend completely or partially about the periphery of the outer sheet and the panel.
The frame can be of any suitable shape, construction and material. Testing to date has been conducted with a steel frame, partly of square hollow section (SHS), with dimensions 20×20×2.5 mm. However, it is clearly possible that alternative sections could be used, such as rectangular hollow section (RHS), or right-angle section.
The frame can have a generally rectangular or square configuration and be located about the periphery or edge regions of the insulating panel, on the opposite side to the outer sheet. However, the frame could be positioned inboard of the edges, or it could extend diagonally across the second face of the panel from each upper corner of the panel to an opposite lower corner. Other frame configurations are possible.
The frame can thus consist of a portion that is positioned adjacent to the second face of the panel and a lip, flange or channel portion that extends about the edges of the panel and the outer sheet to capture or confine the edges.
As indicated above, the frame is required to be substantially resistant to distortion up to a temperature of about 250° C., which is the maximum temperature expected at the second face of the panel if the extreme temperature conditions do not exceed 730° C. for a period of 15 minutes and the maximum temperature does not exceed 840° C. Thus, upon distortion of the outer sheet under extreme temperature conditions, the frame is not caused to distort other than slight or minor distortion. The selection of steel for the frame is considered appropriate for the temperature limit discussed above, while steel also advantageously is capable of gentle distribution of heat throughout the frame structure as the temperature on the internal side of the shutter increases, rather than abrupt distribution or uneven distribution. By this gentle overall increase of the frame temperature, distortion of the frame is minimised.
A seal can be disposed between the side edge regions of the shutter and facing surfaces of the surrounds or frame of the window, door or opening within which the shutter is mounted. The seal can be provided to minimise air exchange from the external side of the shutter to the internal side, and to prevent passage of embers and gases from the external side.
An effective form of seal is an intumescent seal, which increases in volume as the ambient temperature increases. Accordingly, during a fire event, the seal will expand and more firmly engage between the shutter and the frame of the window, door or opening, forming a barrier against air, embers or gases. The advantage of an intumescent seal is that the seal has minimum volume at ambient temperature so that it can be arranged not to interfere with the operation of the shutter in normal temperature conditions. However, the seal expands and forms an interference fit with facing surfaces when the temperature rises to extreme levels. In testing which has been conducted to date, a seal under the name Lorient HP1602AS has been successfully employed.
A seal can also be employed between adjacent shutter leaves and between adjacent sections of a shutter. In fact, a seal can be employed at all joins and openings within the shutter and between the shutter and the surrounds or body within which the shutter is mounted.
A shutter according to the invention can provide an effective barrier against ingress of heat and embers or direct flame to a window, door or other opening to protect the window, door or other opening from failure and thus to protect the building in which the window, door or other opening is installed. A shutter according to the invention can also reduce the temperature increase within the building during an external extreme temperature event, by limiting the transfer of heat from outside the building to inside through the window, door or other opening. Thus, any occupants of the building are likely to be exposed to reduced temperature and are more likely to survive the extreme temperature event. It is to be noted that in bushfires, the fire tends to move through an area relatively quickly and so the period in which building and the building occupants must survive is often a period of minutes rather than hours, but the intensity of the fire is often extremely high for that short period. In testing of a shutter according to the invention undertaken to date, the shutter has survived under simulated extreme bushfire conditions for a typical period under which a building would be subject to the bushfire.
For a better understanding of the invention and to show how it may be performed, embodiments thereof will now be described, by way of non-limiting example only, with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 3 illustrate three different prior art shutter arrangements.
FIG. 4 is a horizontal section of a shutter according to one embodiment of the invention.
FIG. 5 is a vertical section of the shutter of FIG. 4 .
FIGS. 6 to 9 illustrate variations of portions of the shutter illustrated in FIGS. 4 and 5 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 a and 1 b illustrate a 4 panel bi folding “casement” shutter 10 in a respective fully open position ( FIG. 1 a ) and a fully closed position ( FIG. 1 b ). FIG. 1 a illustrates a pair of bi-fold shutters sections 11 and 12 , each formed by a pair of shutter leaves 13 and 14 which are fitted to cover an opening represented by broken line 15 . The opening can be closed by a window or door (not illustrated).
The shutter leaves 13 and 14 are of equal dimension and each of the shutter leaves 13 is connected to the associated shutter leaf 14 by hinges 16 . Likewise, each of the shutter sections 11 and 12 is connected by hinges to the frame or surrounds of the window by hinged connection of the leaves 13 with the frame or surrounds.
In FIG. 1 a , the shutter leaves 13 and 14 are folded open completely, so that shutter leaf 14 overlies shutter leaf 13 , and each shutter section 11 and 12 is fully hinged so that the opening 15 is fully exposed.
Suitable latching arrangements can be employed to retain the shutter sections 11 and 12 in the fully open position of FIG. 1 a , while the same latching arrangements or different latching arrangements can be employed to retain the shutter sections 11 and 12 closed in the FIG. 1 b illustration.
The casement shutter 10 is a form of shutter which exists already and which is easily moved between open and closed positions. Such shutters are therefore popular as covers for windows. However, the casement shutter 10 has not heretofore been used as a fire barrier.
FIGS. 2 a and 2 b illustrate a double panel casement shutter 17 , while FIGS. 3 a and 3 b illustrate a single panel casement shutter 18 , each in closed and open conditions respectively. In each case, the shutter leaves 19 are hinged to the window frame for movement between open and closed positions.
Applicant has developed a shutter arrangement which can form a barrier across a window, door or other opening or the like to protect the window, door or opening against exposure to extreme high temperatures, such as those experienced during an intense bushfire. As explained earlier, openings such as windows and doors are prone to fail during an extreme temperature conditions and allow ingress of flame and embers, and oxygen. Accordingly, protecting windows and doors against failure is important in protecting a building against destruction by fire.
A shutter according to the invention can be formed as a casement shutter of the styles depicted in FIGS. 1 to 3 . Alternatively, a shutter according to the invention can be similar to that depicted in FIGS. 1 a and 1 b , but with a tri-fold arrangement, or greater. Moreover, while the leaves of the shutters illustrated in FIGS. 1 to 3 are hinged along a vertical line, the leaves could be hinged along a horizontal line so that the leaves fold vertically.
FIGS. 4 and 5 illustrate cross-sectional views of a shutter according to the invention through horizontal and vertical sections respectively. Referring first to the horizontal cross-section of FIG. 4 , this depicts a shutter 20 which is fixed over or in front of a window assembly 21 . The window assembly consists of a double glazed window pane 22 which is mounted within side styles 23 . No further discussion will be made in relation to the window assembly 21 given that the window assembly 21 is not important in relation to describing the invention, although it will be appreciated that the shutter 20 of the invention is provided for the purpose of protecting the pane 22 against failure, and for resisting ingress of flame and embers to the window assembly 21 .
The shutter 20 includes a pair of shutter sections 25 and 26 each of which could be formed in a single or bi-fold manner, as illustrated in FIGS. 1 and 2 . The shutter sections 25 and 26 thus include separate shutter leaves 27 and 28 . The shutter leaves 27 and 28 would be connected by one or more hinges (not shown) to further shutter leaves if the shutter sections 25 and 26 were bi-fold sections.
The shutter sections 25 and 26 are connected to opposite vertical frame assemblies 35 and 36 . Each of the frame assemblies includes an angle section 37 which is fixed to the window surround 38 in any suitable manner. The frame assemblies 35 and 36 include hinges (not shown) to which the shutter sections 25 and 26 are connected. The frame assemblies 35 and 36 include a metal frame 42 which cooperates with the angle section 37 . The frame assemblies 35 and 36 can include an infill 41 within the metal frame 42 to support a screw 43 which extends through the frame 42 and the infill 41 and into the angle section 37 to secure the frame 42 to the angle section 37 . The infill can be of any suitable material. An alternative arrangement employs a metal box section, ie 30×30×2.5 mm SHS, to replace the frame 42 and the infill 41 .
The shutter leaves 27 and 28 each comprise an outer metal sheet 50 and a non-combustible insulating panel 51 . The outer sheet 50 is disposed on the fire-side or external side of the shutter 20 , and it can be seen from both FIGS. 4 and 5 , that the outer sheet 50 provides complete coverage for the facing surface of the panel 51 .
On the opposite or internal side of the panel 51 , a frame 52 is located and this comprises a square frame formed of 20×20×2.5 mm SHS section. The frame 52 is formed as a rectangle, about the periphery of the panel 51 .
A rear metal panel 53 extends across the internal side of the shutter 20 and is formed of 0.5 mm steel sheet. The metal panel 53 is attached to the rear side of the frame 52 .
The frame 52 includes a flange or channel 54 which defines a front lip 55 , a rear lip 56 and a base 57 . The flange or channel 54 accepts the periphery of the outer sheet 50 , the insulating panel 51 , and the rear panel 53 . The flange or channel 54 extends fully about the periphery of the respective outer sheet 50 , the insulating panel 51 and the rear panel 53 .
A seal 58 is disposed between the flange or channel 54 and the metal frame 42 of the frame assemblies 35 and 36 of FIG. 4 and the further frame assemblies 59 and 60 of FIG. 5 . The frame assemblies 35 and 36 extend along the side edges of the shutter sections 25 and 26 , while the frame assemblies 59 and 60 extend across the top and bottom edges of the shutter sections 25 and 26 . The frame assemblies 59 and 60 are formed in the same manner as the frame assemblies 35 and 36 and therefore the same reference numerals are employed for the same parts.
The seals 58 are intumescent seals as described earlier. A further intumescent seal 61 is positioned between the angle section 37 and the frame 42 . The seals 58 are prepared seals whereas the seals 61 are a liquid sealant which is applied as one of the last installation steps during installation of shutters according to the invention.
The shutter 20 is easily fitted to the reveal of an existing window, door or other opening. FIG. 5 illustrates a screw 62 which extends through the window surround 38 and it is the case that this form of fixing can be employed about the complete periphery of the shutter 20 . The method of assembly, is that the angle sections 37 are first secured to the window surround 38 , where after the remaining shutter components are fixed to the angle section 37 via the screw 43 . Once that fixing has taken place, the intumescent sealant 61 can be applied to finalise the installation process. The use of the sealant 61 provides some flexibility with tolerances in fitting the shutter 22 a window, as the gap into which the sealant 61 is applied might vary between different windows.
Once installed, it will be appreciated that with the various seals 58 and 61 , that the shutter 20 in a closed condition forms a complete barrier against ingress of embers and direct flames to the window assembly 21 . Referring to FIG. 4 , it can be seen that the seals 58 close all of the gaps in the shutter structure, including between shutter sections 25 and 26 . While not illustrated in FIG. 4 , similar seals 58 can be employed between respective shutter leaves in a bi-fold shutter arrangement.
Moreover, the resistance to conduction of heat from an external side of the shutter to an internal side, protects the window assembly 21 from the extreme heat on the external side of the shutter 20 during an extreme temperature event, such as a bushfire.
To maintain the shutter 20 in a closed condition, suitable latches can be employed and in testing conducted to date, zinc plated steel padbolts have been employed. However, it is clear that various other latching arrangements could be employed, but what is required is that the padbolt, if applied to the external side of the shutter 20 , be able to survive temperatures of the kind that the outer sheet 50 is required to survive and for the same timeframes.
Several variations of the shutter 20 illustrated in FIGS. 4 and 5 have been devised at this stage and include variations illustrated in FIGS. 6 to 9 . Referring to FIG. 6 , this variation involves the extension of the rear panel 53 of FIGS. 4 and 5 about the side edges of the frame 52 , the insulating panel 51 and the outer sheet 50 . Thus, instead of the arrangement of the shutter 20 , in which a separate channel 54 is provided, in the FIG. 6 arrangement, the rear panel 65 extends to a side portion 66 and to a front lip portion 67 . The side and front lip portions 66 and 67 are formed integrally with the rear panel 65 .
In FIG. 7 , a variation is provided in relation to the frame 42 and the infill 41 of the shutter 20 . Instead of the frame 42 and the infill 41 , a SHS 70 is provided through which the screw 43 extends. It is expected that this variation will be employed in practice, although testing to date has not been conducted in relation to this variation and therefore it remains an option only.
The variation illustrated in FIG. 8 is similar to the variation of FIG. 7 , except that a screw 71 extends through the angle section 37 and into only one portion of the SHS 70 .
The variation of FIG. 9 shows the SHS 70 being fixed directly to the wall face 72 which surrounds a window by a screw 73 .
The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the present disclosure.
Throughout the description of this specification the word “comprise” and variations of that word, such as “comprises” and “comprising”, are not intended to exclude other additives or components or integers.
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A shutter 20 including an outer sheet 50 and a non-combustible insulating panel 51 . The panel 51 is positioned between the outer sheet 50 and a frame 52 . The outer sheet 50 overlies a broad face of the panel 51 and the frame 52 is attached adjacent to a second broad face of the panel 51 opposite the first broad face. The outer sheet 50 has a melting point of greater than or equal to about 840° C. The panel 51 is operable to retard heat transmission from the first face to the second face so that when the first face is exposed to a temperature of 730° C. for a period of 15 minutes, the temperature of the second face does not exceed 250° C. Each of the outer sheet 50 and the panel 51 are secured to the frame 52 and the frame is substantially resistant to distortion of up to a temperature of about 250° C.
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FIELD OF THE INVENTION
[0001] The invention relates to locking mechanisms for truck bed closures, or more specifically to manual and/or electrically actuated locking mechanisms for truck bed caps or tonneau covers.
BACKGROUND OF THE INVENTION
[0002] Trucks, e.g. conventional pickup trucks, typically have a cargo bed bounded by a bottom wall and one or more sidewalls and an open portion or bed opening through which cargo is received. It is common to protect such cargo against weather, theft, etc., to selectively close such bed opening with an openable closure, such as a cap or tonneau cover which is supported on the bed walls and overlies the bed opening. Such truck caps and tonneau covers are known to have a locking mechanism that, unlike conventional passenger vehicle doors, are typically simple mechanical devices securing the cover or lift gate by using a pivoting handle actuating a rod or cable to release a latch. The pivoting handle typically has an internal lock tumbler that allows the handle to pivot when placed in the appropriate orientation.
[0003] An improvement to this arrangement was presented in U.S. Pat. No. 6,354,650, having common inventorship with the instant disclosure, wherein an electric actuator was arranged at the latch, whereby the latch anchor points were displaced from the latch in order to release the latch without the need to pivot the handle. The pivoting handle would remain locked, necessitating continued access to the remote actuator, or access to the key in order to open the cover multiple times.
[0004] A further improvement to this arrangement was presented in U.S. Pat. No. 7,363,786, commonly owned, wherein a locking assembly for a truck bed closure was provided, including an internal frame mounting a slider with a dog-receiving aperture, wherein the slider is shiftable between locked and unlocked positions by rotation of a dog within the aperture, or by the action of an electric actuator upon the slider. Upon release of the slider, a shaft-mounted disk could be rotated, drawing upon latch release cables. The components of this arrangement were somewhat bulky, however, and could be exposed to interference or jamming by debris in the truck bed.
[0005] The invention relates to an improved locking handle and power module assembly that provides continued ability to open and close a truck cap or tonneau cover from within or without, and presents an enclosed mechanism to prevent obstruction or jamming.
[0006] Other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a pick up truck with a tonneau cover provided with a locking handle assembly according to the invention.
[0008] FIG. 1A is a perspective view of a locking handle and power module assembly according to the invention.
[0009] FIG. 2 is a side view of the locking handle portion of the assembly of FIGS. 1 and 1A .
[0010] FIG. 3 is a cross sectional view of the locking handle portion of FIG. 2 .
[0011] FIG. 4 is a perspective view of a handle element of the locking handle of FIGS. 2 and 3 .
[0012] FIG. 5 is a bottom perspective view of the handle element of FIG. 4 .
[0013] FIG. 6 is a reverse perspective view of the handle element of FIGS. 4 and 5 .
[0014] FIG. 7 is a cross-sectional view of the handle element taken through line 7 - 7 of FIG. 6 .
[0015] FIG. 8 is a cross-sectional view of the handle element taken through line 8 - 8 of FIG. 7 .
[0016] FIG. 9 is a cross-sectional view of the handle element taken through line 9 - 9 of FIG. 7 .
[0017] FIG. 10 is a perspective view of a key cylinder assembly of the locking handle of FIGS. 2-9 .
[0018] FIG. 11 is a side view of the key cylinder assembly of FIG. 10 .
[0019] FIG. 12 is a back view of the key cylinder assembly of FIGS. 10-11 .
[0020] FIG. 13 is a perspective view of a bushing of the locking handle assembly of FIGS. 2 and 3 .
[0021] FIG. 14 is a plan view of the bushing of Figure
[0022] FIG. 15 is a cross-sectional view of the bushing taken through line 15 - 15 of FIG. 14 .
[0023] FIG. 16 is a bottom view of the bushing of FIGS. 13-15 .
[0024] FIG. 17 is a perspective view of a dust cover cap of the locking handle assembly of FIGS. 2 and 3 .
[0025] FIG. 18 is a bottom view of the dust cover cap of FIG. 17 .
[0026] FIG. 19 is a plan view of a slide bolt of the locking handle assembly of FIGS. 2 and 3 .
[0027] FIG. 20 is a bottom view of a cover of the locking handle assembly of FIGS. 2 and 3 .
[0028] FIG. 21 is an end view of the cover of FIG. 20 .
[0029] FIG. 22 is a perspective view of the power module of the assembly of FIG. 1A according to the invention.
[0030] FIG. 23 is a front view of the power module of FIG. 22 .
[0031] FIG. 24 is a bottom view of the power module of FIGS. 22 and 23 .
[0032] FIG. 25 is a perspective view of a solenoid housing and frame of the power module of FIGS. 22-24 .
[0033] FIG. 26 is a perspective view of a slider of the power module of FIGS. 22-25 .
[0034] FIG. 27 is a reverse perspective view of the slider of FIG. 26 .
[0035] FIG. 28 is a side view of a solenoid for the power module according to FIGS. 22-27 .
[0036] FIG. 29 is a cross sectional view of the locking handle and power module assembly in the locked position.
[0037] FIG. 30 is a cross sectional view of the locking handle and power module assembly in the unlocked position.
[0038] FIG. 31 is a cross sectional view of the locking handle and power module assembly with the key cylinder rotated in the locking position.
[0039] FIG. 32 is a cross sectional view of the locking handle and power module assembly with the key cylinder in the unlocking position.
[0040] FIG. 33 is a perspective view of a key cylinder return spring of FIGS. 29-32 .
[0041] FIG. 34 is a perspective view of a handle return spring of FIGS. 29-32 .
[0042] FIG. 35 is a front view of a slide bolt detent spring of FIGS. 29-32 .
[0043] FIG. 36 is a front view of a U-clip of FIGS. 29-32 .
[0044] FIG. 37 is a front view of an anti-rotation washer of FIGS. 29-32 .
[0045] FIG. 38 is a perspective view of a bushing for a locking handle assembly according to a further embodiment of the invention.
[0046] FIG. 39 is a reverse perspective view of the bushing of FIG. 38 .
[0047] FIG. 40 is an inside perspective view of a locking handle and power module assembly mounted to the inside of a tonneau cover and disposed adjacent a bed portion of a pickup truck.
[0048] FIG. 41 is a perspective view thereof showing a manual release handle assembly.
[0049] FIG. 42 is a top view thereof.
[0050] FIG. 43 is a rear view thereof showing a cover mounted in position.
[0051] FIG. 44 is a right side view thereof with the cover in a rearwardly displaced position.
[0052] FIG. 45 shows the cover in a forwardly displaced position.
[0053] FIG. 46 is a perspective view showing actuator cables connected to the locking handle and power module assembly.
[0054] FIG. 47 is a rear perspective view thereof.
[0055] FIG. 48 is a front view of the release handle.
[0056] FIG. 49 is a rear perspective view of the release handle.
[0057] FIG. 50 is a front perspective view of the release handle.
[0058] FIG. 51 is an enlarged rear perspective view of the release handle mounted to the locking handle assembly.
[0059] FIG. 52 is a further perspective view of the release handle mounted to the locking handle assembly.
[0060] Certain terminology will be used in the following description for convenience and 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 arrangement, and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
DETAILED DESCRIPTION
[0061] FIG. 1 depicts a bed portion 5 of a pickup truck 6 . The bed portion 5 comprises upstanding side walls 10 which typically extend around three sides of the interior storage area of the bed portion 5 which also includes an openable tailgate 11 . The side walls 10 and gate 11 define a bed opening or open portion 12 which provides downward access into the storage area of the bed portion 5 . The bed portion 5 is covered by a tonneau cover 7 which is supported on the side walls 10 and is lockable to the structure of the bed portion B. On an end closure panel or wall 15 of the tonneau cover 7 , a locking handle and power module assembly 100 is provided according to the invention for locking the tonneau cover 7 in the closed position shown. The tonneau cover 7 includes a horizontally enlarged top wall 13 and side walls 14 as well as an end wall 15 which mounts the locking handle and power module assembly 100 thereon.
[0062] The locking handle and power module assembly 100 according to the invention, as shown in FIG. 1A , includes a locking handle assembly 110 for manual opening or latching/unlatching and a power module 120 for electrically locking and unlocking the assembly 100 , wherein the assembly 100 is operable in any combination of manual or electrical locking or unlocking. As such, the locking handle and power module assembly 100 can be tied directly to a vehicle door lock system so as to be unlocked and locked electrically in unison therewith or may also be manually operated independent of the vehicle door lock system so as to permit manual opening of the tonneau cover 7 even if the vehicle door lock system is in the locked condition. Thus, the assembly 100 can be operated with or without electrical power. Even if power is maintained, manual operation of the locking handle and power module assembly 100 is still permitted so as to be operable manually or electrically, which electrical operation can be performed by any electrical switching system such as the aforementioned vehicle door lock system.
[0063] The locking handle assembly 110 , as shown in FIGS. 2 and 3 without the power module 120 , includes an externally-accessible handle 130 , cover 135 , bushing 140 passing through the end closure panel 15 , key cylinder assembly 145 which is lockable, slide bolt 150 , anti-rotation washer 155 , sealing gasket 157 , bushing nut 160 and dust cover cap 165 . The locking handle assembly 110 is non-rotationally secured to the end wall 15 by the washer 155 and nut 160 . The bushing 140 passes through an aperture 16 ( FIG. 2 ) in the closure panel 15 , and includes an outwardly arranged flange 605 at its proximal end 600 ( FIG. 13 ) that traps the sealing gasket 157 against the outer face 17 of the tonneau cover 7 . The bushing 140 is secured in the closure panel 15 by bushing nut 160 , with anti-rotation washer 155 interposed between nut 160 and an inner face 18 of the cover 7 . The dust cover cap 165 covers a lower portion of the bushing 140 that receives the power module 120 when installed. A detailed description of the individual elements follows, and FIG. 3 is described in more detail below under “Assembly”. In this manner, the locking handle and power module assembly 100 is mountable to the tonneau cover wall 15 wherein the handle 130 is rotatable about the rotation axis B of FIG. 2 to allow manual unlatching of the locking handle assembly 110 .
[0064] Referring to FIGS. 4-6 , the handle 130 includes a gripping or interface portion 170 , which is exposed outside of the tonneau cover 7 so as to be manually rotatable, and a shaft portion 175 extending distally from the gripping portion 170 , which is rotatably supported in the bushing 140 and defines the rotation axis B about which the handle 130 rotates. The gripping portion 170 has a flat external face 180 preferably having a tear-drop shape or other suitable shape. Differently-sized first and second apertures or bores 185 , 190 ( FIG. 4 ) are open in the external face 180 of the gripping portion 170 . The relatively large first aperture 185 is centered in the wider end 235 of the external face 180 , and is aligned and centered with the shaft portion 175 of the handle 130 with axis B extending therethrough. The aperture 185 is configured for receiving the key cylinder assembly 145 , as will be further discussed below, and is covered by the cover 135 to seal the cylinder assembly 145 after locking.
[0065] The smaller second aperture 190 is provided to rotatably support the cover 135 over the cylinder assembly 145 , is cylindrical and centered on the narrow end 230 of the external face 180 to one side of the first aperture 185 , and passes through the gripping portion 170 of the handle 130 . A pair of concave pockets 195 , 200 are formed diametrically opposite from one another adjacent to the cylindrical aperture 190 and in line with a longitudinal axis A of the gripping portion 170 . The pockets 195 , 200 serve as a detent for defining the rotation of the cover 135 , which is mounted to the handle 130 through the aperture 190 ( FIG. 3 ).
[0066] To facilitate gripping and handle rotation, the gripping portion 170 of the handle is contoured around its perimeter and has a reduced portion 205 in the distal direction, thereby forming a rounded overhang 210 proximate the external handle face 180 . Opposite the external face 180 , an inner handle face 212 of the gripping portion 170 is formed with cavities 215 , 220 ( FIGS. 5 and 6 ).
[0067] The first cavity 215 is formed about and beneath the cylindrical aperture 190 passing through the face 180 of the gripping portion 170 , for receiving a spring 885 and fastener 890 for securing the cover 135 ( FIG. 3 ) to the handle 130 .
[0068] The second cavity 220 surrounds the shaft portion 175 and extends approximately one quarter of the way around the circumference of the shaft portion 175 and terminates at right and left ends 240 , 245 which interact with the bushing 140 to restrict rotation of the handle 130 as will be described further herein.
[0069] Additional cavities 225 , 227 , 228 are formed during molding adjacent the narrow end 230 of the gripping portion 170 and follow the contour of the wide end 235 of the gripping portion 170 around the shaft portion 175 , respectively. These cavities 225 , 227 , 228 are provided for weight and material savings.
[0070] To rotatably support the handle 130 , the shaft portion 175 of the handle 130 is generally cylindrical, and defines the central axis of rotation B about which the handle 130 is rotatable when seated in the bushing 140 . As the shaft portion 175 extends lengthwise distally away from the gripping portion 170 , the internal and external contours of the shaft portion 175 vary. First, adjacent to the gripping portion 170 , the shaft portion 175 includes a proximal portion 250 having a wide first diameter 255 ( FIG. 7 ). An annular sealing groove 260 having a second, reduced diameter is formed in the proximal portion 250 , separated minimally from the inner face 212 of the gripping portion 170 . The annular groove 260 receives an O-ring 265 ( FIG. 3 ) which is disposed in tight-fitting sealing contact with the bushing 140 to prevent environmental moisture and precipitation from leaking into the handle assembly 110 . A handle return spring pocket 267 ( FIG. 6 ) is formed in a distal shoulder 268 of the proximal portion 250 , for receiving a leg 272 of a handle return spring 273 ( FIGS. 3 and 34 ) which permits handle rotation but biases the handle 130 back to the initial position.
[0071] Axially adjacent to the proximal portion 250 , a central shaft portion 270 has a reduced diameter 275 ( FIG. 7 ). The reduced diameter 275 of the central shaft portion 270 is spaced radially inwardly of the bushing 140 as seen in FIG. 3 to define a clearance space 276 which accommodates the handle return spring 273 therein.
[0072] Referring to FIGS. 4-6 , a tip portion 280 of the shaft portion 175 is formed as a truncated cylinder having oppositely situated flat sides 285 , 290 arranged perpendicularly to the longitudinal axis A of the gripping portion 170 . Convex sides 295 , 300 define a further reduced diameter 305 , forming an axially-facing shoulder 310 at the distal end of the central shaft portion 270 ( FIGS. 5 and 6 ). A pair of aligned arcuate grooves 315 , 320 are formed parallel to each other in the convex sides 295 , 300 , and are axially spaced from each other in the distal or axial direction. The grooves 315 , 320 are configured for receiving a snap ring 317 ( FIG. 3 ) which is installed after the handle 130 is inserted in the bushing 140 and thereby, secures the handle 130 to the bushing 140 by preventing axial removal therefrom.
[0073] In this embodiment, the distal end 325 of the shaft 175 faces axially and is formed with a pocket 330 within the tip portion 280 which has a square profile that opens axially from the end face of the tip portion 280 . An aperture or bore 335 passes sidewardly through each of the flat faces 285 , 290 of the tip portion 280 , in sideward alignment with each other, into the square pocket 330 .
[0074] Referring again to the central shaft portion 270 , a transverse notch 340 is provided in an outer face thereof, wherein a bottom notch face 341 is parallel to flat face 285 ( FIGS. 6 and 7 ). Within the concavity formed by the notch 340 , a pair of apertures 345 , 350 are formed for receiving the legs of a U-clip 347 ( FIG. 36 ) for securing the key cylinder assembly 145 within the handle 130 as will be described herein. The apertures 345 , 350 pass through an interior cylindrical cavity 355 in a distal portion of the central shaft portion 270 , wherein each aperture 345 , 350 is positioned at the outer edges thereof ( FIG. 7 ), and exits through the opposite side of the central shaft portion 270 ( FIG. 5 ). The interior cavity 355 receives the cylinder assembly 145 therein.
[0075] To accommodate the slide bolt 150 ( FIGS. 3 and 29 ) which selectively locks out rotation of the handle 130 relative to the bushing 140 , a transverse passage 360 or bore is formed in the distal portion of the central shaft portion 270 as shown in more detail in FIGS. 7 and 9 . The passage 360 has opposite open ends which open sidewardly. The transverse passage 360 is generally circular in cross section, and includes a radial keyhole portion 365 extending distally and radially from the passage 360 toward the tip 280 of the shaft 175 , for receiving a slide bolt detent spring 366 ( FIGS. 3 , 31 and 35 ) which resists movement of the slide bolt 150 by frictional contact therewith.
[0076] More particularly as to the key cylinder assembly 145 , the central aperture 185 of the shaft portion 175 is configured to receive the key cylinder assembly 145 axially therein through the top of the handle 130 . Referring to FIGS. 8 and 9 , the central aperture 185 has at its proximal end a cup portion 367 having a primary diameter 370 that defines the mouth or open end of aperture 185 . Distal of the cup portion 367 lies a tumbler portion 375 having a reduced diameter 380 . The tumbler portion 375 includes a pair of opposing tumbler cavities 385 , 390 on diametrically opposite sides of the tumbler portion 375 . The tumbler cavities 385 , 390 define an increased diameter equal to diameter 370 so that cavities 385 , 390 open axially into cup portion 367 . A pair of rotation stops 395 , 400 extend axially or proximally from the tumbler portion 375 and project radially inwardly into the cup portion 365 to limit rotation of key cylinder 145 by blocking rotation stops 462 , 463 of the key cylinder 145 ( FIGS. 10-12 ) which project radially outwardly and are disposed circumferentially between the stops 395 , 400 . At the distal end of the tumbler cavity 385 , a central pillar 405 is provided. On either side of the central pillar 405 , a key cylinder return spring channel 410 , 415 extends to a respective key cylinder return spring pocket 420 , 425 .
[0077] Referring now to FIGS. 10-12 , the key cylinder assembly 145 is generally cylindrical, and includes a circular external face 450 having a rectangular slot 455 for receiving a key K ( FIGS. 31 and 32 ) configured to match the arrangement of the key cylinder 145 , as is well known in the art. The slot 455 extends internally within the key cylinder assembly 145 . The slot 455 includes a number of inwardly projecting rails (not shown) that are configured to engage and align a key having matching grooves, for positioning the key laterally and transversely within the cylinder, relative to tumblers 470 carried by a tumbler portion 460 of the key cylinder assembly 145 , as is well known in the art. An O-ring channel 458 is arranged distally of the external face 450 for receiving O-ring 459 ( FIG. 3 ) to seal the cylinder assembly 145 . A pair of aforementioned rotation stops 462 , 463 extend radially outwardly from the tumbler portion 460 , distally of the O-ring groove 458 . The tumbler portion 460 of the key cylinder assembly 145 includes a plurality of transverse slots 465 passing through the tumbler portion 460 generally centered on the longitudinal slot 455 receiving the key. Each of the transverse slots 465 receives one of the tumblers 470 .
[0078] Axially adjacent to the tumbler portion 460 , a distal cylindrical end portion 475 extends. The cylindrical end portion 475 has a smaller diameter than the tumbler portion 460 . A partial cylindrical flange or rib 480 extends distally from the tumbler portion 460 , over the distal cylindrical portion 475 , forming a gap 490 underneath a rib overhang along the peripheral rib edge 491 . The flange 480 includes a proximal first notch 495 and distal second notch 500 on opposing sides of the rib edge 491 for receiving end legs 486 , 487 of a key cylinder return spring 485 ( FIG. 33 ). The distal cylindrical portion 475 further includes an annular groove 505 for engagement with the U-clip 347 ( FIG. 29 ). At the distal end 510 of the key cylinder assembly 145 , a slide bolt engagement tab or drive pin 515 is formed. The slide bolt engagement tab 515 is generally aligned with the key slot 455 ( FIG. 12 ) formed within the key cylinder assembly 145 , and extends distally from the distal end 510 of the key cylinder assembly 145 . The tab 515 is offset radially from the center of the end portion 475 so as to move along an arcuate path when the cylinder assembly 145 is rotated manually by a key.
[0079] To rotatably support the key cylinder assembly 145 , the bushing 140 ( FIGS. 13-16 ) is a generally hollow cylinder, having a proximal outer end 600 and a distal inner end 650 . The outwardly arranged flange 605 is positioned at the proximal end 600 , as shown in FIGS. 13-16 and projects radially outwardly. A rotation stop 610 extends proximally or axially from the face 615 of the flange 605 for seating in the handle cavity 220 above which thereby defines the stop limits for the handle rotation. The rotation stop 610 is adjacent to a central passage 620 extending the length of the bushing 140 . The central passage 620 includes two regions. The first outer region 625 has a larger first interior diameter 630 . The second inner region 635 has a second interior diameter 640 smaller than the first diameter 630 . The interior wall of the passage 620 forms a shoulder 645 defining the transition from the larger diameter 630 of the outer region 625 to the smaller diameter 640 of the inner region 635 . A handle return spring pocket 647 is formed in the shoulder 645 , for receiving a leg 274 of the handle return spring 273 ( FIG. 34 ). The other leg 272 seats within the pocket 267 of the handle portion 130 as described above to normally maintain the handle portion 130 in an initial position while permitting rotation of the handle portion 130 . The distal end 650 of the passage further narrows slightly to define a distal mouth 655 of the passage 620 which allows the slide bolt engagement tab 515 to project axially therethrough as seen in FIG. 29 .
[0080] As to the exterior shape of the bushing 140 , the exterior face 660 of the bushing 140 can be described as generally cylindrical. As shown in the bottom view of FIG. 16 , the rounded “corners” 665 of the exterior 660 of the proximal portion of bushing 140 lie on and define a circle of a given radius. These rounded corners 665 are threaded (not shown) for receiving and threadedly engaging the bushing nut 160 seen in FIG. 3 . Between each of the rounded corners 665 , the external face 660 of the bushing 140 forms diametrically opposed flat faces 670 .
[0081] The external face 675 of the end portion of the bushing 140 likewise includes rounded “corners” 680 and flat faces 685 therebetween. In at least one of the flat faces 685 , a guidance key or groove 690 is provided. In the pair of opposing flat faces 685 adjacent to the guidance key 690 , a passage 695 is provided, passing transversely or sidewardly through the distal portion of the bushing 140 . Axially inwardly of this transverse passage 695 , a concave trough 700 extends axially from a respective one of the passages 695 , which trough 700 is formed on the outer face 685 of the end portion of the bushing 140 and extends to the distal end 650 of the bushing 140 . Further, a circumferential groove 705 is provided at an outer end 710 of the distal portion of the bushing 140 , for optionally receiving a snap ring 707 ( FIG. 29 ) which optionally holds the power module 120 on the handle assembly 110 when mounted thereon.
[0082] Referring to FIGS. 38 and 39 , a preferred, alternative embodiment of a bushing 1400 is provided. The bushing 1400 has an outer end 1410 and a distal inner end 1420 . The proximal end 1410 is formed with a teardrop-shaped flange 1430 . The shape of the flange 1430 substantially correlates to the shape of the gripping portion 170 of the handle 130 , so that when the handle assembly 110 is assembled, the gripping portion 170 of the handle 130 substantially overlies the entirety of the flange 1430 . A rotation stop 1440 extends axially from the proximal face 1450 of the bushing 1400 adjacent to the central passage 1460 to limit rotation of the handle 130 when received in handle cavity 220 . Referring to FIG. 39 , a blind bore or cavity 1470 , generally cylindrical in nature, is formed in an underside 1480 of a free end 1490 of the flange 1430 . The cavity 1470 is configured for receiving an anti-rotation pin 1500 . The pin 1500 is illustrated as comprising an enlarged head 1510 for fitting into the cavity 1470 and a cylindrical shank portion 1520 having a smaller diameter than the head 1510 which seats in the cover 7 and prevents relative rotation of the bushing 1400 . It is also conceived that the pin 1500 would have a uniform diameter along its full length, extending from the cavity 1470 . The remainder of the bushing 1400 is structurally identical to the bushing 140 described above. In use, the end closure panel 15 receiving the locking handle assembly 110 would include a primary aperture like aperture 16 for receiving the locking handle assembly 110 , and a smaller secondary aperture 1525 ( FIG. 45 ) for closely receiving the pin 1500 in a locking fashion. By this arrangement, the bushing 1400 is prevented from rotating within the primary aperture 16 of the closure panel 7 by the action of the anti-rotation or locking pin 1500 . The bushing 1400 is further secured to the closure panel 7 by a bushing nut 160 with or without an anti-rotation washer 155 as described elsewhere herein.
[0083] To enclose the above components, the dust cover cap 165 , shown in FIGS. 2 and 17 - 18 , is formed as a generally octagonal cylindrical sleeve having rounded “corners” 720 and flat sides 725 , substantially corresponding to the cross section of the distal portion of the bushing 140 . At a distal end 730 of the dust cover cap 165 , a shoulder 735 is provided, forming a round opening 740 slightly larger than the opening 665 in the distal end 650 of the bushing 140 . At the proximal end 745 of the dust cover cap 165 , inwardly directed prongs or snap locking tabs 750 are provided. The prongs 750 are configured to engage the circumferential groove 705 adjacent the end 710 of the outer end portion 675 of the bushing 140 ( FIG. 15 ), to removably attach the dust cover cap 165 onto the end portion of the bushing 140 as seen in FIG. 3 .
[0084] The above components serve to drive the slide bolt 150 for locking and unlocking. The slide bolt 150 , as shown in FIG. 19 (and also in the cross sections of FIGS. 3 and 29 - 32 ), is cylindrical, having a primary diameter 805 , defining a first portion 810 and a third portion 815 . The first and third portions 810 , 815 are connected by a second, reduced portion 820 . The reduced portion 820 forms the basis for an annular cavity 825 between the first and third portions 810 , 815 of the slide bolt 150 . The slide bolt 150 fits into transverse passage 360 . The diameter 805 of the first and third portions 810 , 815 is defined so as to provide smooth movement within the transverse passage 360 of the handle shaft 175 . A fourth portion 830 of the slide bolt 150 , opposite from the first portion 810 , is formed with a predefined diameter 835 for engaging the passage 695 in the bushing 140 or similar passage 1495 in bushing 1400 to selectively prevent rotation of handle 130 when engaged with the bushing 140 or 1400 . The external faces 838 , 840 of the first and fourth portions 810 , 830 of the slide bolt 150 are formed with a specified radius to provide clearance within the bushing 140 or 1400 while housed completely within the transverse passage 360 of the shaft 175 . Operation of the slide bolt 150 will be described further herein.
[0085] To selectively enclose the exterior key slot of the cylinder assembly 145 , the cover 135 , as shown in FIGS. 20-21 , has a tear-drop shape to match the gripping portion 170 of the handle 130 and is rotatably mounted on the handle 130 so to swing open and closed to provide access to the key cylinder. The cover 135 has an outer face 850 and an inner face 855 . The inner face includes a cylindrical depression 860 (see also FIG. 3 ) which covers the cylinder assembly 145 . A cylindrical post 865 extends normally from the inner face 855 and fits in handle aperture 190 in rotatable engagement therewith. The post 865 includes an internal aperture 870 . A pair of convex ridges 875 , 880 extend from the inner face 855 on opposing sides of the post 865 so as to seat within the handle recesses 195 and 200 , and in alignment with a longitudinal axis of the cover 135 . The ridges 875 , 880 and recesses 195 , 200 have cooperating arcuate surfaces which effect a camming action during swinging of the cover 135 and thereby lift the cover 135 upwardly to permit continued swinging movement of the cover 135 that exposes the lock cylinder 145 . A coil spring 885 resiliently resists this lifting movement while a screw fastener 890 prevents removal of the cover 135 from handle 130 . In this manner, the handle 130 can be manually locked and unlocked by the key K.
[0086] While the handle 130 allows for manual locking and unlocking, the power module 120 illustrated in FIG. 1 and FIGS. 22-28 , and is a preferred addition to the locking handle assembly 110 for providing remote electrical locking and unlocking capability to the locking handle assembly 110 . The power lock assembly 120 includes a solenoid housing and frame 1000 , a cover 1010 , a lock solenoid 1020 ( FIG. 28 ), a slider plate 1030 , and a manual lock/unlock knob 1040 . The frame 1000 mounts to the distal end 650 of the bushing 140 to align for engagement with the locking handle assembly 110 , as will be further described below.
[0087] The solenoid housing and frame 1000 includes a housing portion 1050 and a frame portion 1055 . The frame portion 1055 extends laterally of the housing portion 1050 and is connected to the housing portion 1050 by a bridge portion 1060 . A slider mounting plate 1065 ( FIG. 25 ) extends over the bridge portion 1060 , from the housing portion 1050 , and further extends over the frame portion 1055 . The mounting plate 1065 includes two slider mounting posts 1070 , 1075 . In the region of the bridge portion 1060 , the slider mounting plate 1065 includes a groove 1080 aligned with a notch 1085 in the housing portion 1050 .
[0088] The housing portion 1050 defines an interior cavity 1090 for receiving the solenoid 1020 ( FIG. 28 ), and includes a power connection recess 1095 formed distally from the frame portion 1055 and the notch 1085 to accommodate a power connection to the solenoid 1020 .
[0089] The frame portion 1055 is substantially flat, and includes a central, generally octagonal opening 1100 . The periphery of the opening 1100 includes flat sections 1105 and curved sections 1110 , substantially corresponding to the exterior configuration of the distal end 650 of the bushing 140 . One of the flat portions 1105 includes a guidance key 1115 for engaging the groove 690 formed in the distal end 650 of the bushing 140 . Each of the posts 1070 , 1075 includes a respective collar portion 1130 , 1135 .
[0090] The slider plate 1030 ( FIGS. 26 and 27 ) is generally rectangular in configuration. A pair of oval slots 1150 , 1155 are arranged parallel to a longitudinal axis of the slider plate 1030 , along an upper edge thereof, to define stop limits for sliding movement of the slider plate 1030 . A cutout portion 1160 is arranged opposite the oval slots 1150 , 1155 . The cutout portion is bounded by a locking projection 1165 and an unlocking projection 1170 , each directed in the longitudinal direction of the sliding plate 1030 and along a lower edge 1175 thereof. At a proximal end 1180 of the slider plate 1030 , relative to the housing 1050 , a raised flange portion 1185 is provided. The raised flange 1185 includes an aperture 1190 and further defines a recess 1195 on an undersurface thereof adapted to be driven by the solenoid 1020 .
[0091] Referring to FIG. 28 , the solenoid 1020 includes a main drive body 1200 , electrical connection 1210 , and reciprocating actuation arm 1220 . The actuation arm 1220 includes a longitudinal portion 1225 for reciprocal movement into and out of the body 1200 and a vertical drive portion 1230 . As shown in FIGS. 22-24 , the actuator 1220 extends distally from the housing 1050 toward the opening 1100 for engagement with the slider plate 1030 . The vertical portion 1230 turns away from the face of the slide frame 1000 and passes through the aperture 1190 in the slide plate 1030 so that the plate 1030 and arm 1220 reciprocate together. The vertical portion 1230 is capped by the unlock knob 1040 .
[0092] The slider plate 1030 is slidably received on the face of the slide frame 1000 , with the slide plate posts 1070 , 1075 each passing through the respective slot 1150 , 1155 . The slide plate 1030 is retained on the slide frame by push nuts 1240 , 1245 ( FIGS. 22 and 23 ). A washer 1250 is interposed between each push nut 1240 , 1245 and the face 1255 of the slide plate 1030 .
[0093] Under the powered action of the solenoid 1020 which is powered by 12 volt pulses or power from the vehicle electrical system, the actuation arm 1220 selectively moves the slider plate 1030 either toward or away from the housing portion 1050 . In the disclosed embodiment, movement of the slider plate 1030 proximally to or toward the housing portion 1050 will extend the unlocking projection 1170 into the opening 1100 . As will be described below, this movement will effect an unlocking of the handle assembly 110 ( FIG. 30 ). Conversely, distal away movement of the slider plate 1030 will extend the locking projection 1165 into the opening 1100 ( FIG. 29 ). This movement will effect a locking of the handle assembly 110 .
Assembly
[0094] A detailed cross-section of the locking handle assembly 110 is shown in FIG. 3 . To assemble the locking handle assembly 110 , the first step is to insert the slide bolt detent spring 366 into the keyhole portion 365 of the transverse opening 360 of the shaft 175 . The slide bolt 150 is then inserted into the transverse passage 360 and centered so it does not extend beyond the exterior circumference of the shaft 175 of the handle 130 , as in the “unlocked” orientation of FIG. 30 .
[0095] O-ring 459 is placed in O-ring channel 458 on key cylinder assembly 145 . The key cylinder return spring 485 (see also FIG. 33 ) is assembled onto the assembled key cylinder assembly 145 so that each leg 486 , 487 of the key cylinder spring 485 engages the appropriate notch 495 , 500 ( FIG. 10 ) on the tumbler extension 480 , placing the spring 485 under tension. The legs 486 , 487 are aligned with the key cylinder return spring slots 410 , 415 ( FIG. 8 ) within the tumbler portion 385 of the shaft 250 of the handle 130 . The key cylinder assembly 145 is then inserted into the central aperture of the handle 130 so that the slide bolt engaging tab 515 enters the gap 825 between the first and third portions 810 , 815 of the slide bolt 150 , and so that the circumferential groove 505 aligns with the apertures 345 , 350 within the notch 340 of the shaft 175 . The legs of the U-clip 347 are inserted through the apertures 345 , 350 , engaging the groove 505 to retain the key cylinder assembly 145 within the handle 130 .
[0096] The cover 135 may then be assembled to the handle 130 . As shown in FIG. 3 , the post 865 is received in the aperture 190 in the narrow end 230 of the gripping portion 170 of the handle 130 . With the post 865 received in the aperture 190 , the ridges 875 , 880 can be received in the pockets 195 , 200 on the face 180 of the gripping portion 170 . A compression spring 885 is placed over the post 865 within the cavity 220 and is secured on the post 865 by a threaded fastener 890 . The internal aperture 870 can be pre-threaded, or threads formed by self-tapping by the fastener 890 . The cover 135 is biased by the spring 885 toward the face 180 of the gripping portion 170 , with the ridges 875 , 880 in the pockets 195 , 200 . In the position shown in FIG. 3 , the cylindrical cavity 860 is positioned over the aperture 185 holding the key cylinder assembly 145 .
[0097] To install the handle 130 , the O-ring 265 is placed within the annular groove 260 of the handle 130 . The handle return spring 273 is also slid over the shaft 175 so that a first leg 272 is inserted into the hole 267 ( FIG. 6 ) in the shoulder 268 of the shaft 175 . The shaft 175 can then be inserted into the bushing 140 , taking care to align the second leg 274 of the handle return spring 273 with the hole 647 in the shoulder 645 within the bushing 140 ( FIG. 14 ) so that the handle 130 is normally based to its initial position. Snap ring 317 is clipped over the tip 280 of the shaft portion, into the first of the grooves 315 ( FIG. 4 ) to hold the shaft 175 within the bushing 140 .
[0098] The locking handle assembly 110 can now be inserted through opening 16 in closure panel 15 . First, gasket 157 is placed on an underside of the outwardly extending flange 605 of bushing 140 . The shaft of the bushing 140 is then inserted through the opening in the closure panel 15 . An anti-rotation washer 155 slides over the bushing 140 , with flats 161 and wedges 156 engaging opposing bushing flat faces 685 . A smooth washer 159 is placed over the anti-rotation washer 155 , and bushing nut 160 is threaded onto the rounded corners 665 of the bushing 140 until the wedges 156 bite into the closure panel 15 and wedge between the aperture 16 in the closure panel 15 and the flat faces 685 of bushing 140 . Teeth 158 engage the inner face 18 of the closure panel 15 .
[0099] In a non-powered application, the dust cover 165 can then be applied to the distal portion of the bushing 140 so that the tip 380 of the handle 130 extends through the opening 740 of the dust cover 165 , as shown in FIG. 2 . In one configuration, a rotation disk (not shown) can be connected to a latching mechanism of the closure panel and is mounted on the tip 380 and secured by a second retaining clip (not shown) that is received in the distal slot 320 . This disk would rotate with the handle 130 . Other release mechanisms are available, which can be adapted to engage the square cavity 330 in the tip 280 .
[0100] In a powered application, the locking handle assembly 110 is secured to the closure panel 15 as described above, but the dust cover 165 need not be employed. The distal end 650 of the bushing 140 is exposed. The power module 120 is slid over the distal end 650 of bushing 140 with the guidance key 1115 engaging the groove 690 to ensure proper orientation, as the power module 120 can be constructed for right or left side installation and therefore is adaptable to different configurations of closure. The troughs 700 on each side of the distal end 650 of the bushing 140 are provided so that the locking projection 1165 and the unlocking projection 1170 can pass over the distal portion of the bushing 140 to align with the passage 695 . The frame 1055 , when fully engaged onto the distal end 650 of the bushing 140 , abuts the proximal end 710 of the distal portion, exposing the groove 705 . The snap ring 707 can then be received within the groove 705 , securing the power module 120 onto the locking handle assembly 110 . The locking and unlocking projections 1165 , 1170 are thus aligned with the passage 695 for engaging the slide bolt 150 , as shown in FIGS. 29-32 . The slide bolt 150 remains engageable by the key cylinder assembly 145 .
Operation
[0101] In FIG. 29 , the locking handle assembly 110 is shown in the locked position, with no key inserted in the key cylinder 145 , and with the key cylinder 145 in the centered position, biased into this position by the key cylinder return spring 485 . In this position, the slide bolt engagement tab 515 is centered, allowing the slide bolt 150 to slide freely from the locked position ( FIG. 29 ) to the unlocked position ( FIG. 30 ). The locking projection 1165 of the power module 120 extends through the passage 695 to maintain or push the slide bolt 150 to the left. In this locked position, the end portion 830 of the slide bolt 150 extends through the passage 695 , preventing relative rotation of the shaft 175 within the bushing 140 .
[0102] Referring to FIG. 30 , the unlocking projection 1170 has been actuated to extend into the passage 695 so that the end portion 830 of the slide bolt 150 is fully received or retracted within the shaft 175 of the handle 130 . The locking portion 1165 is simultaneously withdrawn from the passage 695 , thereby allowing complete freedom of rotation of the shaft 175 within the bushing 140 by the handle 130 .
[0103] In order to operate the locking handle assembly 110 using a key, it is necessary to expose the key cylinder assembly 145 . The cover 135 need only be pushed to the side and rotated about the post 865 . A ramping action between the ridges 875 , 880 and the pockets 195 , 200 will compress the spring 885 and lift the cover 135 above the face 180 of the gripping portion 170 of the handle 130 , to provide clearance and prevent scratching of the face 180 . When the cover has rotated 180° about the post 865 , the ridges 875 , 880 will drop into the opposite respective pocket 195 , 200 , and remain in the uncovered position until manually returned to the covered position of FIG. 3 . In FIGS. 31 and 32 , the cover 135 has been rotated to expose the key cylinder 145 and is not shown.
[0104] FIG. 31 shows a key K engaged in the key cylinder 145 and rotating the key cylinder 145 . This rotation of the key cylinder 145 causes the slide bolt engagement tab 515 to engage the first portion 810 of the slide bolt 150 to center the slide bolt 150 within the shaft 175 . The first portion 810 of the slide bolt 150 presses the locking projection 1165 out of the shaft 175 to allow free rotation of the handle 110 .
[0105] In FIG. 32 , the key K is shown inserted into the key cylinder 145 , but rotated in the opposite direction. Rotation of the key cylinder assembly 145 by the key K causes the slide bolt engagement tab 515 to be pressed against the third portion 815 of the slide bolt 150 to extend the end portion 830 through the passage 695 , thus preventing rotation of the handle 130 . The extension of the end portion 830 presses against the unlocking projection 1170 to displace it so that the end portion 830 can occupy the passage 695 . Displacement of the unlocking projection 1170 simultaneously draws the opposed locking projection 1165 into the passage 695 to further secure the shaft 175 against rotation relative to the bushing 140 .
[0106] In a preferred embodiment of the invention, the above-described locking handle and power module assembly 100 is mounted to the end wall 15 of the tonneau cover 7 according to the above-described mounting procedures. The handle assembly 100 preferably also includes a manually operable release handle 1200 which projects out of a main cover 1201 , which cover 1201 is provided as seen in FIG. 40 so as to almost fully enclose the locking handle and power module assembly 100 . This release handle assembly 1200 is drivingly connected to a latching mechanism 1202 , which latching mechanism 1202 comprises two actuator cables 1203 and 1204 (FIGS. 40 and 46 - 47 ) wherein the release handle assembly 1200 may be automatically operated by its interconnection to the locking handle assembly 110 which may be manually operated from the exterior of the tonneau cover 7 by rotation of the handle portion 130 . The release handle assembly 1200 also is accessible from the interior of the tonneau cover 7 and may be manually rotated from the interior of the tonneau cover 7 so as to actuate the cables 1203 and 1204 independently of the exterior handle 130 and even if the handle 130 is locked. This allows for emergency release of the inventive handle assembly 130 even under a locked condition.
[0107] The assembly 100 is preferably formed with the above-described bushing 1400 which includes the anti-rotation pin 1500 which projects from the bushing and engages a secondary aperture 1525 ( FIG. 45 ) that is formed on the exterior of the tonneau cover end wall 15 to prevent unwanted rotation of the bushing 1400 within the end wall 15 .
[0108] In this preferred embodiment, the bushing 1400 includes side grooves 1496 , which grooves 1496 include the apertures 1495 on the opposite sides of the bushing 1400 that align with each opposite end of the transverse passage 360 in the handle shaft 175 described above so as to permit the power module 120 to operate the slide bolt 150 as also described above. Hence, bushing 1400 also has the opening 1497 ( FIGS. 38 and 39 ) wherein the shaft portion 175 projects out of the bushing opening 1497 for mounting of the release handle assembly 1200 thereon. Hence, operation of the release handle assembly 1200 causes rotation of the handle shaft 175 .
[0109] Referring to FIGS. 51 and 52 , the shaft portion 175 of the handle 130 has a modified construction in that the tip portion 280 is formed with a flat end face 1210 and a mounting hub 1211 projecting therefrom. The mounting hub 1211 has opposite arcuate side edges 1212 and a pair of straight edges 1213 on the top and bottom thereof. In the interior of the hub 1211 , a short hub extension 1214 is provided which also has two arcuate edges and a pair of straight edges on the top and bottom thereof. The center of the hub extension 1214 includes a fastener bore 1215 for mounting the release handle assembly 1200 thereon as will be described further hereinafter. As such, the release handle assembly 1200 is typically disposed within the interior storage compartment of the truck bed portion 5 , and is accessible from this space to independently operate the latching mechanism 1202 even if the handle assembly 110 is in a locked condition, and without require operation of either the handle 130 or the power module 120 . The primary function served by the release handle assembly 1200 is that it would allow release of the latching mechanism 1202 and opening of the tonneau cover 7 , for example, if a person was trapped in the storage compartment.
[0110] First as to the cover 1201 , this cover 1201 encloses the entire locking handle and power module assembly 100 , and also includes cable guides 1210 and 1211 at the opposite cover ends which allow for the passage of cables 1203 and 1204 sidewardly therethrough. The cable guides 1210 and 1211 allow the cables to exit the cover 1201 at a variety of angles depending upon the destination of the routing of the cables 1203 and 1204 on the tonneau cover 7 . For example, cables 1203 and 1204 are shown in FIG. 40 extending along first paths in a first configuration wherein cable 1203 angles downwardly to a tubular cable channel 1214 formed in the cover end wall 15 while cable 1204 angles upwardly past a flange 1215 . The guide channels 1210 and 1211 are sized to also permit the cables to angle in alternate configurations.
[0111] For example, the flange 1215 may include a guide bore 1216 through the cable 1204 would angle farther upwardly in the second configuration designated as 1204 - 1 . In another example, cable 1203 could instead angle upwardly in the second configuration designated as 1203 - 1 . Referring to FIGS. 43 and 44 , the guide channels 1210 and 1211 preferably are horizontally elongate and formed in the respective cover end walls 1217 and 1218 which allows the cables 1203 and 1204 to not only vary in their vertical angular orientation shown in FIG. 40 but also may vary in their horizontal angular orientation since the guide channels 1217 and 1218 are horizontally elongate. Further, these guide channels 1217 and 1218 are open on the front side or end disposed proximate the cover end wall 15 ( FIG. 44 ) to allow the cover 1201 to be fitted into position when the cables 1203 and 1204 are already connected to the release handle assembly 1200 as seen in FIG. 47 .
[0112] To secure the cover 1201 in position, the power module 120 is provided with cover mounts 1220 , 1221 and 1222 ( FIGS. 47 and 46 ) which are formed as open-ended bores and threadedly engage with fasteners 1223 , 1224 and 1225 respectively ( FIGS. 43 and 44 ). Each of the fasteners 1223 , 1224 and 1225 passes through a fastener slot 1226 ( FIG. 45 ) formed in the cover 1201 which slots 1226 are elongate to permit the cover 1201 to be adjusted from a first outward position seen in FIG. 44 , and a second inward position seen in FIG. 45 . This allows the cover 1201 to be snugged up tightly against the inside surface of the cover end wall 15 during installation.
[0113] The power module 120 also is formed with cable guide 1228 to ensure that the cable 1204 extends to the end of the power module 120 without interference, and as the cable 1204 exits the cable guide 1228 , the cable 1204 can bend at a desired angle depending upon the routing of the cable 1204 , as previously described relative to FIG. 40 . The cable guide 1228 preferably is defined by a downwardly projecting flange 1229 formed by the housing of the power module 120 . The flange 1229 is positioned closely proximate the respective guide channel 1210 formed in cover 1201 .
[0114] The cover 1201 also includes a handle slot 1230 which is vertically elongate and allows the release handle assembly 1200 to be operated therethrough. The release handle assembly primarily comprises a release handle 1232 ( FIGS. 41 and 48 ), but also includes a washer 1233 and a fastener 1234 which connect the release handle 1232 to the handle 130 . The end of the handle 1232 has an overmolded cover 1235 ( FIG. 43 ) which is formed of a phosphorescent ABS material or other similar photoluminescent material. As such, the cover 1235 is readily visible in the dark, such as in an emergency when a person is trapped in the truck bed. This person can readily see the handle cover 1235 when it glows in the dark, and can see the visible indicia on the cover 1235 (see Figure re) which provides operational instructions, preferably by a picture which shows the cover being opened and has arrows indicating how to escape. The release handle 1232 is driven in one rotational direction by the handle 130 when the handle is used to operate the latching mechanism 1202 , but also is independently movable in the opposite rotational direction so that the release handle 1232 can independently release the latching mechanism 1202 without regard to operation of the handle 130 and without regard to whether the handle assembly 110 is locked or not.
[0115] Generally as shown in FIGS. 48-50 , the release handle 1232 comprises a drive disk 1236 which is circular about most of the circumference, and which has a pair of cable mounting flanges 1237 and 1238 . The mounting flanges 1237 and 1238 extend tangentially from the drive disk 1236 and then bend at right angles to define cable eyelets 1239 and 1240 for engaging cables 1203 and 1204 . As seen in FIG. 47 , the cables 1203 and 1204 extend through their respective eyelets 1239 and 1240 and have enlarged cable heads 1243 and 1244 which prevent the cables 1203 and 1204 from pulling out of the eyelets 1239 and 1240 . Hence, counterclockwise rotation of the handle 1232 ( FIG. 47 ) during rotation of the handle 130 pulls the cables 1203 and 1204 to release the latch mechanism 1202 .
[0116] To mount the release handle 1232 to the end 280 of the handle shaft 175 as seen in FIGS. 51 and 52 , the shaft portion 175 of the handle 130 has the modified construction in that the tip portion 280 is formed with a flat end face 1210 and a mounting hub 1211 projecting therefrom. The handle drive disk 1236 includes a central disk aperture 1242 ( FIGS. 48 and 51 ) which rotatably mounts on the hub 1211 . The disk aperture 1242 has non-circular shape although it includes two diametrically opposite, arcuate rotation edges 1243 which define two segments of a circle. The rotation edges 1243 fit closely adjacent the opposite arcuate side edges 1212 of the mounting hub 1211 so that the side edges 1212 and rotation edges 1243 have a common center axis and the release handle 1232 rotates about such axis.
[0117] The disk aperture 1242 also includes two radial projections 1245 which project radially inwardly and are each defined by two stop faces 1246 and 1247 which essentially face in opposite clockwise and counterclockwise directions. The clockwise-facing stop faces 1246 are normally disposed in contact with straight hub edges 1213 on the top and bottom of the hub 1211 as seen in FIG. 51 . The cables 1203 and 1204 normally pull the release handle 1232 clockwise until the aperture stop faces 1246 abut against the hub edges 1213 . As a result, counterclockwise rotation of the handle shaft 175 causes the drive disk 1236 to pull the cables 1203 and 1204 and release the latch mechanism 1200 . The cables 1203 and 1204 are normally resiliently biased against such movement by springs or other biasing elements that maintain the cables in tension such that release of handle 130 allows the cables to return to their initial position ( FIG. 47 ) with the stop faces 1246 remaining in contact with the hub edges 1213 . As such, the release handle 1232 serves to connect the cables 1203 and 1204 to the handle 130 so that the handle 130 controls actuation of such cables during clockwise rotation thereof ( FIG. 47 ).
[0118] However, the release handle 1232 is unrestrained in the counterclockwise direction and is relatively movable counterclockwise without effecting any rotation of handle 130 . In particular, the counterclockwise-facing stop faces 1247 of the disk aperture essentially define a clearance space 1250 along half of the straight hub edges 1213 which thereby allows the release handle 1232 to rotate counterclockwise while the hub 1211 and its associated handle 130 remains stationary. In particular, the release handle 1232 is captured on the hub 1211 by the aforementioned washer 1233 and fastener 1234 but the washer 1233 still permits counterclockwise rotation of the release handle 1232 until the point when counterclockwise stop faces 1247 come into contact with the hub edges 1213 . While rotation is thus limited, this rotation of the release handle 1232 is sufficient to pull cables 1203 and 1204 to release the latching mechanism 1200 , simply by manual rotation of the release handle 1232 . Since the cables 1203 and 1204 are in tension and subject to a resilient restoring force, this restoring force will return the release handle 1232 to the initial position of FIGS. 51 and 52 in the absence of any movement of the handle 130 . Hence, the handle 130 may be stationary and may even be locked such that rotation of handle 130 is prevented, yet the release handle 1232 still may be manually rotated counterclockwise to release the latching mechanism 1200 such as in an emergency.
[0119] The washer 1233 includes center bore 1252 ( FIG. 49 ) which has a non-circular shape corresponding to the shape of hub extension 1214 , which namely is provided with two arcuate edges and a pair of straight edges on the top and bottom thereof. This prevents any rotation of washer 1233 relative to hub 1211 during rotation of the release handle 1232 , which prevents the washer 1233 from tending to unthread the fastener 1234 . The center of the hub extension 1214 includes the fastener bore 1215 which threadedly engages the fastener 1234 for mounting the release handle 1232 on the hub 1211 . Hence, the release handle 1232 serves as a drive disk to drivingly interconnect the handle 130 to the cables 1203 and 1204 yet also is unrestrained in a second condition to permit release of such cables independently of the handle 130 and without regard to whether the handle 130 is locked.
[0120] While the release handle assembly 1200 could be replaced with direction connection between handle shaft 175 and cables 1203 and 1204 that does not provide any release function, the release handle assembly 1200 is preferred. Further, the release handle assembly 1200 may be used with or without the power module 120 .
[0121] Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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An improved locking handle and power module assembly provides continued ability to open and close a truck cap or tonneau cover from within or without, and presents an enclosed mechanism to prevent obstruction or jamming. A release handle is provided to permit unlatching of a latch mechanism operated by the locking handle without regard to whether the locking handle is locked or not.
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FIELD OF THE INVENTION
This invention relates to a metal cutting tool consisting of a tool holder and at least one cutting insert releasably retained within a pocket formed in the tool holder.
BACKGROUND OF THE INVENTION
With such a cutting tool, the or each cutting insert is releasably retained in a respective pocket formed in a tool holder by, for example, a clamping screw which extends through a central hole formed in the insert into an appropriate tapped bore formed in the tool holder or, alternatively, by some other suitable clamping system. In many cases, a metal shim is interposed between the insert and the bottom wall of the tool holder pocket, this shim serving to protect the tool holder proper from excessive wear or damage through use. Additionally, shims of differing heights can be employed so as to vary as required the specific location of the cutting insert with respect to the tool holder and in particular that of the cutting edge. In most cases where such shims are employed with screw bolted inserts, the shim is retained in position in the pocket by means of the same screw used to secure the insert, which screw passes through an aperture formed in the shim aligned with the bore of the insert. It will be readily appreciated that this method of securing the shim to the tool holder is inconvenient, particularly in view of the fact that during replacement of an insert, the shim is no longer secured to the holder and can either become lost or forgotten when the operator may forget to replace the shim.
In order to overcome this problem, and also to ensure that the shim is effectively secured to the tool holder even when the insert is retained by means other than a through-going bolt, it has been proposed, particularly in connection with milling tools, to retain the shim in position with respect to the tool holder quite independently of the releasable retention of the insert, and this by means of a special retaining pin which is inserted into the tool holder and retains the shim in position. It has been found in practice, however, that the retaining pin often becomes broken and this in itself can have undesirable consequences in the use of the cutting tool. Additionally, with shims so retained, difficulties are often encountered in releasing the shim for replacement and such replacement may become time consuming.
BRIEF SUMMARY OF THE INVENTION
It is an object of the present invention to provide a metal cutting tool with new and improved means for the retention thereon of the insert seating shim.
It is an object of the present invention to provide a metal cutting tool with new and improved means for the retention thereon of a replaceable cutting insert.
As used in the present specification, the term "replaceable element" shall be deemed to include both the replaceable cutting insert and also a replaceable insert shim where such is provided.
According to the present invention there is provided a metal cutting tool comprising a tool holder; a pocket in said tool holder defined by a pair of side walls and base walls; an elongated, tubular recess formed in said tool holder and opening into said pocket; a replaceable element having outer, base and side surfaces and a split, tubular coupling portion formed integrally with one of said surfaces and insertable, upon spring-like compression thereof, into said tubular recess so as to be retained therein.
In accordance with a preferred embodiment of the present invention, the replaceable element is constituted by an insert seating shim having an outer, substantially planar face upon which the insert is to be supported.
In accordance with another embodiment of the present invention, the replaceable element is constituted by a cutting insert.
Thus, with a metal cutting tool in accordance with the invention, the insert seating shim or cutting insert is integrally formed with means (the split, tubular coupling portion) facilitating its ready, secure, releasable mounting in the tool holder pocket without the necessity of providing for separate retaining means.
BRIEF SUMMARY OF THE DRAWINGS
For a better understanding of the present invention, and to show how the same may be carried out in practice, reference will now be made to the accompanying drawings, in which:
FIG. 1 is a perspective view of a rotary milling head (prior to the mounting thereon of cutting inserts) and constituting a cutting tool in accordance with the present invention;
FIG. 2 is a perspective view of the milling head shown in FIG. 1 with the cutting inserts mounted into position;
FIG. 3 is an exploded view on an enlarged scale of a detail of the cutting tool shown in FIG. 2;
FIG. 4 is a partially sectioned side elevation of the insert seating shim shown in FIG. 3;
FIG. 5 is a plan view from above of the seating shim shown in FIG. 4;
FIG. 6 is a side elevation of a further form of insert seating shim in accordance with the invention;
FIG. 7 is a front elevation of the seating shim shown in FIG. 6;
FIG. 8 is a plan view from above of a modified form of the seating shim in accordance with the present invention;
FIG. 9 is a side view of the seating shim shown in FIG. 8;
FIG. 10 is a side view of a milling head with a cutting insert shown seated on a seating shim as shown in FIGS. 8 and 9 of the drawings;
FIG. 11 is a cross-sectional view of a portion of the milling head shown in FIG. 10 taken along the line XI--XI;
FIG. 12 is a plan view of a seating shim blank;
FIG. 13 is a side view of the seating shim blank shown in FIG. 12;
FIG. 14 is a side view of the seating shim formed from the blank shown in FIGS. 12 and 13;
FIG. 15 is an exploded view corresponding to that shown in FIG. 3 of the drawings, wherein a modified form of seating shim and tool holder are shown;
FIG. 16 is a perspective view of a still further form of seating shim;
FIG. 17 is a plan view from above of a cutting tool incorporating a seating shim as shown in FIG. 16 of the drawings; and
FIG. 18 is a longitudinally sectioned view of the cutting tool shown in FIG. 17 taken along the line XVIII--XVIII.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference will now be made to FIGS. 1, 2 and 3 of the drawings, which illustrate the application of the invention to a cutting tool in the form of a substantially standard milling cutter head 1 which is formed with a plurality of peripherally distributed recesses 2, each recess having formed therein an insert retaining pocket 3 shown clearly in FIG. 3 of the drawings. Each pocket 3 is defined by a pair of side walls 4 and 5 and a base wall 6. An elongated tubular recess 7 is formed at the junction of the side wall 5 and the base wall 6 and opens into the pocket 3 via an elongated slot 8 which is codirectional with the linear junction of the side wall 5 and the base wall 6. Extending centrally into the base wall 6 is a tapped aperture 9.
An insert seating shim 11 is constituted by a substantially rectangular planar base portion 12 having outer, base and side surfaces and which substantially corresponds in shape and area to the base wall 6 of the pocket 3 and in which is formed a central, through-going aperture 13. Formed integrally with a side edge of the base portion 12 is a split, tubular side portion 14 which is coextensive with the edge to which it is connected.
In order to retainably locate the seating shim 11 in position in the pocket 3, the tubular side portion 14 is springily compressed and is inserted into the tubular recess 7 with the planar portion 12 projecting through the elongated slot 8. In this position, the seating shim 11 is securely retained within the pocket and is ready to have placed thereon a cutting insert 15 which is clamped thereto and to the milling head by means of a clamping screw 16. FIG. 2 shows the milling head provided with cutting inserts, each of which is seated on a seating shim of the kind shown and described with reference to FIG. 3 of the drawings.
FIGS. 6 and 7 of the drawings show a modified form of seating shim 21 having, as before, a substantially planar, rectangular base portion 22 and a split, tubular side portion 23. Additionally, the seating shim is formed integrally with an edge thereof perpendicular to the tubular side portion 23 with an abutment shoulder 24 against which an insert 25 is designed to abut when the shim is retainingly placed in position in the pocket 3.
In the embodiment shown in FIGS. 8 through 11 of the drawings, the seating shim is, as in the embodiment shown in FIGS. 6 and 7, provided with an insert abutment shoulder but in the case of this embodiment, the abutment shoulder is constituted by a portion of the split, tubular side portion. As seen in FIGS. 8 through 11, an insert seating shim 31 comprises a substantially rectangular base portion 32 having a through-going aperture 33 and having a split, tubular side portion 34 formed integrally with a side edge thereof. As distinct from the embodiment previously described, in the present embodiment the tubular side portion 34 is not coextensive with the edge of the base portion with which it is integral, but is constituted by a first section 35 which is formed integrally with a portion of the side edge of the base portion 32 and a second section 36 which projects beyond the side edge of the base portion 32. As seen in FIG. 11 of the drawings, a tool pocket 3' is formed with an inwardly extending tubular recess 37 into which the tubular side portion section 36 is inserted so as to retain in position the shim 31 within the pocket 3'. As can be clearly seen in FIG. 10 of the drawings, with this construction the tubular side portion section 36 constitutes an abutment shoulder for an insert 15 which rests on the seating shim 31 and is secured thereto by the clamping screw 16.
Whilst in the embodiments specifically described above, the seating shim together with its integrally formed side portion are produced by suitable casting, in the embodiment shown in FIGS. 12, 13 and 14 of the drawings a seating shim blank 41 constituted by a substantially rectangular base portion 42, with which is integrally formed a side blank 43 also of substantially rectangular shape. The side blank 43 is joined to the base portion 42 via an intermediate tapering portion 44. As can be clearly seen in FIG. 14 of the drawings, when the side blank 43 is bent into a substantially circular shape, it effectively constitutes the split, tubular side portion which can be used, upon insertion into a corresponding tubular recess, for the retention of the seating shim in the pocket.
In the modification shown in FIG. 15 of the drawings, a seating shim 51 is formed with a split tubular coupling element 52 which is integral with a corner of the seating shim 51 via a neck portion 53. As before, a tool holder 54 is formed with a retaining pocket 55 defined by a base wall 56 and a pair of side walls 57 and 58. At the intersection of the walls 57 and 58 is formed a tubular recess 59 which opens into the pocket via a narrow slot 60.
In order to retainably locate the seating shim 51 in position in the pocket 55, the tubular coupling element 52 is springily compressed and is inserted into the tubular recess 59 with the neck portion 53 projecting through the slot 60. In this position, the seating shim 51 is securely retained within the pocket 55 and is ready to have placed thereon a cutting insert 61 which is clamped thereto and to the tool holder 54 by means of a clamping screw 62.
In the further modification shown in FIGS. 16, 17 and 18 of the drawings, a seating shim 65 is formed with a central, downwardly depending, split tubular coupling element 66. A tool holder 67 (in this example, of a turning or grooving tool) is formed with a pocket having a base wall 68 and a pair of side walls 69 and 70. A tubular recess 71 is formed in the base wall 68 corresponding in crosssectional shape to that of the coupling element 66, this tubular recess being coaxial with and constituting an extension of a tapped clamping bore 72.
The seating shim 65 is placed in position within the pocket by springily compressing the tubular coupling element 66 which is then inserted into the correspondingly shaped tubular recess 71 to prevent relative rotational displacement of the seating shim 65 with respect to the tool holder 67. A cutting insert 73 is placed on the seating shim 65 with a pair of side walls thereof abutting the side walls 69 and 70 of the pocket. The insert 73 and seating shim 65 are then clamped in position by means of a clamping screw 74 which is screwed into the clamping bore 72.
Whilst in the embodiments specifically described and illustrated above the seating shim has been provided with a throughgoing aperture it will be readily appreciated that this is not essential seeing that retention and clamping is quite independent of a throughgoing screw or bolt. Furthermore, whilst the invention has been specifically described when applied to milling tools the invention is equally applicable in the case of other cutting tools such as those used in turning, drilling and parting off operations and the like.
Although the invention has been specifically described as applied to an insert seating shim, the principle underlying the retention means as described with reference to the seating shim can be readily applied to the retention of the cutting insert itself. Thus, the cutting insert can be provided with an integrally formed split tubular coupling element which can be retained within a corresponding tubular recess formed in the tool holder. In this connection, inserts with integrally formed, split tubular coupling elements corresponding in general shape to the shims shown in FIGS. 4, 5; FIG. 15; and FIGS. 16, 17 and 18, can be employed.
It will be readily appreciated that, by virtue of the specific construction of the seating shim in accordance with the present invention and its use in conjunction with metal cutting tools provided with an appropriate recess for receiving the integrally formed tubular attachment of the seating shim, the disadvantages accompanying the use of known seating shims, such as the necessity for providing separate attaching means, are completely avoided or overcome.
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A metal cutting tool having a tool holder and a pocket formed in the tool holder in which an insert is to be replaceably retained, there being formed in the tool holder an elongated tubular recess which opens into the pocket and there being furthermore provided a replaceable element having a split tubular coupling portion formed integrally therewith so as to be insertable upon spring-like compression into the tubular recess. This replaceable element is preferably constituted by an insert seating shim.
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CROSS REFERENCE TO RELATED APPLICATION elongated direction
This application is related to U.S. application Ser. No. 07/663,3451, filed on even date herewith in the names of Bryan Beaman et al and entitled "Z-Axis Dimensional Control in Manufacturing an LED Printhead."
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates, in general, to non-impact printheads and more specifically, to optical printheads such as LED printheads for use in copiers, duplicators and printers.
2. Description of the Prior Art
Optical printheads are used in copiers, duplicators and printers to expose a photoconductive surface or film in the apparatus in such a manner that a latent image is formed on the film. The image is later developed and transferred to paper for producing a hard copy output from the apparatus. Normally, optical printheads use light-emitting diodes (LED's) to generate or produce the radiation necessary to expose the photoconductive film. Such printheads may also be used to expose photographic film or other photosensitive materials. In conventional printheads, the LED's are arranged in a linear array of LED's having a designed density to provide a resolution of a predetermined number of dots per inch. In other words, the greater the number of dots per inch desired to be printed, the greater will be the number of LED's grouped together in a linear length. In high resolution printheads, the requirements for the spacing between the LED's becomes critical.
In most cases, the LED's are provided on separate chip assemblies with each chip having several LED's such as 128 per chip. Printheads having several thousands LED's in a linear array, therefore, require many chips to construct such an array. Since any spacing between the chips which is greater than the spacing between the individual LED segments on each chip will produce undesirable prints or copies, it has been disirable, according to the prior art, to mount the chips as closely to the specified pitch between adjacent LED's as possible. With lower resolution systems, this has not become a major problem. However, with the desire to go to higher resolution printing, and thus more closely spaced LED's, the spacing in the printhead between the LED chips is of critical significance. Not only is it a mechanical problem in spacing the LED chips, it becomes a problem of thermal expansion since printheads can develop a considerable amount of heat. Thus, regardless of the ability to position the LED chips close together because of the structure of the chips, unless some means for compensating for the expansion of the printhead due to changes in temperature are present, a satisfactory printhead cannot be obtained for high resolution printing.
Thermal expansion of the printhead elements also can cause mechanical failure between the bonds of various members and surfaces within the printhead. In order to prevent this type of failure, it is necessary to allow for the difference in the thermal coefficient of expansion of the various members and materials used to construct the printhead. Therefore, it is desirable to provide an optical printhead which can have the LED's arranged for high density printing and which can compensate for or tolerate materials in the construction of the printhead having significantly different coefficients of thermal expansion.
There is disclosed in U.S. Pat. No. 4,821,051 an optical LED printhead. The printhead includes a main printed circuit board having a rectangular opening therein. Modular daughter boards, or tiles, are arranged within the rectangular opening of the printed circuit board. Each of these tiles includes chips and circuitry containing a string of light-emitting diodes. The tiles are constructed of a stainless steel material with a gold coating having a thermal coefficient of expansion substantially the same as that of the elements and chips bonded thereto to form the circuit on the tile. Interconnection between the circuits is accomplished by small jumper wires.
Each of the separate modular tiles used to construct the optical printhead is bonded to a backing plate, or mother board, which is also constructed of stainless steel to match the thermal coefficient of expansion of the individual tiles. The backing plate is mounted underneath the printed circuit board and between the printed circuit board and a rigid aluminum heatsink or heat-dissipating structure with a precise flat mounting surface which is used to remove heat from the printhead elements. In order to provide a workable system even though the thermal coefficients of expansion of the heatsink and the backing plate are different, a system of guides and pins is used. This permits relative movement between the backing plate and the heatsink but limits the direction of this movement so that it will be consistent with the alignment of the LED's.
In an improvement described in U.S. application Ser. No. 07/455,125, filed Dec. 22, 1989 the main printed circuit is eliminated and signal distribution is accomplished by daisy-chaining signals from one tile to the next tile through interconnection of corresponding spreader boards located on each tile.
While the above constructions work well, it is an object of the invention to further simplify construction of such LED printheads.
SUMMARY OF THE INVENTION
These and other objects which will become apparent from reading of the description provided below are realized by a non-impact printhead assembly, comprising: a plurality of modular circuit assemblies each including a plurality of recording elements and associated integrated circuit drivers; a plurality of circuit assembly mounting tiles; a rail mounted to said tiles; a heatsink for supporting the tiles; and means engaging the rail for resiliently urging the tiles into intimate thermal coupling with the heatsink.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view shown in schematic of a printhead assembled in accordance with the invention;
FIG 2 is a section of the printhead taken along the line A--A of FIG. 1;
FIG. 3 is an enlarged section of a portion of the printhead illustrated in FIg. 2; and
FIG. 4 is a view similar to that of FIG. 3, but illustrates an alternative embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Because apparatus of the type described herein are well known, the present description will be directed in particular to elements forming part of or cooperating more directly with the present invention.
With reference to FIG. 1-3, an LED printhead 10 is formed using a series of tile modules 20a, b, . . . l, m. Tile module 20a is typical and has a series of gallium arsenide or gallium aluminum arsenide LED dice 30a, 30b, 30c mounted end to end to form a row of such dice on a central axis of the front face of the tile. To each side of the row of dice, there will be provided a corresponding number of integrated circuit silicon driver chips 40a,b,c and 42a,b,c so that two driver chips are associated with each LED die. Typically, an LED die 30 may have say 128 LED's arranged in say a row so that each driver chip 40, 42 drives 64 of the LED's formed within a corresponding die. Also, typically, the silicon driver chips each have 64 channels, i.e. current-generating circuits that may provide regulated driving currents to respective LED'S that are selected to be activated. Printed circuit or spreader boards 36a, 36b are mounted to the front face of the tile to provide a means for distribution of electrical signals such as data, power and clock signals to the driver chips. A specific spreader board that is preferred is described in U.S. application Ser. No. 07/455,125, filed Dec. 22, 1989. The spreader boards will be located on the tile to the outboard side of each row of driver chips.
The spreader boards each include a series of bond pads 38a, 38b along opposite edges thereof for connection of signals to adjacent spreader boards or to termination boards 50, 52 that are present at the ends of printhead 10.
As noted with more detail in U.S. application Ser. No. 07/455,125, bus bar assemblies 60a, 60b are provided for carrying power and ground signals along the length of the printhead to the various spreader boards for distribution of such signals to the various driver chips. Only tile module 20a is illustrated to show the various components mounted on the tile. In addition to the illustrated components, there will be bonding wires for connecting such components together.
As may be seen in FIG. 2, the tiles 20 are mounted upon stainless steel rails 70a, 70b which rails extend for the length of the printhead; i.e., the length of the tile assemblies, so as to support the tiles thereon. The tiles are assembled one by one onto the rails 70a, 70b using adhesive. Each tile is prepared in accordance with the method described in the cross-referenced application so that the assembly of driver chips and LED dice are accurately formed on the tile. With the spreader boards and wiring also attached to the tile, the tile module may be tested and suitably burned in. Satisfactory tile modules are then carefully assembled to the metal rails 70a, 70b to ensure that all the LED's are accurately aligned in a row. Prior to placement of the tile on the rails, the rails are each covered with two different adhesives. Each rail is a two-legged rail with the inner leg receiving a two-part structural epoxy adhesive 14 that can be cured at room temperature. The outer leg of each rail receives a UV curable epoxy 12 that is promptly cured by application of UV light after each tile has been placed in position on the rails. After all the tiles have been mounted on the rails, the assembly is placed upon a heatsink 19. The heatsink surface that is to be thermally coupled to the undersides of the tiles is coated with a thermal grease 16 or in lieu thereof, a thin sheet (0.001" thick) of aluminum foil ooated with thermally eleotrioally conductive rubber that serves as a grease replacement material may be used between the heatsink and the tiles. This construction allows for thermal expansion of the tiles relative to the heatsink by allowing sliding movement between them.
In order to ensure intimate thermal coupling between the tiles and the heatsink, the tiles are spring-urged towards the heatsink using cantilevered spring steel leaf springs 85a, 85b. The leaf springs shown in FIG. 3 extend the length of the rails and are positioned each within a slot formed within each rail. As shown in FIG. 3, a bottom cover 18 for the printhead includes a central upstanding wall on either side of the sides of the heatsink. Side extensions 64 of the heatsink extend above these side walls 66. Screw holes are provided in these upstanding walls 66 and the side extensions 64 to the heatsink to allow screws, S, to connect the side extensions 64 to the bottom cover. The leaf springs 85a, 85b are also positioned between the upstanding walls 66 and the side extensions 64 of the heatsink and include apertures through which screws, S, can pass so that when clamped together by the screws, the leaf springs 85a, 85b cantileveredly extend into the slots 75a, 75b, respectively, in the rails. An offset "d" is provided between the bottom walls of the slots 75a, 75b and the top surfaces of the upstanding walls 66 prior to clamping by the screws. Upon clamping of the heatsink to the upstanding wall 66 by tightening of the screws, S, the leaf springs are flattened between the upstanding wall 66 and the side extensions 64 of the heatsink. The cantilevered portions of the leaf springs in slots 75a, 75b distort to urge the rails downwardly in FIG. 3 thereby resiliently urging the tiles into thermal coupling with the heatsink.
While only two screws are illustrated in the Figures, it will be understood that there are a series of the screws provided and spaced along the length of the printhead beneath every other tile. As may be seen in FIGS. 1 and 2, the rails each include two depending pins, P1, P2, P3, P4, at their respective ends that engage within recesses formed in the bottom cover member. Two diagonally opposite recesses R1, R4, formed in the bottom cover are slots, one (R1) elongated in the direction of the printhead, the other (R4) elonqated in a direotion transverse to this dimension. These recesses allow the tile and rail assemblage to shift relative to the bottom cover and heatsink during operation of the printhead wherein the thermal expansion occurs.
If desired, the heatsink may be adhesively attached to the tiles using a thermally conductive adhesive. In addition, a lens such as a Selfoc lens, trademark of Nippon Sheet Glass Company, Ltd., is used to focus light from the LED's and a glass cover plate placed over the bottom of member to seal the assembly from dust.
While a preferred embodiment has been described with reference to stainless steel rails and spring steel leaf springs, other materials may be used; for example, the rails may be aluminum and the leaf springs may be formed of a beryllium copper. The materials used depend on the anticipated temperature ranges of operation.
An alternative embodiment is illustrated in FIG. 4 wherein reference numerals indicated with a prime refer to similar parts to that described for FIG. 3. In the embodiment of FIG. 4, a leaf spring 85a' is rigidly attached to a rail 70a' by screws, S'. The side extensions 64' of the heatsink engage the cantilevered end of the leaf spring to urge the rail downwardly and, thus, the tiles such as tile 20b, are urged or biased towards the heatsink. A similar arrangement is provided on the opposite side of the heatsink. In this embodiment the rail and spring could be assembled and the heatsink slid in from the end.
It will be appreciated that an improved printhead has been provided that is of relatively simple structure and provides for thermal considerations of the various parts of the assemblage.
While the invention has been described with reference to recording elements such as LED's, other recording elements such as laser diodes, ink jet, thermal, light valve, etc. may also make use of the teachings contained herein.
The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
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A non-impact printhead such as an LED printhead includes a plurality of modular circuit assemblies, each including a plurality of recording elements and associated integrated circuit drivers. Each modular circuit assembly is mounted upon a tile. Rails are attached to the underside of the tiles to join the tiles together. A heatsink supports the tiles. The tiles are urged into engagement with the heatsink by cantilevered leaf springs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/361,627, filed Feb. 11, 2003 now U.S. Pat. No. 7,102,286 which claims the benefit of Japanese Patent Application No. 2002-116038 filed on Apr. 18, 2002, in the Japanese Patent Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plasma display panel (PDP) having a dielectric layer that covers display electrodes and a partition that divides a discharge space.
It is desired that a PDP has a panel structure suitable for a display with high luminance and high resolution.
2. Description of the Related Art
A surface discharge type is adopted for an AC type PDP for a color display. According to this surface discharge type, in display discharge for securing luminance, display electrodes to be anodes and cathodes are arranged in parallel on a front or a back substrate, and address electrodes are arranged so as to cross pairs of display electrodes. The surface discharge type PDP needs a partition for localizing discharge in the longitudinal direction of a display electrode (i.e., the row direction). As a simplest partition pattern that has a good productivity, a so-called stripe pattern is known well, in which band-like partitions that are linear in a plan view are arranged at boundaries between columns of a matrix display.
There is an arrangement form of the display electrodes in the surface discharge type, in which the number of rows N plus one of display electrodes are arranged substantially at a constant pitch. In this form, neighboring display electrodes make an electrode pair for surface discharge, and each of the display electrodes except both ends of the arrangement works for an odd row and an even row in a display. This form has an advantage in high definition (reduction of a row pitch) and in effective usage of a display screen.
In the conventional PDP that has display electrodes arranged at a pitch equal to the pitch of the partitions of the stripe pattern, an odd row display and an even row display share one display electrode. Accordingly, a display form is limited to an interlace form. In the interlace form, a half of the total number of rows in a whole screen are not used for a display in each of odd and even fields in such a way that even rows are not lighted in an odd field. Therefore, luminance in the interlace form is lower than that in the progressive form. In addition, since the interlace form causes flickers in a display of a still picture, it is difficult to satisfy the request of a display quality that is necessary for a high quality image device such as a DVD or a full-spec HDTV.
A display of the progressive form can be achieved by adopting a partition having a mesh pattern that divides a discharge space into cells. However, a PDP having a mesh pattern partition has a low productivity of filling a gas in the manufacturing process. Since an inner resistance to ventilation is large, vacuum exhaustion process needs a long time.
In order to reduce the resistance to ventilation, there is a method of cutting off the partition in part. Alternatively, the structure disclosed in Japanese unexamined patent publication No. 2001-216903, in which the dielectric layer is raised in part, has a sufficient ventilation path. However, the method of cutting off the partition or raising the dielectric layer in part causes increase of manufacturing steps and a cost of the product.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a PDP having a structure suitable for a progressive display with high definition and a good productivity.
According to one aspect of the present invention, a dielectric layer that covers display electrodes is made a layer whose surface has projections and depressions along undulations of the surface on which the dielectric layer is formed, and a partition is disposed so as to face the projections of the surface of the dielectric layer. The surface layer of the dielectric layer has a step corresponding to the thickness of the display electrode, and a gap corresponding to the step size is formed as a ventilation path between the partition and the dielectric layer. The ventilation path enables exhausting process in manufacturing a PDP to be efficient. Even if the partition has a mesh pattern, the ventilation path enables the exhausting process to be performed quickly. This means that the cell structure is suitable for stabilizing discharge characteristics by cleaning the inside sufficiently. As a method for forming the dielectric layer, a plasma chemical vapor deposition process is suitable. Since the layer that is formed by this process covers groundwork in an isotropic manner, a special process for forming a ventilation path is not required.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing a cell structure of a PDP according to a first embodiment.
FIG. 2 is a diagram showing an electrode structure of the PDP according to the first embodiment.
FIG. 3 is a cross section showing an inner structure of the PDP according to the first embodiment.
FIG. 4 is a plan view showing an electrode structure of a PDP according to a second embodiment.
FIG. 5 is a cross section showing an inner structure of the PDP according to the second embodiment.
FIG. 6 is a plan view showing an electrode structure of a PDP according to a third embodiment.
FIG. 7 is a cross section showing an inner structure of the PDP according to the third embodiment.
FIG. 8 is a plan view showing an electrode structure of a PDP according to a fourth embodiment.
FIG. 9 is a cross section showing an inner structure of the PDP according to the fourth embodiment.
FIG. 10 is a plan view showing an electrode structure of a PDP according to a fifth embodiment.
FIG. 11 is a cross section showing an inner structure of the PDP according to the fifth embodiment.
FIG. 12 is a plan view showing a partition pattern and display electrodes of a PDP according to a sixth embodiment.
FIG. 13 is a plan view showing a partition pattern and display electrodes of a PDP according to a seventh embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be explained more in detail with reference to embodiments and drawings.
FIG. 1 shows a cell structure of a PDP according to a first embodiment, and FIG. 2 shows an electrode structure of the PDP according to the first embodiment. The PDP 1 comprises a pair of substrate structural bodies (a structure of a substrate on which cell elements are disposed) 10 and 20 . Display electrodes X and Y are arranged at a pitch equal to a row pitch on the inner surface of a glass substrate 11 that is a base of the front substrate structural body 10 . The row means a set of cells having the same order in the column direction. Each of the display electrodes X and Y is made of a linear band-like transparent conductive film 41 for forming a surface discharge gap and a metal film (a bus conductor) 42 that is overlaid on the transparent conductive film 41 at the middle in the column direction. The metal film 42 is drawn out to the outside of the display screen so as to be connected to a driver circuit. The display electrodes X and Y are covered with a dielectric layer 17 , which is coated with a protection film 18 made of a magnesia (MgO). Address electrodes A are arranged on the inner surface of a glass substrate 21 that is a base of the back substrate structural body 20 so that one address electrode corresponds to one column, and the address electrodes A are covered with a dielectric layer 24 . On the dielectric layer 24 , a mesh pattern partition 29 having the height of approximately 150 microns is arranged. The partition 29 has a grid pattern in a plan view comprising a first portion dividing a discharge space into columns (hereinafter referred to as vertical walls) 291 and a second portion dividing the discharge space into rows (hereinafter referred to as horizontal walls) 292 . In addition, fluorescent material layers 28 R, 28 G and 28 B of red, green and blue colors for a color display are arranged so as to cover the surface of the dielectric layer 24 and side faces of the partition 29 . Italic letters (R, G and B) in FIG. 1 indicate light emission colors of the fluorescent materials. The color arrangement has a repeating pattern of red, green and blue colors in which cells in a column have the same color. The fluorescent material layers 28 R, 28 G and 28 B emit light when being excited by ultraviolet rays emitted by the discharge gas. As shown in FIG. 2 , the metal film 42 is arranged so as to overlap the horizontal wall 292 of the partition 29 , and the transparent conductive film 41 protrudes at both sides of the horizontal wall 292 so as to form a surface discharge gap for each cell in cooperation with the neighboring transparent conductive film 41 . In FIG. 2 , four cells 51 R, 51 G, 52 R and 52 G are shown by dot-dashed lines as representatives. Since the partition pattern is a mesh or grid pattern, which is different from a stripe pattern in which horizontal walls are omitted, discharge interference does not occur in the column direction. Namely, in the PDP 1 , a progressive display can be realized without a complicated driving sequence. In addition, the fluorescent material is provided also at the side faces of the horizontal wall 292 , so that the light emission efficiency is improved. By arranging the metal films 42 of the display electrodes X and Y so as to overlap the horizontal wall 292 , light shielding of display light by the metal film 42 can be eliminated. As a result, 10-20% improvement can be recognized.
FIG. 3 is a cross section showing an inner structure of the PDP according to the first embodiment. In the PDP 1 , the transparent conductive film 41 is made of ITO, whose thickness is 0.1 microns. The metal film 42 is made of three layers including chromium (Cr), copper (Cu) and chromium, and its thickness is set to a value within the range of 2-4 microns. The dielectric layer 17 is made of silicon dioxide (SiO 2 ) and is formed at a constant thickness by the plasma CVD process. The thickness of the dielectric layer 17 is preferably a value within the range of 5-10 microns. As shown in FIG. 3 , the dielectric layer 17 has surface in which the projections and depressions of the forming surface (a part of the substrate surface and the surface of the display electrode) are reproduced faithfully. This is a feature that cannot be obtained by a usual forming process in which a paste is applied before burning. Since the surface of the dielectric layer 17 has projections and depressions, a gap to be a ventilation path 37 is formed between neighboring display electrodes X and Y The ventilation path 37 crosses over the vertical wall 291 and is continuous over a plurality of cells arranged along the display electrode. The size of the ventilation path 37 in the direction of the thickness of the substrate is 2-4 microns, substantially the same as the thickness of the metal film 42 and is sufficiently larger than the roughness of the surface of the dielectric layer 17 (measured value is approximately one micron). Because of this ventilation path 37 , the time necessary for exhaustion in producing the PDP 1 is similar to the conventional PDP having the stripe pattern partition. Supposing that the display electrodes X and Y are thick film electrodes (such as silver electrodes) having the thickness of 8-10 microns, the time for exhaustion can be shortened so that cost efficiency of the production can be improved.
FIG. 4 is a plan view showing an electrode structure of a PDP according to a second embodiment. FIG. 5 is a cross section showing an inner structure of the PDP according to the second embodiment. Each of display electrodes Xb and Yb of the PDP 1 b is made of an I-shaped transparent conductive film 41 b arranged at each column and a linear band-like metal film 42 . The display electrodes Xb and Yb are covered with a dielectric layer 17 b and a protection film 18 b . Since a gap to be a ventilation path 37 b is formed between neighboring display electrodes Xb and Yb also in the PDP 1 b , rapid exhaustion can be performed in its production. The transparent conductive film 41 b is disposed so that the portion protruding from the metal film 42 is like a t-shape. Thus, discharge current is limited, so that light emission efficiency is improved, and capacitance between electrodes can be reduced.
FIG. 6 is a plan view showing an electrode structure of a PDP according to a third embodiment. FIG. 7 is a cross section showing an inner structure of the PDP according to the third embodiment. Each of display electrodes Xc and Yc of the PDP 1 c is made of a T-shaped transparent conductive film 41 c arranged at each column and a linear band-like metal film 42 c . The display electrodes Xc and Yc are covered with a dielectric layer 17 c and a protection film 18 c . Since a gap to be a ventilation path 37 c is formed between neighboring display electrodes Xc and Yc also in the PDP 1 c , rapid exhaustion can be performed in its production. Since the display electrodes Xc and Yc are independent for each row, a progressive display can be driven easily.
FIG. 8 is a plan view showing an electrode structure of a PDP according to a fourth embodiment. FIG. 9 is a cross section showing an inner structure of the PDP according to the fourth embodiment. Each of display electrodes Xd and Yd of the PDP 2 is made of a band-like metal film that is patterned in a shape having a gap that restricts discharge current. The display electrodes Xd and Yd are covered with a dielectric layer 17 d and a protection film 18 d . Since a gap to be a ventilation path 38 is formed between neighboring display electrodes Xd and Yd also in the PDP 2 , rapid exhaustion can be performed in its production.
FIG. 10 is a plan view showing an electrode structure of a PDP according to a fifth embodiment. FIG. 11 is a cross section showing an inner structure of the PDP according to the fifth embodiment. Each of display electrodes Xe and Ye of the PDP 2 b is made of a linear band-like metal film. The display electrodes Xe and Ye are covered with a dielectric layer 17 e and a protection film 18 e . Since a gap to be a ventilation path 38 b is formed between neighboring display electrodes Xe and Ye also in the PDP 2 b , rapid exhaustion can be performed in its production.
FIG. 12 is a plan view showing a partition pattern and display electrodes of a PDP according to a sixth embodiment. The pattern of a partition 29 f of the PDP 3 is a honeycomb pattern that is a type of the mesh pattern, and the shape of a cell is a hexagon. Each of display electrodes Xf and Yf is made of a linear band-like transparent conductive film 41 f and a band-like metal film 42 f that is meandering along the partition 29 f so as to minimize light shield.
FIG. 13 is a plan view showing a partition pattern and display electrodes of a PDP according to a seventh embodiment. The partition pattern of the PDP 3 b is a stripe pattern made of a meandering band-like partition 29 g . The partition 29 g is arranged so as to form a column space in which wide portions and narrow portions are arranged alternately. Since the partition pattern of the PDP 3 b is a stripe pattern, ventilation is free in the column direction crossing the display electrodes Xf and Yf. The ventilation path, which is formed by forming a dielectric layer similar to the above-mentioned embodiment, causes air flow in the direction along the display electrodes Xf and Yf, so that ventilation is performed rapidly.
While the presently preferred embodiments of the present invention have been shown and described, it will be understood that the present invention is not limited thereto, and that various changes and modifications may be made by those skilled in the art without departing from the scope of the invention as set forth in the appended claims.
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A plasma display panel having a structure that enables high definition progressive display and has good productivity is provided. A dielectric layer that covers display electrodes is made a layer whose surface has projections and depressions along undulations of the surface on which the dielectric layer is formed. A partition is arranged so as to face the projections of the surface of the dielectric layer for ensuring a ventilation path for exhausting air.
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BACKGROUND OF THE INVENTION
Electrically controlled audible devices are so ubiquitous that the casual hearer seldom considers the wide range and quality of sounds that are produced by the various devices. Audible devices may include common doorbells, chimes, fire alarms, police or fire sirens, and many other varieties which will occur to one who listens with discrimination. In order to be able to describe the various types of sounds that are produced, an attempt has been made, within the industry, to assign names to the various sounds. These names have included: fast whoop; slow whoop; wail; horn; hi-lo; chimes; yeow; ding-dong; bell; warble; yelp; beep; and stutter. Other and/or alternate names have also been employed. At least on a local basis, certain types of audible sounds have become associated with certain emergency conditions or activities. For example, although there may not be an entirely universal sound for police sirens, it is conventional for all police vehicles, in any given locality, to employ an identical sound. By convention, anyone else needing an alarm sound would employ a different tone. Thus, the fire fighting vehicles, ambulances, and air raid warning signals would all have a different characteristic making it easy for the hearer to identify the meaning of the sound. Within large buildings such as offices, factories, department stores, hospitals, schools, etc., it is often desirable to be able to produce different tones indicative of selected conditions. For example, it might be desirable to use audible devices to indicate such conditions as: start time; end time; change time; lunch time; stand by for voice message; evacuate the building; fire alarm; dangerous condition; or any number of other conditions which it may be desirable to signal by audio device according to the needs and operation of the facility.
In those situations wherein it is desirable to be able to selectively produce one of a plurality of different audio signals, it is convenient and economical to be able to produce the full range of audio signals with a single device thereby eliminating the need for multiple devices and control systems. Systems with these features and characteristics are not broadly new and are believed to be too familiar to require further elaboration.
The present invention relates to a convenient, compact, and economical device which is capable of selectively producing any one of a plurality of distinguishable, audible signals. U.S. Pat. No. 4,065,767 issued Dec. 27, 1977 to Jacob Neuhof et al. and assigned to the same assignee as the present invention discloses a programmable electronic siren and the means for controlling it. While the present invention may have some features and characteristics in common with the cited patent, it will be shown that the structure of the present invention includes numerous features and characteristics combined with convenience and economy which are not available in the prior art. Other devices having some features or characteristics in common with the present invention are disclosed in the following patents:
U.S. Pat. No. 3,137,846 issued June 16, 1964 to H. G. Keeling and entitled Electronic Siren;
U.S. Pat. No. 3,882,275 issued May 6, 1975 to G. S. Carroll and entitled Sound Communication System;
U.S. Pat. No. 3,889,256 issued June 10, 1975 to R. F. Sieslak et al and entitled Automatic Control for Audible Electronic Warning System;
U.S. Pat. No. 3,905,016 issued Sept. 9, 1975 to C. J. Peterson and entitled Reverse Signal Alarm System;
U.S. Pat. No. 3,981,007 issued Sept. 14, 1976 to R. F. Sieslak et al and entitled Industrial Control for Audible Electronic Warning System; and
U.S. Pat. No. 4,016,496 issued Apr. 5, 1977 to P. Eastcott and entitled Method and Apparatus for Producing Ramp Signals with Rounded Inflection Points.
SUMMARY OF THE INVENTION
The present invention comprises a stand alone multiple tone audible signaling device capable of selectively producing one of a plurality of distinguishable signals, amplifying the signal, and producing an audible sound through a speaker. While the unit may have wide utility, it is anticipated that it will find primary application in industrial locations where high audible output and solid state reliability are advantageous. The unit operates from a local power supply and is capable of producing a plurality of unique and readily distinguishable audio signals. Obviously the number of signals that may be produced is a matter of design choice, but the commercial application of this invention is capable of producing 13 different audible signals. Some models may be able to produce all 13 signals while others may produce a lesser number at least some of which may be selectively controlled to be any one of the plurality of available signals. The system includes a power supply, a speaker, an audio amplifier, a microcomputer, and a control circuit.
From the foregoing, it will be seen that it is a principal object of the invention to provide a stand alone audible signaling device with multiple tone generating capability.
It is a more specific object of the invention to provide an audible signaling device with multiple tone generating capability wherein the tone generated may be selectively controlled. It is another object of the invention to provide an audible signaling device of the type described which employs a microcomputer for the production of electronic signals, which when amplified, produce the desired audible signals.
It is another object of the invention to exercise control over the microcomputer so that signals indicative of the desired output audible signal will be reproduced in response to selected input signals.
It is another object of the invention to provide a start control means wherein a signal indicating that a predetermined audible tone should be produced will take priority and terminate any signal being produced and originate the priority signal.
It is another object of the invention to provide start control means for permitting an input signal on a predetermined signal lead to initiate the sounding of any one of the plurality of available audible signals.
It is another object of the invention to be able to produce both percussive and non-percussive signals.
It is yet another object of the invention to initiate a reset pulse to the microcomputer in response to the initial application of power to the system.
It is another object of the invention to be able to respond differently to output signals from the microcomputer indicative of percussive tones at repetition rates varying by at least an order of magnitude.
It is yet another object of the invention to include output signal control means for distinguishing between output signals from the microcomputer indicative of percussive and non-percussive tones.
Other features, objects, and advantages of the invention will readily become apparent as the following description proceeds.
BRIEF DESCRIPTION OF THE DRAWING
The drawing comprises two figures which, when arranged side by side comprises a circuit diagram of the system. The circuit diagram employs conventional symbols for the various components. However, in order to further facilitate perusal and understanding of the invention, a system of designation has been employed which will aid in identifying both the character and location of the element. More specifically, when the element constitutes an electrical device, the first character of the designation will comprise a letter indicative of the nature of the device. For example, when the first letter of the designation is C, D, or R, the designated element is a capacitor, diode, or resistor, respectively. When the first letter is a T or Z, the element is a transistor, or a Zener diode, respectively. Identifiers without an initial alpha character indicate other elements such as: terminals, junctions, individual wires, or other devices. The second character of elements starting with an alpha character will give some indication of the location of the element. More specifically, when the second letter is C or M, the elements relate to a common circuit or a microcomputer, respectively. When the second character of the identifier is 1, 2, 3, or 4, the elements relate to the first, second, third, or fourth, respectively, start circuits of the start control means. When the second character of identifiers starting with an alpha character is a 5, the elements are elements in the output signal control circuit. When the numeral following an initial letter is 6, the elements are part of the regulated power supply and initial power-on reset pulse generator.
FIG. 1A includes the start control circuit and the microcomputer; and
FIG. 1B includes the output signal control circuit, the regulated power supply and initial power-on pulse generator, the audio amplifier, and the speaker.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The multi-tone signaling device of the present invention comprises a start control circuit 100 which provides input and control signals to a microcomputer 200. Output leads of the microcomputer 200 are fed to the output signal control circuit 300 and the output of this circuit is an input to an audio amplifier 400 which drives speaker 450. A regulated power supply 500 provides DC power to the system and also provides an initial reset pulse to the microcomputer 200 when the regulated power supply is originally turned on. The regulated power supply provides a DC potential having a positive potential with a nominal value of 9.1 V and a negative potential with respect to the 9.1 volts which is indicated by the conventional ground symbol. It should be understood that all points designated 9.1 V are coupled together and that all points designated as connected to ground are coupled together.
Although a single audio amplifier 400 and speaker 450 are shown, it should be understood that an audio amplifier 400 could drive a plurality of speakers 450 and furthermore, the output signal control circuit 300 could drive a plurality of audio amplifiers. Accordingly, although the system illustrated in the drawing employs a single speaker, it will be readily understood that if a plurality of speakers 450 are required, such speakers may be used with one or more audio amplifiers 400 as may be required and all speakers 450 will sound in synchronism under control of the system as described herein below.
Considering first the regulated power supply and initial power-on reset pulse generator, there will be seen an AC power supply 510 which is coupled to a transformer 520 feeding a diode bridge 530. As may be seen, one terminal of the output of the diode bridge 530 is coupled to ground and the other terminal 531 is coupled to the audio amplifier 400 and to the remainder of the power supply 500. When the power is first turned on, the potential at terminal 531 will rise from a zero value. As the potential at terminal 531 rises, transistors T61 and T62 are turned on and the power supply terminal designated +9.1 V rises from 0 V towards 9.1 V. As the output potential of the power supply 500 rises towards the 9.1 volt value, this potential is fed to the microcomputer 200 through pin 20. This can begin to activate the microcomputer 200 and the various circuits therein may "wake-up" in any state. Accordingly, in order to set the microcomputer 200 to a predetermined state, it is necessary to provide an initial reset pulse on pin 9 of the microcomputer 200. When the system is turned off, the capacitor CM1 associated with the microcomputer 200 is discharged from ground on one side of the diode DM1 through the capacitor CM1 to ground at resistor R62. As the potential at terminal 531 rises towards the zener value of zener diode Z61, the transistor T63 will suddenly conduct and charge capacitor CM1 thereby providing a pulse at pin 9 of the microcomputer 200. The zener diode Z61 clamps the base of transistor T63 to a regulated value and thereby regulates the value of the output potential designated +9.1 v. Depending upon the characteristics of the various components, the output potential may vary somewhat from 9.1 volts.
The reset pulse provided through capacitor CM1 to pin 9 of the microcomputer 200 resets the microcomputer 200, and all the circuits therein, so that they are in a known and predetermined state ready to receive control signals and produce output signals. The diode DM1 prevents the application of a negative potential to pin 9 of the microcomputer 200 when the power 510 is turned off and there is no longer a potential at the lower terminal of the capacitor CM1.
The microcomputer 200 comprises the Texas Instrument TMS 1000 NLL Series 4-bit microcomputer. Further information concerning its input control terminals and output signals on the output terminals will be given herein below.
Multiple Tone Signals Available
The multiple-tone signaling device is capable of producing a plurality of distinct and identifiable signals. In the system shown in the drawing, 13 separate audible signals may be produced. However, it will be apparent that systems with a greater or lesser number N, of unique and distinctly different audible output signals could be produced. It is difficult to describe audible signals with words. However, names for certain types of audible signals have been used in the art and the signaling device of this invention is designed to produce audible signals usually and customarily referred to as: slow whoop; fast whoop: hi-lo; chime; yeow; ding-dong; bell; warble; siren; beep; stutter; fast siren; and horn. Of these audible signals, the chime, ding-dong, and bell have percussive sounds. The start control circuit 100, by selectively coupling together one lead from a group of three, to another lead from a group of five input control terminals to the microcomputer, will cause the microcomputer 200 to produce an output signal which will eventually cause production of the desired tone. The group of three input leads are designated K1, K2, and K4 and are coupled to pins 5, 6, and 7, respectively, of the micro-computer 200. The group of five input leads are designated J0, J1, J2, J3, and J4, and are coupled to pins 21, 22, 23, 24, and 25 of the microcomputer 200. There follows some approximate characteristics of each audible sound together with the K and J leads which must be coupled to originate the sound:
______________________________________No. Leads Sound Characteristics______________________________________1 K1 J4 Slow Whoop 600-1250 Hz upward sweep in four seconds and repeat. Duty Factor decreases 65 to 25%.2 K2 J2 Fast Whoop 600-1250 Hz upward sweep in one second and repeat. Duty Factor decreases 65 to 25%.3 K4 J0 Hi-Lo 780 and 600 Hz alternately, 0.52 seconds each. 50% duty factor.4 K2 J3 Chime Percussive 570 Hz tone damped to 0, repeated 1 per second.5 K3 J2 Yeow 1250-600 Hz downward sweep in 1.6 seconds and repeat. Duty factor 25-65%6 K4 J3 Ding-Dong Percussive pairs of 700 and 750 Hz tones, each damped to 0, re- peated in two seconds.7 K1 J3 Bell Percussive 816 Hz tone, lightly damped, reinitiated every 20.5 ms.8 K1 J1 Warble 575 and 770 Hz alternately, 87 ms each. 50% duty factor.9 K1 J2 Siren 600-1250 Hz up and down sweep in 8 seconds and repeat. 65 to 25% duty factor.10 K2 J0 Beep 470 Hz, 50% duty factor, 0.55 seconds on, 0.55 seconds off.11 K2 J1 Stutter 470 Hz, 50% duty factor, 83 ms on, 109 ms off.12 K4 J1 Fast Siren 600-1250 up and down sweep in 0.25 seconds and repeat. Duty factor 65 to 25%.13 K1 J0 Horn 470 Hz continuous, 50% duty factor.______________________________________
Start Control Circuit
The start control circuit is shown generally as 100 and as illustrated provides five input leads although other numbers could be provided. There is a common input lead 100 also designated common and four other input leads designated:
(111) Programmable optional priority
(121) Programmable
(131) #1 fixed; and
(141) #2 fixed.
Coupling the common lead 101 to any one of the other four input leads will initiate sounding of any one of the plurality of N available tones. As indicated, the programmable optional priority input lead 111 and the programmable input lead 121 may be programmed to initiate sounding of any desired one of the N available sounds. Furthermore, the programmable optional priority input lead 111 may include a priority wiring which will cause termination of any audible signal already in progress and initiation of the programmed signal. The programmable input lead 111 may be programmed to initiate sounding of any desired one of the available plurality of N audible signals. The #1 fixed and #2 fixed input leads 131 and 141, respectively, are hard-wired to originate specific audible sounds. It will be apparent that additional input leads could be provided in systems which require more than four distinct different audible sounds. As already mentioned with respect to the microcomputer, each audible sound is initiated in response to coupling together one of the K leads and one of the J leads. Thus, for example, when the common lead 101 is coupled to the #2 fixed lead, it will be shown that the K1 lead of the microcomputer is coupled to the J0 lead by rendering the conduction control device comprising transistor T41 conducting. In similar manner, the K4 lead is coupled to the J1 lead when the conduction control device comprising transistor T31 is rendered conducting. Associated with the programmable optional priority input lead 111 and with the programmable input lead 121 are switches 110 and 120, respectively. As will be seen, the emitter of transistor T11 is connected to five terminals of the switch 110 and the collector of transistor T11 is connected to three terminals of the switch 110. In like manner, the emitter and collector of transistor T21 are connected to terminals of switch 120. As may be readily visualized from the pictorial representation of the switches 110 and 120, selections means are provided for coupling together any pair of vertically opposed terminals. Accordingly, by appropriate switch actuation, the emitters of transistors T11 and T21 may be coupled to any one of the five J input leads to the microcomputer 200; and the collectors of these transistors may be selectively coupled to any one of the three K input leads of the microcomputer 200. Thus, in response to rendering transistor T11 or T21 conducting, a predetermined pair of K and J leads are coupled together to initiate a predetermined audible tone.
Considering now more specifically the circuit actuation of the start control circuit 100, it will be seen that the common lead 101 is at a predetermined potential, namely ground potential, and that capacitor CC1 is charged. T11, T21, T31, and T41 are conduction control devices comprising PNP transistors and therefore will be in a state of non-conduction unless the base is negative with respect to the emitter. The base of each transistor T11, T21, T31, and T41, is held at positive potential from the 9.1 volt supply through the resistor R11, R21, R31, and R41, respectively. In response to coupling the common lead 101 to the #1 fixed input lead, for example, it will be seen that the ground, or negative potential, on the common lead 101 will be coupled to the #1 fixed lead 131 thereby providing a negative potential on the base of transistor T31. With the base of transistor T31 at a negative potential, the state of conducton of the transistor T31 will change to conducting and the J1 lead from the microcomputer 200 will be coupled from the emitter to the collector of transistor T31 to the K4 lead of the microcomputer 200. As may be seen from the table given hereinabove, this will originate the audible sound designated fast siren. It will be apparent that if the emitter and collector of transistor T31 had been hard-wired to any other pair of K and J terminals, it would have been possible to cause the application of ground to the #1 fixed input lead 131 of the start control circuit 100 to originate actuation of any other desired audible signal. In like manner, application of ground to the #2 fixed input lead 141 of the start control circuit 100 will couple together the K1 lead and J0 lead to initiate sounding of the horn signal.
Priority Signal
If it is desired to use the priority option, the resistor RP1 will be included in the circuit. For manufacturing convenience, it may be expedient to always provide the resistor RPI and include a loop of wire which is cut when it is desired to eliminate the priority option. If the circuit for the priority system is employed and the RP1 resistor is wired as shown, it will be seen that in response to the application of ground to the programmable optional priority lead 111, ground will be applied to the base of the transistor TP1. This will render that transistor conducting and the 9.1 volt power supply potential will be coupled from the emitter to collector of transistor TP1 and through diodes D22, D32, and D42, to apply the positive power supply potential to the bases of the transistors T21, T31, and T41, respectively, thereby rendering them non-conducting. Accordingly, if any one of the transistors T21, T31, or T41, had been conducting it will be turned off and any audible signal initiated in response to the conduction of these transistors will be terminated. In addition to turning on the priority transistor TP1, the ground on the programmable optional priority input lead 111 will turn on transistor T11, thereby coupling its emitter and collector and coupling together a K and J lead in accordance with the connections made in switch 110. Accordingly, application of ground to the programmable optional priority lead 111 will terminate any audible signal in progress and initiate a priority audible signal which may be any one of the plurality of available signals as controlled by the programming of the selection means comprising switch 110.
It will be apparent that when ground is removed from any one of the input leads of the start control circuit 100, the associated transistor will be turned off and the audible signal associated therewith terminated.
Microcomputer
The microcomputer 200 serves as a signal generator and comprises a MOS/LSI 1-chip microcomputer of the TMS 1000 NLL family manufactured by the Texas Instruments Corporation. It is one of a family of P-channel MOS 4-bit microcomputers with a ROM, a RAM, and an arithmatic logic unit on a single semi-conductor chip. Tone requirement specifications determined the software that is reproduced during wafer processing by a single, level mask technique that defines a fixed ROM pattern.
The microcomputer 200 has several pin connections and pertinent ones are shown in FIG. 2. As may be seen, ground is applied to pins 4 and 8 and also through a resistor RM1 to pins 18 and 19. The positive 9.1 volt DC power supply is coupled at pin 20. As already mentioned, a reset pulse is provided at pin 9 to reset the microcomputer 200 when power is initially applied. The microcomputer 200 is capable of producing 13 unique output signals, any one of which may be selected by coupling together one of the leads from pins 5, 6, and 7 to one of the leads from pins 21 through 25. Selectively programmable means for doing this has been described with respect to the start control circuit 100.
The audible signals that are to be reproduced fall into two broad catagories, namely percussive and non-percussive. The percussive sounds are the bell, chime, and ding-dong. It should be noted that the percussive rate for the bell is high as compared with the percussive rate for the chime or ding-dong. That is, as set forth in a table hereinabove, the percussive signals for the bell are initiated every 20.5 milliseconds, while those for the chime are repeated once per second, and for the ding-dong once every 2 seconds. Thus the chime and ding-dong have repetition rates at least an order of magnitude greater than that of the bell. When the microcomputer 200 senses that the output signal is to be one of the percussive tones, a ground is placed on pin 28; and conversely, when the audible signal to be reproduced is one of the non-percussive signals, the microcomputer 200 does not connect a ground to pin 28. In addition, at the start of each cycle of audible tone a pulse is placed on pin 2 and a square wave of appropriate frequency is placed on pin 1.
The manner in which the output signals on pins 1, 2, and 28 of the microcomputer 200 are caused to produce the desired audible signals at the speaker 450 will be explained more fully in connection with the output signal control circuit 300.
Output Signal Control Circuit
The output signal control circuit 300 receives power from the regulated power supply 500 and receives input signals from pins 1, 2, and 28 of the microcomputer 200 which has signals thereon as explained with respect to the microcomputer 200. The output signal control circuit 300 operates on the signals received from the microcomputer 200 and produces an output signal on lead 350 to the audio amplifier 400 which, in turn, activates the speaker 450.
It will be observed that the conduction control device comprising transitor T52 is of the NPN type and that therefore, when the microcomputer 200 places a ground on pin 28 indicating that the output signal is a percussive signal, the ground on pin 28 will be applied through resistor R51 to hold transistor T52 turned off. Conversely, when the microcomputer 200 produces a signal indicative of non-percussive tones, pin 28 goes to a high level and the transistor T52 will be allowed to be turned on.
Time Constant Circuits
As mentioned hereinabove, the microcomputer 200 places a pulse on pin 2 at the start of each cycle of the audible signal. It will be seen that the pulse on pin 2 can pass through diodes D51 and D53 to charge capacitor C51 and C52, respectively. Capacitor C52 and resistor R56 comprise a first time constant circuit and capacitor C52 and resistor R55 comprise a second time constant circuit. Because of the relative values of these capacitors and resistors, the time constant circuit of capacitor C52 and resistor R56 provide a long time constant as compared with the time constant of the circuit comprising capacitor C51 and resistor R55. That is the product of R56 and C52 is greater than the product of C51 and R55. The function of these time constant circuits will be explained more fully herein below.
Percussive Tones
As already mentioned, the system produces three audible percussive tones designated bell, ding-dong, and chime. The repetition rate of the bell is 20.5 milliseconds while the repetition rate of the chime and ding-dong are 1 and 2 seconds, respectively. It will be seen that the long time constant circuit comprising C52 and R56 will be used in connection with the ding-dong and chime and that the short time constant circuit comprising C51 and R55 will be used with the bell signal.
It is characteristic of a percussive tone that the tone decays exponentially or logarithmically. As the discussion proceeds, it will be seen that the time constant circuits are instrumental in producing the appropriate decay to simulate a percussive audible signal.
Chime and Ding-Dong Percussive Tones
When either the chime or ding-dong percussive tone is to be produced, the microcomputer 200 will place a predetermined potential such as ground on pin 28 to hold transistor T52 turned off and a pulse will be placed on pin 2 to initiate each percussive cycle. Finally, a square wave pulse of appropriate duration will be placed on pin 1. In response to the pulse on pin 2, the capacitors C51 and C52 will be charged. At the start of the pulse on pin 2, the base of transistor T51 has a high voltage placed thereon by the pulse. After the pulse has terminated, the time constant circuits described hereinabove begin to control the base potential of the transistor T51. The capacitor C51, the capacitor of the short time constant circuit, discharges rather quickly, but the capacitor C52 discharges much more slowly and controls the potential at the base of transistor T51. During this time, the diode D52 is back biased. While the capacitor C51 is discharging, the base potential of transistor T52 drops at a rapid initial rate, but when capacitor C51 is discharged and capacitor C52 is in control of the potential of the base of transistor T51, the rate of decay is reduced. It will be recalled that a square wave of an appropriate period is placed on pin 1 of the microcomputer 200 and this is applied to the collector of transistor T51 and passed to the emitter and through the diode D54 to the junction 340 between resistor R59 and diode D55. This signal is then applied on lead 350 to the audio amplifier 400. As the capacitor C52 discharges through resistor R56, the base potential of transistor T51 decays, thereby decreasing the base drive and the potential across the emitter resistor R59 decreases. The decaying voltage across resistor R59 decays at a logarithmetic rate due to the control of the time constant circuit on the base of transistor T51 and this signal is presented to the audio amplifier 400. Accordingly, the signal presented to the audio 400 is representative of a percussive tone.
The action just described will repeat for each cycle of the percussive tone which will occur at one and two second intervals for the chime and ding-dong, respectively. Obviously, the repetition rate could be different, if desired; and/or the rate of decay could be modified by a change in the time constant circuit.
Bell Percussive Tone
The bell audible tone comprises a series of percussive signals repeating approximately every 20.5 milliseconds and therefore having a pulse repetition rate more than an order of magnitude greater than that for the chime or ding-dong. The circuit functions is substantially the same manner as that described with respect to the chime and ding-dong percussive signals, except that the pulse on pin 2 to charge the capacitors of the time constant circuits is applied once every 20.5 milliseconds rather than once every one or two seconds. In this application, the time constant circuit comprising capacitor C52 and resistor R56 is relatively long, and the capacitor C52 has no significant discharge between successive pulses on pin 2 of the microcomputer 200. However, the short time constant circuit comprising capacitor C51 and resistor R55 is able to decay significantly between successive pulses on pin 2, and thereby this time constant circuit exercises control on the base of transistor T51. The base potential of transistor T51 cannot go as low with the bell tone as it did with the chime and ding-dong because capacitor C52 remains substantially fully charged. However, the base of transistor T51 does start to decline logarithmatically as capacitor C51 discharges and this produces a decaying signal at point 340 and this decaying signal simulates a bell sound.
Non-Percussive Signals
For non-percussive signals, no ground is applied to pin 28 of the microcomputer 200 and therefore, the transistor T52 is not held turned off. As before, at the start of each cycle, a pulse is placed on pin 2 thereby charging the capacitors C51 and C52 as heretofor described with respect to percussive signals. However, as will be seen, with transistor T52 conducting, the diode D54 isolates any signal passing through transistor T51 and therefore, such signals are not applied at point 340 and do not effect the audio amplifier.
With pin 28 at 9.1 volts, the transistor T52 is turned on and the square wave signal at pin 1 is divided across resistors R57 and R58 serving as voltage dividers, and the signal at the junction point provides base current to the transistor T52. Accordingly, with transistor T52 turned on, a voltage is produced across resistor R59 and the signal potential at point 340 is applied on lead 350 to the audio amplifier 400. The potential at point 340 back biases diode D54 to prevent the percussive control circuit from introducing a percussive decay on non-percussive signals. The signal at pin 1 of the microcomputer 200 for non-percussive tones is as described in a table reproduced herein before.
Miscellaneous
The capacitor CC1 in the start control circuit 100 provides a discharge path for any stray or extraneous pulses that may appear on the common lead 101. The diode DC1 prevents any stray potential which may appear on the common lead 101 from feeding back into the microcomputer circuit 200. Capacitor C11 and R11 serve as a discharge path for any stray transients that may appear. The resistor RP3 serves to limit the emitter-collector current in the priority transistor TP1. Diode DM1 is provided to discharge capacitor CM1 on a power loss, and to prevent a negative charge from being applied to the microcomputer 200.
It should be observed that the entire circuit may be packaged as a unit in a housing that is scarcely larger than that required for accommodating the speaker 450. Accordingly, there is provided a small, effective, efficient, and economical self-contained unit which may be used anywhere that a power supply is available. However, it should also be understood that rather than providing a regulated power supply circuit it would also be possible to operate the system from battery power and/or to provide a stand-by battery to operate the system in the event of a commercial power failure. Furthermore, it is also evident that the system could be redesigned using different components to function with a different voltage level.
______________________________________Typical Values of Selected Elements In The Systemohms______________________________________R11 470 C11 .001 mfR12 10K CM1 .1 mfRM1 187K C51 .1 mfR51 390K C52 .22 mfR52 10K C53 470 pfR53 22K C61 .1 mfR54 390K C62 2.2 mfR55 150KR56 910KR57 6.8KR58 2KR59 10KR61 10KR62 10KR63 10K______________________________________
While there has been shown and described what is considered at present to be a preferred embodiment of the invention, modifications thereto will readily occur to those skilled in the related arts. For example, in another structure provision might have been made for a different number of audible signals or for more or less programmable inputs and/or a different number of fixed inputs. It is believed that no further analysis or description is required and that the foregoing so fully reveals the gist of the present invention that those skilled in the applicable arts can adapt it to meet the exigencies of their specific requirements. It is not desired, therefore, that the invention be limited to the embodiments shown and described, and it is intended to cover in the appended claims all such modifications as fall within the true spirit and scope of the invention.
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A compact and economical circuit for a multitone horn employing a microcomputer. The system also includes an audio amplifier, a speaker, a power supply, and start control means. The start control means includes a common lead and a plurality of star leads. Connecting the common lead to a predetermined one of the start leads will initiate a predetermined one of the plurality of available tones. A selected one of the start leads may have priority to terminate any pre-existing signal and initiate an alternate signal. At least one of the start leads, including the priority start lead, may be coupled to programming means whereby the signal activated may be preprogrammed to be any selected one of the plurality of available signals. The power supply includes a pulse generator for resetting the microcomputer in response to initial application of power. The available tones include both percussive and non-percussive tones and the total number of available tones may be greater than the number of start leads.
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[0001] This application is a continuation of Ser. No. 10/523,973, filed on Feb. 8, 2005
FIELD OF THE INVENTION
[0002] This invention is directed to an apparatus (typically in the form of a small box) which can better distribute the smoke from a mosquito coil/candle etc or which can better distribute the vapor from a vaporizer. In a broad form, the invention is directed to a fan containing apparatus which can better distribute any type of beneficial vapor/smoke/gas etc. The beneficial action may comprise an insect repellent, a fragrance, a deodorizing agent and the like.
BACKGROUND ART
[0003] A very common way to deter or repel mosquitoes and biting insects is to place a mosquito coil or a mosquito candle in the area where the deterrent effect is required. The smoke from the mosquito coil and the vapor from the mosquito candle provides a deterrent to biting insects. A disadvantage with these coils and candles is that the effective deterrent area is not very large. If the mosquito coil or candle is placed in a closed room, it is found that the greatest deterrent occurs above the coil or candle as the smoke/vapors tend to move upwardly. Conversely, if the mosquito coil or candle is placed outside, a breeze will tend to blow the smoke/vapor away from the deterrent area.
[0004] With mosquitoes, it is noticed that mosquitoes tend to congregate in certain areas. In a room, it is noticed that mosquitoes tend to congregate about the corners of the room. However, the smoke from the mosquito coil or the vapor from a mosquito candle does not effectively extend into this area.
[0005] Many types of vaporizing devices are known. One common type of vaporizing device is electrically operated and can be plugged into a power socket. The device contains a small reservoir of liquid repellent/fragrance/deodorizing agent etc and contains a small heating device which heats the liquid or a proportion of liquid. Again, a disadvantage with this device is that the treatment area is not very large. To properly deodorize an entire room, or to provide a repelling action in an entire room, it takes a long time before the vapors/smoke extends throughout the room.
[0006] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.
OBJECT OF THE INVENTION
[0007] The present invention is directed to a simple yet extremely useful device or apparatus which can assist in dispersing the smoke from a mosquito coil, the vapor from a mosquito candle, the vapor from a vaporizer etc in a more efficient manner.
[0008] It is an object of the invention to provide an apparatus which may overcome at least some of the above-mentioned disadvantages and/or provide the public with a useful or commercial choice.
[0009] In one form, the invention resides in an apparatus to dispense a beneficial gas/smoke/vapor, the apparatus having an enclosure, the enclosure adapted to contain a gas/smoke/vapor generating device, a fan to pass air at least partially through the enclosure and to entrain at least some of the gas/smoke/vapor, an outlet through which the gas/smoke/vapor can pass.
[0010] The term “beneficial gas/smoke vapor” includes the smoke from a mosquito coil, vapors from a vaporizing device such as a candle, an electrically operated vaporizer, and other devices that generate a smoke/gas/vapor that repels, kills or otherwise deters insects, moths and other undesirable creatures.
[0011] It is preferred that an elongate tube is provided, and that the tube has at least one opening which is operatively associated with the outlet such that gas/smoke/vapor passing through the outlet passes at least partially through the tube. The tube may have a length of between 1-10 m or even more, and may have a diameter of between 5-50 mm or even more. The tube may be perforated at least partially along its length and therefore make comprise a perforated ducting. Preferably, the tube is perforated along its length which allows the smoke/gas/vapor to pass out of the perforations. The tube may comprise a tube having sections which are not perforated and sections which are perforated. The smoke/gas/vapor will pass along the non perforated section of the tube and through the openings in the perforated section of the tube. This allows the tube to be laid in such a manner that the smoke/gas/vapor only passes into a desired area. This can be achieved, if necessary, by providing separate tubes which can be fitted together with one tube not been perforated and another tube being perforated. This concept can be extended to include tube lengths having different types, sizes and numbers of perforations to control the volume of smoke/gas/vapor passing out of the tube at any particular place.
[0012] The tube, or perforated ducting, can be made of any suitable material which may include plastics. The tube is preferably sufficiently flexible to allow it to be placed in desired areas. Alternatively, the tube may be at least partially rigid, particularly where the tube forms part of a fixed system, as opposed to a portable system for the dispersion of the smoke/gas/vapor. Such a fixed system may be installed about a building for example.
[0013] The tube may have closeable openings to provide versatility to the device. This can be in the form of a collar which is slidable over the tube and which can close off some openings. Valves, taps and the like can also be present to direct the smoke to desired parts of the tube.
[0014] The tube may be substantially circular if desired although this is not necessary. Alternatively, the tube may be rectangular, oval, or have other shapes. It is considered that the tube may have a discreet or “low-profile” and this can be achieved by giving the tube a flattened oval shape, or giving the tube a rectangular shape having a low-profile.
[0015] The tube may be positioned along the ground to enable the smoke etc to be directed into a suitable region. In one form, the tube may be simply laid along the ground. However, the tube may also be suspended from a wall, post, or anchored to the ground or otherwise placed in position. Thus, the invention may also comprise fasteners, attachment, clips, or other types of accessories to enable the tube to be placed in a desired position. These fasteners etc may be separate and the tube may be attached to the fasteners; alternatively, the fasteners make comprise part of the tube or may be otherwise attached to the tube.
[0016] Suitably, the fan passes air from outside the enclosure and into the enclosure. In this manner, the smoke laden air does not pass through the fan. However, in another form, the fan may form part of a fan enclosure which has an inlet and an outlet, the inlet of the fan enclosure being in communication with the enclosure, and the outlet of the fan enclosure being in communication with the outside of the apparatus. In this version of the invention, the smoke laden air does pass through the fan.
[0017] In another form, the invention resides in an apparatus, the apparatus having a first enclosure adapted to contain a mosquito coil/candle/vaporizing device, an inlet to allow air to pass into the first enclosure, a fan enclosure which has an inlet and an outlet, a fan, the inlet of the fan enclosure being in communication with the first enclosure, and the outlet of the fan enclosure being in communication with the outside of the apparatus.
[0018] Thus, in accordance with the invention, a commercially available mosquito coil or mosquito candle can be lit and placed in the enclosure. The fan can then be started which will blow the smoke containing air more vigorously into a room/outside area etc. There is no need to provide a complicated system to produce the smoke/vapor as the apparatus allows a conventional mosquito coil, mosquito candle etc to be used.
[0019] In an extremely broad form, the invention can comprise an apparatus having a single enclosure in which the mosquito coil etc can be placed. A fan can blow air through the enclosure and through an outlet to direct smoke laden air to a desired area. The fan can be placed in the enclosure, next to the enclosure etc. The fan can be reversed such that the air can be sucked through the enclosure from the outlet and through the inlet. Other changes and modifications are envisaged.
[0020] The apparatus is typically box shaped in configuration and small enough to be placed on the ground, on a shelf, on a stand etc. However, there is no need for the apparatus to be box shaped and other types of shapes are envisaged. However, the apparatus will typically have a top wall, a bottom wall, a rear-wall, sidewalls and a front wall. The enclosure should be large enough to accommodate the mosquito coil etc which is to be placed in the enclosure. The size of this can vary to suit.
[0021] The enclosure typically has an air inlet to allow air to pass into the enclosure. The air inlet may comprise a series of perforations in one or more walls of the enclosure, although other arrangements are envisaged.
[0022] The enclosure is typically provided with some form of door/flap or other type of access means to allow the mosquito coil etc to be placed into the first enclosure. Typically, a side wall of the apparatus may be hinged to provide a door. However, it is preferred that a portion of one side wall is removable from the enclosure. This allows the apparatus to be simple in design.
[0023] It is preferred that the air inlet comprises one or more apertures in the door. Thus, the door can be seen as a vented door. However, the air inlet may be another part of the apparatus. For instance, if the fan draws air from the outside of the enclosure, the air inlet may comprise the inlet of the fan.
[0024] It is preferred that the enclosure is made of heat resistant material. This minimizes any chance of damage to the first enclosure by virtue of a mosquito candle, a lit mosquito coil etc.
[0025] In one embodiment of the invention, the apparatus may comprise a pressurized unit. In this version, the fan may have an inlet communicating with the outside of the enclosure, and an outlet communicating with the inside of the enclosure. Thus, air is blown into the inside of the enclosure causing a degree of pressurization. The enclosure may comprise an outlet through which the pressurized air can pass. The outlet may be attached to or otherwise in communication with a perforated ducting as described above. Suitably, the mosquito coil/candle/vaporizing device etc is positioned in the enclosure.
[0026] In another embodiment of the invention, the apparatus is provided with a venturi. The venturi may comprise a tube in the enclosure. One end of the tube is associated with the fan outlet such that pressurized air blows from the fan outlet and into the venturi. The other end of the venturi can be associated with the outlet. As the air blows into the venturi, it provides a region of low-pressure which sucks in adjacent air. The adjacent air comprises the smoke/gas/vapor laden air in the enclosure. An advantage of this arrangement is that smoke does not pass through the fan.
[0027] The apparatus may have a fan enclosure. The fan enclosure typically comprises a shroud about a fan, the shroud having an inlet and an outlet. Other types of arrangements are envisaged however it is preferred that the design of the fan and fan enclosure is such that there is little mixing of incoming air and exiting air as the function of the fan is to blow the smoke/vapor laden air out of the apparatus. The fan enclosure may be formed in a second enclosure of the apparatus. The second enclosure may be separated from the first enclosure and this can be achieved using a partition wall and the like. This arrangement can prevent damage to the fan. The inlet of the fan enclosure may be in communication with the first enclosure. Typically, the fan enclosure is attached to one wall of the first enclosure, and an opening is provided in the wall to allow air to pass into the inlet of the fan enclosure. If desired, a screen, filter etc may be provided. The outlet of the fan enclosure can communicate with the outside of the apparatus. In a simple form the outlet may communicate with or be part of a tube, conduit, or other type of enclosure which funnels the air passing through the outlet towards an outlet in the apparatus.
[0028] The outlet in the apparatus may comprise a valve or other type of opening. The advantage of this arrangement is that a flexible hose can be attached to the outlet. The hose may be perforated and blocked at the end to force the mosquito coil smoke etc to pass through the perforations in the hose. The hose may be several meters long and may be placed wherever necessary in a room or an outdoor area to provide a much greater repellent action than would be possible with a single mosquito coil or even a number of mosquito coils. Thus, one advantage of the apparatus is that a single mosquito coil/mosquito candle can be as effective in a larger area which previously would require a large number of candles/coils etc. Moreover, by using the flexible hose the repellent smoke/vapor etc can be channeled to precisely where needed.
[0029] Alternatively, the apparatus may be provided with a second enclosure/third enclosure and like which may be provided with an open top, an elongate slot etc to allow smoke/vapor to pass from the apparatus. While this arrangement does not contain a flexible hose, it will still disperse the smoke/vapor more efficiently.
[0030] The fan may be electrically powered. In one form of the invention, the fan may be powered by a battery. In another form of the invention, the fan may be powered by a rechargeable battery and the battery can be recharged from a power source using conventional techniques. In another form, the fan may be powered from a vehicle cigarette lighter socket, or mains power. It is envisaged that the fan may also be solar powered. It is envisaged that the fan may be a variable speed fan and some form of control knob etc can be provided to adjust the rotational speed of the fan. The fan may be controlled by an on/off switch or by any other suitable means.
[0031] The apparatus need not be limited to use with a mosquito coil, mosquito candle, an oil or any other product which is lit or burnt to provide the repellent action. For instance, the apparatus is sufficiently versatile to enable it to be used with a vaporizing device. A typical well-known vaporizing device plugs into a power socket. Therefore, the apparatus may be provided with a power socket in the first enclosure to enable a conventional vaporizing device to be simply plugged into the socket in the first enclosure.
[0032] According to an alternative embodiment, the invention resides in an apparatus to dispense a beneficial gas/smoke/vapor, the apparatus having a housing with at least one opening therein, the housing containing a gas/smoke/vapor generating device, a fan located in the housing to pass air at least partially through the enclosure and to entrain at least some of the gas/smoke/vapor, and an outlet through which the gas/smoke/vapor can pass.
[0033] As with the previous embodiments, it is preferred that an elongate perforated tube is provided, and that the tube has at least one opening which is operatively associated with the outlet such that gas/smoke/vapor passing through the outlet passes at least partially through the tube.
[0034] The housing is typically connected to a power source and provided with a control system to control the gas/smoke/vapor generating device and the fan. Typically, the control system is provided internally within the housing, with a control panel on the exterior of the housing with which to adjust and/or program the control system.
[0035] The housing is typically an enclosure having a plurality of breather openings in at least one side wall in order to draw in air from outside the enclosure with which to entrain the gas/smoke/vapor within the enclosure. Locating the fan within the enclosure forms a pressure differential between the interior of the enclosure and the exterior of the enclosure with the fan directing the gas/smoke/vapor and air into the outlet and perforated tube, thus preventing or minimizing the amount of gas/smoke/vapor which can escape through the breather openings in the housing.
[0036] Typically, the gas/smoke/vapor generating device includes a reservoir with a vaporizing means associated therewith. Normally, the reservoir and vaporizer will be a substantially closed unit with a minimal number of openings. Therefore, the device of the present invention will have the preferred configuration of a substantially closed reservoir located within the substantially enclosed housing.
[0037] Preferably, the vaporizing means is provided with an outlet which is located adjacent the fan. Thus, in use the vaporized material (gas/smoke/vapor) will either will disperse within the housing and be entrained by the air drawn in through the breather openings when the fan is operational or the air drawn into the housing by the fan will more directly entrain the vaporized material as both flow towards the fan.
[0038] In a particularly preferred embodiment, the vaporizing means may be provided as the lid (cap or closure) for the reservoir.
[0039] It is particularly preferred that the fan is provided with a fan housing again with the fan housing located with in the housing of the device. In the fan housing preferably includes at least two portions, namely a first annular portion in which the fan itself is located and a second in directing portion which communicates with the annular portion and links the annular portion with the outlet from the housing. It is preferred that the hand and fan housing are located on a rear wall of the housing, preferably above and slightly behind the reservoir. As the material within the reservoir is converted into gas/smoke/vapor, the gaseous material will normally rise, and thereby be entrained by the air entering through the breather openings in the housing.
[0040] According to a particularly preferred embodiment, the vaporizing means is spaced from the lower wall of the housing with the breather openings located at a similar level to the vaporizing means to promote the proper flow of air (and air entrained gas/smoke/vapor) to the outlet.
[0041] A portion of one side wall is removable from the enclosure to allow removal and replacement of the vaporizing means.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] Embodiments of the invention will be described with reference to the following drawings in which:
[0043] FIG. 1 illustrates an apparatus for use with a mosquito coil/mosquito candle etc.;
[0044] FIG. 2 illustrates an apparatus for use with a plug in vaporizer;
[0045] FIG. 3 illustrates a further embodiment of the apparatus in the form of a pressurized unit;
[0046] FIG. 4 illustrates a further embodiment of the apparatus containing a venture;
[0047] FIG. 5 illustrates a perspective view of an apparatus for distributing an insect repellant according to a further embodiment; and
[0048] FIG. 6 illustrates a cutaway view of an apparatus for distributing an insect repellant according to the embodiment illustrated in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0049] Referring to the drawings and initially to FIG. 1 there is illustrated an apparatus 10 which can better disperse a repellent/fragrance/deodorizing composition etc in a particular area. The apparatus 10 is substantially box like and can have a length of between 20-60 cm, a width of between 10-40 cm and a height of between 10-30 cm. These dimensions can of course vary to suit. The apparatus can be made of any suitable material but it is preferred that the material is substantially waterproof (to allow the apparatus to be used outdoors) and fireproof (to allow a mosquito candle etc. to be placed in the apparatus). Thus, the material may comprise metal, fiber cement and the like.
[0050] The apparatus has a top wall, a bottom wall, a rear wall, a pair of closed sidewalls, and a front wall, these walls being substantially continuous and attached to form a substantially enclosed container. However, the front wall comprises a door 11 . Door 11 is hinged at the top by a horizontal hinge 12 which allows the door to naturally fall into a closed position allowing the door to have a very simple yet effective design. However, the door can also be hinged by a bottom hinge, a side hinge, can be a sliding door, a clip on door or any other type of door.
[0051] The door forms one side of a first enclosure 13 . The first enclosure 13 is large enough to hold a mosquito coil/mosquito candle or any other device which is to be placed within the first enclosure. The first enclosure is defined by part of the top wall, part of the bottom wall, and part of each side wall as well as the door 11 . In the particular embodiment, the rear wall does not form part of the first enclosure. Door 11 is provided with an array of vent openings 14 to allow air to pass into the first enclosure. While this is a simple arrangement, the invention is not to be limited to this particular type of air inlet to the first enclosure.
[0052] The first enclosure 13 is also defined by an intermediate partition wall 15 . Wall 15 is provided with an opening which forms part of the inlet to the fan enclosure 16 . The partition wall 15 is spaced from rear wall 17 to form a second area 18 which is separated from the first enclosure 13 .
[0053] The second area 18 contains the fan enclosure 16 . The fan enclosure 16 is a cylindrical shroud which passes about the fan. The enclosure 16 has a fan inlet which extends into the first enclosure 13 , and a fan outlet which comprises a tapering tube 19 which tapers to an outlet 20 passing through a side wall of the container. The outlet 20 allows a flexible perforated hose 21 to be attached to the outlet. The hose 21 can have any suitable length and diameter and allows the exhaust from the fan (containing the mosquito smoke etc) to be dispersed to any suitable area simply by positioning the perforated hose in that area. This provides a real and substantial advantage over other devices.
[0054] The fan can be powered either by a 12 volt power source (typically a vehicle cigarette lighter) or by a transformer to transform mains power into a lower voltage. In the embodiment, a power socket 22 is provided on one side wall into which the cigarette lighter attachment can plug or into which the transformer can plug, providing versatility to the apparatus.
[0055] When camping, the apparatus can be placed next to a campsite and can be powered by the cigarette lighter attachment in a vehicle. The flexible hose 21 can be positioned around the area which is to be protected. In a house, the apparatus can be placed on the ground or anywhere else and the flexible hose can be placed against the wall of the room as an extremely efficient and effective deterrent. It is also found that use of the fan provides better burning of a mosquito coil by providing a continual draft of air to assist in the burning action. This again adds to the efficiency of the apparatus.
[0056] Referring to FIG. 2 , there is described an apparatus which is similar to the apparatus of FIG. 1 except that one wall of the first enclosure 13 is provided with a socket 25 to enable a plug in vaporizer 26 to be simply plugged into the socket 25 inside enclosure 13 . A fan 27 can then be operated to suck air through the first enclosure in a manner similar to that described above. In this arrangement and other compartment 28 is provided. This compartment can contain the rear portion of socket 25 and can be electrically insulated from the remainder of the container.
[0057] Referring to FIG. 3 , there is illustrated a pressurized unit. One advantage of this unit is that the smoke laden air does not pass through the fan. The unit comprises a box like housing 30 . At the bottom of the housing is a fan 31 . The fan 31 draws air into housing 30 through a number of air inlet openings 32 . The openings 32 communicate with the outside of housing 30 . A mosquito coil/candle/repellent 33 is positioned above fan 31 . This material is placed in a tray 34 . The tray is made of solid material and is positioned above fan 31 . As the fan blows air against the bottom of tray 34 , the air passes around the sides of the tray and towards outlet 35 . During this process, the smoke from the mosquito coil etc will be mixed with the air such that smoke laden air will pass through outlet 35 . Tray 34 prevents the coil etc from burning to quickly by preventing air from blowing directly against the coil. The unit can also contain a vaporizing device (not illustrated) which can be plugged into plug 36 and this can be connected to a source of electrical power in a manner already described above which may include mains power via a transformer 37 or battery power via a cigarette lighter socket 38 . Of course, other types of power sources are envisaged such as solar power etc. The outlet 35 communicates with the perforated ducting 39 already described above which allows the smoke laden air to be dispensed in any desirable place.
[0058] FIG. 4 illustrates another variation which again has the benefit of preventing smoke laden air passing through the fan. This variation can be seen as the “venturi variation”. In this variation, a venturi pipe 40 is provided, one end of which forms the outlet 41 . The perforated ducting 39 is connected to outlet 41 in a manner similar to that described above. The other end of the venturi has a flared opening 42 . The fan 43 draws air in from the outside of the unit and through a fan housing 44 which has a nozzle like outlet 45 which blows pressurized air into the flared opening 42 . By doing so, an area of low-pressure is created which sucks adjacent air through venturi 40 . The adjacent air is the smoke/vapor laden air inside the unit. The unit contains the mosquito coil/candle or a vaporizing device similar to that described above. An advantage of this arrangement is that the unit is not pressurized. Further inlet openings 45 are provided in the vented door 46 to replace air which passes through the venturi by virtue of the “venturi effect”.
[0059] The apparatus may have an alternative configuration according to an alternative embodiment as illustrated in FIGS. 5 and 6 . The apparatus illustrated in these Figures has an external housing 50 in which all components except the perforated tube 52 are contained. The housing includes a plurality of breather openings 51 in the sidewalls. The housing 50 contains a gas/smoke/vapor generating device 53 a fan 54 located in the housing 50 to pass air at least partially through the housing 50 and to entrain at least some of the gas/smoke/vapor, and an outlet 55 through which the gas/smoke/vapor can pass prior to passing through (along) the perforated tube 52 .
[0060] The housing 50 is typically connected to a power source (not illustrated) and provided with a control system to control the gas/smoke/vapor generating device 53 and the fan 54 . A circuit board 56 for the control system is provided within the housing 50 , with a control panel 60 with display 61 on the exterior of the housing 50 with which to adjust and/or program the control system.
[0061] Locating the fan 54 within the enclosure forms a pressure differential between the interior of the housing 50 and the exterior of the housing 50 with the fan 54 directing the gas/smoke/vapor and air into the outlet 55 and perforated tube 52 , thus preventing or minimizing the amount of gas/smoke/vapor which can escape through the breather openings 51 in the housing 50 . Power is provided to the device through a connection 62 to a power source.
[0062] The gas/smoke/vapor generating device according to this illustrated embodiment includes a reservoir 57 with a vaporizer 58 provided as the lid (cap or closure) for the reservoir 57 . Normally, the reservoir 57 and vaporizer 58 are provided as a closed unit with a minimal number of openings. A door 63 is provided for removal and replacement of the reservoir 57 .
[0063] The vaporizer 58 is provided with an outlet which is located adjacent the fan 54 . Thus, in use the vaporized material (gas/smoke/vapor) will either disperse within the housing 50 and be entrained by the air drawn in through the breather openings 51 when the fan 54 is operational or the air drawn into the housing 50 by the fan 54 will more directly entrain the vaporized material as both flow towards the fan 54 .
[0064] The fan 54 is provided with a fan housing 59 with the fan housing 59 located with in the housing 50 . The fan housing 59 includes a first annular portion in which the fan itself is located and a second, directing portion which communicates with the annular portion and links the annular portion with the outlet from the housing. According to the illustrated embodiment, the fan 54 and fan housing 59 are located on a rear wall of the housing 50 , above and slightly behind the reservoir 57 . As the material within the reservoir 57 is converted into gas/smoke/vapor, the gaseous material will normally rise, and thereby be entrained by the air entering through the breather openings 51 in the housing 50 .
[0065] According to the illustrated preferred embodiment, the vaporizer 58 is spaced from the lower wall of the housing 50 with the breather openings 51 located at a similar level to the vaporizer 58 to promote the proper flow of air (and air entrained gas/smoke/vapor) to the outlet 55 .
[0066] It should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.
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A fan containing apparatus has a first enclosure which can accommodate a conventional mosquito coil/mosquito candle/vaporizing device, etc. The smoke/vapors are blown by the fan through an outlet in the apparatus to provide a much better distribution of the gas/smoke/vapor into a room. A perforated hose can be attached to the outlet to provide a much better positioning of the gas/smoke/vapor in a room or outdoor area.
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FIELD
This invention relates to the field of computer based analysis of data. More particularly, this invention relates to extensible and upgradeable software analysis Structures.
BACKGROUND
Most monolithic integrated circuits are fabricated as batches of devices on a common substrate, typically referred to as a wafer. By having many such devices on a single wafer, the devices are easier to handle and fabrication costs can be reduced. Because the functional elements within each of the devices tend to be extremely small, they can be easily damaged. For example, particulate matter can be extremely detrimental to a device, regardless of whether that particulate matter is air borne or liquid borne. Any particles landing on the surface of the wafer, if they are not removed in a timely manner, may interfere with the fabrication process and cause the device to fail. In a similar fashion, scratches and other physical interferences with the desired fabrication process may also cause the devices to fail.
Because it is so important that the causes of such physical anomalies, generally referred to as defects herein, be identified and corrected as soon as possible, wafers are typically given a physical inspection at various stages of the fabrication cycle. Inspectors try to determine not only the type of defect, whether it be for example scratches or particulate matter, but also the source of the defect. In many cases the type of defect and the pattern of the defect can provide clues as to the source of the defect. Typically, such inspections have been done manually by a trained technician or engineer who studies one or more of the wafers under a microscope of some kind, searching for defects and trying to determine their origin from any clues that his experience may have taught him.
Manual inspection of each wafer is cumbersome and the results may be inaccurate and inconsistent due to factors such as fatigue, inexperience, or carelessness. Spatial signature analysis provides the ability to automatically track problems in an integrated circuit wafer process. Spatial signature analysis can be performed on wafers at different stages of the fabrication process to detect certain patterns of defects on them. Identified patterns can be mapped to a different process that the wafer underwent. For example, a defective chemical mechanical planarization process may cause long curved scratches. Thus process problems can be quickly detected automatically, without resorting to the scrutiny of a subset of the microscopic defects, which typically requires a scanning electron microscope review station. This in turn leads to quicker corrective actions, improving the yield and increasing the profit.
Unfortunately, spatial signature analysis has heretofore been a very inflexible process, and often tends to miss the forest for the trees. In other words, such automated routines have a tendency to over analyze defects individually, and do so repeatedly, without recognizing the patterns of defects that may be present. Thus, spatial signature analysis typically has a problem determining the nature of defects, tends to take too long to be used with modem equipment, and is not expandable or reconfigurable past its originally implemented capabilities and parameters. Additionally, there is no provision for users to selectively employ multiple versions of software modules within such a system, or maintain a baseline when upgrading or otherwise moving between different software modules.
What is needed, therefore, is a spatial signature analysis system that overcomes problems such as these.
SUMMARY
The above and other needs are met by a system for determining an assigned classification for a set of physical events on a substrate. Sensors sense the physical events on the substrate and produce event data. A plug in rule module manager receives and manages any number of plug in rule modules. Each plug in rule module has an input, a local filter, an analyzer, and an output. The input receives the event data and confidence values from preceding plug in rule modules. The local filter analyzes the received confidence values from the preceding plug in rule modules and selectively by passes the plug in rule module based at least in part upon the received confidence values from the preceding plug in rule modules. The analyzer analyzes the event data in view of a given classification associated with the plug in rule module, and assigns a confidence value based at least in part upon how well the event data fits the given classification. The output provides the confidence value to subsequent plug in rule modules. A post processor receives the confidence values provided by the plug in rule modules, and makes a final selection of the assigned classification to be associated with the set of physical events from the given classifications based at least in part upon a comparison of the confidence values produced by all plug in rule modules.
In this manner, as many plug in rule modules as desired may be used. However, an increasing number of plug in rule modules does not necessarily produce a commensurate increase in processing time, because the local filter for a given plug in rule module can be set to selectively by pass the given plug in rule module if a confidence value assigned by a preceding plug in rule module is high enough. Thus, processing time is not wasted by processing subsequent plug in rule modules when a sufficiently high confidence has been achieved with a preceding classification. On the other hand, because all confidences assigned by the various plug in rule modules are arbitrated by a post processor, the system does not merely select the first classification that is associated with a relatively high confidence value. Thus, both an increase in general accuracy of the classification process, and a general decrease in the processing time are achieved.
In various preferred embodiments, the input of the plug in rule module is further adapted for receiving a user specified weight value, where the weight value selectively increases and decreases the confidence value produced by the plug in rule module. The input of the plug in rule module may also be adapted for receiving a user specified contrast value, where the contrast value selectively increases and decreases a resolution of the event data from other data collected from the substrate. In addition, the input of the plug in rule module may be adapted for receiving a user specified interference value, where the interference value selectively increases and decreases a grouping of the event data.
The system preferably includes a common data storage for receiving the event data and for providing the event data to the at least one plug in rule module. A compatibility module preferably manages multiple versions of a given plug in rule module within the system. In a first embodiment, the compatibility module has a user selectable setting for always using a reference version of the given plug in rule module. In a second embodiment, the compatibility module has a user selectable setting for always using a newest version of the given plug in rule module, and for adapting output from the newest version of the given plug in rule module to have a same baseline with respect to a reference version of the given plug in rule module. In a third embodiment, the compatibility module has a user selectable setting for always using a newest version of the given plug in rule module, regardless of whether output from the newest version of the given plug in rule module has a same baseline as a reference version of the given plug in rule module.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the invention arc apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein:
FIG. 1A is a representation of a cluster having a high contrast relative to the background,
FIG. 1B is a representation of a cluster having a low contrast relative to the background,
FIG. 2A is a representation of a cluster interpreted with a high interference level,
FIG. 2B is a representation of a cluster interpreted with a low interference level,
FIG. 3 is a graphical representation of resolving clusters from the background using a contrast level,
FIG. 4A is a representation of scratches having a lower interference,
FIG. 4B is a representation of scratches having a higher interference,
FIG. 5 is a graphical representation of resolving clusters one from another using an interference level,
FIG. 6 is functional representation of a tool incorporating the system described herein, and
FIG. 7 is a functional representation of a plug in rule module as described herein.
DETAILED DESCRIPTION
Spatial signature analysis as disclosed herein provides the ability to automatically track problems in a wafer process. It involves classification of groups of events on a wafer. An event is a measurable physical characteristic on the surface of a wafer, such as a point defect whose location is known. The described system is a flexible and extendible approach to ruled based spatial signature analysis. Each rule is in the form of a plug in component. Thus, given the spatial signature analysis framework described herein, new plug ins may be released for use as they become available. This spatial signature analysis framework is also extendible to use feature based spatial signature analysis rules, as described in more detail below.
The new spatial signature analysis described herein follows a Bayesian approach to assign a confidence value to each classified event and uses soft decision to perform local filtering at the rule level based on the Bayesian confidence. Local filtering by the plug in rules reduces the probability of inaccurate classification and increases the probability of accurate classification. In addition, the local screening of previously assigned confidence values by subsequent rules tends to improve classification speeds, as some or all subsequent rules may be skipped, based on the previously assigned confidence values. Classifications based on different plug in rules are finally arbitrated by a post processor, which uses Bayesian confidence to determine the final signature and class identification. Parameters of plug ins are also preferably grouped into three categories, as described below. Common parameters for plug ins are preferably intuitive for the user to understand.
The present system is rule based and not feature based because feature based approaches tend to be handicapped by dimensionality and the peaking phenomenon. In addition, feature based systems require a classifier that typically consumes a lot of user time to prepare. However, rules can be easily customized for a particular process. Segmentation is tailored to the rules, unlike in feature based approaches. Further, improved speeds can be achieved since unnecessary spatial signature analysis features are not calculated, and segmentation algorithms are cheaper since they are not generic. However, the new spatial signature analysis framework described herein is extensible enough to allow plug in rules that are feature based, if so desired.
As used herein, the term signature is not the same as a cluster. A cluster can be a signature, whereas a signature need not be a cluster. Events in a cluster are grouped together based on their proximity. Events in a signature may not be proximal neighbors at all. It is more difficult to train a feature based classifier to recognize signatures than it is to train it to recognize clusters. Thus, the system described herein, being rule based, is better adapted at recognizing the defect signatures present on a wafer.
Another benefit of having user selectable plug in rules, is that newer versions of the rules can be plugged in as desired. In addition, several versions of the same rule can be maintained and selectively deployed by the user. Preferably, the system described herein provides the ability to adjust a baseline of a given version of a rule to match that of a prior or subsequent version of a rule. In this manner, a user can select between different versions of a plug in module as desired, and either maintain a given baseline or use the different baseline provided by the different plug in rule module version.
System Architecture
The system described herein preferably resides within a tool 10 , as functionally represented in FIG. 6 . The tool 10 is preferably one such as is configurable to determine physical defects like scratches and particulate matter on a wafer. The tool 10 preferably has specialized hardware components, represented as data acquisition module 12 , such as sensors for detecting the physical defects. Also included in the data acquisition module 12 data input circuits for transferring data from the sensors to the other portions of the tool 10 . As described in more detail hereafter, the data is most preferably stored in a common data storage 24 , which is available to the other components of the tool 10 in a manner that multiple redundant copies of the data do not need to be made.
Other portions of the tool 10 are preferably configured as a programmable computer system, the programming for which can be changed as desired. Portions of the programming are preferably stored in relatively more permanent memory, and other portions of the programming are preferably stored in relatively more rewritable memory. For example, the tool operation software 16 is preferably stored in a relatively more permanent memory. The tool operation software 16 preferably controls the operation of the sensors and the other hardware aspects of the tool 10 .
The tool 10 includes an event classification module 18 , which analyzes the data stored in the data storage 24 , so as to classify the events represented by the data. Within the event classification module 18 are various plug in modules such as 20 a , 20 b , and 20 c , which are described in more detail elsewhere herein. It is appreciated that either a greater or lesser number of plug in modules 20 may be used, and the FIG. 6 is representational of functions only. Also included in the event classification module 18 is a post processor 22 , which is the final arbiter of the various preliminary assessments submitted by the various plug in modules 20 , and which provides a final classification for the various events represented by the data. A compatibility module 14 provides the ability to have multiple versions of a single plug in module 20 a , 20 b , or 20 c installed in the tool 10 , while selectively maintaining a common historical baseline between the different versions of the same plug in module, as describe in more detail below.
The plug in rules 20 receive certain data and provide certain output, as functionally depicted in FIG. 7. A brief overview of the operation of the plug in 20 is provided at this point, with more detailed descriptions of the various operations, inputs, and outputs described hereafter. Included in the input for the plug in 20 is the raw data 200 , which represents the data from the sensors of the data acquisition module 12 , as depicted in FIG. 6 . As described in more detail hereafter, the raw data 200 is most preferably accessed from the common data storage 24 . The plug,in 20 also receives a weight value 202 , which is most preferably user definable. The plug in 20 receives confidence values 204 , which are produced by previously implemented plug ins 20 . The weight 202 and the confidence 204 are received by a local filter 206 in the plug in 20 , which decides whether the plug in 20 will analyze the raw data 200 or not. If an analysis is called for, then the raw data 200 is analyzed such as by the module 208 , in light of a user provided contrast value 206 and a user provide interference value 208 . Finally, a confidence value 204 is output, in which the confidence for this particular plug in 20 is added to the confidence values 204 which have been provided by the prior plug ins 20 .
There are several new ideas introduced by the current rule based approach. These ideas are described in more detail below, and include a flexible framework, plug in rules, dynamic confidence levels, assignable weights, local filtering, post processing, common parameter categories, common clustering parameters, the ability to have a feature based plug in, and baseline shift control between version of a plug in.
Flexible Framework
With reference now to FIGS. 6 and 7, the present system has a single spatial signature analysis framework in which multiple rules 20 can be plugged in. The new spatial signature analysis framework has a common data repository (data manager) 24 that is used by any number of plug ins 20 , which are invoked by an execution scheme (algorithm manager) 18 . The selection and sequence of execution of the various plug ins 20 used is configurable by the user. The selection and sequence of execution of the plug ins 20 , along with the parameters for each plug 20 in selected, is called a recipe. Efficient data transfer and data storage without redundant copies of data are achieved through use of shared memory 24 by the various plug in rules 20 .
This structure provides for easier and faster deployment of new rules 20 to customers who already have the spatial signature analysis framework. It also provides for a faster analysis than existing ruled based systems because data transfer is through a common framework that uses a shared memory 24 . Redundant copies of data are avoided across different plug in components 20 . The system software preferably uses an object oriented component object model which tends to be much easier to maintain than a monolithic application consisting of libraries.
Plug In Rules
Each rule 20 preferably represents a pattern of interest, such as an annular ring pattern, arcing patterns, or parallel line patterns. It is preferably in the form of a component object model, as mentioned above. Each category of pattern is called a class. Each instance of this class is a signature. The number of plug ins 20 can be as many as possible, each specializing in detecting signatures of a particular class. Each plug in 20 is directly independent of each other.
Such a system promotes accuracy of defect identification. Most pattern recognition algorithms have a segmentation step that typically depends on the pattern of interest. Use of separate plug in rules allows segmentation tailored to the class of interest. This is not possible in feature based systems. Further, since each plug in 20 is isolated from other plug ins 20 , it is much easier to fix bugs in the present system than in a monolithic application consisting of libraries. In addition, users can pick which rules 20 to use for classification. This reduces or eliminates unnecessary spatial signature analysis rules 20 and improves speed. For example, if the user does not care about processes that cause scratches, then the corresponding plug in rule 20 may not used. This may also reduce inaccurate classifications that unnecessary spatial signature analysis rules 20 may produce.
Dynamic Confidence Levels
Each plug in rule 20 assigns two different Bayesian confidence levels 204 to each event, namely (i) signature based weights and (ii) event based weights. Signature based weight is the confidence on the membership of a detected signature to the class that it was classified. Event based weight is the confidence on the membership of an event to the signature that it is part of. Each plug in component 20 calculates the signature based weights and event based weights specific to the rule it applies for detection. Thus the weights are more reliable estimates of Bayesian confidences than those produced by other systems.
Assigned Weights
The user has the ability to select which classes are more important than others to detect. For example, a user may wish to give more importance to a ring than to a scratch, because the presence of a ring may mean more damage to the wafer. These weights 202 are also called class based weights. In practice, signature based weights and event based weights 204 are sufficient, since they are dynamically calculated. The effective confidence of classification of an event can be obtained from class, signature, and event based weights using Bayesian rules. Thus, the user has the ability to select which classes are more important to detect.
Local Filtering
Each plug in rule 20 has a local filter 206 , which can perform either (i) hard subtraction (ii) hard inclusion or (iii) soft subtraction of events entering it. This determines which events are considered for the current rule 20 . Use of this filter 206 not only reduces and preferably eliminates reclassification of events that were already classified with high enough confidence 204 , but also improves the detection of signatures since this improves the signal to noise ratio. Hard inclusion and hard subtraction are filtering that is preferably based on hard coded class identifications. Soft subtraction is preferably based on Bayesian confidence 204 of classifications provided by previously implemented rules. Normally, soft subtraction is sufficient for most applications. Hard inclusion and hard subtraction are available for advanced customization by the user.
Thus, if the previous rules 20 classified events on the wafer with a sufficiently high confidence 204 , these events are preferably excluded from analysis by subsequent rules 20 with the local filtering 206 provided by the subsequent rules 20 . This reduces interference of multiple classifications and thereby improves detection. However, only events whose prior classification has a high enough confidence 204 are disregarded. In traditional approaches, any classified event is disregarded for subsequent classification. This method increases accurate detection by subsequent rules 20 and rejects inaccurate classification by prior rules 20 . This also reduces sensitivity to the exact sequence of plug in rules 20 . Further, since classified events with high enough confidence 204 are disregarded, there tend to be fewer events for consideration by subsequent rules 20 , thus improving classification speed.
Post Processing
After the spatial signature analysis is completed by each of the plug in rules 20 , or the plug in 20 is skipped as the case may be, each event is preferably assigned only one class identification and one signature identification. Each plug in rule 20 assigns a class identification and signature identification to each event. The post processor 22 arbitrates the final assignment of signature and class identifications based on the effective confidence of the classification of that event as part of a signature belonging to a particular class.
This tends to produce less classification bias. In traditional approaches, the final class identifications and signature identifications depend on the exact sequence of a limited library of classification rules. The first rule to classify always won, regardless of whether or not it was an inaccurate classification. In the system described herein, final signature and class identifications are assigned based on the effective confidence 204 of classification of each event by the post processor 22 .
Common Parameter Categories
Parameters are preferably grouped into three categories, being clustering, classification, and filtering. Clustering parameters are used for segmentation, classification parameters are the rules that define a class of interest, and filtering parameters are parameters for local fitters 206 in each plug in rule 20 . Preferably, a user only adjusts the clustering parameters. Because these parameter categories have an intuitive meaning, they tend to be very user friendly. Once set, classification and filtering parameters are preferably hidden from the graphical user interface and are available only to advanced users.
Feature Based Plug In
The system described herein allows the possibility of a new spatial signature analysis plug in 20 to be feature based. Thus, the advantages of feature based classification may be obtained by using a plug in rule 20 that is feature based. Performance is preferably improved by combining the advantages of rule based and feature based classifications.
Version Baseline Shift Control
Prior art analysis applications have only made available one version of a given analysis capability at a time. Furthermore, evolution of an analysis capability required a new software release which offered no provision for customers to maintain their baseline on their current device data or technology data The present invention solves these three problems, such as with the compatibility module 14 . There are preferably three ways in which a user may configure the system in regard to different versions of the plug in rule modules 20 : they want to run only a particular version of the component; they want to run the latest version that has no baseline shift with respect to a prior reference version; and they want to run the latest version irrespective of baseline shift. The user may specify the desired configuration such as through a flag for compatibility along with a reference version of the component. This flag can take, for example, three different values, such as e_ThisVersion, e_NoBaseLineShift and e_BaseLineShiftOK.
E_This Version
This configuration is typically used to strictly specify the use of a particular version of a component, and does not look any further for compatibility. It is desirable when the user is not willing to switch to any advancement in a particular component, or the user is interested in characterizing a particular version of a component With this configuration, the user has strong control over which version of a component is being executed, and the user may test and characterize a particular component while a different version is being used by the same system at the same time.
E_Nobaselineshift
This configuration may be used when the user desires to pick the best version that is installed and licensed, without any baseline shift from prior or reference versions of the plug in rule 20 . With this configuration, the user is typically willing to accept new advancements in a component, provided the final outcome is the same as before. As long as the best version produces identical results, the user does not care much about the actual version being used. Thus, as long as the user is comfortable with the results of a reference version, the user does not have to worry about the actual version being used, since the best version does not introduce any baseline shift. T he user gets the advantages of the newer version at ease. Further, the user may test and characterize the best component, even without knowing the actual version of the component, without introducing any baseline shift, while a particular version of the same component is being used by the same system at the same time.
E_Baselineshiftok
This configuration may be used when the user desires to pick the best version of the component, such as a plug in 20 , that is installed and licensed, and a baseline shift is acceptable. Thus, the user is willing to accept any new advancement in a component, as long as the best version is more accurate or faster. The user does not care much about the actual version being used. This may be a user with a stronger interest in performance than in any baseline shifts that may occur in the statistical process control charts, and who thus takes advantage of more accurate or faster analysis by the best version. In this manner, the user may test and characterize the best component, even without knowing the actual version of the component, while a particular version of the same component is being used by the same system at the same time.
This is preferably achieved by each component, such as a plug in rule module 20 , advertising a compatibility table. Each component preferably contains the information that is necessary for a main compatibility algorithm to select the appropriate component version from the recipe. For example, each component preferably provides a list of compatible components, i.e. a list of component versions that are compatible with this version. For each compatible version in the list, the component preferably provides a Boolean flag indicating whether the listed component introduces baseline shift or not. In addition, component versions are preferably ordered by preference. This gives an ordered list of versions. In practice, components may be ordered based on the release data. In other words, the latest compatible version becomes the best compatible version. Additionally, the user preferably supplies a reference version and compatibility. When the user wants to execute a particular component, a reference version can be passed along with the intended compatibility flag.
An algorithm to select the best compatible component is next described. Let A be a versioned component that performs some kind of analysis. If Compatibility=e_ThisVersion, then check if component A is installed and licensed. If so, return A, else report that the requested component is not available. If Compatibility=e_NoBaseLineShift, then search for all components that list A in their compatibility table as a component without any baseline shift. Among the found components, select only those that are installed and properly licensed. Repeat this procedure for all components that are installed and properly licensed. At the end of this process, there is a set of compatible components with no baseline shift. Out of this set, select the component with the highest order, as described above. If this set is empty, follow the steps as given when Compatibility=e_ThisVersion.
If Compatibility=e_BaseLineShiftOK, then search for all components that list A in their compatibility table without considering their baseline shift information. Among the found components, select only those that are installed and properly licensed. Repeat this procedure for all components that are installed and properly licensed. At the end of this process, there is a set of compatible components. Out of this set, select the component with the highest order as described above. If this set is empty, again follow the steps as given when Compatibility=e_ThisVersion.
This algorithm has many new features and benefits. For example, the compatibility table of previously released versions need not be updated when a newer version is released. In addition, multiple versions of the same plug in rule 20 may be installed and users can easily choose which one to run based on criteria such as device or technology. These versions may be baseline-shifted or not. Further, users can install a newer version of a plug in rule 20 and run it without changing the logic in which the original component was invoked, as long as an appropriate compatibility flag is used.
If the user invokes the versioned plug in rule 20 by means of the recipe, then the user gets more benefits, because the user can also install a new component and run it without changing their recipes, as long as the appropriate compatibility flag is set in the recipe. Users can additionally run newly created recipes for a device for which no baseline exists, hence creating a new baseline using the latest available component. These same users can maintain existing baselines for existing devices by running existing recipes with the appropriate compatibility flag.
Bayesian Confidence
Event based weight is the confidence of the membership of an event to the signature that it is part of. It can be different for each event. A weight of 1 implies that the event is most likely to be a member of the signature it was classified to be part of. A weight of 0 implies that the event is probably not part of any signature. One approach to determine event based weights is to use the local density near the event with respect to the average density of the signature it belongs to. Event based weight of an event is the probability that it is a member of signature s, given that it is classified to be part of signature s.
Signature based weight is the confidence of the membership of a detected signature to the class that it was classified. These are preferably the same for all events that belong to the same signature. However, events from different signatures can have different signature based weights. The following example illustrates one way of to calculate signature based weights.
Let a i and b j be finite numbers of positive fractions such that their sum equals unity. Define f i u as a function that depends directly on the user (hence the superscript u) parameter for classification. For example, length min may be a user parameter for classification of a scratch. Let f j p be a function that depends on the intrinsic properties (hence the superscript p) of the signature, especially those not covered directly by the user parameter. Both f i u and f j p lie in the unit interval [0, 1].
The signature based weight for a given signature may be evaluated as:
w=Σ i a i ƒ i u +Σ j b j ƒ j p
This method gives a general approach to calculate signature based weights for an arbitrary signature. A weight of 1 implies that the signature found most likely belongs to the class/signature assigned to it. A weight close to 0 implies that the signature found most likely does not belong to the class assigned to it. Thus, signature based weight of a signature is the probability that it is a member of class c, given that it is classified to be of class c.
These are preferably the same for all events that belong to the same class. However, events from different classes can preferably have different class based weights as assigned by the user. Higher weight is assigned to the class that the user gives importance to or in which the user has more confidence on the classification result for that class. Class based weight of a class may be treated as a prior probability of a particular class.
Post Processing Based on Bayesian Confidence
Let e be an event whose event, signature and class based weights are p j , w j and U j respectively. Where, j=1, 2, . . . , n correspond to rules r 1 , r 2 , and r n respectively. The rules are numbered according to the order of execution. Note that the same rule may appear more than once. Let c and s be the unique class and signature identifications to be assigned to event e, respectively. Let c j and s j be the class and signature identifications assigned to the event by rule r j , respectively.
The post processor uses the following decision rule:
C=C j , for j such that the product p j *w j *u j is maximum and
S=S j , for j such that the product p j *w j *u j is maximum.
If there are more than one j for which the product p j *w j *u j is maximized, then the least j is chosen. This means that in the event of a tie, the earlier rules in the sequence preferably take priority over the later rules. However, this could be altered.
If there are more than one j for which the product p j *w j *u j is maximized, then the least j is chosen. This means that in the event of a tie, the earlier rules in the sequence take priority over the later rules. Again, this could be selectively altered, as desired.
Common Clustering Parameters
Each plug in 20 preferably has as clustering parameters only contrast level 206 and interference level 208 . Some of the plug ins 20 may have neither or only one of these two parameters. Contrast level 206 (similarly clustering level) indicates the same thing for all plug ins 20 . This makes it easier for the user to set parameters because there can be at most only two clustering parameters for each plug in 20 , and they have the same meaning. This makes it easy for the user to create a recipe.
The contrast of a cluster describes the relative density of the cluster with respect to its background. A large absolute difference means that the contrast is high and vice versa. FIGS. 1A and 1B illustrate two distributions with the same cluster but with different backgrounds. The cluster 100 in FIG. 1A has a relatively high contrast against the background 102 , while the cluster 104 in FIG. 1B has a relatively low contrast against the background 106 . Thus, the distributions in FIGS. 1A and 1B both have the same signature, but because of the difference in contrast the signature depicted in FIG. 1B may be more difficult to detect.
FIGS. 2A and 2B illustrate the effect of selecting different contrast levels 206 for the same distribution. The contrast level 206 can adjust the size of the signature, since there is a variation in contrast across the cluster. Both FIGS. 2A and 2B are assumed to have exactly the same distribution of events, even though they do not visually appear so. A relatively lower contrast level 206 is selected in FIG. 2A and a relatively higher contrast level 206 is selected in FIG. 2 B. Thus, with the selection of a relatively high contrast level 206 as depicted in FIG. 2A, the signature is more readily identifiable as the cluster 108 against the background 110 . However, with the selection of a relatively low contrast level 206 as depicted in FIG. 2B, the signature is more readily identifiable as a unified cluster 108 plus 110 .
FIG. 3 depicts a simple approach to use contrast level 206 to control the clustering algorithm using a one dimensional example where the local density of events is plotted against position. The broken line 112 sets the contrast level 206 . All events with a density above this contrast level 112 are considered for clustering (segmentation). The proximate events are clustered together.
The interference level 208 of clusters in a distribution is a level of interaction between clusters. The interference level 208 of clusters in a distribution is affected by the mutual separation between clusters. This can be used to used to merge or split clusters. The example in FIGS. 4A and 4B illustrates the interference level 208 in two distinct distributions. FIG. 4A has low interference because the scratches 114 - 118 do not interfere severely with each other. However, in FIG. 4B the scratches 114 - 118 interfere with each other, which tends to cause poor detection of the scratches. Thus, the interference level in FIG. 4B is higher than the interference level in FIG. 4 A.
FIG. 5 depicts a simple approach to use interference level 208 to control merging of clusters, using a one dimensional example in which the local density of events is plotted against position. The interference level 208 determines the distance 120 between the two broken lines 122 and 124 . Effectively, clusters within the mutual distance set by interference level 208 are considered for merging together. In other words, if the distance 120 between two events 122 and 124 is less than the value set for the interference level 208 , then the two events 122 and 124 are merged into a single event. Similarly, if the distance 120 between two events 122 and 124 is greater than the value set for the interference level 208 , then the two events 122 and 124 are identified as different events.
The interference level 208 tends to be more meaningful if the contrast level is also known or supplied. The contrast level controls the clustering (segmentation) algorithm applied to the events by either resolving or blending the edge of a cluster against the background. Whereas, interference level controls the clustering (segmentation) algorithm applied to clusters by either uniting or separating clusters one from another.
Thus, the spatial signature analysis system described herein exhibits at least the following six novel attributes: plug in rules to a flexible framework that is driven by means of a recipe; class based, signature based, and event based weights and confidences with a probabilistic interpretation; local filtering based on the probabilistic confidences assigned by previous classification rules; post processing based on the probabilistic confidences assigned by all classification rules; uniform definition of parameter categories and common clustering parameters (contrast and interference levels) that enables easier usage; ability to have a user defined rule along with the other basic classification rules; and the ability to deploy plug ins that take into account non spatial attributes such as class codes.
The foregoing description of preferred embodiments for this invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the invention and its practical application, and to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as is suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.
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A system for determining an assigned classification for a set of physical events on a substrate. Sensors sense the physical events on the substrate and produce event data. A plug in rule module manager receives and manages any number of plug in rule modules. Each plug in rule module has an input, a local filter, an analyzer, and an output. The input receives the event data and confidence values from preceding plug in rule modules. The local filter analyzes the received confidence values from the preceding plug in rule modules and selectively by passes the plug in rule module based at least in part upon the received confidence values from the preceding plug in rule modules. The analyzer analyzes the event data in view of a given classification associated with the plug in rule module, and assigns a confidence value based at least in part upon how well the event data fits the given classification. The output provides the confidence value to subsequent plug in rule modules. A post processor receives the confidence values provided by the plug in rule modules, and makes a final selection of the assigned classification to be associated with the set of physical events from the given classifications based at least in part upon a comparison of the confidence values produced by all plug in rule modules.
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BACKGROUND
[0001] 1. Technical Field
[0002] The disclosure relates to display devices, and particularly to a display device for computing systems.
[0003] 2. Description of Related Art
[0004] Display devices of computing systems have a display portion and a supporting portion. The supporting portion includes a bracket and a base. Usually, the base has no function beyond being used to support the display portion and real estate on desks is consumed for very little return. In addition, in many offices where the display devices are used, fixed telephones may be required which require their own space on the desks. Further, the fixed telephone may have a small display for displaying communication information. The displayed communication information may be limited and not clear enough due to dimensions of the small display. Therefore, there is room for improvement in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The accompanying drawings are included to provide a further understanding of the disclosure, and are incorporated in and constitute a part of this application. The drawings illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.
[0006] FIG. 1 is a schematic view of a display device according to an exemplary embodiment.
[0007] FIG. 2 is a schematic view of a touch screen of the display device rotated out from a receiving groove of FIG. 1 .
[0008] FIG. 3 is an exploded schematic view of the display device of FIG. 1 .
DETAILED DESCRIPTION
[0009] Examples of the present embodiments are illustrated in the accompanying drawings. Wherever possible, the same or similar reference numbers are used, in the drawings and the description, to refer to the same or like parts.
[0010] Referring to FIG. 1 to FIG. 3 , a display device 100 according to an exemplary embodiment is shown. The display device 100 includes a display portion 1 , a supporting portion, a touch screen 33 , a telephone receiver 37 , and a communication module 39 . The display portion 1 displays information under the control of an electronic device electronically connected to the display portion 1 . The display portion 1 includes a display screen and a shell that accommodates and supports the display screen.
[0011] The supporting portion 20 includes a bracket 21 and a base 22 . In this embodiment, the base 22 is in shape of an elongated circle. One end of the bracket 21 is perpendicularly fixed to the base 21 , and another end of the bracket 21 is fixed to or pivots from the shell of the display portion 1 to support the display portion 1 .
[0012] One side of the base 22 defines first receiving groove 38 . As shown in FIG. 3 , the first receiving groove 38 is defined at the right side of the bracket 21 and is cuboid shaped. The telephone receiver 37 is fixed to and partially received in the first receiving groove 38 . The communication module 39 is embedded within the inner space of the first receiving groove 38 to communicate with external communication devices (e.g., other phones) and the telephone receiver 37 . The communication module 39 receives electronic signals from the external communication devices and audibly outputs the received electronic signals through the telephone receiver 37 . Further, the communication module 39 receives sounds input by a user using the telephone receiver 37 , and transmits the sounds as signals to an external communication device which communicates with the communication module 39 . In one embodiment, the telephone receiver 37 is a wireless receiver. The communication module 39 may include a wireless communication module, such as a BLUETOOTH® module, corresponding to the telephone receiver 37 , to establish a wireless communication between the telephone receiver 37 and the communication module 39 .
[0013] Size of the touch screen 33 is smaller than that of the screen of the display portion 1 , and is electronically connected to the communication module 39 . The touch screen 33 displays information relevant to the communication module 39 , such as phone numbers of incoming calls, phone directory, communication counts and durations, and other information. The touch screen 33 includes a virtual keypad to provide a dialing function for the communication module 39 . In an alternative embodiment, a physical keypad is defined on the telephone receiver 37 , to provide the dialing function of the communication module 39 .
[0014] The base 22 further defines a second receiving groove 330 . In this embodiment, the second receiving groove 330 is defined in front of the bracket 31 and spaced from the first receiving groove 38 . The second receiving groove 330 receives and supports the touch screen 33 . The touch screen 33 includes a rotating shaft 32 at a side, to rotatably attach the touch screen 33 to a sidewall of the second receiving groove 330 far away from the bracket 21 . In the embodiment, the sidewall of the second receiving groove 330 far away from the bracket 21 defines two notches. Two opposite ends of the rotating shaft 32 are inserted into the notches. Thus, the touch screen 33 can be laid flush in the second receiving groove 330 (as shown in FIG. 1 ) by rotating the touch screen 330 towards the bracket 21 . When the touch screen 33 is rotated up and out of the second receiving groove 330 , the touch screen 33 stands on the base 22 at an angle between the touch screen 33 and the base 22 (as shown in FIG. 2 ).
[0015] In the embodiment, the display device 100 further includes a speaker 30 , a microphone 31 , a switching button 34 , a hands free button 35 , and a network interface 36 . The microphone 31 , the switching button 34 , and the hands free button 35 are lined along a line in front of the second receiving groove 330 . The speaker 30 is defined at another side of the base 22 opposite to the telephone receiver 37 . The microphone 31 , the speaker 30 , and the hands free button 35 are electronically connected to the communication module 39 to provide a hands free communication function for the communication module 39 . When the communication module 39 receives an incoming call from the external communication device, signals of the incoming call are output as audio through the speaker when the hands free button 35 is pressed. At this time, the microphone 31 receives sounds input by the user and transmits the sounds as signals to the external communication device through the communication module 39 , thereby realizing the hands free communication function of the communication module 39 .
[0016] The network interface 36 is defined at a backside of the base 22 , to connect the display device 100 to a network.
[0017] The switching button 34 is configured to switch information between display on the display portion 1 and display on the touch screen 33 . For example, when the switching button 34 is pressed, the information displayed on the display portion 1 is switched to the touch screen 33 , conversely the information displayed on the touch screen 33 is switched to the display portion 1 .
[0018] In the embodiment, the display device 100 further comprises an image capturing device 11 installed on the display portion 1 . The image capturing device 11 captures images of the scene in front of the display device 100 to realize a video communication function of the display device 100 . When a video communication is established between the display device 100 and an external communication device, one of the display portion 1 and the touch screen 33 displays the images captured by the image capturing device, and another of the display portion 1 and the touch screen 33 displays images transmitted from the external communication device. The images captured by the image capturing device 11 are transmitted to the external communication device through the communication module 39 . The image capturing device 11 may be, for example, a camera mounted on the top edge of the display portion 1 .
[0019] In other embodiments, the display screen of the display portion 1 may be touch screen which includes a virtual keyboard, to provide the dialing function of the communication module 39 using the display screen of the display portion 1 .
[0020] Although numerous characteristics and advantages of the present embodiments have been set out in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only; and changes may be made in detail, especially in the matters of shape, size and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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A display device on a supporting base utilizes the surface area of the support base to house a handset of a wireless telephone, a small touch screen, a microphone, a loudspeaker, and a switch. A communication module within the support base permits wireless communication between all components, incoming and outgoing calls may be managed on a hands-free basis, and the display of information relevant to external communications may be switched between the touch screen and a large upper screen of the display device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to co-pending, prior-filed U.S. Provisional Patent Application No. 62/217,169, filed Sep. 11, 2015, the entire contents of which are hereby incorporated by reference.
BACKGROUND
[0002] The present disclosure relates to the field of mining machines, and particularly to a trapping shoe for a longwall shearer mining machine.
[0003] Conventional longwall shearers include a frame and a pair of cutting assemblies mounted on each end of the frame. Each cutting assembly includes a cutting drum for engaging a mine wall. As the frame traverses a mine wall, the cutting drums cut material from the mine face. In some embodiments, the material is deposited on a conveyor and carried away from the mine face. The shearer includes a drive mechanism for moving the machine with respect to the mine wall.
SUMMARY
[0004] In one aspect, a system for guiding movement of a chassis of a mining machine along a rack includes a shoe and a fluid line for receiving fluid from a fluid source. The shoe is configured to be coupled to the chassis and slidably engage the rack. The shoe is configured to extend at least partially around the rack. The shoe includes a first end, a second end, an inner surface, and an outer surface. At least a portion of the inner surface is configured to be positioned adjacent the rack. The fluid line includes an outlet positioned proximate the shoe for dispensing the fluid at an interface between the shoe and the rack.
[0005] In another aspect, a drive system for driving a mining machine along a rack includes a drive mechanism configured to engage the rack to move the mining machine relative to the rack, a shoe positioned adjacent the drive mechanism, and a fluid system for conveying a lubricant. The shoe is configured to slidably engage the rack. The shoe aligns the drive mechanism relative to the rack. The shoe includes a first end and a second end. The fluid system including an outlet positioned adjacent at least one of the rack and the shoe.
[0006] In yet another aspect, a mining machine is movable along a rack and includes a chassis, a cutter assembly, a shoe coupled to the chassis, and a fluid line for receiving a fluid from a fluid source. The cutter assembly includes an arm and a cutting drum. The arm includes a first end pivotably coupled to the chassis and a second end supporting the cutting drum for rotation relative to the arm. The shoe is configured to extend at least partially around the rack. The shoe includes a first surface and a second surface, and the first surface is configured to be positioned adjacent the rack. The fluid line includes an outlet positioned proximate the shoe for dispensing fluid to at least one of the rack and the shoe.
[0007] Other aspects will become apparent by consideration of the detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a mining machine.
[0009] FIG. 2 is end view of the mining machine of FIG. 1 engaging a mine wall.
[0010] FIG. 3 is an enlarged perspective view of a portion of the mining machine of FIG. 1 .
[0011] FIG. 4 is a perspective view of a drive mechanism.
[0012] FIG. 5 is an end view of a trapping shoe.
[0013] FIG. 6 is a perspective view of a fluid reservoir.
[0014] FIG. 7 is a perspective view of a drive mechanism and a lubrication system.
[0015] FIG. 8 is a perspective view of a trapping shoe and a lubrication system according to another embodiment.
[0016] FIG. 9 is an end view of the trapping shoe of FIG. 5 engaged with a rack.
DETAILED DESCRIPTION
[0017] Before any embodiments are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Use of “including” and “comprising” and variations thereof as used herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Use of “consisting of” and variations thereof as used herein is meant to encompass only the items listed thereafter and equivalents thereof. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.
[0018] FIG. 1 illustrates a mining machine (e.g., a longwall shearer 10 ) including a chassis or frame 14 and a pair of cutting assemblies (i.e., a first cutting assembly 18 a and a second cutting assembly 18 b ). Each cutting assembly 18 includes a ranging arm 22 and a cutting drum 26 . Each ranging arm 22 is pivotably coupled to the frame 14 and rotatably supports the associated cutting drum 26 . Each cutting drum 26 includes a generally cylindrical body. In some embodiments, each cutting drum 26 includes one or more helical vanes (not shown) and a plurality of cutting bits (not shown) positioned along the edges of each vane. For example, each cutting drum may be formed as shown in U.S. Publication No. 2014/0084666, filed Sep. 20, 2013, the entire contents of which are incorporated by reference herein. Each drum 26 is coupled to the respective ranging arm 22 and is rotatable about a respective drum axis. In the illustrated embodiment, each drum axis is generally perpendicular to the mining machine's directions of movement 38 , 42 .
[0019] As shown in FIGS. 1 and 2 , the frame 14 is configured to tram or move along a mine face or wall 34 ( FIG. 2 ) of material to be mined. In the illustrated embodiment, the frame 14 moves in a first direction 38 ( FIG. 1 ) and a second direction 42 opposite the first direction 38 . The first direction 38 and the second direction 42 are generally parallel to the mine face ( FIG. 2 ).
[0020] Referring now to FIG. 2 , each drum 26 is configured to engage the mine wall 34 to cut material from the wall 34 . As each cutting drum 26 rotates about its axis, the vanes (not shown) carry the cut material from the wall 34 toward a rear end of each drum 26 , where the cut material is deposited onto a face conveyor 46 . As the frame 14 moves, for example, in the first direction 38 , the first cutting assembly 18 a is in a first or leading position and the second cutting assembly 18 b is in a second or trailing position. In the embodiment shown in FIG. 1 , each cutting assembly 18 a, 18 b is in an elevated position. However, in other embodiments, each cutting assembly 18 a, 18 b may be positioned independently of the other (e.g., a leading cutting assembly may be positioned in an upper position and a trailing cutting assembly may be positioned in a lower position) to cut the material from the upper portion and a lower portion of the mine wall 34 in the same pass. In the illustrated embodiment, the mining machine 10 further includes a cable handler 114 to manage electrical, communication, and fluid conduits that are in communication with the machine 10 .
[0021] With reference to FIGS. 3-5 , the shearer frame 14 includes a downdrive or drive mechanism 50 configured to engage a rack 54 ( FIG. 3 ) and drive the frame 14 . More specifically, the drive mechanism 50 includes a sprocket 58 ( FIG. 5 ) rotationally coupled to a shaft (not shown) and driven by a motor (not shown) to engage the rack 54 . The sprocket 58 and rack 54 form a rack-and-pinion connection such that rotation of the sprocket 58 drives the frame 14 to move along the rack 54 . The trapping shoe 30 is pivotably coupled to the housing of the downdrive 50 (e.g., by a pin 62 ). The shoe 30 may also include a hook portion 64 extending around a portion of the rack 54 and engaging an underside or bottom surface of the rack 54 (see e.g., FIG. 9 ). The hook portion 64 maintains engagement between the shoe 30 and the rack 54 and guides the shoe 30 as it slides relative to the rack 54 . In one embodiment, an upper surface of the shoe 30 includes an opening and a portion of the sprocket 58 extends through the opening. The sprocket 58 includes teeth 66 extending around the perimeter of the sprocket 58 , which engage the rack 54 ( FIG. 3 ). The shoe 30 guides the movement of the frame 14 relative of the rack 54 and insures that the sprocket 58 remains aligned and engaged with the rack 54 . Although only one shoe 30 is shown in the illustrated embodiment, it is understood that one or more additional shoes 30 can be coupled to another portion of the frame 14 .
[0022] Referring now to FIGS. 6 and 7 , the mining machine 10 also includes a lubrication system to provide a lubricant directly to the rack 54 . In one embodiment, the lubrication system includes a hydraulic fluid reservoir 70 ( FIG. 6 ) at least one fluid line 74 in communication with the reservoir 70 via outlets 78 a - d, and a hydraulic pump 82 for displacing fluid through the fluid line 74 . It is understood that there may be fewer or more outlets (e.g., 78 e - j ) than shown in FIG. 6 . In some embodiments, the lubricant source (i.e., the reservoir 70 ) is supported separate from the frame 14 and remotely pumps fluid to the mining machine 10 via the fluid line 74 . The fluid line 74 may be supported by the cable handler 114 ( FIG. 2 ) as the mining machine 10 moves along the mine wall.
[0023] In the embodiment as illustrated in FIG. 7 , a distal end 86 of the fluid line 74 terminates at the downdrive 50 , and is spaced apart from the trapping shoe 30 . A passage 90 in communication with the fluid line 74 may be positioned on an exterior surface of the downdrive 50 . Fluid from the passage 90 may be sprayed or dripped onto the rack 54 . In one embodiment, the fluid flows onto the rack 54 in direction 94 . In this particular embodiment, the fluid is pumped from one of the outlets 78 a - j, through the fluid line 74 and the passage 90 , and expelled out of a port 98 at the distal end 86 . Although the passage 90 is illustrated in FIG. 7 on the exterior of the downdrive 50 , it is understood that the passage 90 could also be disposed on the interior of the downdrive 50 .
[0024] FIG. 8 illustrates another embodiment in which the fluid line 74 extends through an internal passage 290 formed in the body of the shoe 30 . In one embodiment, the fluid line 74 is coupled to a first elbow fitting 102 coupled to the downdrive 50 , and a second fluid line 274 is in fluid communication with a second elbow fitting 104 coupled to the trapping shoe 30 . An internal passage 290 extends through the body of the shoe 30 between an outer surface 106 and an inner surface 110 of the shoe 30 . A distal end 286 of the internal passage 290 terminates at the inner surface 110 , forming an opening or port 298 . Thus, fluid is conveyed through each fluid line 74 , 274 , the respective elbow fittings 102 , 104 , the passage 290 , and is expelled at a port 298 positioned on the inner surface 110 of the shoe 30 . As such, the fluid is applied directly to the rack 54 .
[0025] In the illustrated embodiment, the port 298 is located on a vertical wall of the inner surface 110 , between an upper portion and the hook portion 64 . In other embodiments, the fluid lines and passages may be formed in a different manner. Although only one fluid line 274 is shown, more than one fluid line 274 may be provided in the trapping shoe 30 , and multiple fluid lines may convey fluid to multiple ports positioned at various locations on the inner surface 110 of the shoe 30 . In some embodiments, each fluid line 274 may be in fluid communication with each outlet 78 a - d ( e - j ). Also, in the illustrated embodiment, the fluid line 274 is provided with sufficient length to permit movement of the trapping shoe 30 relative to the downdrive 50 while minimizing stress on the fluid lines 74 , 274 and the fittings 102 , 104 .
[0026] For each of the previously described embodiments, the reservoir 70 can either be positioned on-board or off-board the frame 14 . In the case where the reservoir 70 is separate from the machine (i.e., off-board), the fluid line 74 , 274 may be supported by the cable handler 114 ( FIG. 2 ) of the frame 14 , such that the fluid line 74 , 274 is able to extend from at least one of the outlets 78 a - d ( e - j ) to the downdrive 50 and/or the trapping shoe 30 without becoming entangled with the shearer 10 . Positioning the reservoir 70 away from the machine 10 may be advantageous for maintaining a low profile of the machine 10 , especially for low mine seam applications.
[0027] With reference to FIG. 9 , during operation the shoe 30 is exposed to large loads (e.g., due to the weight of the shearer 10 ). The large loads increase friction between the shoe 30 and the rack 54 . As a result, the shoe 30 may experience wear in multiple zones (e.g., zones A, B, C, D, and E). Furthermore, debris (e.g., lumps of rock or the like) cut from the mine wall 34 clogs the space between the shoe 30 and the rack 54 , which compounds the amount of wear on the shoe 30 . Wear on the shoe 30 may result in poor engagement between the sprocket 58 and the rack 54 . By supplying lubricant via the lubrication system, friction is decreased between the rack 54 and the shoe 30 , thereby decreasing wear and prolonging the working life of the rack 54 and the shoe 30 . As a result, the rack 54 and sprocket 58 may maintain sufficient engagement for a longer period of time. In some embodiments, the lubrication system may provide lubricant directly to each one of zones A, B, C, D, and E, or some subset thereof.
[0028] Although some aspects have been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects as described.
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A system for guiding movement of a chassis of a mining machine along a rack includes a shoe and a fluid line for receiving fluid from a fluid source. The shoe is configured to be coupled to the chassis and slidably engage the rack. The shoe is configured to extend at least partially around the rack. The shoe includes a first end, a second end, an inner surface, and an outer surface. At least a portion of the inner surface is configured to be positioned adjacent the rack. The fluid line includes an outlet positioned proximate the shoe for dispensing the fluid at an interface between the shoe and the rack.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system and method for providing maximum regenerative braking with a vehicle having regenerative braking capability installed on multiple axles.
2. Disclosure Information
Although regenerative braking has been used for many years with electro-drive vehicles, such usage has been primarily in the context of vehicles having but a single drive axle. The present invention is directed to provision of both regenerative and friction braking on all axles of a vehicle. This presents a particular challenge, coupled with an opportunity to increase the amount of regenerative braking. This must be accomplished seamlessly, without causing issues with respect to anti-lock braking of the vehicle. The inventors of the present invention have determined a method and system for achieving maximum regenerative braking with all axles of the vehicle participating in the regenerative braking.
SUMMARY OF THE INVENTION
A method for operating regenerative braking in an automotive vehicle having a plurality of axles includes the steps of determining the brake demand for a first axle, determining the availability of regenerative braking of the first axle to satisfy the brake demand, determining brake demand for a second axle, and determining availability of regenerative braking of the second axle to satisfy the braking demand for the second axle. In the event that the regenerative braking available for the first axle is greater than the brake demand for the first axle, and in the further event that the regenerative braking available for the second axle is less than the braking demand for the second axle, the surplus regenerative braking will be applied to the first axle in an amount not greater than the amount needed to satisfy the unmet braking demand for the second axle. The present method further comprises the step of applying friction braking to a second axle in the event that the surplus regenerative braking available with the first axle is insufficient to satisfy the braking demand of the second axle when combined with the regenerative braking available with the second axle.
The brake demand for the first axle and the brake demand for the second axle are determined according to inputs from a driver of the vehicle, and from balanced braking requirements. The availability of regenerative braking for an axle of the vehicle is determined by comparing at least one regenerative braking limit with the lesser of the brake demand for the axle and the maximum regenerative braking which may be achieved by the axle. At least one regenerative braking limit comprises the lesser of the maximum regenerative braking which may be achieved by the axle and a calculated maximum regenerative braking amount following the end of an antilock braking event. This calculated maximum post-ABS braking amount is set at first to a level which is equivalent to the brake torque which the axle achieved at the end of the ABS event. Thereafter, the post-ABS maximum regenerative braking may be increased by setting the post-ABS regenerative braking for any particular axle equal to the total braking on that particular axle at the time the post-ABS maximum value is reset.
According to another aspect of the present invention, a method for operating regenerative braking on an automotive vehicle having a plurality of axles further includes the steps of determining braking demand for a first axle of the vehicle, and determining the availability of regenerative braking of the first axle to satisfy the brake demand. Thereafter, the brake demand for a second axle and the availability of regenerative braking of the second axle to achieve braking demand for that axle as determined. In the event that the regenerative braking available for the second axle is greater than the brake demand for the second axle, and in the further event that regenerative braking available for the first axle is less than the braking demand for the first axle, surplus regenerative braking will be supplied to the second axle in an amount not greater than the amount needed to satisfy the unmet braking demand for the first axle. Then, friction braking will be applied to the first axle in an amount sufficient to satisfy the brake demand of the first axle in the event that the surplus regenerative braking available at the second axle is insufficient to satisfy the brake demand for the first axle when combined with the regenerative braking available with the first axle.
According to another aspect of the present invention, a control system for operating regenerative and friction brakes on a plurality of axles of an automotive vehicle includes a plurality of sensors for providing a plurality of outputs corresponding to a plurality of vehicle operating parameters, and a controller for receiving inputs from the plurality of sensors. An operating system housed within the controller determines the unique brake demand for each of the plurality of axles and determines the regenerative braking available for each axle. The controller applies regenerative braking to a first one of the axles in an amount greater than the brake demand for the first axle in the event that surplus regenerative capacity is present for the first axle, and insufficient regenerative braking is available to meet the brake demand for a second one of the axles. The controller applies friction braking to the second axle in the event that the sum of the first axle surplus regenerative capacity and the second axle regenerative braking is less than the brake demand for the second axle.
It is an advantage of the present invention that a method and system for operating regenerative brakes in a vehicle provides maximum capability to achieve regeneration of vehicle batteries, by taking advantage of the capability to increase braking on an axle where surplus regenerative braking capability is available.
It is a further advantage of the present invention that maximum regenerative braking may be achieved while minimizing operation in an anti-lock braking mode. In general, operation in anti-lock braking mode is undesirable because braking is usually achieved through the use of friction brakes, to the detriment of regenerative braking.
Other advantages, as well as objects and features of the present invention, will become apparent to the reader of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a braking system according to the present invention.
FIG. 2 is a block diagram of a method according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1 , a multiple axle regenerative braking system according to the present invention is operated by controller 200 which comprises a micro-processor controller drawn from the class of vehicle power train controllers known to those skilled in the art and suggested by this disclosure. Controller 200 operates friction brakes 204 and regenerative brakes 206 . The regenerative braking equipment includes reversible traction motor/generators and associated batteries or other energy storage devices such as an ultracapacitors. Alternatively, the regenerative braking equipment may include a hydraulic wheel motor/pump which regeneratively charges a hydraulic accumulator. In any event, axles 208 are braked both by the friction brakes 204 and regenerative brakes 206 .
A method according to present invention is shown in FIG. 2 . Beginning at start block 300 , controller 200 moves to block 302 wherein total braking demand is determined from driver inputs. In general, the determination of brake demand relies on input from one or more sensors 202 , such as a brake pedal position sensor, a brake pedal force sensor, and an accelerator position sensor. Such sensors are known to those skilled in the art and suggested by this disclosure. For example, when the vehicle's driver has lifted his/her foot from the accelerator, it may be inferred that the driver wishes to cause the vehicle to slow. This is an element of brake demand. Another element is brake pedal position. Another may be the rate of change of brake pedal position.
At block 304 , controller 200 determines whether a braking event is in progress. If the answer is “no” at block 304 , the routine ends at block 326 . If, however, the answer is “yes” at block 304 , the routine moves to block 306 , wherein the front braking demand and rear braking demand are determined from the total braking demand and balanced braking requirements. The reader will recall that the total braking demand was determined at block 302 from inputs provided by the vehicle's driver. Balanced braking requirements dictate that during normal conditions, due to the fact that wheel loadings from static vehicle weight distribution and dynamic distribution often vary from the front to rear of the vehicle, the same amount of brake torque cannot be applied to each of the axles of the vehicle. Balanced braking occurs when brake torques are applied in accord with the wheel loading for each axle of the vehicle. Thus, at block 306 controller 200 determines the front braking force to be developed and rear braking force to be developed. At the core of the present invention is the notion that these balanced braking torques are only a guideline, because the presence or absence of sufficient regenerative capacity to meet the balanced braking requirement for a particular axle may cause an application of regenerative braking at a level which is more or less than the balanced braking torque.
At block 308 , controller 200 determines a front maximum regenerative braking limit and a rear maximum regenerative braking limit. These limits are system limits which are dictated by the current battery charge, ambient temperature, battery temperature, the capacity of the rotating machine, the transmission means between the road wheels of a particular axle and the associated electric machine, and other variables known to those skilled in the art and suggested by this disclosure. The front and rear maximum regenerative limits set the maximum regenerative braking capacity for a particular axle. At block 310 , the regenerative and friction braking levels are adjusted for both the front and rear axles, based upon the front and rear braking demand and maximum regeneration limits.
At block 312 , controller 200 inquires as to whether an anti-lock braking event is in progress. If the answer at block 312 is “no”, the routine returns to block 302 . If, however, the answer is “yes” at 312 , the routine moves to block 314 , wherein regenerative braking limits are set for anti-lock operation. The regenerative braking limits are in general, the amount of braking force which may be achieved without interfering with anti-lock operation. This may be determined by recording the brake torques during the immediate prior antilock braking event.
At block 316 , controller 200 once again determines the total braking demand from driver input in the manner described in connection with block 302 . Then, the routine moves to block 318 , wherein the front braking demand and rear braking demand are once again determined from total braking demand and balanced braking requirements as in block 306 . Then, continuing to block 320 , controller 200 adjusts friction and regenerative braking levels according to the front and rear braking demand and the regenerative limits and the anti-lock control limits. In general, this means that the vehicle will be braked according to the driver's desire as dictated by the front and rear braking demand and balanced braking requirements, but consistent with the regenerative braking limits and further the limits necessitated by the avoidance of locked road wheels.
At block 322 , controller 200 inquires as to whether the anti-lock event has ended. If the answer is “no”, the routine returns to block 316 and continues. If however, the answer is “yes” at block 322 , the controller continues to block 324 wherein the status of the braking event is inquired into. If there is no braking occurring, the strategy ends at block 326 . If however, if braking is continuing, the strategy moves to 330 where a post-ABS timer is set equal to zero. This means that although the ABS event has ended, braking is continuing. Then, turning to block 332 , controller 200 sets the front brake post-ABS regenerative limit to the total braking of the front axle at the cessation of the ABS event. This means that the ABS-consistent regenerative braking limit is set equal to the contemporaneous total braking i.e. friction braking and regenerative braking on the front axle. Then, the routine moves to block 334 wherein the post-ABS, or following-ABS regenerative limit for the rear axle is set equal to the total braking on the rear axle. Then, the routine moves to block 336 wherein the front maximum regenerative limit and rear maximum regenerative limit are determined as before, consistent with system considerations such as battery temperature and state of charge, the capacity of the motor/generator, and the power transmission connecting the road wheels and the motor/generator.
After block 336 , controller 200 moves to block 340 wherein a question is asked regarding the front axle post-ABS regenerative limit versus the front brake system maximum regenerative limit. If the front post-ABS regenerative limit is greater than or equal to the front max regen limit, and the answer is “yes” at block 340 , controller 200 moves to block 342 , wherein the rear post-ABS regen limit is compared with the rear max regen limit. If the rear post-ABS regen limit is greater than or equal to the rear max regen limit, the answer is “yes” at block 342 , and controller 200 continues to point 350 which leads to block 302 and continues. If however, the answer is “no” at block 342 or at block 340 , controller 200 moves to block 346 , where total driver braking demand is once again determined as at block 302 . Then, controller 200 moves to block 348 , wherein the status of the braking event is determined. If the braking event has ended, controller 200 moves at point 344 to point 302 and continues. If however, the braking event has not ended at block 348 , the answer is “no” at block 348 , and controller 200 moves to block 352 , wherein the front braking demand and the rear braking demand are determined from total driver braking demand and balanced braking requirements as at block 306 . Then, controller 200 moves to block 354 , wherein rear regen is determined as the minimum value of rear maximum regen limit which is the previously described system limit, and the rear brake demand. Then, at block 356 controller 200 moves to point 358 and then to block 360 . At block 360 , the rear regen value is compared with the rear post-ABS limit. If the rear regen value is greater than the rear post-ABS limit, controller 200 moves to block 364 , wherein the rear post-ABS regen limit is reset to the value of the rear regen. Thus, the rear post-ABS limit may be increased according to driver demand and balanced braking requirements so as to maximize regenerative capability. Then, at block 366 rear available regen is set equal to zero.
If the answer is “no” at block 360 , controller 200 moves to block 362 , wherein the rear available regen is set to the minimum value of the rear max regen limit and the rear post-ABS regen limit, minus the rear regen value. Although it appears that the post-ABS regen limit can never exceed the max regen limit, the max regen limit may drop below the post-ABS regen limit due to slowing of the vehicle. If the answer at block 360 is “yes”, controller 200 moves to block 364 , where the rear post ABS regenerative braking limit is set equal to the previously determined rear regen value. Then, at block 366 , the rear available regen is set equal to zero.
At block 368 , controller 200 compares rear brake demand with the current rear regen value. If rear brake demand is greater than rear regen, the answer is “yes” at block 368 and at block 372 rear excess brake demand is calculated as rear brake demand minus the rear regen value. A positive value for rear excess brake demand means that the desired rear braking cannot be satisfied by the rear axle regenerative braking. If the answer at block 368 is “no”, this means that rear brake demand is less than rear regenerative capability and the rear excess brake demand equals zero.
At block 378 , controller 200 compares the current front regenerative braking value with the front post-ABS regen limit. If the front regen value is greater than front post-ABS limit, the answer to the question at block 378 is “yes”, and at block 380 controller 200 sets the front post-ABS regen limit equal to the front regen amount. Then, at block 382 the front available regen is set equal to zero. If however, the answer to the question posed at block 378 is “no”, the front available regen is set equal to the minimum of a first group of values consisting of the front max regen limit and the front post-ABS regen limit. This minimum is then debited by the amount of the front regen to develop the value of the front available regen. Then, the routine moves to block position 4 at 384 , then at 386 controller continues at block 388 , wherein the front brake demand is compared with the front regen. If the front demand is greater than the front regen, the answer is “yes” at block 388 and controller 200 moves to block 392 , wherein the front excess brake demand is set equal to front brake demand minus front regen. If however, the question posed at block 388 is “no”, front excess brake demand is set equal to zero at block 390 . In either event, controller 200 continues to block 394 where a question is asked regarding the magnitude of front excess brake demand. If the demand is less than or equal to zero, the front friction braking is set to zero at block 395 . If however, the front excess brake demand is greater than zero a question is posed at block 396 regarding the rear available regen as compared with front excess brake demand. If rear available regen is greater than front excess brake demand, rear regen is set at block 400 to the previous value of rear regen plus front excess brake demand, and at block 404 front friction braking is set equal to zero. In other words, at block 400 rear regenerative braking is set equal to previous value of rear regenerative braking plus the front excess brake demand. If the answer to the question posed at block 396 is “no”, rear regen is set equal to the rear post ABS regen limit at block 402 and the routine moves to block 406 wherein the front friction braking is set equal to front excess brake demand minus the rear available regenerative value.
If rear regen is set equal to the prior value of rear regen plus front excess brake demand at block 400 , controller 200 sets front friction braking equal to zero at block 404 . Then, the routine continues at block 408 , wherein rear excess brake demand is compared to a null value. If rear excess brake demand is greater than zero, controller 200 moves to block 410 wherein front available regen is compared with rear excess brake demand. If the front available regenerative braking is greater than rear excess brake demand, controller moves to block 412 wherein front regenerative braking is set equal to previous value of front regenerative braking plus rear excess brake demand. If, however the answer is “no” at block 410 , controller 200 moves to block 414 wherein front regen is set equal to front post ABS regen limit and then, at block 418 rear friction braking is set equal to rear excess brake demand minus front available regen.
At block 416 , controller 200 sets rear friction braking equal to zero in the event that front regen is reset at block 412 . Rear friction braking will also be set equal to zero at block 409 in the event that a negative response is issued at block 408 . In block 420 , the post ABS timer is updated and at block 422 if the post ABS timer has reached the time limit, the routine moves back to normal braking at block 302 via point 426 . If however, the post ABS timer has not run its course, at point 424 the routine will be returned to block 336 for further operations.
Although the present invention has been described in connection with particular embodiments thereof, it is to be understood that various modifications, alterations, and adaptations may be made by those skilled in the art without departing from the spirit and scope of the invention set forth in the following claims.
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A system and method for maximizing the post-ABS regenerative braking capability of an automotive vehicle having regenerative braking available for more than one axle determines the availability of surplus regenerative braking capacity on a first axle and then uses the surplus, if any, to satisfy the brake demand for another axle having insufficient regenerative braking capacity. This system restores regenerative braking without causing the regenerative braking to trigger a subsequent ABS event.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a United States National Phase application of International Application PCT/EP2008/002605 and claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2007 020 938.1 filed May 4, 2007, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a device for detecting and monitoring of damage to anti-friction bearings.
BACKGROUND OF THE INVENTION
For various applications, more particularly for large-size anti-friction bearings employed in off-shore applications, with cranes or buoys it is purposive to provide testing appliances which, working in non-destructive manner and without requiring a disassembly of the bearing, are capable of detecting cracks at the race and/or adjacent regions of the bearing rings. With a prior art device of the initially designated species (EP 0 529 354 B1), detecting and monitoring of damage to races or the like is accomplished by the aid of a measuring device arranged in the anti-friction bearing chamber and having sensors supplied with operating energy in contact-less manner from the outside by way of inductive means. For this purpose, a first coil acting as energy source is arranged in the anti-friction bearing chamber to supply the required electrical energy to the measuring device, whereas an induction coil connectible to an exterior power net and inductively coupled to the first coil is provided in one of the bearing rings, said induction coil being located in a circumferential groove open towards the anti-friction bearing chamber and extending over the entire bearing circumference. A uniform and even transfer of energy to the first coil is thus made possible irrespective of the momentary position of the bearing rings.
However, such devices are considered expensive in that the circumferential groove destined to accommodate the induction coil must be configured in the mostly hardened area of the relevant bearing ring, the area facing the anti-friction bearing chamber. In case the bearings are of a type that does not permit two complete revolutions in one direction or another during the measurement, but still call for monitoring the complete bearing rings, it is necessary to provide for several measuring devices. To avoid reciprocal interferences on transmission of data, it is expedient to provide a number of induction coils and a corresponding number of circumferential grooves that corresponds to the number of measuring devices, which multiplies expenditure and cost involved. Irrespective thereof, it is only possible to accommodate a maximum of two induction coils for lack of space, thus entailing restrictions with regard to measuring possibilities.
SUMMARY OF THE INVENTION
Now, therefore, it is the object of the present invention to configure the device of the initially designated species in such a manner that it can be manufactured at less expenditure, thus being less costly and requiring no circumferential grooves.
According to the invention, a device is provided for detecting and monitoring damage to races or adjacent regions of bearing rings of anti-friction bearings. The device comprises a measuring device disposed in the anti-friction bearing chamber. The invention also relates to a combination anti-friction bearing and device for detecting and monitoring damage to races or adjacent regions of bearing rings. The measuring device is disposed at least partially in the anti-friction bearing chamber. The measuring device has a sensor for transmission of measuring signals and a sensor measurement data transmission means for transmitting measuring signals outside the anti-friction bearing chamber. The measuring device has an energy source comprising a first coil to supply the electrical energy required by the measuring device. The first coil is disposed in the anti-friction bearing chamber. The measuring device has a second coil disposed outside the anti-friction bearing chamber for inductive transfer of electrical energy to the first coil. The second coil extends only over a part of the bearing circumference. The energy source further comprises an energy accumulator connected to the first coil for storing electrical energy received by the first coil from the second coil.
The present invention bears an advantage in that the second coil only needs to be inductively coupled over a very small part of the bearing circumference to a first coil allocated to it and accommodated in the anti-friction bearing chamber. Energy transferred during the inductive coupling can be stored in an energy accumulator connected to the first coil and, if properly dimensioned, it is sufficient to take the desired measurements. Analogously it is possible to store emitted measuring data intermediately in a data memory and to transfer the data only if both coils stand opposite to each other. Therefore, the hardened area allocated to the anti-friction bearing chamber needs to be interrupted only in the area of a small bore accommodating the second coil. As the additionally required electronic components take little impact on overall costs, it results a low-cost flexibly applicable monitoring device.
The second coil may advantageously be arranged in a sleeve introduced into a bore of one of the bearing rings. The sleeve may advantageously be provided with a contact system arranged on a circumferential area of the bearing ring accommodating the sleeve, said contact system for connection to a voltage source
The energy accumulator may advantageously comprise a capacitor or rechargeable battery (storage cell) and a rectifier arranged between the capacitor or rechargeable battery and the first coil.
The measuring device may advantageously be accommodated in a part of a cage for guidance and separation of anti-friction bearing bodies, said part of the cage extending over several anti-friction bearing partitions. Several measuring devices may advantageously be provided that are accommodated in several cage parts of said cage arranged in a distribution spread at the bearing circumference.
The measuring device and energy source may also be accommodated in an anti-friction bearing body configured as a measuring roll.
The measuring device may advantageously further comprise a data memory.
Transmission means may advantageously comprise inductive elements coupled to each other. The inductive elements may advantageously be the first coil and the second coil.
The invention is now elucidated in greater detail in connection with the enclosed drawings showing some embodiments. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic radial sectional view through an anti-friction bearing with parts of an inventive device;
FIG. 2 is a schematic view showing the set-up of a measuring appliance of the device according to FIG. 1 ;
FIG. 3 is an enlarged partial cross-sectional view through the anti-friction bearing showing a first embodiment for accommodating the measuring device and a pertinent energy source of the device according to FIG. 1 ;
FIG. 4 is a longitudinal sectional view through a sleeve of the device according to FIG. 1 , the sleeve provided with a coil;
FIG. 5 is a front-end view of the sleeve according to FIG. 4 ;
FIG. 6 is a schematic view showing an embodiment example for an electrical circuit of the energy source of the device;
FIG. 7 is an enlarged partial cross-sectional view through the anti-friction bearing according to FIG. 1 showing a second embodiment example for accommodating the measuring device and a pertinent energy source of the device; and
FIG. 8 is a schematic cross-sectional view through the anti-friction bearing according to FIG. 1 and an embodiment example comprised of several measuring appliances of the inventive device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in particular, the embodiment example of the inventive device as schematically represented in FIG. 1 shows a large-size anti-friction bearing comprised of a turnable bearing ring 1 , a stationary bearing ring 2 , and a retainer ring 3 which is rigidly connected to the afore-mentioned rings, in between of which anti-friction bearing chambers are provided at three levels. These anti-friction bearing chambers are bordered by races 4 , 5 for anti-friction bearing bodies 6 here configured as cylinder rolls. Moreover, to guide and separate the anti-friction bearing bodies 6 , cages 7 are provided for in the anti-friction bearing chambers as shown in FIG. 1 for the uppermost level only, the cages having webs 7 a engaging between the anti-friction bearing bodies 6 . Races 4 and 5 as well as the adjacent areas, more particularly the transitions between races 4 , 5 and the bearing rings, are basically provided with a hardening layer.
To monitor races 4 and 5 as well as the adjacent areas and to detect eruptions and cracks 8 ( FIG. 2 ) developing in them, an electrical measuring device 9 is accommodated in at least one of the anti-friction bearing chambers, more particularly in a web 7 a of one of the cages 7 . The measuring device at least comprises one sensor 10 which in the embodiment example shown here is configured as a high-frequency coil that closely stands opposite to one of the races 4 , 5 or to an adjacent area as shown in FIG. 2 , with an air gap being formed, and which generates a high-frequency electromagnetic alternating field 11 that entails eddy currents in races 4 , 5 and transitions made of steel. The magnetic coupling thus produced entails an attenuation of an oscillating circuit of measuring device 9 , the oscillating circuit comprising sensor 10 , and the attenuation being dependent upon the variation in the air gap. The variation in amplitude resulting hereof determines the magnitude of measuring signals.
Conditioning and treatment of these measuring signals is executed in an electrical circuit configuration of measuring device 9 , the electrical circuit configuration being connected to sensor 10 and the components of which being accommodated in the same or in an adjacent web of the relevant cage 7 , depending on prevailing space conditions. Finally, the measuring device 9 is comprised of a means, here configured as a sending aerial 12 , for transmission of measuring signals to the exterior where the measuring signals are picked-up, for example by means of a receiving aerial 14 accommodated in the bearing ring 2 , and passed on for further processing and evaluation.
The operating energy for sensors 10 and the electrical and/or electronic components of measuring device 9 is also furnished by an energy source 15 arranged in the relevant anti-friction bearing chamber, the energy source comprising a first coil 16 mounted to the relevant cage 7 and a rectifier 17 connected to the coil. The first coil 16 extends only over a small part of the bearing circumference and it is inductively coupled to a second coil 18 arranged outside the relevant anti-friction bearing chamber, preferably in bearing ring 2 , and which serves to transfer the electrical energy required by measuring device 9 from the outside inductively to the first coil 16 .
Devices of the kind described hereinabove are known, for example from publication EP 0 529 354 B1 (corresponding to U.S. Pat. No. 5,226,736) which for avoidance of repetitions is hereby made an object of the present disclosure by taking reference to it. U.S. Pat. No. 5,226,736 is hereby incorporated by reference.
According to the present invention, the second coil 18 also extends only over a part of the bearing circumference, preferably over a very small part of the bearing circumference extending over a few anti-friction bearing body partitions, as is particularly shown in FIG. 3 . Therefore, on turning the bearing ring 1 in the direction of the double arrow w ( FIG. 3 ), electrical energy can only be transferred to the first coil 16 if the second coil 18 stands opposite to the first coil 16 according to FIG. 3 so that there is a sufficiently strong magnetic coupling. However, in order to assure sufficient energy supply even for those relative positions of bearing rings 1 , 2 in which the coils 16 , 18 are not inductively coupled, the energy source 15 is inventively provided with an energy accumulator 19 which is only indicated schematically in FIG. 3 . For example, this energy accumulator 19 at least comprises a high-capacitive condenser (capacitor) or at least an accumulator (Storage cell—rechargeable battery). Thus it is achieved that the energy accumulator 19 is recharged whenever the second coil 18 approaches the first coil 16 and/or runs past it. If the time for full charging of the energy accumulator on turning the bearing is too short, the bearing ring 1 can also be held-up for a short time. Capacitors suitable for this purpose, for example, are those capacitors that are obtainable on the market under the designations “Gold Cap” or “Super Cap” and which have capacitances ranging for example from 1 F up to any beyond 100 F, depending on their size and voltage. Just to put an example, it should be noted that the energy source 15 with a capacitor of 11 F and an admissible voltage drop of 0.8 V can supply an electric current of 10 mA for a period of approx. 14 minutes to the measuring device 9 .
Pursuant to FIGS. 1 , 3 , 4 , and 5 the second coil 18 is fastened in one end of sleeve 20 and mounted on a conventional pot-shaped shell and/or ferritic core 21 or the like. At the opposite end, sleeve 20 comprises a flanged plate 22 acting as arrest stop and provided with screw holes 23 to allow for its fastening to the inside of bearing 2 , for example. Furthermore, at least one equalizer capacitor 24 connected to coil 18 may be provided in the sleeve 20 . Finally, the flanged plate 22 is protruded by a plug-type and/or socket-shaped contact system 25 , the contacts of which are connected to coil 18 , equalizer capacitor 24 and to other components, if any. In accordance with FIG. 6 , such another component may be the receiving aerial 14 which is also accommodated in the sleeve 20 and which is connected to an allocated contact of contact system 25 . In this case, the sending aerial 12 is preferably arranged near the first coil 16 . Besides, the sleeve 20 may be filled with a grouting compound 20 a.
FIG. 6 schematically shows the electrical circuit of energy source 15 with the first coil 16 , a ferritic core 6 carrying the coil, the energy accumulator 19 , rectifier 17 arranged between the energy accumulator 19 and coil 16 , and a smoothening capacitor 27 . The connection contacts of energy accumulator 19 are connected with inputs of the measuring device 9 . The same applies to a connecting contact of sending aerial 12 . Furthermore, the second coil 18 with the ferritic core 21 , equalizer capacitor 24 , receiving aerial 14 and contact system 25 connected to these components are recognizable from FIG. 6 . As a matter of fact, the configuration is so purposive and expedient that coil 18 automatically takes the proper position for the intended energy transfer when sleeve 20 with its flanged plate 22 leans to bearing ring 2 after it has been introduced into the bore of bearing ring 2 .
As is furthermore shown in FIG. 6 , in case of checking the bearing for those faults outlined hereinabove, it is merely required to connect a testing appliance 28 to the contact system 25 , the testing appliance comprising a power pack 29 destined for being connected to the second coil 16 and a data processing unit 30 to be linked to the receiving aerial 14 , with it also being possible for the data processing unit to be a PC or a laptop. Then, by means of testing appliance 28 , the alternating voltage required in a given case is supplied to the second coil 18 in order to recharge the energy accumulator 19 via the rectifier 17 by the aid of the first coil 16 whenever it runs past sleeve 20 . Thereby it is ensured that the measuring device 9 receives the required direct current even in case that both coils 16 , 18 do not stand opposite to each other. At the same time, by means of the data processing unit 30 , the measuring data transmitted from sending aerial 12 to receiving aerial 14 can be picked-up and be directly evaluated or loaded into a data memory of the data processing unit 30 for subsequent evaluation, depending on requirements. Upon completion of the bearing check-up, the testing appliance 28 is again disconnected from the contact system. As a matter of fact, it would also be conceivable to leave the testing appliance 28 as a stationary unit at the bearing and to provide it with a connecting socket for the connecting cable of a voltage source or the like.
Unless data transmission is accomplished in radio mode, the transmission of measuring data from the sending aerial 12 to the receiving aerial 13 is basically only possible if both aerials 12 , 14 are mainly exactly positioned opposite to each other. Therefore, in a further development of the present invention, it is envisaged to provide the measuring device 9 with an additional data memory in which the measuring data determined with a full (or partial) revolution of the bearing can be intermediately stored. A transmission of measuring data to the receiving aerial 14 is performed whenever both aerials 12 , 14 are aligned to each other. The data memory is comprised of a memory chip adapted to a processor that controls the internal sequencing and that builds-up the communication.
Instead of a data transmission by means of aerials, it is also possible to transmit data with magnetically coupled inductive elements, with it being possible with special advantage that these inductive elements are the same coils 16 and 18 which serve for energy transfer. Such a transfer can be performed simultaneously or consecutively for better separation of data transmission from energy transfer. For example, with a simultaneous transmission and/or transfer, reactions are measured that result because of the operation of sensor 10 with regard to amplitude, phase or frequency in the currents and/or voltages of the second coil 18 . Conversely, a data transmission that is independent of the energy transfer can be accomplished, for example, by arranging a third coil upstream or downstream of the first coil 16 in the direction of rotation of bearing ring 1 , the third coil merely serving for data transmission and transmitting data to the second coil 18 as it runs past the second coil. Inversely, another second coil 18 might also be provided for in a manner that a data transmission and then an energy transfer (or vice versa) can be accomplished with the same first coil 16 , depending on which second coil 18 momentarily stands opposite to the first coil 16 . In these cases, too, the data are intermediately stored in a data memory of the measuring device 9 for as long as the relevant coils do not stand opposite to each other.
In principle, the described components of measuring device 9 can be distributed to an arbitrary number of cages 7 preferably arranged side by side and in some cases being configured as mere intermediate pieces between the anti-friction bearing bodies 6 . Depending of spatial conditions, it is furthermore possible to remove individual anti-friction bearing bodies 6 to create space for the components of measuring device 9 . If there are cages 7 made of plastic material, it may be expedient to remove some of these cages 7 and anti-friction bearing bodies guided by them and to install a cage made of steel into the part of the anti-friction bearing chamber thus cleared. Hereby it can be avoided that deformation, if any, of plastic cages evolving on operation takes an adverse impact on measuring accuracy.
Alternatively it is furthermore possible to configure at least one of the anti-friction bearing bodies 6 as a measuring roll. For this purpose, the energy source 15 with the first coil 16 and the measuring device 9 connected to it and comprised of sensor 10 are accommodated in one of the anti-friction bearing bodies 6 . This is schematically indicated in FIG. 7 , according to which coil 16 is arranged in a front-end area of one of anti-friction bearing bodies 6 , the front-end area facing the bearing ring 2 , and according to which the coil 16 can rotate together with the anti-friction bearing body. The measuring device 9 and the other parts of energy source 15 are accommodated—which is not shown here—in the same anti-friction bearing body 6 . Energy transfer and data transmission occur whenever the relevant anti-friction bearing bodies 6 stand opposite to the second coil 18 .
FIG. 8 shows an embodiment example of the present invention with several cages 7 a , 7 b , and 7 c arranged at a certain spacing in the circumferential direction of the bearing and in which a separate energy source 15 each as well as a measuring device 9 linked to it are arranged. As the energy and data, in turn, are only transferred and/or transmitted at one point of the bearing circumference where the sleeve 20 with the second coil 18 is located, the various measuring devices 9 cannot influence each other reciprocally. The embodiment example shows three cages 7 a , 7 b , and 7 c which are staggered by approx. 120° each in circumferential direction, but as a matter of fact only two or more than three cages 7 , too, can be provided with energy sources and measuring devices. Theoretically, by analogy with FIG. 7 , one separate energy source 15 and one measuring device 9 each might be arranged in each individual anti-friction bearing body 6 .
The present invention is not restricted to the examples of embodiments described herein. In particular, this applies to the number and arrangement of the totally existing first and second coils 16 , 18 and the facilities connected and linked to them. The application of several both first and second coils 16 , 18 arranged at a certain spacing to each other in circumferential direction, for example, would have an advantage in that the races 4 , 5 and the adjacent areas could be checked all around without it being necessary for the cages 7 to execute a full rotation. Furthermore, the aerials 12 , 14 need not be integrated into the coil 16 or sleeve 20 . Instead they can be arranged in another bore of bearing ring 2 , the bore being spaced by a few centimeters either to the one or to the other side of sleeve 20 . In FIG. 8 , this is schematically indicated by a line 31 . A clean separation of data transmission from energy transfer can be achieved hereby, too. Moreover, the possibilities for data transmission as outlined hereinabove should be noted as examples only, because there are other possibilities for a contact-less data transmission. Furthermore, it is obvious that measuring device 9 in principle just needs to comprise the sensor (high-frequency coil 10 ) and a means for transmission of measuring signals received by means of this sensor, because the complete processing and evaluation of measuring signals could also be performed with a computer or the like connected to the contact system 25 . Finally, it is self-evident that the various features can be applied in combinations other than those described and outlined herein.
While specific embodiments of the invention have been described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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The invention relates to a device for detecting and monitoring damage to races or adjacent regions of bearing rings ( 1, 2, 3 ) of anti-friction bearings. The device includes a measuring device, disposed in the anti-friction bearing chamber, having a sensor and structure for supplying sensor measurement data to the outside. The device has an energy source, which is also disposed in the anti-friction roller bearing chamber and which comprises a first coil ( 16 ) for the measuring device and a second coil ( 18 ) disposed outside the anti-friction bearing chamber and destined for inductive transfer of electrical energy to the first coil ( 16 ). The second coil ( 18 ) extends only over a part of the bearing circumference and the energy source comprises an energy accumulator ( 19 ) connected to the first coil ( 16 ).
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FIELD OF THE INVENTION
[0001] The present invention refers to a method of producing a nonwoven material comprising forming a fibrous web of continuous filaments and natural fibres and/or synthetic staple fibres, and subsequently hydroentangling the fibrous web while supported by an entangling member.
BACKGROUND OF THE INVENTION
[0002] Hydroentangling or spunlacing is a technique introduced during the 1970'ies, see e.g. CA 841,938. The method involves forming a fibre web which is either drylaid or wetlaid, after which the fibres are entangled by means of very fine water jets under high pressure. Several rows of water jets are directed against the fibre web which is supported by an entangling member in the form of a movable wire or a perforated rotatable drum. The entangled fibre web is then dried. The fibres that are used in the material can be synthetic or regenerated staple fibres, e.g. polyester, polyamide, polypropylene, rayon or the like, pulp fibres or mixtures of pulp fibres and synthetic staple fibres. Spunlaced materials can be produced with high quality to a reasonable cost and have a high absorption capacity. They can e.g. be used as wiping material for household or industrial use, as disposable materials in medical care and for hygiene purposes, etc.
[0003] Through EP-B-333,211 and EP-B-333,228 it is known to hydroentangle a fibre mixture in which one type of fibres is meltblown fibres. The polymers used for the continuous filaments are mostly polyolefins, especially polypropylene and polyethylene, or polyethylene terephtalate, polybutylene terephtalate, polyvinyl chloride etc. The base material, i.e. the fibrous material which is exerted to hydroentangling, either consists of at least two preformed fibrous layers, where one layer is composed of meltblown fibres or of a “coformed material”, in which an essentially homogeneous mixture of meltblown fibres and other fibres is airlaid on a wire.
[0004] Through EP-A-308,320 it is known to bring together a web of bonded continuous filaments with wetlaid fibrous material containing pulp fibres and staple fibres. The separately formed fibrous webs are hydroentangled together to form a laminate. In such a material the fibres of the different fibrous webs will not be well integrated with each other since the continuous fibres are pre-bonded. This pre-bonding of the continuous filament will during the hydroentangling procedure limit the mobility and thereby result in a material with limited integration.
[0005] Through WO 92/08834 it is known to air-lay staple fibres on a forming wire and on top thereof air-lay defibrated pulp fibres. The formed fibrous web is then subjected to three steps of hydroentanglement. In the first step the web is hydroentangled against a fine-mesh wire and is then transferred to coarse-mesh screen on which it is exerted to a second hydroentangling. In this second hydroentangling step the water jets will press loose fibre ends through the coarse meshes in the wire. The web is then transferred to a third fine-mesh wire and hydroentangled a third time in order to ensure that those loose fiber ends will be folded against the fine-mesh wire and be intertwined and firmly secured to the web. This is told to produce a spunlace material having a high wear resistance.
[0006] Through U.S. Pat. No. 5,459,912 it is known to make patterned spunlace materials comprising woodpulp fibers and synthetic fibers. The synthetic fibers may be in the form of textile staple fibers or spunbonded fibers. The spunbonded fibers are in the form of a spunbonded web of filaments, which means that the filaments are thermally bonded to each other and cannot move and integrate with the other fibers during the hydroentangling.
[0007] WO 99/20821 discloses a method of making a composite nonwoven material, wherein a fibres and a web of continuous filaments, such as a spunbond or meltblown web, are hydroentangled, a bonding material is applied to the web, which is subsequently creped. Again the web of continuous filaments is a web wherein the filaments are bonded to each other.
[0008] Through EP-B-938,601 it is known to bring together a web of continuous filaments with foam formed fibrous material containing pulp fibres and synthetic staple fibres. The resulting web is then hydroentangled together to a composite material in one hydroentangling step. The continuous filaments are substantially free from each other before hydroentangling and the resulting material will show an integration between the foam formed material and the continuous filaments.
[0009] There is however still room for improvements especially with respect to hydroentangled materials having a patterned and/or apertured structure and a good integration between continuous filaments and other fibers contained in the web.
SUMMARY OF THE INVENTION
[0010] The object of the present invention is to provide a method of making a hydroentangled nonwoven material comprising continuous filaments and natural fibres and/or synthetic staple fibres, in which the continuous filaments are well integrated with the other fibers and the material has a patterned and/or apertured structure. This has according to the invention been obtained by forming a web of continuous filaments on a forming member, the continuous filaments being free from each other without any thermal or adhesive bonds therebetween, and applying a wetformed fiber dispersion containing natural fibers and/or synthetic or regenerated staple fibers on top of said synthetic filaments, thus forming a fibrous web containing said continuous filaments and said natural fibers and/or staple fibers and subsequently hydroentangling the fibrous web, the web during hydroentangling being supported by a first entangling member, wherein the fibrous web is hydroentangled, from the side on which the natural fibers and/or staple fibers are applied, in two subsequent hydroentangling stations and is between said hydroentangling stations transferred from said first entangling member to a second entangling member, wherein said first entangling member has a mesh value of at least 20 mesh/cm and the second entangling member has a mesh value of no more than 15 mesh/cm. After the second hydroentangling station the web is dried without additional hydroentangling.
[0011] According to one aspect of the invention no hydroentangling of the fibrous web takes place from the side on which the continuous filaments are applied.
[0012] According to one embodiment the natural fibres and/or the synthetic staple fibres are deposited on top of a web of continuous filaments.
[0013] According to a further embodiment the natural fibres and/or the synthetic staple fibres are applied in the form of a wet- or foam formed fiber dispersion on top of the continuous filaments.
[0014] In one aspect of the invention the first entangling wire has a mesh value of at least 30 mesh/cm, preferably a mesh value between 30 and 50 mesh/cm. It further may have a count value of at least 17, preferably at least 23 count/cm, and more preferably it has a count value between 23 and 35 count/cm.
[0015] In a further aspect of the invention the second entangling wire has a mesh value of no more than 12 mesh/cm, preferably-no more than 10 mesh/cm and most preferably it has a mesh value between 6 and 10 mesh/cm. The second entangling wire may further have a count value of no more than 15, preferably no more than 12, more preferably no more than 11 and most preferably it has a count value between 6 and 11 count/cm.
[0016] In one embodiment the continuous filaments are spunlaid filaments.
[0017] In a further embodiment the fibrous web comprises between 0.5 and 50% by weight, preferably between 15 and 30% by weight, continuous filaments.
[0018] In one aspect of the invention the fibrous web comprises between 20 and 85% by weight, preferably between 40 and 75% by weight natural fibers.
[0019] The natural fibers are according to one embodiment pulp fibers.
[0020] In a further aspect of the invention the fibrous web comprises between 5 and 50% by weight, preferably between 5 and 20% by weight synthetic or regenerated staple fibers.
[0021] According to one embodiment at least a major part of the synthetic staple fibres have a fiber length between 3 and 7 mm.
[0022] According to one aspect of the invention apertures are formed in the fibrous web in the second entangling station.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention will below be closer described with reference to an embodiment shown in the accompanying drawings.
[0024] FIG. 1 shows schematically an embodiment of a process for producing a hydroentangled nonwoven material according to the invention.
[0025] FIG. 2-4 show ESEM images of a nonwoven material produced according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The hydroentangled composite material according to the invention comprises a mixture of continuous filaments and natural fibers and/or synthetic staple fibers. These different types of fibers are defined as follows.
[0027] Continuous Filaments
[0028] The continuous filaments are fibers that in proportion to their diameter are very long, in principle endless. They can be produced by extruding a molten thermoplastic polymer through fine nozzles, whereafter the polymer will be cooled and drawn, preferably by the action of an air flow blown at and along the polymer streams, and solidified into strands that can be treated by drawing, stretching or crimping. Chemicals for additional functions can be added to the surface.
[0029] Filaments can also be regenerated fibers produced by chemical reaction of a solution of fiber-forming reactants entering a reagent medium, for example by spinning of regenerated cellulose fibers from a cellulose xanthate solution into sulphuric acid. Examples of regenerated cellulose fibers are rayon, viscose or lyocell fibers.
[0030] Continuous filaments may be in the form of spunlaid filaments or meltblown filaments. Spunlaid filaments are produced by extruding a molten polymer, cool and stretch to an appropriate diameter. The fiber diameter is usually above 10 μm, e. g. between 10 and 100 μm. Production of spunlaid filaments is described for example in U.S. Pat. Nos. 4,813,864 and 5,545,371.
[0031] Meltblown filaments are formed by means of a meltblown equipment 10, for example of the kind shown in the U.S. Pat. Nos. 3,849,241 or 4,048,364. The method shortly involves that a molten polymer is extruded through a nozzle in very fine streams and converging air streams are directed towards the polymer streams so that they are drawn out into continuous filaments with a very small diameter. The filaments can be microfibers or macrofibers depending on their dimension. Microfibers have a diameter of up to 20 μm, but usually are in the interval between 2 and 12 μm in diameter. Macrofibers have a diameter of over 20 μm, e. g. between 20 and 100 μm.
[0032] All thermoplastic polymers can in principle be used for producing spunlaid and meltblown filaments. Examples of useful polymers are polyolefins, such as polyethylene and polypropylene, polyamides, polyesters and polylactides. Copolymers of these polymers may of course also be used.
[0033] Tow is another type of filaments, which normally are the starting material in the production of staple fibers, but which also is sold and used as a product of its own. In the same way as in the production of with spunlaid fibers, tow is produced from fine polymer streams that are drawn out and stretched, but instead of being laid down on a moving surface to form a web, they are kept in a bundle to finalize drawing and stretching. When staple fibers are produced, this bundle of filaments is then treated with spin finish chemicals, are often crimped and then fed into a cutting stage where a wheel with knives will cut the filaments into distinct fiber lengths that are packed into bales to be shipped and used as staple fibers. When tow is produced, the filament bundles are packed, with or without spin finish chemicals, into bales or boxes.
[0034] The continuous filaments will in the following be described as spunlaid fibers, but it is understood that also other types of continuous filaments, e. g. meltblown fibers, can be used. Preferably spunlaid filaments are used, since they result in a stronger material. In this case it is an advantage having the stronger spunlaid filaments, as they withstand the mechanical agitation exerted by the water jets. The spunlaid filaments are easily movable by the action of the water jets and will create patterns and apertures in the web material. The weaker meltblown filaments may break during hydroentangling.
[0035] Natural Fibers
[0036] The natural fibers are usually cellulose fibers, such as pulp fibers or fibers from grass or straw. Pulp fibers are the most commonly used natural fibers and are used in the material for their tendency to absorb water and for their tendency to create a coherent sheet. Both softwood fibers and hardwood fibers are suitable, and also recycled fibers can be used, as well as blends of these types of fibers. The fiber lengths will vary from around 2-3 mm for softwood fibers and around 1-1.5 mm for hardwood fibers, and even shorter for recycled fibers.
[0037] Staple Fibers
[0038] The staple fibers used can be produced from the same substances and by the same processes as the filaments discussed above. They may either be synthetic fibers or regenerated cellulose fibers, such as rayon, viscose or lyocell. The cutting of the fiber bundles is normally done to result in a single cut length, which can be altered by varying the distances between the knives of the cutting wheel. The fiber lengths of conventional wetlaid hydroentangled nonwovens are usually in the interval 12-18 mm. However according to the present invention also shorter fiber lengths, from about 2-3 mm, can be used.
[0039] The Process
[0040] According to the embodiment shown in FIG. 1 continuous filaments 11 in the form of spunlaid fibers are produced by extruding a molten polymer, cool it and stretch it to an appropriate diameter. The fiber diameter is usually above 10 μm, e. g. between 10 and 100 μm.
[0041] In an alternative embodiment meltblown fibers are formed by means of a meltblown equipment. The meltblown technique shortly involves that a molten polymer is extruded through a nozzle in very fine streams and converging air streams are directed towards the polymer streams so that they are drawn out into continuous filaments with a very small diameter.
[0042] The fibers can be microfibers or macrofibers depending on their dimension. Microfibers have a diameter of up to 20 μm, but usually are in the interval between 2 and 12 μm in diameter. Macrofibers have a diameter of over 20 μm, e. g. between 20 and 100 μm.
[0043] All thermoplastic polymers can in principle be used for producing spunlaid and meltblown fibers. Examples of useful polymers are polyolefins, such as polyethylene and polypropylene, polyamides, polyesters and polylactides. Copolymers of these polymers may of course also be used.
[0044] According to the embodiment shown in FIG. 1 the spunlaid fibers 11 are laid down directly on a forming wire 12 where they are allowed to form a relatively loose, open web structure in which the fibers are relatively free from each other. This is achieved by making the distance between the spunlaying nozzle and the wire relatively large, so that the filaments are allowed to cool down before they land on the wire 12 . The basis weight of the formed spunlaid layer should be between 2 and 50 g/m 2 and the bulk between 5 and 15 cm 3 /g.
[0045] An aqueous or a foamed fibrous dispersion 13 from a headbox 14 is laid on top of the spunlaid filaments. In wet laying technique the fibers are dispersed in water, with optional additives, and the fiber dispersion is dewatered on a forming fabric to form a wet laid fibrous web. In the foam forming technique, which is a special variant of wet-laying, a fibrous web is formed from a dispersion of fibers in a foamed liquid containing water and a surfactant. The foam forming technique is described in for example GB 1,329,409, U.S. Pat. No. 4,443,297, WO 96/02701 and EP-A-0 938 601. A foam-formed fibrous web has a very uniform fiber formation. For a more detailed description of the foam forming technique reference is made to the above mentioned documents.
[0046] The spunlaid filaments and the fiber dispersion of natural fibers and/or synthetic staple fibers may be formed on the same or on different wires. The web of spunlaid filaments laid on the wire 12 has a rather low basis weight and is substantially unbonded, which means that the web is very weak and has to be handled and transferred to the next forming station, the headbox 14 , very gently.
[0047] In order to provide a certain consolidation of the web of spunlaid filaments and avoid that the web is damaged on its way to the headbox, moisture is according to one embodiment of the invention applied to the web by a spray bar 15 or gentle shower before laying the wet- or foam formed fiber dispersion on the web of the continuous filaments. By this the web of continuous filaments is flattened out and a firm contact between the web and the forming wire is established before it enters the headbox zone, in which the wet- or foam formed fiber dispersion is laid on top of the web of continuous filaments. The wettening of the filaments takes place at a very low pressure so that no substantial bonding or sideways displacement of the fibers take place. The surface tension of the water will adhere the filaments to the wire so the formation will not distort while entering the headbox. The term “no substantial bonding” as used herein means that there will be no substantial bonding effect in addition to what is caused by the surface tension of the liquid used. In some cases, when hydrophobic polymers are used for forming the spunlaid filaments, a small amount of a surfactant, between 0.001 and 0.1% by weight, may be added to the water used for moistening the spunlaid filaments.
[0048] Fibers of many different kinds and in different mixing proportions can be used for making the wet laid or foam formed fibrous web. Thus there can be used pulp fibers or mixtures of pulp fibers and synthetic staple fibers, e g polyester, polypropylene, rayon, lyocell etc. Varying fiber lengths can be used. However, according to the invention, it is of advantage to use relatively short staple fibers, below 10 mm, preferably in the interval 2 to 8 mm and more preferably 3 to 7 mm. This is for some applications an advantage because the short fibers will more easily mix and integrate with the spunlaid filaments than longer fibers. There will also be more fiber ends sticking out form the material, which increases softness and textile feeling of the material. For short staple fibers both wet laying and foam forming techniques may be used.
[0049] As a substitute for pulp fibers other natural fibers with a short fiber length may be used, e. g. esparto grass, phalaris arundinacea and straw from crop seed.
[0050] It is preferred that the fibrous web comprises as least between 20 and 85% by weight, preferably between 40 and 75% by weight natural fibers, for example pulp fibers.
[0051] It is further preferred that the fibrous web contains between 10 and 50% by weight, preferably between 15 and 30% by weight, continuous filaments, for example in the form of spunlaid or meltblown filaments.
[0052] The fiber dispersion laid on top of the spunlaid filaments is dewatered by suction boxes (not shown) arranged under the wire 12 . The short pulp fibers and synthetic staple fibers are formed on top of the spunlaid web, which provides the necessary closeness and acts like an extra sieve for the formation of the short fibers.
[0053] The thus formed fibrous web comprising spunlaid filaments and other fibers is then hydroentangled in a first entangling station 16 including several rows of nozzles, from which very fine water jets under high pressure are directed against the fibrous web. In the embodiment shown the same wire 12 is used for supporting the web in the first entangling station 16 as for the formation of the web. Alternatively, the fibrous web can before hydroentangling be transferred to a special entangling wire. In both cases the web is entangled from the natural/staple fiber side in order to obtain a penetration of the short natural fibers/staple fibers into the filament web.
[0054] The wire or screen 12 supporting the web in the first hydroentangling step is relatively fine mesh, at least 20 mesh/cm and preferably at least 30 mesh/cm. Most preferably the wire supporting the web in the first hydroentangling station has a mesh value between 30 and 50 mesh/cm. For a woven wire mesh value is herewith defined as the number of monofilament strands in the warp direction of the wire.
[0055] The wire 12 may be woven wire or another fluid permeable screen member adapted to support a fibrous web during hydroentangling. An example of such a screen is a moulded, close-mesh screen of thermoplastic material as disclosed in WO 01/88261. The mesh number is in this case defined as the number of strands of thermoplastic material extending between apertures of the screen in the machine direction. A similar definition is given the mesh value for other types of screens adapted for hydroentangling.
[0056] The wire further has a count of at least 17 and preferably at least 23 count/cm. Most preferably it has a count value between 23 and 35 count/cm. For a woven wire the count value is defined as the number of monofilament strands in the shute direction per cm of the wire. For other types of screens which are not woven wires, the count value is defined as the number of strands of material extending between apertures of the screen in cross direction.
[0057] After the first hydroentangling station the web is transferred to a second hydroentangling wire or screen 17 , which supports the fibrous web in a second hydroentangling station 18 including several rows of nozzles, from which very fine water jets under high pressure are directed against the fibrous web. The hydroentangling takes place from the same side of the fibrous web as in the first hydroentangling station, i.e. from the natural fiber/staple fiber side. The wire or screen 17 used in the second hydroentangling step is relatively coarse and has a mesh value of no more than 15, preferably no more than 12 and more preferably no more than 10 mesh/cm. Most preferably the wire 17 has a mesh value between 6 and 19 mesh/cm. Mesh value is defined for woven wires and for other screens as above.
[0058] The wire or screen 17 further has a count value, as defined above, of no more than 15, preferably no more than 12 count/cm and preferably no more than 11. Most preferably it has a count value between 6 and 11 count/cm.
[0059] It is important that the filaments are relatively unbonded and displaceable after the first hydroentangling step, so as to permit a certain rearrangement and mobility of the fibers and filaments in the second hydroentangling station 18 by the action of the water jets. This will create a good penetration of the short natural fibers/staple fibers into the filament web and thus a good integration of the fibers and filaments. Due to the relatively coarse wire or screen 17 a patterning effect and even the creation of apertures in the fibrous material are obtained in the second hydroentangling station 18 .
[0060] In a preferred embodiment a woven wire is used at least in the second hydroentangling step, since a woven wire normally has a more pronounced three-dimensional structure as compared to a screen of other kind.
[0061] Fibrous webs having a three-dimensional patterned structure and/or apertures have certain advantages for example when used as wiping material, since they provide an improved cleaning effect especially for viscous substances and particles.
[0062] After the hydroentangling the material 17 is dried and wound up. The material is then converted in a known manner to a suitable format and is packed. Since it is preferred to have closed loops of process water as far as this is possible, the water that has been dewatered at the forming, moistening and hydroentangling steps is preferably recirculated.
EXAMPLE
[0063] A hydroentangled fibrous web was produced containing a combination of spunlaid filaments and pulp fibers. The following proportion of filaments and fibers were used:
[0064] 25% by weight spunlaid filaments, PP 3 dtex; 75% by weight pulp fibers.
[0065] The pulp fibers were supplied by wet-laying. The fibrous web was hydroentangled in a first hydroentangling station while supported on a Flex 310 K wire supplid by Albany International, which has a mesh value of 41 and a count value of 30.5 per cm. The energy input in the first hydroentangling step was relatively low, about 100 kWh/t. The first hydroentangling station comprised 1 row of nozzles with a pressure of 79 bar (1×79 bar). The web was fed through the first entangling station at a speed of 24 m/min. The web was subsequently hydroentangled in a second hydroentangling station while supported on a Combo 213 B wire supplied by Albany International having a mesh of 9 and a count of 10 per cm. The second hydroentangling station comprised 3 rows of nozzles with a pressure of 100 bar (3×100 bar). The web was fed through the second entangling station at a speed of 144 m/min and the energy input in the second hydroentangling station was 80 kWh/t,
[0066] The resulting material had a thickness of 799 μm, a grammage of 86.7 g/m 2 and a bulk of 9.2 g/m 3 .
[0067] ESEM images of the material are shown in FIGS. 2-4 , wherein FIG. 2 shows a cross section through the material in a magnification of 200×. FIG. 3 shows the material in a magnification of 65× from the pulp fiber/staple fiber side and FIG. 4 shows the material in a magnification of 65× from the spunlaid filament side. The spunlaid filaments are denoted by the numeral 11 and the shorter pulp fibers/staple fibers are denoted by the numeral 13 .
[0068] It can be seen from the images that the material has a distinct three-dimensional structure as viewed from the pulp fiber/staple fiber side, from which it has been hydroentangled. Apertures 20 extending through the material are also created which can be seen from FIGS. 3 and 4 . FIGS. 1 and 2 further show that the pulp fibers/staple fibers have penetrated into and even through the spunlaid filament web and are protruding from the spunlaid side of the material. This indicates a good integration between the different types of fibers contained in the material.
[0069] The mechanical properties of the produced material is shown in Table 1 below. The properties are satisfactory and show that the patterned and apertured material according to the invention can be achieved without sacrificing other properties.
TABLE 1 Basis weight (g/m 2 ) 86.7 Thickness 2 kPa (μm) 799 Bulk 2 kPa (cm 3 /g) 9.2 Tensile stiffness MD (N/m) 13228 Tensile stiffness CD (N/m) 1406 Tensile strength dry MD (N/m) 1431 Tensile strength dry CD (N/m) 801 Stretch MD (%) 58 Stretch CD (%) 108 Work to rupture MD (J/m 2 ) 793 Work to rupture CD (J/m 2 ) 599 Work to rupture index (J/g) 7.9 Tensile strength MD, wet (N/m) 1081 Tensile strength CD, wet (N/m) 828 Abrasion resistance dry (Taber) 3.5
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A method of producing a patterned and/or apertured nonwoven material wherein a web of continuous filaments are formed on a forming member, the continuous filaments being free from each other without any thermal or adhesive bonds therebetween, and applying a wetformed fiber dispersion containing natural and/or synthetic or regenerated staple fibers on top of the synthetic filaments. The web is hydroentangled, from the side on which the natural fibers and/or staple fibers are applied, in two subsequent hydroentangling stations and is between the hydroentangling stations transferred from a first hydroentangling wire having a mesh value of at least 20 mesh/cm, to a second hydroentangling wire, having a mesh value of no more than 15 mesh/cm. A nonwoven material is obtained having one side with predominantly continuous filaments and one side with predominantly natural fibers and/or synthetic staple fibers, wherein the material on the side with predominantly natural fibers and/or synthetic staple fibers has a three-dimensionally patterned structure and that natural fibers and/or synthetic staple fibers are penetrating into the layer of continuous filaments and are protruding through the layer of continuous filament.
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RELATED US PATENT APPLICATIONS
This is a Divisional United States Non-Provisional Utility Patent Application, which claims the benefit of United States Non-Provisional Utility patent application Ser. No. 12/757,998, filed on Apr. 10, 2010, which is a Continuation-In-Part Application of Non-Provisional application Ser. No. 11/518,830 filed on Sep. 11, 2006 (Now issued as U.S. Pat. No. 7,694,435 on Apr. 13, 2010), which are incorporated in their entireties by reference herein.
FIELD OF THE INVENTION
The present invention relates generally to footwear, more specifically, a footwear item that incorporates a formed hinge allowing the footwear to be folded for storage.
BACKGROUND OF THE INVENTION
People wear footwear to protect their feet from hazards, heat, and other items when walking. Flip Flops are one form of footwear, generally a style of footwear that is associated with a more causal environment. Further, that style of footwear is conducive to being a carry along type of item for such scenarios as a trip to the beach, where the flip flops would only be worn at the destination and packed during travel.
Tartaglia, et al. teaches, in U.S. Pat. No. 7,032,327, footwear that is collapsible. Tartaglia, et al. teaches a footwear comprising an intermediate portion includes sufficient flexibility to significantly reduce the size of the sandal by folding the sole into a stored orientation defined by the front and rear portions disposed in at least partially overlying relation to one another. The design of the intermediate portion of Tartaglia, et al. is limited in that the fold section is not a favorable and reliable hinge design. Further, as said intermediate section continues to flex, not only will the flexible section allow the sole to collapse as designed, but it will also allow the heel section of the sole to hang downward when walking causing potential injury to the wearer and excessive wear to the heel section of the footwear.
What is desired is inexpensive footwear that is foldable for storage. Further desired is a foldable mechanism that is reliable and ensures the heel section of the footwear remains in a planar configuration when worn.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides an apparatus for wearing on a person's feet, more specifically foldable footwear. The footwear incorporates a hinge for folding said footwear into a more compact shape for storage.
A first aspect of the present invention is a flip flop style of footwear.
A second aspect of the present invention is a flip flop style of footwear with a foldable section.
A third aspect of the present invention is a flip flop style of footwear with a foldable section, wherein said foldable section provides a hinge that is transverse to the flip flop.
A fourth aspect of the present invention is a flip flop style of footwear with a foldable section, wherein said foldable section provides a hinge that is longitudinally to the flip flop.
A fifth aspect of the present invention is a flip flop style of footwear with two foldable sections, wherein said foldable sections provides a first hinge that is transverse to the flip flop and a second hinge that is longitudinally to the flip flop.
A sixth aspect of the present invention is a hinge design wherein said hinge is molded into a sole of the flip flop.
A seventh aspect of the present invention is a hinge design wherein said hinge is molded into the sole of the flip flop, wherein said hinge comprising an aperture or slot along the length of the hinge.
An eighth aspect of the present invention is a hinge design wherein said hinge is molded into the sole of the flip flop, wherein said hinge comprising a limit feature to ensure that the sole of the flip flop remains planar in a worn configuration.
A ninth aspect of the present invention is a hinge design wherein said hinge is molded into the sole of the flip flop, wherein said hinge comprising a limit feature to ensure that the sole of the flip flop remains planar in a worn configuration, wherein said limit feature further comprising a contact point.
A tenth aspect of the present invention is wherein said hinge is of a symmetric design.
An eleventh aspect of the present invention is a hinge upper clearance section.
A twelfth aspect of the present invention is an upper shoe section for removably coupling said flip flop to a wearer's foot.
A thirteenth aspect of the present invention is wherein said hinge sections are oriented approximately at the center of the footwear.
A fourteenth aspect of the present invention is wherein said hinge sections are oriented approximately at the center of the footwear and in a transverse orientation.
A fifteenth aspect of the present invention is wherein said hinge sections are oriented approximately at the center of the footwear and in a longitudinal orientation.
A sixteenth aspect of the present invention is the inclusion of a storage bag for said footwear.
A seventeenth aspect of the present invention is the inclusion of a storage bag for said footwear, wherein said bag is sized to store said footwear in a folded configuration.
An eighteenth aspect of the present invention incorporates the transverse hinged sole into any footwear form factor.
A nineteenth aspect of the present invention incorporates the transverse hinged sole into a boot.
A twentieth aspect of the present invention incorporates the transverse hinged sole into a casual shoe.
A twenty-first aspect of the present invention incorporates the transverse hinged sole into a flat.
A twenty-second aspect of the present invention incorporates the transverse hinged sole into a slipper.
The disclosed aspects of the present invention define each aspect individually, wherein it is understood that each of the aspects can be combined to provide various embodiments of a foldable flip flop.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention, together with further objects and advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIG. 1A presents a side view of a flip flop incorporating the present invention;
FIG. 1B presents a bottom view of a flip flop incorporating the present invention;
FIG. 1C presents a top view of a flip flop incorporating the present invention;
FIG. 2A presents a side view of a flip flop incorporating the present invention, further detailing a moldable hinge section;
FIG. 2B presents a enlarged side view of a section of the flip flop incorporating the present invention, shown in a planar configuration;
FIG. 2C presents a enlarged side view of a section of the flip flop incorporating the present invention, shown in a folded configuration;
FIG. 3 presents an isometric view of a flip flop incorporating the present invention; and
FIG. 4 presents a detailed cross sectional view of the molded hinge section respective to the present invention;
FIG. 5 presents a boot comprising a sole having an integrated transverse molded hinge;
FIG. 6 presents a casual shoe comprising a sole having an integrated transverse molded hinge;
FIG. 7 presents a flat comprising a sole having an integrated transverse molded hinge; and
FIG. 8 presents a slipper comprising a sole having an integrated transverse molded hinge.
Various like features are shown throughout the drawings. It is recognized that the features described for a transverse hinge can be applied to a longitudinal hinge.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper”, “lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, and derivatives thereof shall relate to the invention as oriented in FIG. 1 . Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
FIG. 1 presents various orientations of a foldable flip flop 10 , including a side view as illustrated in FIG. 1A , a bottom view as illustrated in FIG. 1B and a top view as illustrated in FIG. 1C . Said foldable flip flop 10 comprising a flip flop sole with molded hinge 12 and a flip flop upper strap member 24 . Said flip flop sole with molded hinge 12 is a single, molded sole that is generally fabricated of molded rubber. Said flip flop upper strap member 24 is assembled to said flip flop sole with molded hinge 12 to provide an upper member for coupling said foldable flip flop 10 to a wearer's foot (not shown). Said flip flop upper strap member 24 couples to said foldable flip flop 10 at a midpoint via a upper front securing aperture 26 . Said flip flop upper strap member 24 can be of a woven canvas, molded plastic, molded rubber, leather, and the like. It is recognized that jewels and other decorative items can be added to said flip flop upper strap member 24 . Various features of said foldable flip flop 10 comprise a sole toe section 14 and a sole heel section 16 . Additionally introduced are a foot contact surface 20 and a ground contact surface 22 . Said foldable flip flop 10 incorporates a molded hinge section 18 . Several features respective to said molded hinge section 18 located on the ground contact surface 22 of said foldable flip flop 10 include a transverse hinge stop contact section 30 and a longitudinal hinge stop contact point 32 . Further, features respective to said molded hinge section 18 located on the foot contact surface 20 of said foldable flip flop 10 include a transverse hinge top slot 34 and a longitudinal hinge top slot 36 .
FIG. 2 presents a more detailed illustration of said molded hinge section 18 shown in both a wearable state as illustrated in FIG. 2B and a stored state as illustrated in FIG. 2C . FIG. 2A illustrates said foldable flip flop 10 of FIG. 1 , further presenting said enlarged detailed hinge section 50 , wherein said enlarged detailed hinge section 50 is to illustrate said molded hinge section 18 in more detail. FIG. 2B illustrates said molded hinge section 18 in a wearable configuration, wherein said molded hinge section 18 comprising said transverse hinge stop contact section 30 and said transverse hinge top slot 34 as introduced in FIG. 1 . Said molded hinge section 18 incorporates a flexible hinge slot 38 and a molded flexible hinge section 40 which combined provide a flexible cross section of said molded hinge section 18 . Said transverse hinge top slot 34 is a recess incorporated to reduce any bulging or creasing of the material of said flip flop sole with molded hinge 12 , wherein when said flip flop sole with molded hinge 12 is folded as shown in FIG. 2C . Without said transverse hinge top slot 34 , the material of said flip flop sole with molded hinge 12 would bulge or crease along said foot contact surface 20 . Said flexible hinge slot 38 provides a reduced cross sectional area about said molded hinge section 18 , thus creating a more flexible section about said molded flexible hinge section 40 . To ensure that said sole heel section 16 does not droop when a wearer is wearing and walking in said foldable flip flop 10 , the present invention incorporates an inventive footwear hinge limitation contact section 42 . Said hinge limitation contact section 42 is presented as a ridge that runs generally parallel to said molded hinge section 18 . It is preferred that said hinge limitation contact section 42 is incorporated into said molded hinge section 18 as a pair, one said hinge limitation contact section 42 associated on a sole toe section 14 side and an opposing said hinge limitation contact section 42 associated on a sole heel section 16 side wherein said hinge limitation contact section 42 contact along said transverse hinge stop contact section 30 . Said hinge limitation contact section 42 provides a feature of said molded hinge section 18 that maintains said flip flop sole with molded hinge 12 in a normal state when worn, ensuring that said sole heel section 16 section does not flex downward towards the ground when said foldable flip flop 10 is worn. It is recognized that other form factors can be incorporated to provide the same features as said hinge limitation contact section 42 as illustrated. FIG. 2C illustrates said foldable flip flop 10 in a stored orientation. When storing said foldable flip flop 10 , the user would fold said foldable flip flop 10 as illustrated contacting along said foot contact surface 20 and having said ground contact surface 22 on the outer or exposed side of the fold. The illustration presents the benefit of said transverse hinge top slot 34 as well as the flexibility of said molded flexible hinge section 40 resulting from the area reduced by the incorporation of said flexible hinge slot 38 .
It is recognized that the features are illustrated respective to a hinge that is oriented transverse to said flip flop sole with molded hinge 12 , the same features are incorporated in a hinge that is oriented longitudinal to said flip flop sole with molded hinge 12 , such as along said longitudinal hinge stop contact point 32 and said longitudinal hinge top slot 36 presented in FIG. 1 .
FIG. 3 illustrates an isometric view of said foldable flip flop 10 , presented for additional clarity of the present invention. One alternate embodiment of said flip flop upper strap member 24 is illustrated wherein said flip flop upper strap member 24 comprising a pair of straps, wherein each side is secured to said flip flop sole with molded hinge 12 (as understood by FIGS. 1 and 2 ) and secured at a toe section via a upper front securing member 28 that is coupled to said flip flop sole with molded hinge 12 via said upper front securing aperture 26 . The illustration presents said molded hinge section 18 respective to said transverse hinge top slot 34 , incorporated transverse to said flip flop sole with molded hinge 12 . It is understood that a similar said molded hinge section 18 could optionally be incorporated respective to an optional said longitudinal hinge top slot 36 , incorporated longitudinal to said flip flop sole with molded hinge 12 .
FIG. 4 illustrates said molded hinge section 18 , further presenting dimensional properties in conjunction with a preferred embodiment of the present invention. Said flip flop sole with molded hinge 12 would have a thickness of sole thickness at hinge 52 at the region proximate said molded hinge section 18 . Said flexible hinge slot 38 would be of a diameter respective to hinge aperture height 54 , wherein said hinge aperture height 54 is optimally ⅓ of said sole thickness at hinge 52 . Said hinge aperture height 54 can be anywhere between 1/10 of said sole thickness at hinge 52 and ¾ of said sole thickness at hinge 52 . Said molded flexible hinge section 40 would have a cross sectional thickness designated by molded flexible hinge section thickness 56 , wherein said molded flexible hinge section thickness 56 is optimally ⅓ of said sole thickness at hinge 52 . Said molded flexible hinge section thickness 56 can be anywhere between ¼ of said sole thickness at hinge 52 and 9/10 of said sole thickness at hinge 52 . Said transverse hinge top slot 34 would have a depth of approximately 1/10 of said sole thickness at hinge 52 . Said hinge limitation contact section 42 would have a thickness of the balance of material, approximately ⅓ of said sole thickness at hinge 52 .
It is also recognized that the features illustrated respective to the hinge 18 can be inverted, aiding in folding the foldable flip flop 10 in a reverse direction, positioning the ground contact surfaces 22 of the sole toe section 14 and sole heel section 16 against one another. The hinge aperture height 54 would be measured downward from the foot contact surface 20 . The transverse hinge top slot 34 would be located on the ground contact surface 22 side of the flip flop sole with molded hinge 12 .
FIG. 5 illustrates an exemplary embodiment of the present invention in a form factor referred to as a folding soled boot 110 . The folding soled boot 110 comprises a boot upper section 124 disposed upon to a boot sole with molded hinge 112 . The boot upper section 124 is shaped in a form factor having the features of a common boot, including a foot covering and an ankle/lower leg covering extending upwards from the foot covering. The boot upper section 124 is preferably of a soft, flexible material to ensure long term wear of the folding soled boot 110 . The boot sole with molded hinge 112 has a lower surface defined as a ground contact surface 122 and an upper surface defined as a foot contact surface 120 . The boot sole with molded hinge 112 can be portioned into a sole toe section 114 and a sole heel section 116 being separated by a molded hinge section 118 . The molded hinge section 118 is provided in a transverse orientation and shaped having the same dimensions and features as previously presented in FIG. 4 . This configuration offers the shoe owner the ability to fold the folding soled boot 110 for any desired reason, including storage.
FIG. 6 illustrates an exemplary embodiment of the present invention in a form factor referred to as a folding soled casual shoe 210 . The folding soled casual shoe 210 comprises a casual shoe upper section 224 disposed upon to a casual shoe sole with molded hinge 212 . The casual shoe upper section 224 is shaped in a form factor having the features of a common casual shoe, including a comfortable foot covering. Some included features may include a strap 230 , a tie 232 , and the like. The casual shoe upper section 224 is preferably of a soft, flexible material, such as canvas, a woven material, and the like to ensure long term wear of the folding soled casual shoe 210 . The casual shoe sole with molded hinge 212 has a lower surface defined as a ground contact surface 222 and an upper surface defined as a foot contact surface 220 . The casual shoe sole with molded hinge 212 can be portioned into a sole toe section 214 and a sole heel section 216 being separated by a molded hinge section 218 . The molded hinge section 218 is provided in a transverse orientation and shaped having the same dimensions and features as previously presented in FIG. 4 . This configuration offers the shoe owner the ability to fold the folding soled casual shoe 210 for any desired reason, including storage.
FIG. 7 illustrates an exemplary embodiment of the present invention in a form factor referred to as a folding soled flat 310 . The folding soled flat 310 comprises a flat upper section 324 disposed upon to a flat sole with molded hinge 312 . The flat upper section 324 is shaped in a form factor having the features of a common flat, including a foot covering generally designed to slip onto the wearer's foot. The flat upper section 324 is preferably of a soft, flexible material, such as canvas, vinyl, cloth, and the like to ensure long term wear of the folding soled flat 310 . The flat upper section 324 normally comprises a toe upper section and a heel upper section joined by a section of elastic (not shown). The flat sole with molded hinge 312 has a lower surface defined as a ground contact surface 322 and an upper surface defined as a foot contact surface 320 . The flat sole with molded hinge 312 can be portioned into a sole toe section 314 and a sole heel section 316 being separated by a molded hinge section 318 . The molded hinge section 318 is provided in a transverse orientation and shaped having the same dimensions and features as previously presented in FIG. 4 . This configuration offers the shoe owner the ability to fold the folding soled flat 310 for any desired reason, including storage.
FIG. 8 illustrates an exemplary embodiment of the present invention in a form factor referred to as a folding soled slipper 410 . The folding soled slipper 410 comprises a slipper upper section 424 disposed upon to a slipper sole with molded hinge 412 . The slipper upper section 424 is shaped in a form factor having the features of a common slipper, including a foot covering generally designed to slip onto the wearer's foot. The slipper upper section 424 is preferably of a soft, flexible material, such as fleece, and the like to ensure long term wear of the folding soled slipper 410 . The slipper upper section 424 normally comprises a toe upper section and a heel upper section joined by a section of elastic (not shown). The slipper sole with molded hinge 412 has a lower surface defined as a ground contact surface 422 and an upper surface defined as a foot contact surface 420 . The slipper sole with molded hinge 412 can be portioned into a sole toe section 414 and a sole heel section 416 being separated by a molded hinge section 418 . The molded hinge section 418 is provided in a transverse orientation and shaped having the same dimensions and features as previously presented in FIG. 4 . This configuration offers the shoe owner the ability to fold the folding soled slipper 410 for any desired reason, including storage.
Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
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A pair of foldable footwear, each footwear incorporating a flexible hinge within a sole of the footwear. The flexible hinge consists of a molded flexible hinge section 40 , a molded hinge aperture 38 , a hinge top slot 34 and a hinge limitation contact section 42 . The molded flexible hinge section 40 and molded hinge aperture 38 provides a flexible and reliable member allowing the sole to be folded. The sole can comprise a hinge section along a transverse orientation or a longitudinal orientation about the center of the sole. The hinge limitation contact section 42 ensures that a heel section of the sole remains in a wearable configuration during use.
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BACKGROUND OF INVENTION
[0001] Oil-based sludges of various types and consistencies are commonly generated as waste streams during oil or other hydrocarbon production processes. These sludges arise during well tests and initial production, as a by-product waste stream of hydrocarbon production, and as tank bottom sediments. The basic components of sludges are hydrocarbon oils of various consistencies, water, and solids of an inorganic and organic nature. Oil-based sludge typically refers to a complex water-in-oil emulsion stabilized by salts of organic compounds and fine solids. The oil phase contains a complex mixture of hydrocarbons of various consistencies including waxes and asphaltenes which may be solid or semi-solid at ambient temperature.
[0002] The chemistries of oil-based sludges and the relative proportions of the oil, water, and solid phases of sludges vary greatly and can change over time. To dispose of the waste, sludge is often stored in open pits where it may be left for considerable time before being treated. During such aging periods, the sludge or “pit sludge” undergoes overall chemical composition changes due to the effects of weathering, including: volatilization of lighter hydrocarbons; temperature induced crosslinking of hydrocarbons; addition of rain water; and, invariably, the introduction of a variety of other contaminants, particulates, and debris. In addition to a variable complex chemistry, oil-based sludge typically has a high solids content. Sludge solids normally include both high density and low density solids. High density solids, i.e., high gravity solids, may be large solids introduced into the drilling fluid during the drilling of a formation (e.g., formation solids, drill bits, etc.) or other solids that are relatively dense such as barite or hermatite. While low density solids, i.e., low gravity solids, are those solids within the sludge that have a lower density or are relatively small fine solids (e.g., entrained solids such as sand).
[0003] Currently, treatment of sludge is a major operational cost for producers. Sludge is collected, stored, and then disposed of in tanks or delivered to a sludge pit. One challenge of sludge treating systems is that the recovery of marketable oil from the sludge is generally not cost-effective and thus not commercially viable. Due to wide variability in sludge composition, different sludge processing systems may be needed to optimize the processing of sludge for recovering oil of sufficient quality in a cost efficient manner. The quality of oil is frequently characterized by its Basic Sediment and Water (BS&W) content, in vol. %. The current marketable BS&W of recovered oil is less than about 2 vol. %. Furthermore, it is desirable to treat pit sludge to reduce the risk of contamination of the surrounding pit area, in accordance with increasingly strict environmental regulations, as well as decrease the overall waste volume, and ultimately to permit pit closure.
SUMMARY
[0004] The present invention is generally directed to a modular oil-based sludge separation and treatment apparatus that is easily adapted to provide processing flexibility in order to ensure quality oil recovery from oil-based sludge in an efficient and cost-effective manner. The modular approach allows the configuration of processing equipment to be adapted to the oil-recovery processing requirements of the particular oil-based sludge composition. Providing a customizable apparatus maximizes the quantity and quality of the recovered oil while minimizing the processing time and cost to the operator.
[0005] It is an objective of the present invention to provide a modular apparatus having certain processing equipment mounted on portable skids that are adaptable and versatile to permit customized arrangement for oil-recovery processing of a wide range of oil-base sludge compositions in a cost-efficient manner.
[0006] In one aspect, the invention is directed to a modular apparatus for recovering oil from oil-based sludge having a high concentration of low density solids. The modular apparatus includes: a pumping skid having a pump operable to homogenize an oil-based sludge; a shaker skid having a screen that removes particulates from the oil-based sludge as the sludge traverses the screen to form a debris-free sludge; a heating skid having a heat exchanger operable to heat the debris-free sludge as the debris-free sludge flows through the heat exchanger to form a heated sludge; a chemical skid having at least one chemical injection mixer operable to inject a chemical into the heated sludge and mix the chemical with the heated sludge to form a chemically-treated sludge; a phase separator skid having a three-phase separator operable to separate the phases of the chemically-treated sludge to form a first solids component stream, a first water component stream, a first oil component stream, and a first gas component stream; a decanter skid having a decanter centrifuge operable to remove solids from the first oil component stream to form a second solids component stream and a second oil component stream; and an oil purification skid having a disk stack centrifuge operable to remove water and solids from the second oil component stream to form a third solids component stream, a second water component stream, and a third oil component stream.
[0007] In another aspect, the invention is directed to a modular apparatus for recovering oil from oil-based sludge having a high concentration of high density solids. The modular apparatus includes: a pumping skid having a pump operable to homogenize an oil-based sludge; a shaker skid having a screen that removes particulates from the oil-based sludge as the sludge traverses the screen to form a debris-free sludge; a heating skid having a heat exchanger operable to heat the debris-free sludge as the debris-free sludge flows through the heat exchanger to form a heated sludge; a first chemical skid having at least one chemical injection mixer operable to inject a chemical into the heated sludge and mix the chemical with the heated sludge to form a first chemically-treated sludge; a decanter skid having a decanter centrifuge operable to remove solids from the first chemically-treated sludge to form a first solids component stream and a decanter-processed sludge; a second chemical skid having at least one chemical injection mixer operable to inject a chemical into the decanter-processed sludge and mix the chemical with the decanter-processed sludge to form a second chemically-treated sludge; a phase separator skid having a three-phase separator operable to separate the phases of the second chemically-treated sludge to form a second solids component stream, a first water component stream, a first oil component stream, and a first gas component stream; and an oil purification skid having a disk stack centrifuge operable to remove water and solids from the first oil component stream to form a third solids component stream, a second water component stream, and a second oil component stream.
[0008] In still another aspect, the invention is directed to a modular apparatus for recovering oil from oil-based sludge having very low solids content. The modular apparatus includes: a pumping skid having a pump operable to homogenize an oil-based sludge; a shaker skid having a screen that removes particulates from the oil-based sludge as the sludge traverses the screen to form a debris-free sludge; a heating skid having a heat exchanger operable to heat the debris-free sludge as the debris-free sludge flows through the heat exchanger to form a heated sludge; a chemical skid having at least one chemical injection mixer operable to inject a chemical into the heated sludge and mix the chemical with the heated sludge to form a chemically-treated sludge; a phase separator skid having a three-phase separator operable to separate the phases of the chemically-treated sludge to form a first solids component stream, a first water component stream, a first oil component stream, and a first gas component stream; and an oil purification skid having a disk stack centrifuge operable to remove water and solids from the first oil component stream to form a second solids component stream, a second water component stream, and a second oil component stream.
[0009] These and other features are more fully set forth in the following description of preferred or illustrative embodiments of the disclosed and claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
[0011] FIG. 1 is a flow chart depicting a modular skid arrangement optimized for recovering the valuable hydrocarbon component of pit sludge having a high concentration of low density solids, according to an embodiment of the invention;
[0012] FIG. 2 is a flow chart depicting another modular skid arrangement optimized for recovering the valuable hydrocarbon component of pit sludge having a high concentration of high density solids, according to another embodiment of the invention;
[0013] FIG. 3 is a flow chart depicting still another modular skid arrangement optimized for recovering the valuable hydrocarbon component of pit sludge having very low solids content, according to still another embodiment of the invention;
[0014] FIGS. 4 and 5 are schematics of an exemplary modular apparatus for separating and treating an oil-base sludge having a high concentration of low density solids to recover the valuable hydrocarbon component, in accordance with the skid arrangement shown in FIG. 1 ;
[0015] FIGS. 4 and 6 are schematics of an exemplary modular apparatus for separating and treating an oil-base sludge having a high concentration of high density solids to recover the valuable hydrocarbon component, in accordance with the skid arrangement shown in FIG. 2 ; and
[0016] FIGS. 4 and 7 are schematics of an exemplary modular apparatus for separating and treating an oil-base sludge having very low solids content to recover the valuable hydrocarbon component, in accordance with the skid arrangement shown in FIG. 3 .
DETAILED DESCRIPTION
[0017] The claimed subject matter relates to a modular apparatus having one of several skid arrangements depicted in FIGS. 1-3 for recovering the valuable hydrocarbon component of oil-based sludges having a wide variability in sludge composition. Depending upon the particular sludge composition and its solids content, the skid arrangements of the modular apparatus of the present invention may be easily configured, and re-configured, in order to optimize the separation and purification of the recovered oil while minimizing the time and cost to an operator.
[0018] According to an embodiment of the invention, FIG. 1 depicts the skid arrangement of a modular apparatus 100 optimally configured for recovering the valuable hydrocarbon component of sludge 14 initially having a high concentration of low density solids. Modular apparatus 100 comprises a pumping skid 102 , a shaker skid 104 , a heating skid 106 , a chemical skid 108 , a phase separator skid 110 , a gas purification skid 112 , a decanter skid 114 , and an oil purification skid 116 . Each of the skids 102 - 116 are described in more detail in the description that follows with respect to the modular apparatus 100 schematically illustrated in FIGS. 4 and 5 .
[0019] As illustrated in FIGS. 4 and 5 , modular apparatus 100 processes pit sludge through the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the chemical skid 108 , the phase separator skid 110 , the gas purification skid 112 , the decanter skid 114 , and the oil purification skid 116 . Referring to FIG. 4 , the pumping skid 102 includes a hydraulic submersible sludge pump 122 that homogenizes a pit sludge 10 contained in a pit 12 and then pumps a homogenized sludge 14 to the shaker skid 104 . The pump 122 may be mounted on a hydraulic arm in order to reach inner areas of the pit 12 . During ageing, the pit sludge 10 separates into basically three layers or phases, wherein the top layer of the pit is an oil-rich phase, the middle layer of the pit sludge 10 is a water-rich phase, and the bottom layer of the pit sludge 10 is a solids-rich phase. The pump 122 forms a homogeneous mixture or slurry of the three phases contained within the pit in order to provide a generally constant feed composition to the remainder of the apparatus 100 for processing.
[0020] The shaker skid 104 includes a shaker screen 124 and a holding tank 126 mounted thereon and within the confines of the area in the skid 104 so as to maintain portability of the skid 104 . The shaker screen 124 physically separates and removes large particulates such as stones or debris from the sludge 14 . A debris-free sludge 16 exiting the shaker screen 124 collects in the holding tank 126 . Holding tank 126 may be essentially any type of tank that can contain a sufficient amount of sludge to supply and maintain a constant sludge flow rate to a heat exchanger 130 . A first transfer pump 128 in fluid communication with the holding tank 126 transfers the sludge 16 from the holding tank 126 to the heating skid 106 . In a preferred embodiment, the holding tank 126 is an augured V-Tank coupled to the pump 128 which is VFD (variable frequency driver) controlled in order to automatically provide a steady state flow rate of the sludge 16 to the heat exchanger 130 .
[0021] The heating skid 106 has the heat exchanger 130 , a steam boiler 132 , and a fuel tank 134 mounted thereon and within the confines of the area of the skid 106 so as to maintain the portability of the skid 106 . Sludge 16 is heated to a desired temperature as it travels through the heat exchanger 130 . Because oil-based sludges often include waxy hydrocarbons, heating advantageously melts the waxy hydrocarbons into liquid form and lowers the viscosity of the sludge 16 . Also, heating advantageously aids in breaking the emulsion (secondary phase) and promotes phase separation within the sludge 16 . Providing heat to the heat exchanger 130 is accomplished by use of the steam boiler 132 . The steam boiler 132 generates steam and circulates the steam to the heat exchanger 130 via a first steam line 136 and a second steam line 138 . The flow rate, pressure, and temperature of the steam entering the heat exchanger 130 via line 136 are controlled so as to provide adequate heat transfer to the sludge 16 as it flows through the heat exchanger 130 . A heated sludge 18 , having the desired temperature and viscosity, exits the heat exchanger 130 and is subsequently transferred to the chemical skid 108 . In one example, the type of heat exchanger 130 used is a spiral type heat exchanger, wherein sludge 16 flows through the heat exchanger 130 in a path separate from that of the steam, but adjacent to it such that heat from the steam is transferred to the sludge 16 . It is understood that other types of heat exchangers can be used without departing from the scope of this invention.
[0022] Depending upon the particular sludge composition, the sludge 16 is heated to essentially any temperature sufficient to liquefy the sludge 16 and lower its viscosity. When the viscosity is lower, treatment chemicals may be more easily blended with the heated sludge 18 in downstream processing. Furthermore, when the sludge viscosity is lower, entrained solids are more easily released in downstream processing. The desired temperature of the heated sludge 18 and its corresponding rheological profile can be predetermined and optimized using a viscometer, such as an oilfield Fann 35 viscometer available from Fann Instrument Co. In one example, sludge 18 is heated to a temperature in the range from about 65° C. to about 85° C. to sufficiently liquefy the sludge 18 and reduce its viscosity for downstream processing. More preferably, sludge 18 is heated to a temperature in the range from about 70° C. to about 80° C. Although it is desirable to heat the sludge 16 , care should be taken to ensure that the temperature of the heated sludge 18 is lower than the flash point temperature of the sludge 16 . The flash point is that minimum temperature at which there is enough evaporated fuel in the air to start combustion. The flash point of the sludge 16 can be determined by the use of a flash-point measuring device such as the Pensky Martens Closed Cup according to method ASTM D93B.
[0023] Preferably, the fuel tank 134 is co-located on the skid 106 to provide fuel to the steam boiler 132 for heating the steam. Optionally, a power supply (not shown) is provided on the skid 106 to actuate valves (not shown) that regulate the flow rate of the steam through the first and second steam lines 136 , 138 , and also regulate the flow rates of the water supply and the fuel provided to the steam boiler 132 . A control panel (not shown) may be co-located on the skid 106 to monitor and automatically control the valves in order to automate the heating process at the heat exchanger 130 . In addition, the boiler 132 , flow lines 136 , 138 , and heat exchanger 130 are preferably thermally insulated to better maintain temperature uniformity and control.
[0024] Once heated, the sludge 18 is transferred to a chemical skid 108 for chemically altering the sludge 18 to break up the emulsion and promote phase separation. The chemical skid 108 includes a plurality of chemical injection mixers 140 a - d and chemical supply tanks 142 a - d mounted thereon and within the confines of the area of the skid 108 so as to maintain the portability of the skid 108 . Chemical addition is typically required to destabilize the emulsion and change such properties to enhance separation of the water and solids from the sludge 18 , as well as decrease the separation time required. Each of the chemical injection mixers 140 a - d includes a static shear mixer having an injection point. The injection point introduces a chemical into the sludge 18 while the mixer simultaneously blends the chemical and the sludge 18 under the shearing action of the mixer. The chemical injection mixer advantageously provides a homogeneous distribution of the chemical within the sludge 18 to aid in its complete and efficient chemical reaction therein. As depicted in FIG. 5 , four chemicals are added to the heated sludge 18 as the sludge is directed through the chemical injection mixers 140 a - d. Each of the chemical injection mixers 140 a - d has a corresponding chemical supply tank 142 a - d for storing the chemicals until they are transferred via chemical lines 144 a - d to the mixers 140 a - d for injection into the sludge 18 . Once all the chemicals are introduced and blended into the heated sludge 18 , a chemically-treated sludge 20 exits the last chemical injection mixer 140 d and is subsequently transferred to the phase separator skid 110 for further processing.
[0025] Depending upon the particular initial sludge 14 composition, a wide variety of chemicals, may be introduced and blended into the sludge 18 in order facilitate subsequent processing to separate the solid, water, and oil phases of the chemically treated sludge 20 . Suitable chemicals include acids, demulsifiers, wetting agents, surfactants, flocculants, and defoamers. Demulsifiers modify the interfacial tension of the emulsion film to release the water and assist in separating out the water from the oil. Wetting agents alter the wetability of solid particles thereby causing the solid particles to become hydrophilic which increases the solids affinity for water and causes further breakup of the interfacial emulsion film. Flocculants induce the solids to aggregate and form larger solids to facilitate separation of the solids in the sludge. In one example, as the heated sludge 18 travels through the first injection mixer 140 a, the mixer 140 a injects an acid and blends the acid with the sludge 18 therein in order to neutralize adsorbed ions present at the interfacial emulsion film of the sludge 18 and chemically prepare the sludge 18 for chemical treatment with a demulsifier. Subsequently, the sludge 18 is directed through the second injection mixer 140 b wherein a demulsifier is injected and blended into the sludge 18 to break the interfacial emulsion film for release of the secondary water phase. The sludge 18 then passes through the third injection mixer 140 c wherein a wetting agent is injected and blended into the sludge to alter the affinity of the solids towards the water phase. Afterwards, the sludge 18 passes through the fourth injection mixer 140 d wherein a defoamer is injected and blended into the sludge for the purpose of counteracting surfactants (detergents) present in the sludge that may otherwise undesirably cause foaming. After chemical treatment in injection mixers 140 a - d, a chemically-treated sludge 20 exits the chemical skid 108 and is ready for subsequent processing. It should be noted that the present invention is not intended to be limited to the use of any particular chemicals, and other chemicals may be substituted for any of the aforementioned chemicals.
[0026] Furthermore, additional chemicals may be incorporated into the sludge 18 by providing additional injection mixers (e.g., 140 e - n ) on the skid 108 such that all the desired chemicals may be introduced into the sludge. For example, a fifth injection mixer (not shown) may be included on skid 108 to introduce a pour point suppressant into the sludge 18 in order to extend the fluidity of the sludge to lower temperatures. Because wax in the sludge can cause issues for pumping and phase separation in terms of the high viscosity it imparts and coating of entrained solids, pour point suppressants can be added to depress the temperature at which wax molecules in the oil phase of the sludge 18 solidify. Conversely, in another example, fewer chemicals may be incorporated into the sludge 18 by bypassing one or more of the injection mixers 140 a - d or, alternatively, removing one of more of the mixers 140 a - d from the skid 108 .
[0027] Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 a - d is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 18 . The quantity of each of the chemicals introduced into the sludge 18 depends upon the particular initial sludge composition 14 . For example, a dosing pump in fluid communication with the second injection mixer 140 b provides demulsifier in the predetermined amount of 2-3% by volume of sludge 18 . Although essentially any type of dosing pump may be used, in one example each of the dosing pumps is a gear pump with a VFD control panel. In addition, preferably, the chemical injection mixers 140 a - d are thermally insulated to better maintain the sludge temperature and fluidity.
[0028] After chemical treatment, the sludge 20 is directed to the phase separator skid 110 for separating the solid, water, oil, and gas phases of the sludge 20 . The phase separator skid 110 includes a surge tank 146 and a three-phase separator 148 mounted thereon and within the confines of the area of the skid 110 so as to maintain the portability of the skid 110 . The sludge 20 is fed into the vertically-oriented surge tank 146 which separates heavier solids from the sludge 20 and provides a continuous flow of a liquid portion of the sludge 22 to the three-phase separator 148 . The surge tank 146 contains an interior plate that facilitates the small solids (e.g., solids in suspension) within the sludge 20 to aggregate and form larger solids such that gravity is sufficient to separate these heavier solids out of the sludge 20 . Separated solids 24 that settle and accumulate in a bottom region of the surge tank 146 are discharged and directed to a solids receiving tank 150 . The liquid portion of the sludge 22 , which comprises oil, water, gas, and fine solids, is directed to the three-phase separator 148 .
[0029] The liquid portion of the sludge 22 flows into the three-phase separator 148 through an inlet located at one end of the separator 148 . The separator 148 is designed to separate the phases and flow the separated phases to their respective outlets. Within the retention section of the three-phase separator 148 , the liquid portion of the sludge 22 separates into a water-rich phase 28 , an oil-rich phase 30 , and a gas phase 44 . Furthermore, additional solids 26 that may settle out of the sludge 22 and accumulate in a bottom region of the separator 148 , primarily as a result of the re-distribution or separation of the phases, are discharged and directed to the solids receiving tank 150 . The water-rich phase 28 is discharged to a water tank 152 . The oil-rich phase 30 is transferred to the decanter skid 114 for fine solids removal. The gas phase 44 is directed to the gas purification skid 112 to clean the gas for release into the atmosphere. One exemplary three-phase separator 148 is the Horizontal Longitudinal Flow Separator commercially available from NATCO Group Inc., Houston, Tex. However, the present invention is not limited to a particular type of surge tank or three-phase separator. In addition, the surge tank 146 and three-phase separator 148 are both preferably insulated to better maintain the sludge temperature and fluidity.
[0030] The oil-rich phase 30 is transferred to the decanter skid 114 to separate the fine solids out of the oil-rich phase 30 . The decanter skid 114 includes a decanter centrifuge 154 and a heating tank 156 mounted thereon and within the confines of the area of the skid 114 so as to maintain the portability of the skid 114 . For the removal of solids, the decanter centrifuge 154 is particularly useful in reducing the solids content in liquids having a solids concentration in excess of about 3 vol. % to a solids concentration less than about 2 vol. %. Once the oil-rich phase 30 is fed into the decanter centrifuge 154 , centrifugal force causes suspended solids to separate out of the oil-rich phase 30 and coalesce for subsequent removal from the decanter. Solids 32 are discharged through a solids outlet located in the bottom of the decanter centrifuge 154 . At this point in the processing, a decanter-processed oil-rich phase 34 that exits the decanter 154 has a BS&W of less than about 2 vol. %. Suitable decanter centrifuges include decanter centrifuges having a rotational speed of 3000 rpm or greater. Exemplary decanter centrifuges include Model 500 (3000 rpm) and Model 518 (5000 rpm) commercially available from M-I L.L.C., Houston, Tex.
[0031] After the fine solids removal, the decanter-processed oil-rich phase 34 is transferred to the heating tank 156 and optionally heated therein. Because a significant amount of cooling can occur during the various prior processing steps, since being previously heated in the heat exchanger 130 , the oil-rich phase 34 is optionally heated to a desired temperature in the heating tank 156 in order to enhance its final phase separation and purification during the next processing step at the oil purification skid 116 . The heating tank 156 includes a heating element (e.g., a steam coil) capable of heating the contents of the tank 156 . After heating, a heated oil-rich phase 36 is pumped via a second transfer pump 158 to the oil purification skid 116 for final purification. In one example, the heated oil-rich phase 36 is heated to a temperature in the range from about 65° C. to about 85° C.
[0032] The heated oil-rich phase 36 is transferred to the oil purification skid 116 for its final purification and recovery of oil therefrom having a BS&W of less than about 1 vol. %. The oil purification skid 116 includes a disk stack centrifuge 160 . As depicted in FIG. 5 , the heated oil-rich phase 36 is fed into the disk stack centrifuge 160 to further purify the oil. The disk stack centrifuge uses a combination of plates (i.e., the disk stack) and extremely high centrifugal forces to separate the very fine water emulsion and the ultra-fine solids out of the oil-rich phase 36 . After separation, a water stream 38 , a recovered oil stream 40 , and an ultra-fine solids phase 42 are discharged from the centrifuge 160 . After final processing in the disk stack centrifuge 160 , the recovered oil stream 40 has a BS&W less than about 1 vol. % and is commercially marketable. Exemplary disk stack centrifuges are commercially available from Alfa Laval Inc., Richmond, Va.
[0033] The gas phase 44 is transferred to the gas purification skid 112 where the gas phase 44 is treated to remove volatile organic compounds (VOCs) prior to discharge into the environment. The gas purification skid 112 preferably includes a free water knockout pot 162 , at least one mist impinger 166 , and at least one activated carbon filter 168 mounted thereon and within the confines of the area of the skid 112 so as to maintain the portability of the skid 112 . A VFD-controlled vacuum blower 164 attached to the knockout pot 162 is used to draw the gas phase 44 from a gas vent located in an upper side of the three-phase separator 148 through the knockout pot 162 filled with water. The gas phase 44 enters a gas inlet located near the bottom of the knockout pot 162 , and hydrocarbons in the gas phase 44 adhere to the water as the gas travels upwardly through the pot 162 . Water in the knockout pot 162 is periodically emptied into a liquid waste disposal and replaced with fresh water. Because the exiting gas is saturated with water, a wet-gas 46 that exits a gas outlet near the top of the knockout pot 162 is directed through at least one mist impinger 166 to remove water from the gas 46 and provide a dry gas 48 . The dry gas 48 that exits the at least one mist impinger 166 is then transferred to an activated carbon filter 168 to remove contaminants (e.g., remaining VOCs) therefrom in order to ensure a gas 50 that meets the environmental regulatory standards for release to the atmosphere. In one example, as depicted in FIG. 5 , the knockout pot 162 removes hydrocarbons from the gas phase 44 , and afterwards the exiting wet-gas 46 is directed through two mist impingers 166 to adequately dry the gas prior to directing the dry gas 48 through one or more activated carbon filters 168 . When the activated carbon filter 168 becomes exhausted, it may be treated to reactivate the carbon or, alternatively, may be disposed of according to appropriate regulatory procedures.
[0034] According to another embodiment of the invention, FIG. 2 depicts the skid arrangement of a modular apparatus 200 optimally configured for recovering the valuable hydrocarbon component of sludge 14 initially having a high concentration of high density solids. In FIG. 2 the same reference numerals are used to indicate the same skids as those previously described with respect to the apparatus 100 depicted in FIG. 1 . Modular apparatus 200 comprises the pumping skid 102 , the shaker skid 104 , the heating skid 106 , a first chemical skid 118 , the decanter skid 114 , a second chemical skid 120 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . In this embodiment, two chemical skids 118 , 120 are utilized with the decanter skid 114 positioned between the chemical skids 118 , 120 . For sludge 14 initially having a high concentration of high density solids, it is preferable to remove solids from the sludge using a decanter centrifuge prior to delivery of all the chemicals during the chemical treatment of the sludge. Skids 118 and 120 are described in more detail in the description that follows with respect to the modular apparatus 200 schematically illustrated in FIGS. 4 and 6 .
[0035] Illustrated in FIGS. 4 and 6 , modular apparatus 200 processes pit sludge through the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the first chemical skid 118 , the decanter skid 114 , the second chemical skid 120 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . As previously described with respect to FIG. 4 , the modular apparatus 200 processes pit sludge 10 through the pumping skid 102 , the shaker skid 104 , and the heating skid 106 to provide a heated sludge 18 .
[0036] Referring now to FIG. 6 , the heated sludge 18 is transferred to the first chemical skid 118 for chemically altering the sludge 18 to break up the emulsion and promote solids separation. In FIG. 6 the same reference numerals are used to indicate the same features as those previously described with respect to apparatus 100 depicted in FIG. 5 . The chemical skid 118 includes a plurality of chemical injection mixers 140 a, 140 b and chemical supply tanks 142 a, 142 b mounted thereon and within the confines of the area of the skid 118 so as to maintain the portability of the skid 118 . Chemical addition is typically required to destabilize the emulsion and change such properties to facilitate separation of the solids from the sludge 18 and decrease the separation time required. Each of the chemical injection mixers 140 a, 140 b includes a static shear mixer having an injection point for introducing a chemical into the sludge 18 while the mixer simultaneously blends the chemical and the sludge 18 under the shearing action of the mixer. As illustrated in FIG. 6 , two chemicals are added to the heated sludge 18 as the sludge is directed through the chemical injection mixers 140 a, 140 b. Chemical supply tanks 142 a, 142 b store the chemicals until they are transferred via chemical lines 144 a, 144 b to the mixers 140 a, 140 b for injection into the sludge 18 . Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 a, 140 b is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 18 . In addition, the chemical injection mixers 140 a, 140 b are preferably insulated to better maintain the sludge temperature and fluidity. Once the chemicals are introduced and blended into the heated sludge 18 , a first chemically-treated sludge 202 exits the last chemical injection mixer 140 b and is subsequently transferred to the decanter skid 114 to separate the high density solids out of the first chemically-treated sludge 202 . It should be noted that additional chemical injection mixers may be added to the first chemical skid 118 for the introduction of additional chemicals into the sludge 18 .
[0037] Depending upon the particular initial sludge 14 composition, a wide variety of chemicals may be introduced and blended into the sludge 18 in order facilitate subsequent processing to separate the solids out of the first chemically-treated sludge 202 . Suitable chemicals include acids, demulsifiers, wetting agents, surfactants, flocculants, and defoamers. In one example, as the heated sludge 18 travels through the first injection mixer 140 a, the mixer 140 a injects an acid and blends the acid with the sludge 18 therein in order to neutralize adsorbed ions present at the interfacial emulsion film of the sludge 18 . Subsequently, the sludge 18 is directed through the second injection mixer 140 b wherein a wetting agent is injected and blended into the sludge to alter the affinity of the solids towards the water phase. It should be noted that the present invention is not intended to be limited to the use of any particular chemicals, and other chemicals may be substituted for any of the aforementioned chemicals.
[0038] The first chemically-treated sludge 202 is directed to the decanter skid 114 for solids removal. The chemically-treated sludge 202 entering the decanter skid 114 can have a solids content as high as in the range of 6 vol. % to 15 vol. %. As previously described, the decanter skid 114 includes a decanter centrifuge 154 and a heating tank 156 mounted thereon and within the confines of the area of the skid 114 . The decanter centrifuge 154 is used to reduce the solids content in the sludge 202 to a solids concentration less than about 2 vol. %. In the decanter centrifuge 154 , centrifugal force causes solids 204 to separate out of the sludge 202 and coalesce for subsequent removal from the decanter through a solids outlet located in the bottom of the decanter centrifuge 154 . A decanter-processed sludge 206 that exits the decanter centrifuge 154 has a solids content of less than about 2 vol. %. As previously described, suitable decanter centrifuges include decanter centrifuges having a rotational speed of 3000 rpm or greater.
[0039] After reducing the solids in the sludge 206 , the decanter-processed sludge 206 is transferred to the heating tank 156 and optionally heated therein. Because a significant amount of cooling can occur during the previous processing steps since being heated in the heat exchanger 130 , the decanter-processed sludge 206 may be heated to a desired temperature in the heating tank 156 in order to lower its viscosity and facilitate blending of additional chemicals into the sludge 206 during the next processing step at the second chemical skid 120 . After heating, a heated decanter-processed sludge 208 is pumped via the second transfer pump 158 to the second chemical skid 120 . In one example, the heated decanter-processed sludge 208 is heated to a temperature in the range from about 65° C. to about 85° C.
[0040] The heated decanter-processed sludge 208 is transferred to the second chemical skid 120 for chemically altering the sludge 208 to further break up the emulsion and promote phase separation. The chemical skid 120 includes a plurality of chemical injection mixers 140 c, 140 d and chemical supply tanks 142 c, 142 d mounted thereon and within the confines of the area of the skid 120 so as to maintain the portability of the skid 120 . Chemical addition is typically required to further destabilize the emulsion and change such properties to enhance oil-water-solids phase separation during the next processing steps at the phase separator skid 110 . Each of the chemical injection mixers 140 c, 140 d includes a static shear mixer having an injection point for introducing a chemical into the sludge 208 . As illustrated in FIG. 6 , two chemicals are added to the sludge 208 as the sludge travels through mixers 140 c, 140 d. Chemical supply tanks 142 c, 142 d store the chemicals until they are transferred via chemical lines 144 c, 144 d to the mixers 140 c, 140 d. Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 c, 140 d is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 208 . In addition, the chemical injection mixers 140 c, 140 d are preferably insulated to better maintain the sludge temperature and fluidity. Once the chemicals are introduced and blended into the sludge 208 , a second chemically-treated sludge 210 exits the last chemical injection mixer 140 d and is subsequently transferred to the phase separator skid 110 . It should be noted that additional chemical injection mixers may be added to the second chemical skid 120 for the introduction of additional chemicals into the sludge 208 .
[0041] Depending upon the particular sludge 208 composition, a wide variety of chemicals may be introduced and blended into the sludge to promote separation of the water, oil, and solid phases of the second chemically-treated sludge 210 . Suitable chemicals include acids, demulsifiers, wetting agents, surfactants, flocculants, and defoamers. In one example, as the sludge 208 travels through the third injection mixer 140 c, the mixer 140 c injects a demulsifier into the sludge 208 to break the interfacial emulsion film to release the secondary water phase. Afterwards, the sludge 208 is directed through the fourth injection mixer 140 d wherein a defoamer is injected and blended into the sludge for the purpose of preventing foaming. Again, it should be noted that the present invention is not intended to be limited to the use of any particular chemicals, and other chemicals may be substituted for any of the aforementioned chemicals. Furthermore, additional chemical injection mixers may be added to the second chemical skid 120 for the introduction of additional chemicals into the sludge 208 .
[0042] After the second chemical treatment, the sludge 210 is directed to the phase separator skid 110 for separating water and solids from the oil phase of the sludge 210 . As previously described, the phase separator skid 110 includes a surge tank 146 and a three-phase separator 148 mounted thereon. The sludge 210 is fed into the vertically-oriented surge tank 146 which separates solids from the sludge 210 and provides a continuous flow of a liquid portion of the sludge 212 to the three-phase separator 148 . Separated solids 214 that settle and accumulate in a bottom region of the surge tank 146 are discharged to the solids receiving tank 150 . The liquid portion of the sludge 212 which comprises oil, water, gas, and fine solids is directed to the three-phase separator 148 .
[0043] The liquid portion of the sludge 212 flows into the three-phase separator 148 through an inlet located at one end of the separator 148 . After phase separation within the retention section of the three-phase separator 148 , a water-rich phase 218 is discharged to a water tank 152 , an oil-rich phase 220 is transferred to the oil purification skid 116 , and a gas phase 228 is directed to the gas purification skid 112 . Any solids 216 that may settle out of the sludge 212 and accumulate in a bottom region of the separator 148 during separation of the phases are discharged to the solids receiving tank 150 .
[0044] The oil-rich phase 220 is transferred to the oil purification skid 116 for final purification and recovery of oil therefrom having a BS&W of less than about 1 vol. %. As previously described, the oil purification skid 116 includes a disk stack centrifuge 160 mounted thereon. The oil-rich phase 220 is fed into the disk stack centrifuge 160 wherein extremely high centrifugal forces separate the very fine water emulsion and the ultra-fine solids out of the oil-rich phase 220 . After phase separation, a water stream 222 , a recovered oil stream 224 , and an ultra-fine solids phase 226 are discharged from the centrifuge 160 . The recovered oil stream 224 has a BS&W less than about 1 vol. % and is commercially marketable.
[0045] The gas phase 228 is transferred to the gas purification skid 112 where the gas phase 228 is treated to remove VOCs prior to discharge into the environment. As previously described, the gas purification skid 112 preferably includes a free water knockout pot 162 , at least one mist impinger 166 , and at least one activated carbon filter 168 mounted thereon. A VFD-controlled vacuum blower 164 attached to the knockout pot 162 is used to draw the gas phase 228 from a gas vent located in an upper side of the three-phase separator 148 through the knockout pot 162 filled with water. Hydrocarbons in the gas phase 228 adhere to the water as the gas travels upwardly through the pot 162 . A wet-gas 230 that exits a gas outlet near the top of the knockout pot 162 is directed through at least one mist impinger 166 to remove water from the gas 230 and provide a dry gas 232 . The dry gas 232 is transferred to an activated carbon filter 168 to remove contaminants (e.g., remaining VOCs) therefrom in order to ensure a gas 234 that meets the regulatory standards for release to the atmosphere.
[0046] According to still another embodiment of the invention, FIG. 3 depicts the skid arrangement of a modular apparatus 300 optimally configured for recovering the valuable hydrocarbon component of sludge 14 initially having a low concentration of solids. In FIG. 3 the same reference numerals are used to indicate the same skids as those previously described with respect to the apparatus 100 depicted in FIG. 1 . Modular apparatus 300 comprises the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the chemical skid 108 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . This embodiment excludes the use of the decanter skid 114 . For sludge 14 initially having a low concentration of solids, it may be unnecessary to include a decanter centrifuge for the removal of solids.
[0047] Illustrated in FIGS. 4 and 7 , modular apparatus 300 processes pit sludge through the pumping skid 102 , the shaker skid 104 , the heating skid 106 , the chemical skid 108 , the phase separator skid 110 , the gas purification skid 112 , and the oil purification skid 116 . As previously described with respect to FIG. 4 , the modular apparatus 300 processes pit sludge 10 through the pumping skid 102 , the shaker skid 104 , and the heating skid 106 to provide a heated sludge 18 .
[0048] Referring now to FIG. 7 , the heated sludge 18 is transferred to the chemical skid 108 for chemically altering the sludge 18 to break up the emulsion and promote phase separation. In FIG. 7 the same reference numerals are used to indicate the same features as those previously described with respect to apparatus 100 depicted in FIG. 5 . As previously described, the chemical skid 108 includes a plurality of chemical injection mixers 140 a - d and chemical supply tanks 142 a - d mounted thereon. Chemical addition is typically required to destabilize the emulsion and change such properties of the sludge 18 to enhance the its phase separation during the next processing step at the phase separator skid 110 . As previously described, each of the chemical injection mixers 140 a - d includes a static shear mixer having an injection point for introducing a chemical into the sludge 18 while the mixer simultaneously blends the chemical and the sludge 18 under the shearing action of the mixer. As illustrated in FIG. 7 , four chemicals are added to the heated sludge 18 as the sludge is directed through the chemical injection mixers 140 a - d. Chemical supply tanks 142 a - d store the chemicals until they are transferred via chemical lines 144 a - d to the mixers 140 a - d for injection into the sludge 18 . Preferably at least one dosing pump (not shown) in fluid communication with each of the chemical injection mixers 140 a - d is used to provide a predetermined quantity of chemical to the injection point of the mixer for introduction into the sludge 18 . Preferably, chemical injection mixers 140 a - d are thermally insulated to better maintain the sludge temperature and fluidity. Once the chemicals are introduced and blended into the heated sludge 18 , a chemically-treated sludge 302 exits the last chemical injection mixer 140 d and is subsequently transferred to the phase separator skid 110 for separating the water, oil and solid phases of the sludge 302 . Again, it should be noted that additional chemical injection mixers may be added to the chemical skid 108 for the introduction of additional chemicals into the sludge 18 .
[0049] After chemical treatment, the sludge 302 is directed to the phase separator skid 110 for separating water and solids from the oil phase of the sludge 302 . As previously described, the phase separator skid 110 includes a surge tank 146 and a three-phase separator 148 mounted thereon. The sludge 302 is fed into the vertically-oriented surge tank 146 which contains an interior plate that facilitates the small solids within the sludge to aggregate and form larger solids that settle out of the sludge 302 and accumulate in a bottom region of the surge tank 146 . Separated solids 306 that accumulate in the surge tank 146 are discharged to the solids receiving tank 150 . The surge tank 146 also provides a continuous flow of a liquid portion of the sludge 304 to the three-phase separator 148 for oil, water, gas, and solid phase separation.
[0050] The liquid portion of the sludge 304 flows into the three-phase separator 148 through an inlet located at one end of the separator 148 . After phase separation within the retention section of the three-phase separator 148 , a water-rich phase 310 is discharged to a water tank 152 , an oil-rich phase 312 is transferred to the oil purification skid 116 , and a gas phase 320 is directed to the gas purification skid 112 . Any solids 308 that may settle out of the sludge 304 and accumulate in a bottom region of the separator 148 during separation of the phases are discharged to the solids receiving tank 150 .
[0051] The oil-rich phase 312 is transferred to the oil purification skid 116 for final purification and recovery of oil therefrom having a BS&W of less than about 1 vol. %. As previously described, the oil purification skid 116 includes a disk stack centrifuge 160 mounted thereon. The oil-rich phase 312 is fed into the disk stack centrifuge 160 wherein extremely high centrifugal forces separate the very fine water emulsion and the ultra-fine solids out of the oil-rich phase 312 . After phase separation, a water stream 314 , a recovered oil stream 316 , and an ultra-fine solids phase 318 are discharged from the centrifuge 160 . The recovered oil stream 316 has a BS&W less than about 1 vol. % and is commercially marketable.
[0052] The gas phase 320 is transferred to the gas purification skid 112 where the gas phase 320 is treated to remove VOCs prior to discharge into the environment. As previously described, the gas purification skid 112 preferably includes a free water knockout pot 162 , at least one mist impinger 166 , and at least one activated carbon filter 168 mounted thereon. A VFD-controlled vacuum blower 164 attached to the knockout pot 162 is used to draw the gas phase 320 from a gas vent located in an upper side of the three-phase separator 148 through the knockout pot 162 filled with water. Hydrocarbons in the gas phase 320 adhere to the water as the gas travels upwardly through the pot 162 . A wet-gas 322 that exits a gas outlet near the top of the knockout pot 162 is directed through at least one mist impinger 166 to remove water from the gas 322 and provide a dry gas 324 . The dry gas 324 is transferred to an activated carbon filter 168 to remove contaminants (e.g., remaining VOCs) therefrom in order to ensure a gas 326 that meets the regulatory standards for release to the atmosphere.
[0053] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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A modular apparatus having certain processing equipment mounted on portable skids that are adaptable and versatile to permit customized arrangement for oil-recovery processing of a wide range of oil-base sludge compositions in a cost-efficient manner. In one aspect, the invention is directed to a modular apparatus optimally configured for oil recovery of sludge having a high concentration of low density solids, wherein the apparatus may include a pumping skid, a shaker skid, a heating skid, a chemical skid, a phase separator skid, a gas purification skid, a decanter skid, and an oil purification skid. In another aspect, the invention is directed to a modular apparatus optimally configured for oil recovery of sludge having a high concentration of high density solids, wherein the apparatus may include a pumping skid, a shaker skid, a heating skid, a first chemical skid, a decanter skid, a second chemical skid, a phase separator skid, a gas purification skid, and an oil purification skid. In still another aspect, the invention is directed to a modular apparatus optimally configured for oil recovery of sludge having a very low solids content, wherein the apparatus may include a pumping skid, a shaker skid, a heating skid, a chemical skid, a phase separator skid, a gas purification skid, and an oil purification skid.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a pharmaceutical composition used for treating and preventing cancers and the preparation thereof. More specifically, the present invention relates to a cell differentiation agent (CDA-II) obtained from fresh urine, and the method for the preparation thereof. The pharmaceutical composition according to the present invention is effective in treating and preventing cancers.
According to the present invention, CDA-II can correct the ternary methylation enzymes in cancer cells from their abnormal state, thereby promote terminal differentiation of the cancer cells to achieve desired therapeutic effects. This method for treating cancer aimed at eliminating the cause of the disease is effective as demonstrated by clinical trails. CDA-II antagonizes the function of a cancer specific protein bonded to the ternary methylation enzymes of cancer cells, therefore, the method of the present invention is highly selective and has no adverse effect. The active components of CDA-II comprise differentiation inducers, differentiation helper inducers and an anti-cachexia agent. These active components act synergistically to achieve therapeutic effect.
CDA-II has a better anticancer effect when combined with other anticancer drugs, such as thymidine.
Further, CDA-II has a very good anticancer effect when combined with vitamin C and vitamin B 17 .
Cancer includes a variety of very complicated diseases; nevertheless, they all share a common feature that all cancer cells are able to keep on dividing, and can not undergo terminal differentiation. The present inventor has found that the abnormality of ternary methylation enzymes were the major cause of cancer disease, which provides a new strategy for cancer therapy. Cell differentiation agent, which is purified from the urine of normal persons, can transform abnormal ternary methylation enzymes in cancer cells to their normal forms. Thus cancer cells can be induced to undergo terminal differentiation, resulting in the termination of cell replication and/or apoptosis. In this way cancer can be cured. This treatment is safe to patients as the cell differentiation agent acts selectively on cancer cells. Furthermore, healthy persons also rely on this mechanism to fight against cancers. Accordingly, such a treatment of cancer is thus called “natural anticancer method”.
The active components in cell differentiation agent include differentiation inducers and differentiation helper inducers. The differentiation inducer can eliminate the abnormal protein factor (i.e. abnormal tumor specific protein factor) bonded to the ternary methylation enzyme, which is present specifically in cancer cells. The differentiation helper inducer is the inhibitor of the component enzymes of the ternary methylation enzymes, which can potentiate the action of the differentiation inducer. In the cell differentiation agent according to the present invention, the differentiation inducers are PP-0 and OA-0.79, and differentiation helper inducers include 4-hydroxyphenylacetic acid, hippuric acid, 5-hyrdroxyindole acetic acid, uroerythrin and riboflavin. PP-0 is a peptide conjugated with a pigment material which emerges from a gel filtration column of Ultrogel AcA202 with a K av , value of 0. OA-79 is an organic acid which emerges from the same gel column with a K av value of 0.79. In addition, the cell differentiation agent comprises an anti-cachexia component such as phenylacetylglutamine. Because most cancer patients develop the symptom of cachexia, anticachexia agent is helpful to the treatment of cancer. Briefly, the combination of the active components in the cell differentiation agent can provide excellent therapeutic effect. The present inventor further found that the cell differentiation agent of the present invention could give a better anticancer effect when used with the other cytotoxic drugs, such as thymidine. The present inventor also found that the cell differentiation agent of the present invention could also give a much better therapeutic effect when used together with vitamin C and vitamin B 17 .
2. Description of the Prior Art
Oncogenes are parts of human genome; thus, there were human being, there were cancers. However, up to now cancer is still a problem to be overcome by human. Because of the complexity of cancer, it is very difficulty to eradicate cancer cells from the patient. Cancer cells keep on dividing, invade into normal organs and tissues, and finally cause serious diseases to result in death of the patient. Traditionally, the ability to keep on dividing is regarded as the major cause of cancer, and the therapy based thereon is the administration of cytotoxic drugs, which can inhibit the synthesis of DNA and the division of cells. For the last five decades, therapy of cancer has been developed mainly on the technology of using cytotoxic drugs. New therapy of cancer is thus desirable.
Retinoic acid is a differentiation inducer successfully used in the treatment of acute promyelocytic leukemia (Huang et al., 1988; Warrell et al., 1991, ref. 8 and 28). Although it has an excellent anti-cancer effect, cancer cells recur soon (Muindi et al., 1992; Adamson, et al., 1993, ref. 1 and 25). The recurrence is caused by the incompleteness of differentiation associated with the use of differentiation inducer alone. The use of differentiation inducer alone results in the damage of the cell, making it impossible to complete the differentiation processes.
REFERENCES CITED
The references cited in and/or relevant to the present invention are listed below:
1. Adamson P. C., Boylan J. F., Balis F. M., Murfy R. F., Godwin K. A., Gudas L. T., Poplack D. G., Time course of induction of metabolism of all-trans retinoic acid and the up-regulation of cellular retinoic acid binding protein, Cancer Res., 53: 472-476, 1993. 2. Bar-Or D., Greisman S. L., Kastendieck J. G., Detection of appendicitis by measurement of uroerythrin, U.S. Pat. No. 5,053,389, 1991. 3. Borek E., et al., Altered excretion of modified nucleosides and [bgr]-aminoisobutyric acid in subjects with acquired immunodeficiency syndrome or at risk for acquired immunodefociency syndrome, Cancer Res., 46: 2557, 1986. 4. Burzynski, S. R., Treatment of Malignant Brain tumors with Antineoplastons, Adv. Exp. Clin. Chemother, 6/88:45-46, 1988. 5. Clark P. M. S., Kricka L. J., Whitehead T. P., Pattern of urinary proteins and peptides with rheumatioid arthritis investigated with the iso-Dalt technique, Clin. Chem., 26:201, 1980. 6. Doerfler, W., DNA methylation and gene activity, Annu. Rev. Biochem., 52: 92-124, 1983. 7. Epifanova, O. I., Abuladze, M. K., and Zoniovska, A. I., Effect of low concentrations of actinomycin D on the initiation of DNA synthesis in rapidly proliferating and stimulated cell culture, Exp. Cell Res., 92: 25-30, 1975. 8. Huang, M. E., Ye, Y. C., Chen, S. R., Chai, J. R., Lu, J. X., Zhao, L., Gu, L. J. and Wang, Z. Y, Use of all-trans retinoic acid in the treatment of acute promyelocytic leukemia, Blood, 72: 567-572, 1988. 9. Jones, P. A., Altering gene expression with 5-azacytidine, Cell, 40, 484-486, 1985. 10. Kampalath, B. N., Liau, M. C., Burzynski, B., and Burzynski, S. R., Chemoprevention by Antineoplaston A10 of Benzo (a) pyrene-induced Pulmonary Neoplasia, Drugs Exptl. Clin. Res., 13(supplement): 51-56, 1987. 11. Liau, M. C., who is the same inventor of this application case, Smith, D. W., and Hurlbert, R. B., Preferential inhibition by homopoly ribonucleotides of the methylation of ribosomal ribonucleic acid and disruption of the production of ribosomes in a rat tumor, Cancer Res., 35: 2340-2349, 1975. 12. Liau, M. C., Hunt, M. E. and Hurlbert, R. B., Role of ribosomal RNA methylases in the regulation of ribosome production in mammalian cells, Biochem., 15: 3158-3164, 1976. 13. Liau, M. C., Lin, G. W., and Hurlbert, R. B., Partial purification and characterization of tumor and liver S-adenosylmethionine synthetase, Cancer Res., 37: 427-435, 1977. 14. Liau, M. C., Lin G. W., Knight, C. A., and Hurlbert, R. B., Inhibition of RNA Methylation by Intercalating Agents, Cancer Res., 37: 4202-4210, 1977. 15. Liau, M. C., Chang, C. F., and Becker, F. F., Alteration of S-adenosylmethionine synthetase during chemical hepatocarcinogenesis and in resulting carcinomas, Cancer Res., 39: 2113-2119, 1979. 16. Liau, M. C., and Burzynski, S. R., Altered methylation complex isozymes as selective targets for cancer chemotherapy, Drugs Exptl. Clin. Res., 12(supplement): 77-86, 1986. 17. Liau, M. C., Szopa, M., Burzynski, B., and Burzynski, S. R., Chemosurveillance; a novel concept of the natural defense mechanism against cancer, Drugs Exptl. Clin. Res., 12(supplement): 71-76, 1987. 18. Liau, M. C., Lee S. S., and Burzynski, S. R., Differentiation inducing components of antineoplaston A5, Adv. Exptl. Clin. Chemother., 6/88: 9-25, 1988. 19. Liau, M. C., Lee, S. S., and Burzynski, S. R., Hypomethylation of nucleic acids: a key to the induction of terminal differentiation, Intl. J. Exptl. Clin. Chemother., 2: 187-199, 1989. 20. Liau, M. C., and Burzynski, S. R., Separation of active anticancer components of antineoplaston A2, A3 and A5, Intl. J. Tiss. React., 12(supplement): 1-18, 1990. 21. Liau, M. C., Lee, S. S., and Burzynski, S. R., Modulation of cancer methylation complex isozymes as a decisive factor in the induction of terminal differentiation mediated by antineoplaston A5. Intl. J. Tiss. React., 12(supplement): 1-18, 1990. 22. Liau, M. C., Ashraf, A., Lee, S. S., Hendry, L. B. and Burzynski, S. R., Riboflavin as a minor active anticancer component of Antineoplaston A2 and A5, Intl. J. Tiss. React., 12(supplement): 18-26, 1990. 23. Liau, M. C., Liau, C. P., Burzynski, S. R., Potantilation of induced terminal differentiation by phenylacetic acid and related chemicals, Intl. J. Exptl. Clin. Chemother., 8: 9-17, 1992. 24. Liau, M. C., Luong Y., Liau C. P., and Burzynski, S. R., Prevention of drug-induced DNA hypermethylation by antineoplaston components, Intl. J. Exptl. Clin. Chemother, 5: 19-23, 1992b. 25. Muindi, J. R. F., Frankel, S. R., Huselton, C., Degrazia, F., Garland, W. A., Young, C. W., and Warrell, R. P., Clinical pharmacology of oral all-trans retinoic acid in patients with acute promyelocytic leukemia, Cancer Res., 52: 2138-2142, 1992. 26. Muldoon, T. G, Copland, J. A., Hendry, L. B., Antineoplaston A10 activity on carcinogen-induced rat mammary tumors, Intl. J. Tiss. React., 12(supplement): 51-56, 1990. 27. Toniola, D., Weiss, H. K., and Basilio, C. A., Temperature sensitive mutation affecting 28S ribosomal RNA production in mammalian cells, Proc. Natl. Acad. Sci. USA, 70: 1273-1277, 1973. 28. Warrell, R. P. Jr., Frankel, S. R., Miller, W. H., Jr. Sheinberg, D. A., Itri, L. M., Hettelman, W. N., Vyas, R., Andreeff, M., Tafuri, A., Jakubowski, A, Gabrilove, J., Gordon, M. S., and Dmitrovsky, E., Differentiation therapy of acute promyelocytic leukemia with tretinoin (all-trans-retinoic acid), N. Engl. J. Med., 324: 1385-1393, 1991. 29. Spielholz, C., Golde D. W., Houghton, A. N., Nualart, F., and Vera, J. C., Incicased facilitated transport of dehydroascorbic acid without changes in sodium-dependent ascorbate transport in human melanoma cells, Cancer Res., 57: 2529-2537, 1997. 30. Mr. Rentaro Sano, Annihilating Cancer, Shimao Publisher, Taipei, Taiwan, 1997, pp 202-203.
SUMMARY OF THE INVENTION
The invention provides a pharmaceutical composition that can induce cancer cell to differentiate, and the use thereof in treating and preventing cancer. As mentioned above, cancer includes a variety of very complicated diseases. However, a common feature of cancers is that all cancer cells are capable of perpetual cell division, and cannot undergo terminal differentiation. Surprisingly, the inventor of the present invention found that abnormal ternary methylation enzymes were the major cause of cancer, therefore a new strategy to treat and prevent cancer was developed based on this finding.
After extensive study over more than 30 years, the inventor of the present invention found that ternary methylation enzymes were the major cause of cancer. It is the abnormality of these enzymes that renders cancer cells immortal. The ternary methylation enzymes play a very important role in cell division and differentiation. Cells are induced to divide when the activity of these enzymes is increased. On the contrary, cells are induced to synthesize methyl-deficient nucleic acids when the activity of these enzymes decrease, thereby are induced to differentiate into terminally differentiated cells, which are no longer capable of dividing. All cancer cells have abnormal ternary methylation enzymes, and the activity of these enzymes is high in these cells, thus making these cells divide endlessly. Clearly, abnormal ternary methylation enzymes are the cause of cancer. Therefore, an inhibitor of these abnormal enzymes can effectively fight against cancer and can effectively prevent healthy cells to become cancer cells. As a matter of fact, there are enough natural chemical substances in the body of a healthy person to inhibit the formation of abnormal ternary methylation enzymes. Therefore, carcinogenesis takes a very long period of time. In this period, the patient gradually accelerates the excretion of the anticancer chemicals. When the anticancer chemicals decrease to a concentration insufficient to inhibit the abnormal ternary methylation enzymes, the cancer cells take root to develop. Healthy persons excrete a small amount of anticancer substances in the urine. Upon purification, the anticancer substances can selectively inhibit the abnormal ternary methylation enzymes, thus inducing cancer cells to differentiate as normal cells. These naturally occurring anticancer substances do not affect the growth and the function of normal cells, thus the patients will not suffer from adverse effect. This strategy of therapy is thus called “differentiation therapy”.
Generally, the excretion of the anticancer substances can be balanced by the production of such substances in the body of a healthy person, thus sufficient amount of such substances is maintained in the body to keep a check on the evolution of cancer cells. In contrast, a patient suffering from cancer excretes much more of the anticancer substances, and gradually loses the ability to control the evolution of cancer cells. The inventor of the present invention has isolated and purified the anticancer substances, i.e. the cell differentiation agent, from the urine of healthy persons. The cell differentiation agent can transform the abnormal ternary methylation enzymes to their normal forms, induce cancer cells to undergo terminal differentiation, and/or apoptosis. In this way cancer can be treated or prevented.
The active components in cell differentiation agent include differentiation inducers and differentiation helper inducers. The differentiation inducer can antagonize the abnormal protein factor bonded to ternary methylation enzymes, which is present specifically in cancer cells. Differentiation helper inducer is the inhibitor of the component enzymes of the ternary methylation enzymes, which can potentiate the action of the differentiation inducer. Accordingly, the differentiation helper inducer is essential in the “differentiation therapy”, although to a lesser extend compared with the differentiation inducer. In the cell differentiation agent according to the present invention, the differentiation inducers are PP-0 and OA-0.79, and the differentiation helper inducers include 4-hydroxyphenylacetic acid, hippuric acid, 5-hyrdroxyindole acetic acid, uroerythrin and riboflavin. PP-0 is a peptide conjugated with a pigment material which emerges from a gel filtration column of Ultrogel AcA202 with a K av value of 0. OA-79 is an organic acid which emerges from the same gel column with a K av value of 0.79.
In addition, the cell differentiation agent according to the present invention also comprises another component, i.e. anticachexia agent, which is also helpful to the cancer treatment. It is found that phenylacetyl glutamine has the ability to reverse excessive excretion caused by the cachexia of cancer patient [Mr. Liau M. C., (Same invention of this patent application case), et al., 1987; Muldoon et al., 1990, ref. 10 and 26], which is the main component of fraction 4 in FIG. 2 . This component is helpful to the treatment of cancer because most cancer patients have developed the symptom of cachexia. Briefly, the cell differentiation agent can provide an excellent therapeutic effect when a variety of active components are combined to produce synergistic effect.
It is found that the cell differentiation agent can provide a better anticancer effect when used in combination with other cytotoxic drugs such as thymidine.
It is found that the cell differentiation agent can provide a much better anticancer effect when used in combination with vitamin C and vitamin B 17 .
The cell differentiation agent according to the present invention is prepared by collecting normal human urine for the purification of anticancer components that includes ultrafiltration, reverse phase chromatography, evaporation and freeze drying. The product of the present invention can be prepared as a injection formulation, or capsule.
Compared with prior art, the advantage of the present invention is utilizing anticancer substances that naturally exist in human bodies, and the treatment is directed to the root of the disease by making cancer cells differentiate and stop dividing. Therefore, the present invention is an effective therapy aimed at the elimination of the cause of the disease, and the medicine according to the present invention has no adverse effect.
These features and advantages of the present invention will be fully understood and appreciated from the following detailed description of the accompanying Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The above object and the content of the present invention will become more apparent by describing in detail preferred examples thereof with reference to the attached drawings in which:
FIG. 1 is a flow chart showing the process for the preparation of cell differentiation agent according to the present invention.
FIG. 2 shows the cell differentiation agent of the present invention analyzed by the gel filtration. After concentration by lyophilization, the CDA-II injection formulation was separated through column chromatography, in which Bio-Gel P2 chromatographic column (4.1 cm×44 cm) was used. The fractions collected were measured the OD value at A 255nm (O—O), the inhibition of MAT LT activity (O . . . O), weight percent, and differentiation activity on HL-60 cancer cells (represented by % NBT + ).
FIG. 3 shows the relationship between the concentration of uroerythrin (O—O) and vitamin B 2 (O . . . O) as differentiation helper inducers and the decrease index.
FIG. 4 shows the relationship between the concentration of uroerythrin (O—O) and vitamin B 2 (O . . . O) and the inhibition activity toward tRNA methyltransferases.
FIG. 5 shows the enhancement of uroerythrin and vitamin B 2 to the activity of differentiation inducer, the abscissa represents the concentration of retinoic acid μM), the ordinate represents the percentage of NBT (nitroblue tetrazolium)+ cells. O—O represents the control group in which different concentrations of retinoic acid are added; O . . . O represents the group in which 4 μM vitamin B 2 are added. O—.—.—O represents the group in which 4 μM uroerythrin are added.
FIG. 6 shows the synergistic anticancer action between CDA-II of the present invention and thymidine, the abscissa represents dosage (mg/ml), the ordinate represents the relative activity (%) of the cancer cell colony formation. O—O represents the group in which thymidine is used alone; O . . . O represents the group in which CDA-II is used alone; O—.—.—O represents the group in which thymidine and CDA-II are used together (1:1).
The activity of cancer cell colony formation is determined by using HBL-100 breast cancer cells according to the method described in Example 4, which is expressed by the percentage of the activity of cancer cell colony formation in a control group in which none of the chemicals is added. A group in which thymidine is used alone, a group in which CDA-II is used alone, and a group in which thymidine and CDA-II are used together (1:1) were tested. The result is shown in FIG. 6 , which demonstrates that the combined administration give a better therapeutic effect than single administration of CDA-II or thymidine. The synergistic effect is remarkable.
FIG. 7 shows the anticancer effect of CDA-II, antioxidant vitamin C, and vitamin B 17 . The activity of cancer cell colony formation is determined by using HBL-100 breast cancer cells according to the method described in Example 4. Each culture flask contains 5 ml medium, which contains 3000 HBL-100 cells and different amounts of CDA-11, vitamin C or vitamin B 17 . After incubation at 37° C. for 5 days, the cells were stained with Giemsa, and numbers of colonies with more than 8 cells were counted under a microscope.
In the present invention, AdoHcy represents S-adenosylhomocysteine, and SAHH represents S-adenosylhomocysteine hydrolase.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The process for the preparation of cell differentiation agent according to the present invention is illustrated in FIG. 1 . While the present invention is described further referring to the examples below, it is not intended to limit the scope of the invention.
EXAMPLE 1
Preparation of Cell Differentiation Agent
The process for the preparation of cell differentiation agent includes collection of urine, filtration, adsorption, solvent extraction and drying. An aqueous solution without pyrogen was used as the raw material of CDA-II.
When conducting the collection of urine, 1N HCl was added into the collection container in a proportion of 1 liter of HCl to 20 liters of urine. The purpose for this is to maintain the activity of the differentiation agent, which in this way can be maintained at least one month. The urine was filtrated through a nylon cloth after the pH was adjusted to 2, then the substances with molecular weight over 10,000 Dalton were removed by ultra filtration (Millipore filter or the like can be used). Adsorbent XAD-16 (Sigma) was placed in a hop-pocket, and then the hop-pocket was placed in a plastic funnel. Before the adsorbent was put into use, it was washed with 2 volume/weight (v/w) ethanol, then with 2 (v/w) deionized water to remove ethanol, and this step was repeated twice. After the urine had passed through the absorbent XAD-16, it was washed with 4 (v/w) deionized water, and then was eluted with 2 (v/w) ethanol. The ethanol eluant was neutralized, and ethanol was removed by evaporation under vacuum, while the temperature was kept below 50° C. The dried substance was dissolved in distilled water and was used as the raw material of CDA-II.
After elution with ethanol, the adsorbent was washed with 2 (v/w) deionized water, the absorbent can be used in a new cycle of absorption, until the adsorption capacity decreases to about 70% of that of a new adsorbent. Generally, XAD-16 can be reused about 200 times.
Because human body excretes daily a definite amount of creatinine, and the concentration of solid substances in urine is proportional to the amount of creatinine, thus, the quantitation of the chemicals in urine is based on the amount of creatinine. In the urine collected and used in this example, the concentration of creatinine is in the range of 1.2-3.7 g/l, the average of it is 2.4±0.6 g/l. In the first 100 cycles of adsorption, the yield of CDA-II is about 0.51±0.17 g/g creatinine, and the solid substance in urine is about 46.7 g/g creatinine. Therefore, the yield of the CDA raw material is about 1.1% of the solid substances.
EXAMPLE 2
The Preparation of the Injection Formulation of Cell Differentiation Agent
The final concentration of CDA-II in the injection formulation is 40±2 mg/ml, while the concentration of CDA-II in the raw material is above 250 mg/ml. Therefore, the raw material is required to be diluted to the final concentration of the injection formulation. After dilution with distilled water from which pyrogen was removed, the raw material was subjected to a series of filtration. First, the raw material was filtrated with a filter paper, then was filtrated through Millipore membrane filters with pore sizes of 1 μm and 0.45 μm, respectively, and finally was filtrated with a Millpore Pellicone system to remove pyrogen. After adjusted to the desired concentration with deionized water without pyrogen, the solution was passed through a filter with a pore size of 0.22 μm within 8 hours in a sterilized operating room (class 100 decontaminated chamber) to accomplish sterilization filtration. Then, the filtrate was prepared as a 100 ml or a 250 ml differentiation agent injection formulation.
EXAMPLE 3
The Preparation of Cell Differentiation Agent Capsule
After the raw material was filtrated sequentially through a paper filter, and Millipore membranes filters with pore size of 1 μm and 0.45 μm, respectively, the filtrate was dried by lyophilization. The dried material was ground, then packaged with an automatic capsule machine into capsules of 500 mg in weight. Then the capsules were packaged with aluminum foil, and sterilized by radiation.
EXAMPLE 4
Assay of the Anticancer Activity of Cell Differentiation Agent
The anticancer effect of cell differentiation agent is assessed based on the inhibition of the abnormal ternary methylation enzymes of cancer cells, the induction of cancer cells to undergo terminal differentiation, and the termination of cancer cells to divide. That is to say, cell differentiation agent can inhibit the abnormal enzyme MAT LT (methionine adenosyltransferase) of cancer cells, induce the differentiation of HL-60 cancer cells, and inhibit the formation of human breast cancer cell colony. These methods have been described [Liau, et al., 1977a, 1988, 1990a, ref. 13, 18, 20] Three aliquots of CDA-II were used to analyze its anticancer activity, as is described below:
CDA-II injection formulation was used in a dosage of 1 mg/ml. MAT LT was obtained from HL-60 cancer cell. First, the precipitated cells were suspended in a solution of 0.05M Tris, pH 7, 0.5 mM MgCl 2 , and then the cells were homogenized with Dounce homogenizer. The enzyme solution was separated by high-speed centrifugation (226,000×g, 0.5 hr). The enzyme was purified by DEAE-cellulose chromatography, and MAT LT was eluted with a KCl gradient solution and purified [Liau, et al., 1977a, ref. 13]. The activity of MAT LT was determined as previously described [Liau, et al., 1977a, ref. 13]. The 0.05 ml reaction solution containing 0.05 M Tris, pH 8.2, 15 M KCl, 15 mM MgCl 2 , 5 mM DTT (dithiothreitol), 2 mM ATP and 1 μM [ 3 H—CH 3 ] methionine was incubated at 37° C. for 30 minutes to allow reaction to proceed. The reaction was stopped with 0.4M PCA. The supernatant was then transferred to cellulose phosphate paper of 1 square inch. The paper was put into a beaker and washed with 5 mM phosphate buffer, pH 7 to remove unreacted [ 3 H—CH 3 ] methionine. Finally, the radiation of adsorbed [ 3 H—CH 3 ] AdoMet (S-adenosyl methionine) was measured to determine the activity of MAT LT (the result is shown in table 1).
The terminal differentiation of HL-60 cancer cells was analyzed by NBT+ method [Liau, et al., 1988a, ref. 18]. At the beginning, the HL-60 cells were diluted to 1.5×10 5 cells/ml each-culture flask. After incubation for 96 hours, an aliquot was taken from each culture flask for the determination of cell concentration. Another aliquot was centrifuged to pellet the cells, then the cell pellet was suspended in NBT solution and incubated at 37° C. for 30 min. An aliquot was placed in a hemocytometer for the determination of differentiation. The total number of cells and the cells stained as black (NBT+) were counted under a microscope. The percentage of NBT+ indicates the activity of CDA-II to induce cell differentiation.
Another indication of the anticancer activity of CDA-II is the inhibition of colony formation of HBL-100 breast cancer cell. At the beginning, the breast cancer cells growing at the exponential phase were washed with HBS solution, then about 2 ml 0.05% trypsin-0.53 mM EDTA was added, and the solution was incubated at 37° C. for 10 minutes. Thereafter, the cell density was measured, then an aliquot was taken and diluted to 3×10 3 cells/ml. 0.5 ml of the diluted solution was added into 4.5 ml culture medium with or without CDA-II and incubated at 37° C. Five days later, the medium was discarded, and the cells were washed with isotonic saline, then methanol was added to fix cells for 15 minutes. The fixed cells were stained for 30 minutes with Giemsa staining solution diluted 20 fold. After the staining solution was discarded, the cells were washed with water and dried. The colony number above 8 cells was counted under a microscope to determine the anticancer activity of CDA-II (the result is shown in table 1).
EXAMPLE 5
Characterization of the Active Components in Cell Differentiation Agent
The CDA-II cell differentiation agent injection formulation prepared in Example 2 was lyophilized and concentrated to 200 mg/ml. 5 ml of the concentrated solution was added onto a Bio-Gel P2 chromatographic column (4.1 cm×44 cm), then the column was eluted with distilled water. The fractions were collected every 7 minutes into a test tube, which is 10 ml in volume. After the completion of the elution, 25 μl of the eluant from each of the test tube was taken, and diluted with water to 1 ml to determine OD at A 255nm . Another 25 μl of the eluant was taken from each tube to determine the inhibition of MAT LT activity. The MAT LT activity was measured according to the method described in Example 4. The eluant was separated into 8 fractions as shown in FIG. 2 based on the OD at A 255nm . Each fraction was lyophilized and weighed to determine the weight distribution. The dry solid was dissolved in distilled water to determine the differentiation inducing activity of HL-60 cancer cells, which is represented by % NBT+. The differentiation inducing activity is measured according to the method described in example 4, and the result is shown in FIG. 2 .
Of the active anticancer components in cell differentiation agent, the most important one is the differentiation inducer that induces cell to differentiate. The separation, purification and its action have been described [Liau, et al., 1988; 1989; 1990a; 1990b; ref. 18, 19, 20, 21]. The differentiation inducers comprise two major components; one of them is an acidic peptide conjugated with pigment, abbreviated as PP-0, the other one is an organic acid, abbreviated as OA-0.79. PP-0 is in the first fraction shown in FIG. 2 , OA-0.79 is in the fifth and sixth fractions. The active fractions obtained form the Bio-Gel P2 chromatographic column were separately fractionated by gel filtration on a column of Ultrogel AcA202 (60-140 μm, 2.5 cm×58 cm, was obtained from LKB) as described in a separated paper (18). PP-0 is a peptide conjugated with a pigment material which emerges from a gel filtration column of Ultrogel AcA202 with a K av value of 0. OA-79 is an organic acid which emerges from the same gel column with a K av value of 0.79. It should be noted that the demonstrated differentiation activity of the cell differentiation agent does not reflect the activity of the cell differentiation inducer itself, but is contributed by the synergy with the differentiation helper inducers. Surprisingly, differentiation helper inducers are the main components in the cell differentiation agent, the content of the differentiation inducers is very low. Because they have not been sufficiently purified to be characterized, the chemical structure of which is still unknown. As is shown in FIG. 2 , the cell differentiation inducing activity coincides with the activity of MAT LT inhibition. However, in some fractions, such as fraction 2 and fraction 3 have noticeable MAT LT inhibition activity, but have no activity to induce cancer cells to differentiate. Probably these fractions comprise only differentiation helper inducers, and no differentiation inducer, therefore have no activity to induce cancer cells to differentiate.
The differentiation helper inducers are the inhibitors of the component enzymes of the ternary methylation enzymes [Liau, et al., 1992a, ref. 23], which assists the differentiation inducer in transforming the abnormal ternary methylation enzymes to their normal forms, therefore potentiates the differentiation action of the differentiation inducer.
It is known that MAT inhibitors in CDA include phenylacetic acid, indole acetic acid and hippuric acid. Phenylacetic acid, which is found in fraction 6 and fraction 7 in FIG. 2 , is probably the product resulted from the hydrolysis during the drying process of phenylacetyl glutamine, which can be identified with C18 HPLC (High Performance Liquid Chromatography). Indole acetic acid is also found in these fractions. Hippuric acid is the major component in fraction 5. To reach 0.5 reductive index (i.e., the effective dose of the differentiation inducer is reduced to 50% of it), the concentration of these MAT inhibitors are 4 mM phenylacetic acid, 8 mM hippuric acid, and 0.95 mM indole acetic acid. As the differentiation helper inducer, the inhibitor of methyltransferase is much more effective than the inhibitor of MAT. To achieve a certain effect, the amount required for the inhibitor of methyltransferase is only one thousand or less of the amount of the inhibitor of MAT. It is known that there are two inhibitors of methyltransferase in CDA, both of them have excellent activities as the differentiation helper inducers. The two inhibitors are vitamin B 2 and uroerythrin. Vitamin B 2 is found in the latter half of fraction 8 in FIG. 2 , as is described above [Liau, et al., 1990C, ref. 22]. This component, which is yellow in color, can be purified into vitamin B 2 by C18 HPLC, and the content of which is about 0.04% of the CDA-II. Uroerythrin is found in fraction 6 and fraction 7 in FIG. 2 . High purity of uroerythrin can be obtained by Sephadex SH chromatography and silica gel thin layer chromatography, and the content of which is about 0.5% of the CDA-II. Because it is hard to avoid loss during purification, and CDA-II preparation has a remarkable red color, the content of uroerythrin may be more than 0.5%.
EXAMPLE 6
The Determination of the Activity of Uroerythrin and Vitamin B 2 as Differentiation Helper Inducers
The action of the differentiation helper inducer was determined according to the method designed by the present inventor of this application case, Dr. Ming C. Liau [Liau, et al., 1992a, ref. 23]. The differentiation of cancer cells was measured by using leukemic cancer cells HL-60 to quantitate the NBT+ cells. First, HL-60 cells were subcultured at an initial cell density 1.5×10 5 cells/ml, 10 ml/flask. A set of four flasks were used as the control, wherein only retinoic acid was added as differentiation inducer, the amount of which was adjusted to induce NBT+ cells to the range of 15% to 60%. Another flask was used as the blank which was added the solution only. The total amount of methanol in which retinoic acid was dissolved should not exceed 2%, so as not to affect the differentiation of cancer cells. Each of other sets also comprises four flasks, which were added smaller amounts of retinoic acid, and a blank flask with only the solvent. Different amounts of the differentiation helper inducers were added in each set. The cell numbers in every flask were counted after incubation for 96 hours, and NBT was assayed according to the method of Example 4. Generally, the natural differentiation of the HL-60 cells, i.e. without the action of any of the additives, is usually lower than 4%. In the sets containing only differentiation helper inducer, the differentiation of cells is less than 10%. The value of NBT+ in each flask is required to subtract the value of the blank control.
The value of ED 50 , i.e., the amount of the differentiation inducer required when NBT+ is 50%, can be obtained by plotting the amount against NBT+. The reductive index can be calculated from the ED 50 value. Reductive index=ED 50 in the presence of differentiation helper inducer/ED 50 with cell differentiation inducer only. The lower the reductive index, the higher the activity of the differentiation helper induced.
As can be seen from FIG. 3 , the concentrations of vitamin B 2 and uroerythrin are 3.0 μM and 1.8 μM, respectively, to reach the 0.5 reductive index, which are much lower than the MAT inhibitors mentioned above.
EXAMPLE 7
The Inhibition Activity of Uroerythrin and Vitamin B 2 on tRNA Methyltransferase
tRNA methyltransferases were prepared from the high speed supernatant of HL-60 cancer cells shown in Example 4. First, the supernatant was adjusted to pH 5, and the proteins precipitated were separated by centrifugation, then dissolved in 0.05M Tris, pH 7.8, 0.5 mM MgCl 2 and 5 mM HSCH 2 CH 2 OH. After the solution passed though DEAE-cellulose column, tRNA methyltransferase were purified by KCl gradient [Liau, et al., 1977b, ref. 14]. The activity of tRNA methyltransferases were determined in 0.25 ml reaction solution comprising 0.05M Tris, pH 7.8, 0.1M NH 4 Cl, 0.04M NH 4 F, 0.5 mM MgCl 2 , 5 mM DTT, 20 μg Escherichia coli B tRNA, 0.25 μCi [ 3 H—CH 3 ] AdoMet (S-adenosylmethionine) and 25 μg enzymes. The reaction is carried at 37° C. for 30 minutes. tRNA was precipitated with cold 5% TCA (trichloroacetic acid), then was collected on Millipore membrane (pore size is 0.45 μm). After the membrane was dried, the radiation was assayed to determine the activity of tRNA methyltransferases, and the result is shown in FIG. 4 .
The effective amount to inhibit tRNA methyltransferases is much lower than the effective amount as the differentiation helper inducer. The reason for this is possibly related to the physical and chemical conditions for measuring these different activities. Different physical and chemical conditions (such as the concentration of salts) may affect differently the effective contact between chemicals and enzymes. Despite the differences in sensitivity, the activities of different tRNA methyltransferase inhibitors are proportional to the activities of differentiation helper inducers. The tRNA methyltranferase inhibitor with higher activity is a better differentiation helper inducer. We have also found that other tRNA methyltransferase inhibitors, such as ethidium bromide and hycanthone [Liau, et al., 1977b, ref. 14], are excellent differentiation helper inducers as uroerythrin and vitamin B 2 . The concentration of ethidium bromide and hycanthone is 0.95 μM and 2 μM, respectively, to reach 0.5 reductive index. Therefore, it is no doubt that the inhibitors of methyltransferases can be used as effective differentiation helper inducers.
EXAMPLE 8
Analysis of the Differentiation Helper Inducers to Promote Differentiation
Differentiation helper inducers can not only decrease the effective amount of the differentiation inducer, but also promote the completeness of differentiation. HL-60 cancer cells were subcultured at an initial cell density of 1.5×10 5 cells/ml. The culture flasks were grouped into three sets; each set includes 4-5 flasks. One flask was used as the blank without additives. One set was added 0.025-0.15 μM retinoic acid as the control; the other two sets were added 4 μM of uroerythrin or vitamin B 2 . NBT test was conducted as described in Example 4 after incubation for 96 hours. The values thus obtained were subtracted with the value obtained by the blank without additives.
As can be seen from FIG. 5 , the extent of differentiation only reached about 85% when the differentiation inducer is used alone. When combined with uroerythrin or vitamin B 2 , the extent of differentiation reached 100%. It is much more important to achieve the completeness of differentiation than to decrease the effective amount of the differentiation inducer.
EXAMPLE 9
Synergistic Anticancer Action of Cell Differentiation Agent with Other Chemical Anticancer Agent
Ternary methylation enzyme is very active in cancer cells. If DNA synthesis is inhibited by chemicals, over-transfer of methyl is resulted, and genes are repeatedly synthesized. Repeated synthesis of genes result in the formation of drug resistant cells (Liau, et al., 1992b, ref. 24), and this is one of the important reasons causing the failure of chemotherapy. The formation of drug resistant cells can be minimized through inhibition of the abnormal ternary methylation enzymes by using cell differential agent, which is helpful to the treatment of cancer. It has been demonstrated that cell differentiation agent can enhance the therapeutic effect of some anticancer drugs, for example, as is shown with the combination of CDA-II and thymidine in the present invention ( FIG. 6 ).
EXAMPLE 10
The Combination of the Anticancer Action of Cell Differentiation Agent and Antioxidants
Hypoxia can stimulate apoptosis and result in the death of cancer cells. The utilization of vitamin C and vitamin B 17 to create a hypoxia state is especially suitable for the treatment of cancer. Cancer cells are capable of absorbing vitamin C 10-fold more than normal cells [ref. 29], while vitamin B 17 can be selectively decomposed by β-glucosidase present only in cancer cells to yield toxic cyanide, which inhibits the activity of oxidase [ref. 30]. β-glucosidase is highly active in cancer cells, but is much less active normal cells. As is shown in FIG. 7 , CDA-II, vitamin C and vitamin B 17 can inhibit the formation of colonies of HBL-100 human breast cancer cells, and the IC 50 of which is 0.69, 0.53 and 0.13 mg/ml, respectively. The result of combined use of CDA-II and vitamin C or vitamin B 17 is shown in table 2, which demonstrates that the combined use of CDA-II and vitamin C or vitamin B 17 is additive.
TABLE 1
The anticancer action of cell differentiation agent (CDA-II)
% Inhibition to the colony
Lot No.
% MAT inhibiton
% NBT+
formation of breast cancer cells
01
49
58
100
02
55
53
100
03
50
54
100
Notes:
CDA-II used is inhection formulation, the dosage of which is 1 mg/ml.
MAT LT was prepared from HL-60 cancer cells by purification through DEAE-cellulose chromatography and the activity was determined as previously described [Liau, et al., 1977a, ref. 13].
The terminal differentiation of HL-60 cancer cells was determined according to the NBT+ method [18].
The inhibition of colony formation of cancer cells was determined by cell culture using human HBL-100 breast cancer cells [Liau, et al., 1990a, ref. 20].
TABLE 2
The additive action of CDA-II and vitamin C or vitamin B 17
The colony formation of HBL-100 cells:
inhibition percentage
Combined administration
Drugs &
Administered
dosages
mg/ml
alone
Predicted value
Measured value
CDA-II
0.4
16
28
39
C
0.2
12
CDA-II
0.6
38
50
58
C
0.2
12
CDA-II
0.8
65
77
80
C
0.2
12
CDA-II
0.4
16
36
39
B 17
0.05
20
CDA-II
0.6
38
58
58
B 17
0.05
20
CDA-II
0.8
65
85
83
B 17
0.05
20
The experiment was carried out according to FIG. 6 . HBL-100 cells were cultured with different dosages of CDA-II, vitamin C and vitamin B 17 alone, and with the combination of CDA-II and vitamin C, or the combination of CDA-II and vitamin B 17 .
The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof, therefore, the illustrated embodiment should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.
INDUSTRIAL APPLICABILITY
Compared with prior art, the advantage of the present invention is utilizing the anticancer substances naturally occurring in human bodies to treat and prevent cancer, thereby making the cancer cells to differentiate and stop dividing. Therefore, the present invention is an effective treatment to eliminate the cause of the disease present only in cancer cells, and the medicine according to the present invention has no adverse effect.
Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims.
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The present invention relates to a pharmaceutical composition for the treatment and prevention of cancer and the preparation method thereof, especially to a cell differentiation agent named CDA-II which is prepared by reverse phase chromatography of fresh human urine. The pharmaceutical composition is effective for the treatment and prevention of cancer. The active components in CDA-II contain differentiation inducers, differentiation helper inducers and an anticachexia agent, which act cooperatively to achieve the best therapeutic effect.
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RELATED APPLICATIONS
The present application is a Continuation Application of U.S. patent application Ser. No. 12/320,052 filed on Jan. 15, 2009, now U.S. Pat. No. 7,728,925 which was a Divisional Application of U.S. patent Ser. No. 11/980,630, (now U.S. Pat. No. 7,499,123) filed on Oct. 31, 2007, which was a Divisional Application of U.S. patent application Ser. No. 11/134,299 (now U.S. Pat. No. 7,349,043 B2) which was filed on May 23, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Technical Field
The present invention relates to a planar light source, a display device, a portable terminal device, and a ray direction switching element, and in particular, to a planar light source that can change an irradiation angle of illumination light, a display device that can change an angle of field using the planar light source, a portable terminal device that uses the display device, and a ray direction switching element that is incorporated in the planar light source.
2. Description of the Related Art
Background Art
In accordance with the development of technologies in recent years, a liquid crystal display device (LCD), which is wide in an angle of field, that is, visually recognizable in a wide angle range, has been put to practical use. In addition, a portable information terminal mounted with the LCD is also widely used. In such a portable information terminal, it is desirable that the angle of field of the LCD is wide when a user looks at information displayed on the LCD with other people. On the other hand, in the portable information terminal, the user often does not want other people to peep at displayed information. In such a case, it is desirable that the angle of field of the LCD is narrow. In this way, the angle of field is required to be wide and narrow depending on a state of use of the LCD. Conventionally, LCDs meeting such a demand have been proposed.
FIGS. 24( a ) and 24 ( b ) schematically show a first conventional liquid crystal display device that is described in Japanese Patent Laid-Open No. 6-59287. FIG. 24( a ) shows the liquid crystal display device at the time when a voltage is not applied thereto. FIG. 24( b ) shows the liquid crystal display device at the time when a voltage is applied thereto. As shown in FIGS. 24( a ) and 24 ( b ), the first conventional liquid crystal display device includes a liquid crystal panel in which a liquid crystal material (not shown) is sealed by transparent substrates 102 and 108 . A polarizing plate 101 is provided on one surface of this liquid crystal panel. On the other surface, a guest host liquid crystal cell 131 , in which a liquid crystal material consisting of liquid crystal molecules 131 a and elongate pigment molecules 131 b are sealed by two transparent substrates 114 provided with transparent electrodes 110 on surfaces thereof, is provided. The pigment molecules 131 b have a larger amount of absorption of light in a minor axis direction of the molecules than in a major axis direction thereof. When a voltage is not applied to the guest host liquid crystal cell 131 , the liquid crystal molecules 131 a and the elongate pigment molecules 131 b are arranged to be parallel to the surfaces of the transparent substrates 114 in a longitudinal direction. When a voltage is applied to the guest host liquid crystal cell 131 , the liquid crystal molecules 131 a and the elongate pigment molecules 131 b are arranged to be perpendicular to the surfaces of the transparent substrates 114 in the longitudinal direction. The polarizing plate 101 is provided on a surface on the opposite side of a surface opposed to the liquid crystal panel of the guest host liquid crystal cell 131 .
In the first conventional liquid crystal display device constituted in this way, which is described in Japanese Patent Laid-Open No. 6-59287, light in a wide angle range passes through the liquid crystal panel to be made incident on the guest host liquid crystal cell 131 . When an image is displayed at a wide angle of field, a voltage is not applied to the guest host liquid crystal cell 131 to make a light absorbing direction of the guest host liquid crystal cell 131 coincident with an absorbing direction of the polarizing plate 101 , whereby the light passes through the guest host liquid crystal cell 131 directly. Consequently, it is possible to visually recognize a display screen in a wide angle range.
When an image is displayed at a narrow angle of field, when a voltage is applied to the guest host liquid crystal cell 131 , the pigment molecules 131 b are arranged to be perpendicular to the surfaces of the transparent substrates 114 in the longitudinal direction, and an angle of incidence of light deviates largely from a direction perpendicular to the surfaces of the transparent substrates 114 . This light is absorbed by the pigment molecules 131 b and does not pass through the guest host liquid crystal cell 131 . Therefore, even if an angle distribution of light made incident on the display device is wide, an angle distribution of emitted light is narrowed by absorption of the guest host liquid crystal. Consequently, it is possible to reduce a size of a visually recognizable display screen.
FIG. 25 is a diagram schematically showing a second conventional liquid crystal display device that is described in Japanese Patent Laid-Open No. 10-197844. The second conventional liquid crystal display device includes a backlight 113 , as shown in FIG. 25 . A PDLC cell 136 , in which a Polymer Dispersed Liquid Crystal (PDLC) layer 111 is sandwiched by two transparent substrates 109 , is provided on the backlight 113 . A polarizing plate 101 is provided on the PDLC cell 136 , and a Twisted Nematic-Liquid Crystal Display (TN-LCD) is provided on the polarizing plate 101 . A guest host liquid crystal cell is provided on the TN-LCD, and the polarizing plate 101 is provided on the guest host liquid crystal cell. This guest host liquid crystal cell has the same structure as the guest host liquid crystal cell that is used in the first conventional liquid crystal display device described in Japanese Patent Laid-Open No. 6-59287.
In the second conventional liquid crystal display device constituted in this way, which is described in Japanese Patent Laid-Open No. 10-197844, wide field of view display and narrow field of view display are switched by switching ON and OFF of a voltage applied to the guest host liquid crystal cell. In addition, transmission and reflection of light is switched by switching ON and OFF of a voltage applied to the PDLC cell to adjust brightness of a display screen.
Japanese Patent Laid-Open No. 11-142819 discloses a liquid crystal display device in which a condensing element consisting of a prism sheet and a light scattering element consisting of a PDLC cell are provided between a light source and a liquid crystal panel. Japanese Patent Laid-Open No. 11-142819 mentions that it is possible to switch a narrow angle of field and a wide angle of field by increasing directivity of light with the prism sheet and, then, transmitting or scattering light from the prism sheet with the PDLC cell. In addition, Japanese Patent Laid-Open No. 9-105907 discloses a similar liquid crystal display device in which an optical element consisting of a PDLC cell is provided between a light source and a liquid crystal panel.
On the other hand, conventionally, a high directivity backlight, in which an irradiation range of illumination light is fixed but directivity in a specific direction such as the front direction is improved, has been developed (see, for example, monthly magazine “Display” May 2004, pages 14 to 17). FIG. 26 is a perspective view showing a conventional high directivity backlight 213 described in the monthly magazine “Display” May 2004, pages 14 to 17. As shown in FIG. 26 , in this conventional high directivity backlight 213 , an LED 201 is arranged in one location where a light guide plate 202 is provided, and a linear micro-prism is arranged concentrically around the LED 201 in the light guide plate 202 . A prism sheet 203 , in which a prism structure is also arranged concentrically around the LED 201 , is arranged on a light emission surface of the light guide plate 202 . In addition, a reflection sheet 204 is arranged on a surface on the opposite side of the surface of the light guide plate 202 on which the prism sheet 203 is provided.
Exit light from the LED 201 is made incident on the light guide plate 202 and emitted radially along the surface of the light guide plate 202 by the linear micro-prism formed in the light guide plate 202 . At this point, the LED 201 is arranged in one location of the light guide plate 202 , and a longitudinal direction of the linear micro-prism formed in the light guide plate 202 is arranged to be substantially perpendicular to the LED 201 . Thus, even if light guided through the light guide plate 202 hits the linear micro-prism, the light is not deflected in the longitudinal direction of the linear micro-prism but travels linearly and radially around the LED 201 . The light emitted from the light guide plate 202 is refracted by the prism sheet 203 and deflected in a vertical direction with respect to the light emission surface of the light guide plate 202 . Consequently, a high directivity backlight, in which directivity is improved two-dimensionally in a front direction, is realized.
DISCLOSURE OF THE INVENTION
Problems to Solved by the Invention
However, the conventional techniques described above has problems described below. In the liquid crystal display device described in Japanese Patent Laid-Open No. 6-59287, a difference of an amount of absorption of light is small in the minor axis direction and the major axis direction of the pigment molecules in the guest host liquid crystal cell. In other words, a pigment dichroic ratio is low. In addition, liquid crystal molecules near the transparent substrates do not stand at the time of voltage application, and the pigment molecules arranged in parallel to the transparent substrates remains. Consequently, in the guest host liquid crystal cell at the time of voltage application, efficiency of absorbing light, an incident angle of which deviates largely from the direction perpendicular to the surfaces of the transparent substrates, falls, and an angle of field at the time of the narrow field of view display increases.
In addition, in the liquid crystal display device described in Japanese Patent Laid-Open No. 10-197844, the wide field of view display and the narrow field of view display are also switched by switching ON and OFF of a voltage applied to the guest host liquid crystal. Consequently, the same problems as the liquid crystal display device described in Japanese Patent Laid-Open No. 6-59287 occur.
Moreover, in the liquid crystal display device described in Japanese Patent Laid-Open No. 11-142819, light from a light source is condensed by the prism sheet, that is, directivity of light is improved. The light with high directivity passes through the PDLC cell directly, whereby a size of a visually recognizable display screen is reduced. However, since the prism sheet does not have a sufficient effect for improving directivity of light, an angle of field at the time of the narrow field of view display increases. In other words, other people peep at displayed information.
SUMMARY OF THE INVENTION
The invention has been devised in view of such problems, and it is an object of the invention to provide a planar light source having a large variable width of an irradiation angle of illumination light, a display device having a large variable width of an angle of field that uses the planar light source, a portable terminal device that uses the display device, and a ray direction switching element that is incorporated in the planar light source.
Means for Solving the Problems
A planar light source in accordance with the invention includes: a backlight that emits light in a planar shape; a ray direction regulating element that regulates a direction of light made incident from the backlight and emits the light and in which a transparent area for transmitting light and an absorption area for absorbing light are formed alternately in a direction perpendicular to a light regulating direction thereof; and a transparent and scattering switching element that is capable of switching a state in which light made incident from the ray direction regulating element is transmitted and a state in which the light is scattered.
In the invention, the beam direction regulating element, which controls a direction of light, and the transparent and scattering switching element, which can switch the transparent and the scattering state according to ON and OFF of an applied voltage, are provided between the backlight and a liquid crystal panel, whereby it is possible to increase a variable width of an irradiation angle of light in the planar light source.
It is preferable that an emitting direction of light emitted by the backlight spreads radially in an elliptical shape with respect to a direction perpendicular to an emission surface, and the transparent area and the absorption area of the ray direction regulating element are formed alternately in a direction parallel to a long diameter direction of the ellipse.
It is preferable that an emitting direction of light emitted from the back light spreads radially in an elliptical shape with respect to a direction perpendicular to an emission surface and, in the ray direction regulating element, the transparent area and the absorption area are formed alternately in a direction parallel to a short diameter direction of the ellipse. Consequently, since an amount of light of the backlight passing through the ray direction regulating element increases, it is possible to realize a bright planar light source.
An emitting direction of light emitted by the backlight may be condensed radially in a circular shape with respect to a direction perpendicular to an emission surface. Consequently, since a loss of absorption of light by the ray direction regulating element can be reduced, it is possible to realize bright display. In addition, since directivity of the backlight is two-dimensional, it is also possible to switch the narrow field of view display and the wide field of view display concerning a direction orthogonal to the direction in which the transparent area and the absorption area of the ray direction regulating element are arranged alternately.
It is preferable that, in the transparent and scattering switching element, a polymer dispersed liquid crystal layer, in which liquid crystal molecules are dispersed in a polymer film, is sandwiched between a pair of flat electrodes, and the polymer dispersed liquid crystal layer is in a state in which the polymer dispersed liquid crystal layer transmits incident light when a voltage is applied between the flat electrodes and in a state in which the polymer dispersed liquid crystal layer scatters incident light when a voltage is not applied between the flat electrodes. Consequently, since the transparent and scattering switching element does not consume electric power in the state in which the transparent and scattering switching element scatters incident light, the electric power is allocated to a backlight light source. Thus, it is possible to improve brightness of the planar light source at the time of the scattering state.
An orientation state of the liquid crystal molecules at the time when a voltage is applied thereto may be held after the application of the voltage is stopped.
The transparent and scattering switching element and the ray direction regulating element may be formed integrally. Consequently, since the ray direction regulating element can be supported by the transparent and scattering switching element, it is possible to realize a highly stable and thin planar light source.
The transparent and scattering switching element and the ray direction regulating element may have a common substrate.
A substrate of the ray direction regulating element may be only a substrate common to the ray direction regulating element and the transparent and scattering switching element. Consequently, it is possible to further reduce thickness of the planar light source. In addition, it is preferable that an amount of light of the backlight and the transparent and scattering states of the transparent and scattering switching element can be set independently. Consequently, it is possible to set intensity and directivity of light emitted from the planar light source in various ways.
It is also possible that the transparent and scattering switching element is in the state in which the transparent and scattering switching element scatters incident light when a voltage is not applied between the flat electrodes, and in which a voltage is applied to the transparent and scattering switching element when the transparent and scattering switching element is used in the scattering state. Consequently, it is possible to increase a front luminance without significantly decreasing a luminance in an oblique direction at the time when the transparent and scattering switching element is used in the scattering state.
A display device in accordance with the invention includes: a backlight that emits light in a planar shape; a ray direction regulating element that regulates a direction of light made incident from the backlight and emits the light and in which a transparent area for transmitting light and an absorption area for absorbing light are formed alternately in a direction perpendicular to a light regulating direction thereof; a transparent and scattering switching element that is capable of switching a state in which light made incident from the ray direction regulating element is transmitted and a state in which the light is scattered; and a liquid crystal panel that displays an image using light made incident from the transparent and scattering switching element.
In the invention, the beam direction regulating element, which controls a direction of light, and the transparent and scattering switching element, which can switch the transparent and the scattering state according to ON and OFF of an applied voltage, are provided between the backlight and a liquid crystal panel, whereby it is possible to increase a variable width of an angle of field of the display device.
It is preferable that an emitting direction of light emitted by the backlight spreads radially in an elliptical shape with respect to a direction perpendicular to an emission surface and, in the ray direction regulating element, the transparent area and the absorption area are formed alternately in a direction parallel to a long diameter direction of the ellipse.
The white light source may be constituted by a blue LED and a yellow phosphor to adjust an amount of light with pulse modulation. Consequently, it is possible to control chromaticity change of the display device when an amount of light of the white light source is adjusted simultaneously with switching of transparent and scattering.
A direction in which the transparent area and the absorption area of the ray direction regulating element are formed alternately and a pixel arrangement direction of the display panel do not have to be parallel to each other. Consequently, it is possible to reduce moiré due to the ray direction regulating element and the display panel.
The display panel may be a liquid crystal panel, and the liquid crystal display panel may be a panel of a lateral electric field mode, a multi-domain vertical orientation mode, or a film compensation TN mode. Consequently, it is possible to control tone reversal and improve visibility at the time when the transparent and scattering switching element is in the scattering state.
The portable terminal device may have adjusting means that can change an amount of the backlight and the transparent and scattering states of the transparent and scattering switching element independently from each other. Consequently, a user can set an optimum state according to an environment of use of the portable terminal device.
The portable terminal device may have electric power accumulating means, residual amount detecting means for electric power accumulated in the electric power accumulating means, and control means that automatically changes an amount of the backlight and the transparent and scattering states of the transparent and scattering switching element on the basis of detected residual amount information. When the transparent and scattering element is brought into the transparent state, since an amount of light of the backlight can be reduced, it is possible to reduce power consumption when residual battery power is low and extend an operating time of the portable terminal device.
The transparent area and the absorption area of the ray direction regulating element may be formed alternately in a lateral direction of the portable terminal device. Consequently, it is possible to increase a variable width of an angle of field in the lateral direction of the portable terminal device.
A ray direction switching element in accordance with the invention is characterized in that a ray direction regulating element, which regulates a direction of incident light and emits light, and a transparent and scattering switching element, which is capable of switching a state in which light made incident from the ray direction regulating element is transmitted and a state in which the light is scattered, are integrally formed. Consequently, since the ray direction regulating element can be supported by the transparent and scattering switching element, it is possible to realize a highly stable and thin ray direction switching element.
In the ray direction switching element, the transparent and scattering switching element and the ray direction regulating element may be formed on a common substrate. A substrate of the ray direction regulating element may be only a substrate common to the ray direction regulating element and the transparent and scattering switching element.
ADVANTAGE OF THE INVENTION
According to the invention, the ray direction regulating element, that controls a direction of light, and the transparent and scattering switching element, which can switch the transparent and scattering states by turning ON and OFF an applied voltage, are provided between the backlight and the liquid crystal panel, whereby it is possible to increase a variable width of an irradiation angle of light in the planar light source and increase a variable width of an angle of field of the liquid crystal display device that uses the planar light source.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a liquid crystal display device in accordance with a first embodiment of the invention;
FIG. 2 is a perspective view showing an example of a backlight that is used in the liquid crystal display device in accordance with the first embodiment of the invention;
FIG. 3 is a diagram showing a direction of light emitted from the backlight;
FIG. 4 is a plan view showing an example of a louver that is used in the liquid crystal display device in accordance with the first embodiment of the invention;
FIG. 5 is a diagram showing a light distribution characteristic at the time of a wide angle of field of the liquid crystal display device in accordance with the first embodiment of the invention;
FIG. 6 is a diagram showing a light distribution characteristic at the time of a narrow angle of field of the liquid crystal display device in accordance with the first embodiment;
FIG. 7 is a plan view showing an example of a louver that is used in a liquid crystal display device in accordance with a first modification of the first embodiment of the invention;
FIG. 8 is a plan view showing an example of a louver that is used in a liquid crystal display device in accordance with a second modification of the first embodiment of the invention;
FIG. 9 is a diagram showing a light distribution characteristic at the time of a wide angle of field of a liquid crystal display device in accordance with a third modification of the first embodiment of the invention;
FIG. 10 is a diagram showing a light distribution characteristic at the time of a narrow angle of field of the liquid crystal display device in accordance with the third modification of the first embodiment of the invention;
FIG. 11 is a sectional view showing a liquid crystal display device in accordance with a second embodiment of the invention;
FIG. 12 is a sectional view showing a liquid crystal display device in accordance with a third embodiment of the invention;
FIG. 13 is a sectional view showing a liquid crystal display device in accordance with a fourth embodiment of the invention;
FIG. 14 is a sectional view showing a liquid crystal display device in accordance with a fifth embodiment of the invention;
FIG. 15 is a sectional view showing a liquid crystal display device in accordance with a sixth embodiment of the invention;
FIG. 16 is a sectional view showing a liquid crystal display device in accordance with a seventh embodiment of the invention;
FIG. 17 is a sectional view showing a liquid crystal display device in accordance with an eighth embodiment of the invention;
FIG. 18 is a sectional view showing a liquid crystal display device in accordance with a ninth embodiment of the invention;
FIG. 19 is a sectional view showing a liquid crystal display device in accordance with a tenth embodiment of the invention;
FIG. 20 is a graph showing a result of an experiment in which a slight voltage is applied to a transparent and scattering switching element in a scattering state to adjust a scattering property;
FIG. 21 is a perspective view showing a portable terminal device mounted with a liquid crystal display device of the invention;
FIG. 22 is a plan view showing a transparent and scattering switching element of a liquid crystal display device in accordance with a twelfth embodiment of the invention;
FIG. 23 is a plan view showing a liquid crystal display device in which a direction in which a transparent area and an absorption area of a ray direction regulating element are formed alternately and a pixel arrangement direction of a liquid crystal display panel are not parallel to each other;
FIG. 24( a ) is a diagram schematically showing a first conventional liquid crystal display device at the time when a voltage is not applied thereto;
FIG. 24( b ) is a diagram schematically showing a first conventional liquid crystal display device at the time when a voltage is applied thereto;
FIG. 25 is a diagram schematically showing a second conventional liquid crystal display device; and
FIG. 26 is a perspective view showing a conventional high directivity backlight.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Best Mode for Carrying Out the Invention
Embodiments of the invention will be hereinafter explained specifically with reference to the accompanying drawings. First, a first embodiment of the invention will be explained. FIG. 1 is a sectional view showing a liquid crystal display device in accordance with the first embodiment. FIG. 2 is a perspective view showing an example of a backlight that is used in the liquid crystal display device in accordance with the first embodiment. FIG. 3 is a diagram showing a direction of light emitted from the backlight. FIG. 4 is a plan view showing an example of a louver that is used as a ray direction regulating element in the liquid crystal display device in accordance with the first embodiment. FIG. 5 is a diagram showing a light distribution characteristic at the time of a wide angle of field of the liquid crystal display device in accordance with the first embodiment. FIG. 6 is a diagram showing a light distribution characteristic at the time of a narrow angle of field of the liquid crystal display device.
As shown in FIG. 1 , in the liquid crystal display device in accordance with the first embodiment, a backlight 13 is provided, and a louver 12 (a ray direction regulating element) is provided above the backlight 13 . A transparent and scattering switching element 22 is provided above the louver 12 , and a liquid crystal panel 21 is provided above the transparent and scattering switching element 22 .
As shown in FIG. 2 , a linear light source 36 of a prism shape is provided along one end face of the backlight 13 , and white LEDs 25 are provided to be opposed to both ends thereof, respectively. The linear light source 36 includes plural prisms (not shown), which are arranged cyclically, to refract light, which is made incident on the linear light source 36 from the white LEDs 25 , substantially orthogonally in a direction of the backlight 13 with the plural prisms. In this way, the linear light source 36 emits linear light in the direction of the backlight 13 from a side of the backlight 13 . In addition, the backlight 13 includes plural prisms (not shown) that are arranged cyclically in a direction orthogonal to a surface extending in parallel to the linear light source 36 and opposed to the linear light source 36 . These prisms refract linear light made incident from the linear light source 36 in a direction orthogonal to one surface 37 of the backlight 13 and emit planar light from the entire surface 37 . Such a backlight 13 emits light, of which light in a direction parallel to the linear light source 36 has a wider angle than light in a direction orthogonal to the linear light source 36 .
As shown in FIG. 3 , a direction 35 of light emitted from the backlight 13 is defined by a polar angle θ and an azimuth φ. The polar angle θ is an angle formed by the direction 35 and a direction 34 perpendicular to a surface of the backlight 13 . On a projection surface 13 parallel to the backlight 13 , when an X-Y rectangular coordinate with a point, where the direction 34 and the projection surface 33 cross each other, as an origin O is assumed, the azimuth φ is an angle formed by a line, which connects an intersection where the direction 35 and the projection surface 33 cross each other and the origin O, and the X axis. In this way, light emitted from the backlight 13 is diffused light, and θ and φ have wide distributions.
As shown in FIG. 1 , the louver 12 is a ray direction regulating element that improves directivity of light emitted from the backlight 13 . The louver 12 regulates a ray direction of broadening light made incident from the backlight 13 in one direction and emits the light. This light regulating direction is, for example, a direction perpendicular to a surface of the louver 12 . Of the light emitted from the louver 12 , directivity of light in a direction perpendicular to the surface of the louver 12 (light regulating direction) is improved. In this case, the light emitted with the direction thereof regulated by the louver 12 broadens a little, although a polar angle θ is smaller than that of the light emitted from the backlight 13 shown in FIG. 3 .
In the louver 12 , for example, a transparent area 12 a , which transmits light, and an absorption area 12 b , which absorbs light, are formed to be arranged alternately in a direction parallel to the surface of the louver 12 . The direction in which the transparent area 12 a and the absorption area 12 b are arranged alternately is identical with, for example, a direction in which the backlight 13 emits wide angle light, that is, a direction parallel to the linear light source 36 . As shown in FIG. 4 , viewed from a direction perpendicular to the surface of the louver 12 , the transparent area 12 a and the absorption area 12 b of a stripe shape are arranged alternately. The louver 12 can adjust, for example, thickness and an arrangement pitch of the transparent area 12 a and the absorption area 12 b and an absorption amount of light in the absorption area 12 b to adjust an emission angle at the time when incident light is emitted.
As shown in FIG. 1 , in the transparent and scattering switching element 22 , a PDLC layer 11 formed by scattering liquid crystal molecules 11 b in a polymer matrix 11 a is put in electrodes 10 , and a transparent substrate 9 is provided on the each electrode 10 . A voltage is applied to the PDLC layer 11 , which is sandwiched between the electrodes 10 , by the electrodes 10 , whereby an orientation state of liquid crystal molecules in the PDLC layer 11 changes. The PDLC layer 11 is formed by, for example, exposing a mixture of a photo-curing resin and a liquid crystal material to light and hardening the mixture. The transparent and scattering switching element 22 scatters or transmits light made incident from the louver 12 and emits the light to the liquid crystal panel 21 .
In the liquid crystal panel 21 , a polarizing panel 1 , which polarizes light made incident from the transparent and scattering switching element 22 , is provided, and a transparent substrate 8 is provided on the polarizing plate 1 . A pixel electrode 7 defining a pixel area is provided on the transparent substrate 8 in a matrix shape. A liquid crystal layer 6 is provided to cover surfaces of the pixel electrode 7 and the transparent substrate 8 . A common electrode 5 for applying a voltage to the liquid crystal layer 6 is provided on the liquid crystal layer 6 , and the transparent dielectric layer 4 is provided on the common electrode 5 . In the transparent dielectric layer 4 , a groove is formed in a position corresponding to an area of the surface of the transparent substrate 8 , which is not covered by the pixel electrode 7 , and a black matrix 3 , which prevents external light from being projected on the liquid crystal panel, is provided in the groove. A transparent substrate 2 is provided to cover the transparent dielectric layer 4 and the black matrix 3 , and a polarizing plate 1 , which polarizes emitted light from the liquid crystal panel, is provided on the transparent substrate 2 .
As shown in FIG. 5 , light emitted from the backlight 13 has an elliptical distribution 38 spreading widely in an X direction compared with a Y direction. This emitted light distribution indicates that light spreads largely as an area of a distribution area is larger. When light of this distribution 38 is made incident on the louver 12 , light spreading in the X direction is absorbed by the louver 12 to change to light of a distribution 39 with high directivity that is distributed substantially in a round shape. In the case of the wide field of view display, when the light of this distribution 39 is made incident on the transparent and scattering switching element 22 in the scattering state, light of a circular distribution is uniformly scattered to change to light of a circular distribution 40 that spreads more largely. The light of this distribution 40 is transmitted through the liquid crystal panel 21 and emitted to realize the wide field of view display.
As shown in FIG. 6 , when light of the distribution 38 emitted from the backlight 13 is made incident on the louver 12 , light spreading in the X direction is absorbed by the louver 12 to change to light of the distribution 39 with high directivity that is distributed in substantially in a round shape. In the case of the narrow field of view display, when the light of this distribution 39 is made incident on the transparent and scattering switching element 22 in the transparent state, light of a circular distribution is transmitted through the transparent and scattering switching element 22 directly and light of the distribution 39 is emitted. The light of this distribution 39 is transmitted through the liquid crystal panel 21 and emitted to realize the narrow field of view display.
Next, an operation of the liquid crystal display device in accordance with the first embodiment formed as described above will be explained. First, a case of the wide field of view display will be explained. As shown in FIG. 1 , light emitted from the backlight 13 is made incident on the louver 12 . As shown in FIG. 3 , light emitted from the backlight 13 is diffused light, and θ and φ have wide distributions. In the backlight 13 shown in FIG. 2 , as shown in FIG. 5 , light emitted from the backlight 13 has a larger value of θ in the case in which φ is close to 0 degree or 180 degrees than in the case in which φ is close to 90 degrees or 270 degrees. In other words, the light has the elliptical distribution 38 spreading widely in the X direction compared with the Y direction. When the light of this distribution 38 is made incident on the louver 12 , light with large θ is absorbed by the absorption area 12 b of the louver 12 . Light with small θ is transmitted through the transparent area 11 a . Therefore, in light emitted from the louver 12 , the light with large θ is removed and light of the distribution 39 with a small distribution area and high directivity is emitted.
As shown in FIG. 1 , the light of the distribution 39 with high directivity emitted from the louver 12 is made incident on the transparent and scattering switching element 22 . In the case of the wide field of view display, a voltage is not applied to the PDLC layer 11 . Consequently, the PDLC layer 11 is in a state in which the liquid crystal molecules 11 b are scattered at random in the polymer matrix 11 a , and the incident light is scattered. Therefore, as shown in FIG. 5 , light of the circular distribution 39 is uniformly scattered by the PDLC layer 11 to change to light of the circular distribution 40 spreading more largely. In other words, the light, directivity of which is improved by the louver 12 , is scattered by the transparent and scattering switching element 22 to have lower directivity and change to light with a wide angle. As shown in FIG. 1 , the light of the distribution 40 spreading in a wide range is made incident on the liquid crystal panel 21 and emitted while keeping the distribution 40 . In this way, an image is displayed in a wide angle of field.
Next, a case of the narrow field of view display will be explained. As shown in FIG. 6 , as in the case of the wide field of view display, light having the elliptical distribution 38 emitted from the backlight 13 is changed to light of the distribution 39 with a small distribution area and high directivity by the louver 12 .
As shown in FIG. 1 , the light of the distribution 39 is made incident on the transparent and scattering switching element 22 . In the case of the narrow field of view display, a predetermined voltage is applied to the PDLC layer 11 . Consequently, the PDLC layer 11 comes into the transparent state in which the liquid crystal molecules 11 b scattered in the polymer matrix 11 a are oriented. In other words, the PDLC layer 11 transmits incident light directly. Therefore, as shown in FIG. 6 , the light of the circular distribution 39 is transmitted through the PDLC layer 11 directly. In other words, the light, directivity of which is improved by the louver 12 , is emitted from the transparent and scattering switching element 22 in a state of the distribution 39 keeping high directivity. As shown in FIG. 1 , the light of the distribution 39 with high directivity is made incident on the liquid crystal panel 21 and emitted while keeping the distribution 39 . In this way, an image is displayed at a narrow angle of field.
In this way, light with low directivity emitted from the backlight 13 is converted into light with high directivity by the louver 12 , and the light with high directivity is transmitted or scattered by the transparent and scattering switching element, which uses the PDLC layer, to switch the narrow field of view display and the wide field of view display. Consequently, it is possible to increase a variable width of an irradiation angle of light in the planar light source and increase a variable width of an angle of field of the liquid crystal display device that uses the planar light source.
Here, the same liquid crystal display device as the first embodiment is constituted using the conventional prism sheet instead of the louver 12 to measure a relation between an angle of field and a luminance in the case of the narrow field of view display. A range of an angle of field of 0 degree, that is, an angle of field, at which a luminance of a value equal to or larger than half a luminance at the time when the liquid crystal display device is viewed from the front is obtained, is 30 degrees to the left and the right. On the other hand, in the first embodiment, a range of an angle of field, at which a luminance of a value equal to or larger than half a luminance at the angle of field 0 degree is obtained, is 20 degrees to the left and the right. In this way, in the first embodiment, it is possible to realize the narrow field of view display effectively compared with the conventional technique.
Next, a first modification of the first embodiment of the invention will be explained. FIG. 7 is a plan view showing an example of a louver that is used in a liquid crystal, display device in accordance with the first modification of the first embodiment. In the first embodiment described above, as shown in FIG. 4 , the transparent area 12 a and the absorption area 12 b of a stripe shape are arranged alternately on the surface of the louver 12 when the louver 12 is viewed from a direction perpendicular to the surface. Thus, directivity of light made incident on the louver 12 can be improved only in one direction. On the other hand, in the first modification of the first embodiment, as shown in FIG. 7 , a circular transparent area 12 a is arranged in the absorption area 12 b in a matrix shape when the louver 12 is viewed from a direction perpendicular to the surface of the louver 12 . Consequently, it is possible to improve directivity of light made incident on the louver 12 in various directions. Components, operations, and effects in the first modification of the first embodiment other than those described above are the same as those in the first embodiment.
Next, a second modification of the first embodiment will be explained. FIG. 8 is a plan view showing an example of a louver that is used in a liquid crystal display device in accordance with the second modification of the first embodiment. In the first modification of the first embodiment, as shown in FIG. 7 , the circular transparent area 12 a is arranged in the absorption area 12 b in a matrix shape. On the other hand, in the second modification of the first embodiment, as shown in FIG. 8 , a quadrangle transparent area 12 a is arranged in the absorption area 12 b in a matrix shape when the louver 12 is viewed from a direction perpendicular to the surface of the louver 12 . The transparent area 12 a is, for example, a square or a rectangle. Components, operations, and effects in the second modification of the first embodiment other than those described above are the same as those in the first modification of the first embodiment.
Next, a third modification of the first embodiment of the invention will be explained. FIG. 9 is a diagram showing a light distribution characteristic at the time of a wide angle of field of a liquid crystal display device in accordance with a third modification of the first embodiment. FIG. 10 is a diagram showing a light distribution characteristic at the time of a narrow angle of field.
In the first embodiment, as shown in FIG. 5 , light emitted from the backlight 13 has the elliptical distribution 38 spreading in the X direction widely compared with the Y direction. When the light of this distribution 38 is made incident on the louver 12 , the light spreading in the X direction is absorbed by the louver 12 to change to light of the distribution 39 with high directivity that is distributed substantially in a round shape. In the case of the wide field of view display, when the light of this distribution 39 is made incident on the transparent and scattering switching element 22 in the scattering state, light of a circular distribution is uniformly scattered to change to light of the circular distribution 40 spreading more largely. The light of this distribution 40 is transmitted through the liquid crystal panel 21 and emitted to realize the wide field of view display. In addition, as shown in FIG. 6 , when light of the distribution 38 emitted from the backlight 13 is made incident on the louver 12 , light spreading in the X direction is absorbed by the louver 12 to change to light of the distribution 39 with high directivity that is distributed substantially in a round shape. In the case of the narrow field of view display, when the light of this distribution 39 is made incident on the transparent and scattering switching element 22 in the transparent state, light of a circular distribution is transmitted through the transparent and scattering switching element 22 directly and light of the distribution 39 is emitted. The light of this distribution 39 is transmitted through the liquid crystal panel 21 and emitted to realize the narrow field of view display.
On the other hand, in the third modification of the first embodiment, as shown in FIG. 9 , light emitted from the backlight 13 has an elliptical distribution 41 spreading widely in the Y direction compared with the X direction. When the light of this distribution 41 is made incident on the louver 12 , directivity of light spreading in the X direction is further improved by the louver 12 and, in particular, light distributed in the X direction changes to light of a distribution 42 having high directivity. In the case of the wide field of view display, when the light of this distribution 42 is made incident on the transparent and scattering switching element 22 in the scattering state, the light scatters to spread in the X direction to change to light of a distribution 43 . The light of this distribution 43 is transmitted through the liquid crystal panel 21 and emitted to realize the wide field of view display. In addition, as shown in FIG. 10 , when the light of the distribution 41 emitted from the backlight 13 is made incident on the louver 12 , directivity of light spreading in the X direction is further improved by the louver 12 and, in particular, light distributed in the X direction changes to light of the distribution 42 having high directivity. In the case of the narrow field of view display, when the light of this distribution 42 is made incident on the transparent and scattering element 22 in the transparent state, in particular, light of a distribution having high directivity of light distributed in the X direction is transmitted through the transparent and scattering switching element 22 directly and light of the distribution 42 is emitted. The light of this distribution 42 is transmitted through the liquid crystal panel 21 and emitted to realize the narrow field of view display with respect to the X direction.
In the third modification of the first embodiment, compared with the first embodiment, since an amount of light, which is emitted from the backlight 13 and absorbed by the louver 12 , can be reduced, it is possible to realize bright wide field of view display. In particular, since an amount of light of the backlight 13 is limited, the third modification is effective in the case in which switching of an angle of field only in the X direction has to be realized. Components, operations, and effects in the third modification of the first embodiment other than those described above are the same as those in the first embodiment.
Next, a second embodiment of the invention will be explained. FIG. 11 is a sectional view showing a liquid crystal display device in accordance with the second embodiment. In the first embodiment described above, as shown in FIG. 1 , the one louver 12 , in which the transparent area 12 a and the absorption area 12 b of a stripe shape are arranged alternately, is provided between the backlight 13 and the transparent and scattering switching element 22 . On the other hand, in the second embodiment, as shown in FIG. 11 , a louver 15 , in which a transparent area 15 a and an absorption area 15 b of a stripe shape are arranged alternately in one direction, and a louver 14 , in which a transparent area 14 a and an absorption area (not shown) of a stripe shape are arranged alternately in a direction orthogonal to an arrangement direction in the louver 15 , are stacked to be provided between the backlight 13 and the transparent and scattering switching element 22 . Consequently, in the second embodiment, it is possible to improve directivity of light made incident on the louver 12 not only in one direction but also in a direction orthogonal to the direction. Therefore, for example, it is possible to realize the narrow field of view display effectively not only in the horizontal direction but also in the vertical direction. Components, operations, and effects in the second embodiment other than those described above are the same as those in the first embodiment.
Next, a third embodiment of the invention will be explained. FIG. 12 is a sectional view showing a liquid crystal display device in accordance with the third embodiment. In the first embodiment described above, as shown in FIG. 1 , the conventional PDLC layer 11 , in which the liquid crystal molecules 11 b are scattered uniformly in the polymer matrix 11 a , is used as the planar transparent and scattering switching element 22 . On the other hand, in the third embodiment, as shown in FIG. 12 , a PDLC layer 16 , which is modulated such that distribution of liquid crystal molecules 16 b scattered in a polymer matrix 16 a has unevenness cyclically, is used. In the modulated PDLC layer 16 , for example, a portion where the liquid crystal molecules 11 b are dense and a portion where the liquid crystal molecules 11 b are sparse are repeated cyclically in one direction. The modulated PDLC layer 16 scatters incident light intensely in the direction in which the portion where the liquid crystal molecules 11 b are dense and the portion where the liquid crystal molecules 11 b are sparse are repeated cyclically. Consequently, it is possible to increase an angle of field in this direction.
That is, in the transparent and scattering switching element, the polymer dispersed liquid crystal layer 16 may include a high density portion where a density of the liquid crystal molecules is high and a low density portion where a density of the liquid crystal molecules is low, and the high density portion and the low density portion may be formed alternately in a direction perpendicular to the light regulating direction.
It is possible to manufacture such a modulated PDLC layer 16 by using the same material as the conventional PDLC layer for a PDLC layer and subjecting the PDLC layer to exposure and photo-curing via a photo-mask. Light is irradiated on the PDLC layer before curing via a photo-mask on which a linear pattern is formed cyclically. A part irradiated by the light starts to harden. At this point, a concentration gradient of the liquid crystal molecules 16 b occurs between a hardening area and a not-hardening area. After the PDLC layer is subjected to the exposure for a predetermined time via the photo-mask, the entire surface of the PDLC layer is exposed to light, whereby the modulated PDLC layer 16 is obtained. In this modulated PDLC layer 16 , a mixture of two or more kinds of liquid crystal molecules with different sizes may be used as the liquid crystal molecules 16 b . Components, operations, and effects in the third embodiment other than those described above are the same as those in the first embodiment.
Next, a fourth embodiment of the invention will be explained. FIG. 13 is a sectional view showing a liquid crystal display device in accordance with the fourth embodiment. In the fourth embodiment, as shown in FIG. 13 , in addition to the structure of the liquid crystal display device in accordance with the first embodiment, the liquid crystal display device further includes a light source light intensity control unit 26 that controls an amount of an electric current to be supplied to a white LED 25 and adjusts an amount of light, that is, a luminance of the white LED 25 and a transparent and scattering switching element control unit 27 that switches ON and OFF of a voltage of the transparent and scattering switching element 22 . The light source light intensity control unit 26 and the transparent and scattering switching element control unit 27 are constituted to be associated with each other. Components in the fourth embodiment other than those described above are the same as those in the first embodiment.
Next, operations of the liquid crystal display device in accordance with the fourth embodiment constituted as described above will be explained. As shown in FIG. 13 , in the case of the wide field of view display, the transparent and scattering switching element control unit 27 does not apply a voltage to the transparent and scattering switching element 22 . Consequently, light made incident on the transparent and scattering switching element 22 from the louver 12 is scattered. At this point, the light source light intensity control unit 26 supplies an electric current to the white LED 25 such that a front luminance, that is, a luminance at an angle of field of 0 degree of the liquid crystal panel 21 takes a predetermined value. In the case of the narrow field of view display, the transparent and scattering switching element control unit 27 applies a voltage to the transparent and scattering switching element 22 . Consequently, light made incident on the transparent and scattering switching element 22 from the louver 12 is transmitted through the transparent and scattering switching element 22 directly. Therefore, when an amount of an electric current supplied to the white LED 25 is the same, that is, an amount of light emitted from the backlight 13 is the same, a front luminance of the liquid crystal panel 21 is excessively large. Thus, the amount of electric current supplied to the white LED 25 is adjusted such that the front luminance of the liquid crystal panel 21 in the case of the narrow field of view display takes as same value as that in the case of the wide field of view display. Consequently, in the fourth embodiment, the front luminance of the liquid crystal panel 21 is kept constant. Note that, in the case in which the white LED 25 is constituted by a blue LED and a yellow phosphor, an amount of light of the white LED 25 may be adjusted by pulse width modulation of an electric current. In the white LED 25 constituted by the blue LED and the yellow phosphor, the yellow phosphor is excited by a part of blue light emitted by the blue LED to emit yellow light, and the blue light and the yellow light are mixed to generate white light. When an amount of an electric current is adjusted such that the front luminance of the liquid crystal panel 21 in the case of the narrow field of view display takes a value equivalent to that in the case of the wide field of view display, since an emission ratio of the blue light and the yellow light fluctuates, chromaticity change of the liquid crystal panel 21 occurs. On the other hand, when an amount of light is adjusted by the pulse modulation, the adjustment of an amount of light is realized by adjusting a ratio of light emitting time, it is possible to control chromaticity change of the liquid crystal panel 21 . Operations and effects in the fourth embodiment other than those described above are the same as those in the first embodiment.
Next, a fifth embodiment of the invention will be explained. FIG. 14 is a sectional view showing a liquid crystal display device in accordance with the fifth embodiment. In the fourth embodiment described above, as shown in FIG. 13 , the white LED 25 and the linear light source 36 are used. On the other hand, in the fifth embodiment, as shown in FIG. 14 , a light source, in which a red LED 28 , a green LED 29 , and a blue LED 30 are arranged linearly and cyclically, is used instead of the linear light source 36 . The liquid crystal display device includes the light source light control unit 26 that controls amounts of electric currents to be supplied to the red LED 28 , the green LED 29 , and the blue LED 30 and adjusts amounts of lights, that is, luminances of the LEDs. Components in the fifth embodiment other than those described above are the same as those in the fourth embodiment.
Next, operations of the liquid crystal display device in accordance with the fifth embodiment constituted as described above will be explained. As shown in FIG. 14 , lights emitted from the red LED 28 , the green LED 29 , and the blue LED 30 are made incident on the backlight 13 . Red, green, and blue are three primary colors of light, and lights of these colors are superimposed to form white light. The backlight 13 converts incident light into planar light. In the case of the wide field of view display, this light is made incident on the transparent and scattering switching element 22 and scattered. At this point, since a degree of scattering of light depends on a wavelength of the light, light with a shorter wavelength is scattered more intensely and light with a longer wavelength is less likely to be scattered. In other words, blue light is likely to be scattered and red light is less likely to be scattered. Therefore, a display image at the time when the liquid crystal panel is viewed from the front is reddish.
Thus, when light is scattered by the transparent and scattering switching element 22 , for example, an amount of an electric current supplied to the blue LED 30 is increased to intensify blue light that is likely to be scattered, and an amount of an electric current supplied to the red LED 28 is reduced to weaken red light that is less likely to be scattered. In this way, in the wide field of view display and the narrow field of view display, intensity of lights emitted by the red LED 28 , the green LED 29 , and the blue LED 30 are adjusted in association with presence or absence of application of a voltage to the transparent and scattering switching element 22 , whereby a tint of a display image at the time when the liquid crystal panel is viewed from the front can be kept constant. Operations and effects in the fifth embodiment other than those described above are the same as those in the fourth embodiment.
Next, a sixth embodiment of the invention will be explained. FIG. 15 is a sectional view showing a liquid crystal display device in accordance with the sixth embodiment. In the sixth embodiment, in addition to the structure of the liquid crystal display device in accordance with the first embodiment, transparent substrates 121 are provided on both sides of the louver 12 . In an example, a material of the transparent substrates 121 is polyethylene terephthalate. Components in the sixth embodiment other than those described above are the same as those in the first embodiment.
In the liquid crystal display device in accordance with the sixth embodiment constituted as described above, since the transparent substrates 121 are provided on both the sides of the louver 12 , there is an effect that it is possible to improve resistance of the louver 12 against changes in temperature and humidity, and reliability of the liquid crystal display device is improved. Operations and effects in the sixth embodiment other than those described above are the same as those in the first embodiment. In addition, the sixth embodiment can also be applied to the second to the fifth embodiments.
Next, a seventh embodiment of the invention will be explained. FIG. 16 is a sectional view showing a liquid crystal display device in accordance with the seventh embodiment. Whereas the louver and the transparent and scattering switching element are fixed by a couple-face tape in the sixth embodiment, in the seventh embodiment, the louver 12 having the transparent substrates 121 on both the sides thereof and the transparent and scattering switching element 22 are bonded and, as a result, formed integrally. Components in the seventh embodiment other than those described above are the same as those in the sixth embodiment.
In the liquid crystal display device in accordance with the seventh embodiment constituted as described above, the transparent substrates 121 are provided on both the sides of the louver 12 and, in addition, the louver 12 and the transparent and scattering switching element 22 are formed integrally. Thus, it is possible to improve resistance of the louver 12 against changes in temperature and humidity and improve reliability of the liquid crystal display device. It is also possible to reduce thickness of the liquid crystal display device. Operations and effects in the seventh embodiment other than those described above are the same as those in the sixth embodiment.
Next, an eighth embodiment of the invention will be explained. FIG. 17 is a sectional view showing a liquid crystal display device in accordance with the eighth embodiment. Compared with the structure of the liquid crystal display device in accordance with the seventh embodiment, the eighth embodiment is characterized in that the louver 12 and the transparent and scattering switching element 22 are integrally formed and have a common substrate. In this example, the louver 12 has the transparent substrates 121 on both the sides thereof, and the substrate 121 of the louver 12 is also used as a transparent substrate on the transparent and scattering switching element 22 side. Thus, the transparent and scattering switching element 22 does not have the transparent substrate 9 on the louver 12 side. Components in the eighth embodiment other than those described above are the same as those in the seventh embodiment.
As described above, in the liquid crystal display device in accordance with the eighth embodiment, it is possible not only to improve reliability as in the liquid crystal display device in accordance with the seventh embodiment but also to reduce thickness of the liquid crystal display device. In addition, since the number of substrates constituting the liquid crystal display device can be reduced, it is also possible to reduce weight of the liquid crystal display device. Operations and effects in the eighth embodiment other than those described above are the same as those in the seventh embodiment.
Next, a ninth embodiment of the invention will be explained. FIG. 18 is a sectional view showing a liquid crystal display device in accordance with the ninth embodiment. Compared with the structure of the liquid crystal display device in accordance with the eighth embodiment, in the ninth embodiment, the louver 12 has only the transparent substrate 121 common to the louver 12 and the transparent and scattering switching element 22 and does not have a transparent substrate on the backlight 13 side. Components in the ninth embodiment other than those described above are the same as those in the eighth embodiment.
In the liquid crystal display device in accordance with the ninth embodiment constituted as described above, since the transparent substrate on the backlight 13 side of the louver 12 is not provided, reliability is lower than the reliability of the liquid crystal display device in accordance with the eighth embodiment. However, since the transparent substrate 121 is set on the transparent and scattering switching element 22 side, it is possible to improve reliability compared with the first embodiment. In addition, compared with the liquid crystal display device in accordance with the eighth embodiment, in the ninth embodiment, since the transparent substrate of the louver 12 can be removed, it is possible to further reduce thickness and weight of the liquid crystal display device. Operations and effects in the ninth embodiment other than those described above are the same as those in the eighth embodiment.
Next, a tenth embodiment of the invention will be explained. FIG. 19 is a sectional view showing a liquid crystal display device in accordance with the tenth embodiment. Compared with the structure of the liquid crystal display device in accordance with the first embodiment, the liquid crystal display device in accordance with the tenth embodiment is different in that the high directivity backlight 213 described in the monthly magazine “Display” May 2004, pages 14 to 17 is used. Components in the tenth embodiment other than those described above are the same as those in the first embodiment.
In the liquid crystal display device according to the tenth embodiment constituted as described above, since the high directivity backlight 213 with directivity improved two-dimensionally on a light emitting surface thereof is used, it is possible to reduce a loss in absorption of light by the louver 12 and realize bright display. In addition, since the directivity of the backlight is two-dimensional, it is also possible to show an effect of switching of an angle of field concerning a direction orthogonal to the direction in which the transparent area and the absorption area of the louver 12 are arranged alternately. Note that the high directivity backlight suitably used in the embodiment is not limited to the high directivity backlight described in the monthly magazine “Display” May 2004, pages 14 to 17, and it is possible to apply any backlight to the liquid crystal display device as long as directivity thereof is improved two-dimensionally.
FIG. 20 is a graph showing a result of an experiment in which a slight voltage is applied to the transparent and scattering switching element 22 in the scattering state to adjust a scattering property in the liquid crystal display device in accordance with the tenth embodiment. In the graph, a horizontal axis indicates an angle of field and a vertical axis indicates a luminance. A result indicated by a broken line is a luminance distribution in the case in which a voltage is not applied to a PDLC layer constituting a transparent and scattering switching element, and a result indicated by a solid line is a luminance distribution in the case in which a slight voltage (in an example, 1 volt) is applied to the PDLC layer. Note that the slight voltage in this context means a small voltage compared with a voltage for bringing the transparent and scattering switching element into a transparent state. Whereas a front luminance (a luminance in a 0° direction) in the case in which a voltage is not applied to the PDLC layer is 75 cd/m 2 , a front luminance in the case in which a slight voltage is applied is improved to 120 cd/m 2 . On the other hand, in an oblique direction, more specifically, in a range from +25° to +80° or a range from −25° to −80°, although a luminance in the case in which a voltage is applied slightly falls, a degree of the fall in the voltage is extremely small, and a luminance of substantially the same degree as that in the case in which a voltage is not applied is secured. This indicates that it is possible to improve a luminance in a front direction significantly without decreasing the luminance in the oblique direction significantly by applying a slight voltage at the time of scattering of the transparent and scattering switching element to slightly decrease the scattering property. This result is effective in the case in which a front luminance falls in the wide field of view display, due to limited amount of light of the back light. Although the tenth embodiment is explained, the explanation is not limited to the tenth embodiment but is applicable to the other embodiments as well. Operations and effects in the tenth embodiment other than those described above are the same as those in the first embodiment.
Next, an eleventh embodiment of the invention will be explained. FIG. 21 is a perspective view showing a portable terminal device mounted with the liquid crystal display device of the invention. As shown in FIG. 21 , a liquid crystal display device 100 of the invention is mounted on, for example, a cellular phone 90 .
The liquid crystal display device of the invention can be applied to a portable device such as a cellular phone and makes it possible to perform display for switching an angle of field. In particular, in the case in which the liquid crystal display device of the invention is mounted on a cellular phone, a transparent area and an absorption area of a louver serving as a ray direction regulating element are arranged alternately at least in a lateral direction of the cellular phone, whereby it is possible to switch the wide field of view display and the narrow field of view display with respect to the lateral direction of the cellular phone. This makes it possible to prevent a peep by other people from the lateral direction in public transportation facilities and the like. Note that the portable device is not limited to the cellular phone, and it is possible to apply the liquid crystal display device to various portable terminal devices such as a Personal Digital Assistant (PDA), a game machine, a digital camera, and a digital video camera. Moreover, the portable device mounted with the liquid crystal display device of the invention may have a setting for changing amounts of a light source at the time of the wide field of view display and the narrow field of view display independently from each other and may be capable of setting light emitting ratios of the light source in both the cases. Consequently, a user can set an optimum angle of field according to an environment of use. Furthermore, the portable device may have means for detecting residual battery power and have control means that can automatically change an angle of field according to the detected residual battery power. As described above, in the liquid crystal display device of the invention, since an electric power can be reduced more at the time of narrow field of view display than at the time of the wide field of view display, it is possible to reduce power consumption by automatically changing the wide field of view display to the narrow field of view display when residual battery power is low and extend an operating time of the portable device.
Next, a twelfth embodiment of the invention will be explained. FIG. 22 is a plan view showing the transparent and scattering switching element 22 of a liquid crystal display device in accordance with the twelfth embodiment. Compared with the structure of the first embodiment, the twelfth embodiment is different in that at least one side of the electrodes 10 of the transparent and scattering switching element 22 is machined in a line shape. Components in the twelfth embodiment other than those described above are the same as those in the first embodiment.
In the liquid crystal display device in accordance with the twelfth embodiment constituted as described above, it is possible to perform switching of transparent and scattering partially in plane by applying different voltages to the electrodes 10 machined in a line shape of the transparent and scattering switching element 22 . Consequently, for example, it is possible to change the transparent and scattering switching element 22 to transparent only for a portion where confidential information is displayed on the basis of image information displayed on the liquid crystal display device to perform the narrow field of view display. Note that a shape of the electrodes 10 of the transparent and scattering switching element 22 is not limited to the line shape but may be a block shape.
Consequently, it is possible to switch the narrow field of view display and the wide field of view display in a block shape. In addition, in the two transparent substrate arranged above and below the PDLC layer, the electrodes may be machined in a line shape, respectively, and arranged such that longitudinal directions thereof are orthogonal to each other. This makes it possible to perform passive matrix drive for the transparent and scattering switching element 22 and switch an angle of field of an arbitrary portion on a screen. Operations and effects in the twelfth embodiment other than those described above are the same as those in the first embodiment.
Note that, as the PDLC layer that is used in the respective embodiments and the respective modifications, a PDLC layer, which is in the scattering state when a voltage is not applied thereto and is in the transparent state at the time of voltage application. Consequently, the transparent and scattering switching element does not consume electric power when the transparent and scattering switching element is in a state in which the transparent and scattering switching element scatters incident light. Thus, since the electric power is allocated to the backlight power supply, it is possible to improve brightness of the planar light source at the time of the scattering state. However, a form of the PDLC layer is not limited to the above, and a PDLC layer, which is in the transparent state when a voltage is not applied thereto and in the scattering state at the time of voltage application, may be used. Such a PDLC layer is obtained by exposing a material to light to harden the material while applying a voltage thereto. Consequently, in the portable information terminal, it is unnecessary to apply a voltage to the PDLC layer and it is possible to control power consumption in the narrow field of view display that is used frequently.
In addition, cholesteric liquid crystal, ferroelectric liquid crystal, or the like may be used as the liquid crystal molecules used in the PDLC layer. The liquid crystal keeps an orientation state at the time when a voltage is applied thereto even if an applied voltage is turned OFF and has a memory property. It is possible to reduce power consumption by using such a PDLC layer.
As shown in FIG. 23 , a direction in which the transparent area and the absorption area of the ray direction regulating element and a pixel arrangement direction of the liquid crystal display panel may be not parallel to each other. Consequently, it is possible to reduce moiré due to the ray direction regulating element and the display panel and improve an image quality of the liquid crystal display device.
The display panel, which is used in combination with the planar light source of the invention, is not limited to the transparent liquid crystal panel. Any display panel may be used as long as the display panel uses a backlight. In particular, it is possible to use a liquid crystal panel with less dependency on an angle of field suitably. As an example of a mode of such a liquid crystal panel, in a lateral electric field mode, there are an IPS (In-Plane Switching) system, an FFS (Fringe Field Switching) system, an AFFS (Advanced Fringe Field Switching) system, and the like. In addition, in a vertical orientation mode, there are an MVA (Multi-domain Vertical Alignment) system, a PVA (Patterned Vertical Alignment) system, an ASV (Advanced Super V) system, and the like in which a liquid crystal panel is multi-domained to reduce dependency on an angle of field. It is also possible to use the invention in a liquid crystal display panel of a film compensation TN mode suitably. By using these liquid crystal panels with less dependency on an angle of field, it is possible to control tone reversal of display when the transparent and scattering switching element is in the scattering state and improve visibility. In addition, the liquid crystal panel is not limited to the transmission liquid crystal panel, and any panel may be used as long as the panel has a transmission area in each pixel. It is also possible to use a semi-transmission liquid crystal panel, a micro-transmission liquid crystal panel, and a micro-reflection liquid crystal panel that have a reflection area in a part of each pixel. Note that the reflection area does not always need to have reduced dependency on an angle of field, and only the transmission area may have reduced dependency on an angle of field.
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A planar light source includes a backlight that emits light in a planar shape, a ray direction regulating element that regulates a direction of light made incident from the backlight and emits the light, whereby a directivity of the light is improved, and in which a transparent area for transmitting light and an absorption area for absorbing light are formed, and a transparent and scattering switching element that is switchable between a state in which light which is transmitted by the ray direction regulating element and made incident on the switching element is transmitted and a state in which the light is scattered. The transparent areas are formed in a shape of a matrix including a plurality of rows and a plurality of columns, the transparent and absorption areas are formed alternately, and the absorption area is formed so that the transparent areas are separated.
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CROSS-REFERENCE OF RELATED APPLICATIONS
[0001] This application is a divisional which claims the benefit of and priority of U.S. application Ser. No. 11/177,076 filed Jul. 8, 2005 (allowed Nov. 17, 2009, but not yet granted), the disclosure of which is herein incorporated by reference in its entirety. The present application expressly incorporates by reference herein the entire disclosures of U.S. Pub. No. 2007-0007172A1 filed Jul. 8, 2005, U.S. Pub. No. 2007-0007175A1 filed Jul. 8, 2005, U.S. Pub. No. 2007-0007171A1 filed Jul. 8, 2005, U.S. Pub. No. 2007-0007169A1 filed Jul. 8, 2005, U.S. Pub. No. 2007-0007174A1 filed Jul. 8, 2005, and U.S. Pub. No. 2007-0007173A1 filed Jul. 8, 2005, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention is directed to a method for processing the gaseous effluent from hydrocarbon pyrolysis units, especially those units utilizing naphtha or heavier feeds. In particular, this invention relates to a method for upgrading steam cracked tar derived from hydrocarbon pyrolysis.
BACKGROUND OF THE INVENTION
[0003] The production of light olefins (ethylene, propylene and butenes) from various hydrocarbon feedstocks utilizes the technique of pyrolysis, or steam cracking Pyrolysis involves heating the feedstock sufficiently to cause thermal decomposition of the larger molecules. The pyrolysis process, however, produces molecules which tend to combine to form high molecular weight materials known as tars. Tars are high-boiling point, viscous, reactive materials that can foul equipment under certain conditions. Although not wishing to be bound by any particular theory, it is believed that the steam cracked liquid product, as first produced in the steam cracker furnace, contain free radical molecules, vinyl-aromatic molecules, and other reactive species, and is highly reactive at moderately high temperatures commonly found in the downstream processing of steam cracked liquid product. The unsaturated functional groups of such aromatic molecules include those selected from the group consisting of olefinic groups and acetylenic groups. More specifically, such unsaturated functional groups are selected from the groups consisting of indenes, acenapthalenes and other cyclopenteno-aromatics; vinylbenzenes, and other vinyl aromatics having one aromatic ring; divinylbenzenes, vinylnaphthalenes, divinylnaphthalenes, vinylanthracenes, vinylphenanthrenes, and other vinyl- and divinylaromatics having 2 or more aromatic rings. This reactivity of such aromatic molecules tends to lead to reactions which significantly downgrade the properties of the liquid product.
[0004] The formation of tars, after the pyrolysis effluent leaves the steam cracking furnace can be minimized by rapidly reducing the temperature of the effluent exiting the pyrolysis unit to a level at which the tar-forming reactions are greatly slowed.
[0005] One technique used to cool pyrolysis unit effluent and remove the resulting heavy oils and tars employs heat exchangers followed by a water quench tower in which the condensibles are removed. This technique has proven effective when cracking light gases, primarily ethane, propane and butane, because crackers that process light feeds, collectively referred to as gas crackers, produce relatively small quantities of tar. As a result, heat exchangers can efficiently recover most of the valuable heat without fouling and the relatively small amount of tar can be separated from the water quench albeit with some difficulty.
[0006] This technique is, however, not satisfactory for use with steam crackers that crack naphthas and heavier feedstocks, collectively referred to as liquid crackers, since liquid crackers generate much larger quantities of tar than gas crackers. Heat exchangers can be used to remove some of the heat from liquid cracking, but only down to the temperature at which tar begins to condense. Below this temperature, conventional heat exchangers cannot be used because they would foul rapidly from accumulation and thermal degradation of tar on the heat exchanger surfaces. In addition, when the pyrolysis effluent from these feedstocks is quenched, some of the heavy oils and tars produced have approximately the same density as water and can form stable oil/water emulsions. Moreover, the larger quantity of heavy oils and tars produced by liquid cracking would render water quench operations ineffective, making it difficult to raise steam from the condensed water and to dispose of excess quench water and the heavy oil and tar in an environmentally acceptable manner.
[0007] Accordingly, in most commercial liquid crackers, cooling of the effluent from the cracking furnace is normally achieved using a system of transfer line heat exchangers, a primary fractionator, and a water quench tower or indirect condenser. For a typical heavier than naphtha feedstock, the transfer line heat exchangers cool the process stream to about 1100° F. (594° C.), efficiently generating super-high pressure steam which can be used elsewhere in the process. The primary fractionator is normally used to condense and separate the tar from the lighter liquid fraction, known as pyrolysis gasoline, and to recover the heat between about 200° to 600° F. (93° to 316° C.). The water quench tower or indirect condenser further cools the gas stream exiting the primary fractionator to about 100° F. (38° C.) to condense the bulk of the dilution steam present and to separate pyrolysis gasoline from the gaseous olefinic product, which is then sent to a compressor. Sometimes an intermediate boiling range stream known as steam cracked gas oil boiling, say, within the range of about 400° to about 550° F. (204° to 288° C.), is also produced as a sidestream.
[0008] Moreover, despite the fractionation that takes place between the tar and gasoline streams in a primary fractionator, both streams often need to be processed further. Sometimes the tar needs to be stripped to remove light components, whereas the gasoline may need to be refractionated to meet its end point specification. An additional concern relates to providing steam cracked tar having characteristics which make it suitable for high value use.
[0009] Steam cracker tar is the heaviest material made in the steam cracking process, comprising essentially all the product that boils above about 500° F. (260° C.). Such tar contains a high concentration of aromatic compounds produced by chemical reactions which lead to molecular weight growth of steam cracked liquids, e.g., condensation and/or polymerization reactions in the cracking process. These reactions can occur to a large extent in the primary fractionator or quench tower at the temperatures that normally prevail in steam cracker primary fractionator towers. These molecular weight growth reactions leading to asphaltene formation are rather fast and are not as easily reversed as they are prevented.
[0010] The yield of tar depends primarily on the cracker feed type, e.g., about 1 wt % from naphtha and 30% or more from very heavy gas oil. The value of tar is generally based on its use as a fuel or fuel blend stock. Sometimes it can be used as a feedstock for making carbon black. Tar can also be fed to a partial oxidation process where it is converted to synthetic fuel gas.
[0011] Molecules in tar containing more than about seven aromatic rings are insoluble in heptane and are known as asphaltenes. Asphaltenes are high molecular weight, complex aromatic ring structures and may exist as colloidal dispersions. With their aromatic ring structure, asphaltenes are not soluble in straight chain alkanes (hexane, heptane). They are soluble in aromatic solvents like xylene and toluene. Asphaltene content can be measured by various techniques known to those of skill in the art, e.g., ASTM D3279.
[0012] The heavier molecules in tar that are not soluble in toluene are known as toluene insolubles, or TI. Toluene Insolubles (coagulated/uncoagulated) are the solids remaining after oxidation resins, or pentane insolubles, have been diluted with toluene. Insoluble resins are the difference in weight between the pentane insolubles and the toluene insolubles. Toluene insolubles can be measured by methods well known to those skilled in the art, e.g., ASTM D-893, ASTM D4312-05(a)2005, Standard Test Method for Toluene-Insoluble (TI) Content of Tar and Pitch (Short Method), or ASTM D4072-98(2003)e1, Standard Test Method for Toluene-Insoluble (TI) Content of Tar and Pitch.
[0013] Asphaltenes and TI affect the quality and resulting value of the tar in several ways. They make steam cracker tar incompatible with many other fuel oils. For example, asphaltenes tend to precipitate when tar is mixed with paraffinic stocks, such as residua from paraffinic crude oil. This limits the potential marketability of tar into the fuel oil market. Moreover, asphaltenes and TI are not desirable components when tar is used in the manufacture of carbon black. Carbon black producers generally prefer feeds with lower asphaltene and TI concentrations, and they set upper limits on acceptable concentrations of these components.
[0014] Because asphaltenes and TI make tar more viscous, it often becomes necessary to mix a lighter aromatic material such as steam cracked gas oil with the tar, in order to meet product viscosity specifications. For crackers that feed naphtha or highly paraffinic gas oil, the amount of light blend stock required can exceed the quantity of co-produced steam cracked gas oil, which renders the steam cracking process “out of quench balance” inasmuch as the quantity of light blend stock produced in the cracker is insufficient to thin produced steam cracker tar to its desired viscosity. In such cases, an external source of light, highly aromatic material must be added, and this can be difficult to obtain and costly. Alternately, cracking severity must be reduced which imposes yield and conversion restrictions on the steam cracking process.
[0015] In view of the foregoing, it would be useful to provide a method for treating pyrolysis unit effluent, particularly the effluent from the steam cracking of hydrocarbonaceous feeds include naphtha and heavier feeds which yield greater amounts of steam cracker tar than lighter feeds. Accordingly, it would be useful to provide a steam cracking process which produces steam cracker tar having a reduced asphaltenes and/or toluene insolubles content, particularly where the process can be carried out in the presence or absence of a primary fractionator tower and its ancillary equipment, e.g., in processes utilizing a tar knock-out drum.
[0016] U.S. Pat. Nos. 4,279,733 and 4,279,734 propose cracking methods using a quencher, indirect heat exchanger and fractionator to cool effluent, resulting from steam cracking
[0017] U.S. Pat. Nos. 4,150,716 and 4,233,137 propose a heat recovery apparatus comprising a pre-cooling zone where the effluent resulting from steam cracking is brought into contact with a sprayed quenching oil, a heat recovery zone, and a separating zone.
[0018] Lohr et al., “Steam-cracker Economy Keyed to Quenching,” Oil Gas J., Vol. 76 (No. 20) pp. 63-68 (1978), proposes a two-stage quenching involving indirect quenching with a transfer line heat exchanger to produce high-pressure steam along with direct quenching with a quench oil to produce medium-pressure steam.
[0019] U.S. Pat. Nos. 5,092,981 and 5,324,486 propose a two-stage quench process for effluent resulting from steam cracking furnace comprising a primary transfer line exchanger which functions to rapidly cool furnace effluent and to generate high temperature steam and a secondary transfer line exchanger which functions to cool the furnace effluent to as low a temperature as possible consistent with efficient primary fractionator or quench tower performance and to generate medium to low pressure steam.
[0020] U.S. Pat. No. 5,107,921 proposes transfer line exchangers having multiple tube passes of different tube diameters. U.S. Pat. No. 4,457,364 proposes a close-coupled transfer line heat exchanger unit.
[0021] U.S. Pat. No. 3,923,921 proposes a naphtha steam cracking process comprising passing effluent through a transfer line exchanger to cool the effluent and thereafter through a quench tower.
[0022] WO 93/12200 proposes a method for quenching the gaseous effluent from a hydrocarbon pyrolysis unit by passing the effluent through transfer line exchangers and then quenching the effluent with liquid water so that the effluent is cooled to a temperature in the range of 220° to 266° F. (105° to 130° C.), such that heavy oils and tars condense, as the effluent enters a primary separation vessel. The condensed oils and tars are separated from the gaseous effluent in the primary separation vessel and the remaining gaseous effluent is passed to a quench tower where the temperature of the effluent is reduced to a level at which the effluent is chemically stable.
[0023] EP 205 proposes a method for cooling a fluid such as a cracked reaction product by using transfer line exchangers having two or more separate heat exchanging sections.
[0024] U.S. Pat. No. 5,294,347 proposes that in ethylene manufacturing plants, a water quench column cools gas leaving a primary fractionator and that in many plants, a primary fractionator is not used and the feed to the water quench column is directly from a transfer line exchanger.
[0025] JP 2001-40366 proposes cooling mixed gas in a high temperature range with a horizontal heat exchanger and then with a vertical heat exchanger having its heat exchange planes installed in the vertical direction. A heavy component condensed in the vertical exchanger is thereafter separated by distillation at downstream refining steps.
[0026] WO 00/56841; GB 1,390,382; GB 1,309,309; and U.S. Pat. Nos. 4,444,697; 4,446,003; 4,121,908; 4,150,716; 4,233,137; 3,923,921; 3,907,661; and 3,959,420; propose various apparatus for quenching a hot cracked gaseous stream wherein the hot gaseous stream is passed through a quench pipe or quench tube wherein a liquid coolant (quench oil) is injected.
[0027] U.S. Pat. No. 5,215,649 teaches a method for upgrading steam cracker tars by injecting hydrogen donor diluent into a hot cracked product stream at a point downstream of a point where high temperature cracking is stopped by cooling.
SUMMARY OF THE INVENTION
[0028] In one aspect, the present invention relates to a method for treating gaseous effluent from a hydrocarbon pyrolysis unit to provide steam cracked tar of reduced asphaltene and toluene insolubles content. Such a method is suitable for preparing reduced viscosity tar useful as a fuel blending stock, or feedstock for producing carbon black, while reducing or eliminating the need for externally sourced lighter aromatics additives to meet viscosity specifications. The method comprises drawing steam cracked tar from a separation vessel, e.g., a primary fractionator or tar knock-out drum, cooling the tar, and returning it to the separation vessel to effect lower overall tar temperatures within the separation vessel, in order to reduce viscosity increasing condensation reactions.
[0029] In another aspect, the present invention is directed to a method for treating gaseous effluent from a hydrocarbon pyrolysis process unit, the method comprising: (a) cooling said gaseous effluent at least to a temperature at which tar, formed by the pyrolysis process, condenses from the effluent to provide a partially condensed effluent; (b) passing said partially condensed effluent to a separation vessel; (c) removing condensed tar from the separation vessel; (d) cooling said condensed tar; and (e) recycling at least a portion of said cooled tar to said separation vessel at or below the level at which said partially condensed effluent enters said separation vessel.
[0030] In one configuration of this aspect of the invention, the separation vessel is a fractionation column. Typically, cooled tar can be introduced in a smaller diameter boot section of said fractionation column, located at the bottom end of the fractionation column. The boot is designed to reduce the overall residence time of the tar, to reduce asphaltene growth.
[0031] In another configuration of this aspect of the invention, the separation vessel is a tar knockout drum, where the condensed tar separates from the gaseous effluent. The knockout drum can be a simple empty vessel, lacking distillation plates or stages.
[0032] In still another configuration of this aspect of the invention, the temperature of the partially condensed effluent is no greater than about 650° F. (343° C.), typically from about 400° to about 650° F. (204° to 343° C.), e.g., from about 450° to about 600° F. (232° to 316° C.).
[0033] In yet still another configuration of this aspect of the invention, the gaseous effluent is produced by pyrolysis of a heavy hydrocarbon feed.
[0034] In still yet another configuration of this aspect of the invention, the gaseous effluent is produced by pyrolysis of a feed selected from at least one of naphtha, gas oil, kerosine, hydrocrackate, crude oil residua, and crude oil.
[0035] In another configuration of this aspect of the invention, the cooled tar is introduced to the separation vessel at a temperature at least about 100° F. (56° C.), typically at least about 200° F. (111° C.), e.g., at least about 240° F. (133° C.), below the temperature of the effluent entering the separation vessel.
[0036] In yet another configuration of this aspect of the invention, the cooled tar is introduced to the separation vessel so as to provide an average temperature for tar within the separation vessel of less than about 350° F. (177° C.), typically less than about 300° F. (149° C.), e.g., less than about 275° F. (149° C.).
[0037] In another configuration of this aspect of the invention, the cooled tar produced in (d) is cooled to less than about 200° F. (93° C.).
[0038] In still another configuration of this aspect of the invention, the temperature for tar within the separation vessel is taken at a reduced diameter boot of a fractionation column.
[0039] In yet still another configuration of this aspect of the invention, the recycled tar comprises at least about 10 wt %, typically at least about 50 wt %, e.g., at least about 80 wt %, of the tar removed from the separation vessel.
[0040] In still yet another configuration of this aspect of the invention, the tar removed from the separation vessel contains less than about 20 wt %, typically less than about 10 wt %, e.g., less than about 8 wt %, asphaltenes as measured by ASTM D3279, say, less than about 8 wt % asphaltenes as measured by ASTM D3279 after remaining as bottoms for at least 5 minutes in the separation vessel.
[0041] In yet still another configuration of this aspect of the invention, the tar removed from the separation vessel contains less than about 0.5 wt %, typically less than about 0.1 wt %, toluene insolubles as measured by ASTM D893.
[0042] In another configuration of this aspect of the invention, the tar removed from the separation vessel contains asphaltenes and toluene insolubles at levels sufficiently low to provide a carbon black feedstock.
[0043] In yet another configuration of this aspect of the invention, the tar removed from the separation vessel contains asphaltenes and toluene insolubles at levels sufficiently low to provide a blending stock for fuels.
[0044] In still another configuration of this aspect of the invention, the tar removed from the separation vessel contains asphaltenes and toluene insolubles at levels sufficiently low to provide a blending stock for atmospheric resid or vacuum resid fuels.
[0045] In yet still another configuration of this aspect of the invention, the cooled tar is introduced to the separation vessel below the liquid-vapor interface occurring in the vessel. Typically, the cooled tar is introduced to the separation vessel below the liquid-vapor interface above and substantially adjacent to which lies a baffle for reducing liquid-vapor contact.
[0046] In still yet another configuration of this aspect of the invention, a purge stream is introduced to the separation vessel to reduce liquid-vapor contact. Typically, the purge stream is selected from steam, inert gas such as nitrogen, and substantially non-condensible hydrocarbons, such as those obtained from steam cracking, examples of which include cracked gas and tail gas.
[0047] In another configuration of this aspect of the invention, the recycling suffices to reduce viscosity of the tar removed from the separation vessel to an extent sufficient to meet viscosity specifications, in the absence or reduction of an added externally sourced light blend stock otherwise necessary in the absence of said recycling.
[0048] In another aspect, the present invention relates to a method for reducing the formation of asphaltenes in gaseous effluent from a hydrocarbon pyrolysis process unit, the method comprising: (a) passing the gaseous effluent through at least one primary heat exchanger (typically a transfer line heat exchanger), thereby cooling the gaseous effluent and generating high pressure steam; (b) passing the gaseous effluent from step (a) through at least one secondary heat exchanger (typically a transfer line heat exchanger) having a heat exchange surface maintained at a temperature such that part of the gaseous effluent condenses to form a liquid coating on the surface, thereby further cooling the remainder of the gaseous effluent to a temperature at which tar, formed by the pyrolysis process, condenses; (c) passing the effluent from step (b) to a separation vessel, where the condensed tar separates from the gaseous effluent; (d) removing the tar from the bottom of the separation vessel; (e) cooling the tar removed from the separation vessel; and (f) recycling a sufficient volume of the cooled tar to the separation vessel to reduce the temperature of the tar leaving the separation vessel to an extent sufficient to reduce the formation of asphaltenes in the tar.
[0049] In still another aspect, the present invention relates to a hydrocarbon cracking apparatus comprising: (a) a reactor for pyrolyzing a hydrocarbon feedstock, the reactor having an outlet through which gaseous pyrolysis effluent can exit the reactor; (b) at least one means for cooling said gaseous pyrolysis effluent to a temperature at which tar, formed during pyrolysis, condenses; (c) a vessel for separating condensed tar from the gaseous pyrolysis effluent, the vessel having a first inlet through which the gaseous pyrolysis effluent and condensed tar enter, a second inlet lower than the first inlet, and an outlet through which the condensed tar can exit the vessel; and (d) a means for cooling the condensed tar and recycling a portion of the condensed tar to the second inlet of the vessel.
[0050] In one configuration of this aspect of the invention, the at least one means for cooling in step (b) comprises a transfer line heat exchanger.
[0051] In another configuration of this aspect of the invention, the vessel (c) is a fractionation column.
[0052] In yet another configuration of this aspect of the invention, the vessel (c) is a primary fractionator.
[0053] In still another configuration of this aspect of the invention, the vessel (c) is a tar knock-out drum.
[0054] In yet still another configuration of this aspect of the invention, the second inlet is at a level below a liquid-vapor interface within the vessel.
[0055] In still yet another configuration of this aspect of the invention, the apparatus further comprises a baffle above the second inlet.
[0056] In yet another aspect, the present invention relates to a steam cracked tar composition which contains less than about 20 wt % asphaltenes, typically less than about 10 wt % asphaltenes, e.g., less than about 8 wt % asphaltenes as measured by ASTM D3279 and less than about 0.5 wt % toluene insolubles, typically less than about 0.2 wt % toluene insolubles, e.g., less than about 0.1 wt % toluene insolubles as measured by ASTM D893.
[0057] In one configuration of this aspect of the invention, the composition is a carbon black feedstock.
[0058] In another configuration of this aspect of the invention, the composition is a blending stock for fuels, e.g., a blending stock for atmospheric resid or vacuum resid fuels.
[0059] In yet another configuration of this aspect of the invention, the composition further comprises a blendstock selected from the group consisting of cat cracker bottoms, quench oil, steam cracked gas oil, atmospheric residuum, and vacuum residuum.
BRIEF DESCRIPTION OF THE DRAWING
[0060] FIG. 1 is a schematic flow diagram of a method according to the present invention of treating the gaseous effluent from the steam cracking of a gas oil feed to provide high value steam cracked tar while maintaining quench balance of the steam cracking process.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0061] The present invention provides an efficient way of treating the gaseous lower olefin-containing effluent stream from a hydrocarbon pyrolysis reactor so as to remove and recover heat from the stream while providing high value steam cracked tar product and maintaining quench balance.
[0062] Typically, the effluent used in the method of the invention is produced by pyrolysis of a hydrocarbon feed boiling in a temperature range, say, from about 104° to about 1022° F. (40° to 550° C.), such as light naphtha or gas oil. Lighter feeds may also be used, but given their reduced tar make in steam cracking are less advantageously utilized by the present invention. Preferably, the effluent used in the method of the invention is produced by pyrolysis of a hydrocarbon feed boiling in a temperature range from above about 356° F. (180° C.), such as feeds heavier than naphtha. Such feeds include those boiling in the range from about 200° to about 1000° F. (93° to 538° C.), say, from about 400° to about 950° F. (204° to 510° C.). Typical heavier than naphtha feeds can include heavy condensates, gas oils, kerosines, hydrocrackates, condensates, crude oils, and/or crude oil fractions, e.g., reduced crude oils. The temperature of the gaseous effluent at the outlet from the pyrolysis reactor is normally in the range of from about 1400° to 1700° F. (760° to 927° C.) and the invention provides a method of cooling the effluent to a temperature at which the desired C 2 -C 4 olefins can be compressed efficiently, generally less than about 212° F. (100° C.), for example less than about 167° F. (75° C.), such as less than about 140° F. (60° C.) and typically from about 68° to about 122° F. (20° to 50° C.).
[0063] In particular, the present invention can be utilized in a method which comprises passing the effluent through at least one primary transfer line heat exchanger, which is capable of recovering heat from the effluent down to a temperature where fouling is incipient. As needed, this heat exchanger can be periodically cleaned by steam decoking, steam/air decoking, or mechanical cleaning. Conventional indirect heat exchangers, such as tube-in-tube exchangers or shell and tube exchangers, may be used in this service. In one embodiment, the primary heat exchanger cools the process stream to a temperature between about 644° and 1202° F. (340° and about 650° C.), such as about 1100° F. (593° C.), using water as the cooling medium and generating super high pressure steam.
[0064] On leaving the primary heat exchanger, the cooled gaseous effluent is still at a temperature above the hydrocarbon dew point (the temperature at which the first drop of liquid condenses) of the effluent. For a typical heavy feed under cracking conditions, the hydrocarbon dew point of the effluent stream ranges from about 700° to about 1200° F. (371° to 649° C.), say, from about 900° to about 1100° F. (482° to 593° C.). Above the hydrocarbon dew point, the fouling tendency is relatively low, i.e., vapor phase fouling is generally not severe, and there is no liquid present that could cause fouling. Tar liquid is knocked out from such heavy feeds at a temperature ranging from about 400° to about 650° F. (204° to 343° C.), say, from about 450° to about 600° F. (232° to 316° C.).
[0065] Conveniently, a secondary transfer line heat exchanger also can be provided and is operated such that it includes a heat exchange surface cool enough to condense part of the effluent and generate a liquid hydrocarbon film at the heat exchange surface. The liquid film in one embodiment is generated in situ. The liquid film is preferably at or below the temperature at which tar is produced, typically at about 374° F. to about 599° F. (190° C. to 315° C.), such as at about 232° C. (450° F.). This is ensured by proper choice of cooling medium and exchanger design. Because the main resistance to heat transfer is between the bulk process stream and the film, the film can be at a significantly lower temperature than the bulk stream. The film effectively keeps the heat exchange surface wetted with fluid material as the bulk stream is cooled, thus preventing fouling. Such a secondary (or “wet”) transfer line exchanger must cool the process stream continuously to the temperature at which tar is produced. If the cooling is stopped before this point, fouling is likely to occur because the process stream would still be in the fouling regime. This secondary transfer line exchanger is particularly suitable for use with light liquid feeds, such as naphtha.
[0066] In an alternate embodiment, the gaseous effluent from the steam cracker furnace is subjected to direct quench, at a point typically between the furnace outlet and the separation vessel (primary fractionator or tar knock-out drum). The quench is effected by contacting the effluent with a liquid quench stream, in lieu of, or in addition to the treatment with transfer line exchangers. Where employed in conjunction with at least one transfer line exchanger, the quench liquid is preferably introduced at a point downstream of the transfer line exchanger(s). Suitable quench liquids include liquid quench oil, such as those obtained by a downstream quench oil knock-out drum, pyrolysis fuel oil and water, which can be obtained from various suitable sources, e.g., condensed dilution steam.
[0067] After passage through the direct quench and/or transfer line heat exchanger(s), the cooled effluent is fed to the separation vessel (a primary fractionator or at least one tar knock-out drum), wherein the condensed tar is separated from the effluent stream. If desired, multiple knock-out drums may be connected in parallel such that individual drums can be taken out of service and cleaned while the plant is operating. The tar removed at this stage of the process typically has an initial boiling point ranging from about 300° to about 600° F. (149° to 316° C.), typically, at least about 392° F. (200° C.).
[0068] The quenched furnace effluent entering the primary fractionator or tar knock-out drum(s) should be at a sufficiently low temperature, typically at about 375° F. (191° C.) to about 600° F. (316° C.), such as at about 550° F. (288° C.), that the tar separates rapidly.
[0069] In accordance with the present invention, up to about 70 wt % of asphaltenes in steam cracker tar can be prevented from forming by quenching the tar in the bottom of a separation vessel, e.g, a primary fractionator or tar knock-out drum. Toluene insolubles (TI) content is also significantly reduced. Such reduction occurs because a significant percentage of the asphaltenes and TI in steam cracker tar are made in the primary fractionator by reactive components in the raw tar undergoing condensation/polymerization to form higher molecular weight compounds. Such condensation/polymerization is believed to be a function of temperature and holdup time of the tar within the separation vessel. Absent quenching, tar exiting a steam cracking furnace can typically contain from about 4 to about 11 wt % asphaltenes, while tar product taken from the primary fractionator can contain from about 21 to about 30 wt % asphaltenes. Likewise, TI can increase from about 0.02 wt % at the furnace outlet to about 0.13 wt % in tar product from a separation vessel where no tar quenching occurs.
[0070] Quenching of the tar within the separation vessel in accordance with the invention can be accomplished by pumping a stream of tar taken from the bottom of the separation vessel through a tar cooler and recycling it to the separation vessel, e.g. the primary fractionator or tar knock-out drum. A portion of the tar product taken from a point downstream of the tar cooler is recycled. In the example, sufficient material is recycled to reduce the temperature from about 540° to about 300° F. (282° to 149° C.). The rate of asphaltene and TI formation is greatly reduced at this temperature.
[0071] The tar cooler can be any suitable heat exchanger means, e.g., a shell-and-tube exchanger, spiral wound exchanger, airfin, or double-pipe exchanger. Suitable heat exchanger media for tar coolers include, cooling water, quench water and air. Sources of such media include plant cooling towers, and water quench towers. Typical heat exchange medium inlet temperatures for the tar cooler range from about 100° to about 250° F. (38° to 121° C.), e.g., from about 80° to about 220° F. (27° to 104° C.). Typical heat exchange medium outlet temperatures for the tar cooler range from about 100° to about 250° F. (38° to 93° C.), e.g., from about 120° to about 200° F. (49° to 93° C.). The heat exchange medium taken from the outlet can be used as a heating medium for other streams or cycled to the water quench tower or cooling tower.
[0072] Viscosity of the tar taken from the bottom of the separating vessel can be controlled by the addition of a light blend stock, typically added downstream of the pump used to circulate the steam cracker tar. Such stocks include steam cracked gas oil, distillate quench oil and cat cycle oil and are characterized by viscosity at a temperature of 200° F. (93° C.) of less than about 1,000 centistokes (cSt), typically less than about 500 cSt, e.g., less than about 100 cSt.
[0073] The tar liquid recycle stream is introduced to the separation vessel in a way that minimizes contacting with the vapor in the separation vessel. If the recycle stream were simply sprayed into the vapor space, it would tend to heat up as a result of mixing with the large quantity of hot vapor present and would also absorb light components from the vapor, which is not desired. Instead, the recycle should be introduced near or preferably just below the liquid-vapor interface in the bottom of the vessel. This ensures that the tar is cooled to the desired temperature and minimizes the absorption of light components in the tar. An optional baffle placed above the vapor-liquid interface reduces contact of the recycle with hot vapor.
[0074] The gaseous overhead of the separation vessel is directed to a recovery train for recovering C 2 to C 4 olefins, inter alia.
[0075] The invention will now be more particularly described with reference to the examples shown in the accompanying drawings.
[0076] Referring to FIG. 1 , in the method of an example of the invention, a quenched furnace effluent 100 from a steam cracking reactor which has been quenched to a temperature ranging from about 450° to about 580° F. (232° to 304° C.) is at or slightly below the temperature at which the tar of satisfactory quality condenses. The mixed liquid and vapor effluent is passed into at least one primary fractionator 105 (or alternately, a tar knock-out drum) and is separated into a tar fraction 110 removed as bottoms from boot 115 and a gaseous fraction containing cracked gas taken as overhead 120 for further processing. A baffle 125 is located slightly above the boot 115 (and the normal liquid level of the bottoms 110 ) to prevent or reduce vapor-liquid mixing within the separation vessel 105 . The bottoms 110 maintained within the separation vessel 105 at an average temperature of about 300° F. (149° C.), are taken from the boot 115 and directed via line 140 to tar pump 145 and thence via line 150 to tar cooler 155 through which heat exchange medium is added via tar cooler heat exchange medium inlet 160 and withdrawn via tar cooler heat exchange medium outlet 165 , with heat exchange medium inlet temperature of about 90° F. (32° C.), and heat exchange medium outlet temperature of about 110° F. (43° C.). Light blend stock may be added for viscosity control via line 147 upstream of the tar cooler 155 . The tar cooler 155 typically reduces tar temperature by at least about 20° F. (11° C.), e.g., at least about 50° F. (28° C.). At least a portion of the tar effluent from the tar cooler 155 cooled to about 120° F. (49° C.) is directed via line 170 to the boot 115 at a level at or just below the liquid-vapor interface in the bottom of the primary fractionator 105 . Cooled tar can be removed via line 175 .
[0077] The invention typically reduces the asphaltene level in tar leaving the primary fractionator by about two-thirds. In those instances where the concentration of asphaltenes in furnace effluent tar is about 4 wt %, after quenching of the furnace effluent to 540° F. (282° C.) and transport to the primary fractionator for 10 seconds, the asphaltene content would increase to about 6.3 wt %. If this tar remains for 12 minutes at 540° F. (282° C.) in the bottom of the primary fractionator, the asphaltene level typically increases to about 23.2 wt % in the tar product. In an embodiment of the present invention, wherein tar in the separation vessel is cooled to about 300° F. (149° C.) and held for 12 minutes, the asphaltene level in the tar product would only be about 7.2 wt %. In one embodiment, cooling the tar product to less than about 200° F. (93° C.), e.g., less than about 150° F. (66° C.), say about 120° F. (49° C.) mitigates further asphaltene growth during long term storage. In another embodiment, the tar product is blended with other blendstock, including but not limited to cat cracker bottoms, quench oil, steam cracked gas oil, atmospheric residuum, and vacuum residuum. Blending with such materials reduces the further formation of asphaltenes during storage and handling by diluting the asphaltene precursors in the blended stream.
[0078] The present invention is especially suited to use with primary fractionator systems employing distillate-quench technology. With this type of primary fractionator, implementing the invention is relatively straightforward and cooling the tar does not have a significant impact on energy efficiency, because most of the furnace effluent heat is recovered using a distillate pumparound that is not affected by use of the invention. The invention can also be used in steam cracker processes that utilize a tar knock-out drum in lieu of a primary fractionator for treating quenched furnace effluent. However, the invention would not be particularly suitable for use with primary fractionators that employ bottoms-quench technology because a bottoms quench primary fractionator uses a tar pumparound to recover a significant quantity of heat from the furnace effluent. Inasmuch as efficient recovery of this heat requires that the tar be kept at elevated temperature for quite a long time, cooling the tar in the bottoms of such a primary fractionator in accordance with the present invention would likely incur a significant debit for reduced heat recovery.
[0079] While the invention has been described in connection with certain preferred embodiments so that aspects thereof may be more fully understood and appreciated, it is not intended to limit the invention to these particular embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the scope of the invention as defined by the appended claims.
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A method is disclosed for treating gaseous effluent from a hydrocarbon pyrolysis unit to provide steam cracked tar of reduced asphaltene and toluene insolubles content. The method is suitable for preparing reduced viscosity tar useful as a fuel blending stock, or feedstock for producing carbon black, while reducing or eliminating the need for externally sourced lighter aromatics additives to meet viscosity specifications. The method comprises drawing steam cracked tar from a separation vessel, e.g., a primary fractionator or tar knock-out drum, cooling the tar, and returning it to the separation vessel to effect lower overall tar temperatures within the separation vessel, in order to reduce viscosity increasing condensation reactions. An apparatus for carrying out the method is also provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a novel electron acceptor compound which is useful as an organoelectronic material, and a process for preparing the same.
2. Description of the Related Art
Tetracyanoanthraquinodimethine and derivatives thereof are known and are conventionally useful as organoelectronic materials for organic semiconductors (for example, U.S. Pat. Nos. 4,500,459 and 4,478,753). However, these materials have characteristics which make them inadequate for use as semiconductors.
SUMMARY OF THE INVENTION
The present invention provides a compound, and a method of preparing that compound, having a triple ring structure wherein heterocyclic rings are condensed onto a pyrazine ring. This compound, which was hitherto unknown, is bis[1,2,5]thiadiazolo[3,4-b:3',4'-e]pyrazine, and is represented by the following formula: ##STR2## This pyrazine derivative is an electron acceptor and is useful as an organoelectronic material. Accordingly, there is provided a method of using this compound in an amount effective for use as an organoelectronic material in a semiconductor. There are also provided novel products which are obtained as intermediates in the preparation of this compound.
DETAILED DESCRIPTION
The bis[1,2,5]thiadiazolo[3,4-b:3',4'-e]pyrazine of this invention can be prepared in accordance with the reaction mechanism set forth below. ##STR3##
The cyclization reaction of o-diaminobenzene (compound II) in an aqueous solution of glyoxal and sodium hydrogen sulfite gives quinoxaline (compound III; See R. G. Jones et al., Org. Syn. Collective Vol. IV, page 824). Quinoxaline is in turn oxidized by an aqueous solution of potassium permanganate to produce 2,3-pyrazinedicarboxylic acid (compound IV; See R. G. Jones et al., Org. Syn. Collective Vol. IV, page 824). 2,3-pyrazinedicarboxylic acid is then chlorinated with phosphorus pentachloride at 300° C. to produce 2,3,5,6-tetrachloropyrazine (compound V; See C. G. Allison et al., J. Chem. Soc. (C), 1970, page 1023). The reaction of 2,3,5,6-tetrachloropyrazine with ammonium chloride at a temperature of 120° C. gives 2,3-diamino-5,6-dichloropyrazine (compound VI; See Palamidess et al., Ed. Sc. XXI-fasc, 11, 1966, page 810). The cyclization reaction of 2,3-diamino-5,6-dichloropyrazine with thionyl chloride in the presence of pyridine in xylene produces 5,6-dichloro-[1,2,5]thiadiazolo[3,4-b]pyrazine (compound VII; See Y. C. Tong, J. Heterocyclic Chem., 12, 1975, page 451 ). The 5,6-dichloro-[1,2,5]thiadiazolo[3,4-b]pyrazine is reacted with potassium phthalimide in the presence of dimethyl formamide (DMF) at a temperature of 60° C. to produce 5,6-diphthalimido[1,2,5]thiadiazolo[3,4-b]pyrazine (compound VIII; See Example 1). The 5,6-diphthalimido-[1,2,5]thiadiazolo[3,4-b]pyrazine is then reacted with an aqueous solution of hydrazine at 0° C. to produce 5,6-diamino-[1,2,5]thiadiazolo[3,4-b]pyrazine (compound IX; See Example 2). Finally the cyclization reaction of 5,6-diamino[1,2,5]thiadiazolo[3,4-b]pyrazine with thionyl chloride in the presence of pyridine in methylene chloride gives bis[1,2,5]thiadiazolo[3,4-b:3',4'-e]pyrazine (compound I; See Example 3).
5,6-di-phthalimido-(1,2,5)thiadiazolo(3,4-b)pyrazine and 5,6-diamino-(1,2,5)thiadiazolo(3,4-b)pyrazine are novel intermediate products useful for the preparation of the compound of claim 1.
The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, preparations, and reported data set forth to illustrate the principles and practice of the invention are exemplary and should not be construed as limiting the scope of the invention.
EXAMPLE 1
Preparation of Compound (VIII) from Compound (VII)
2.0 Grams of the compound (VII) (9.7 mmol), which was prepared in accordance with the methods described in the literature above, were reacted with 4.3 grams (23.2 mmol) of potassium phthalimide and 50 ml of DMF. The reaction mixture was stirred at 60° C. for a period of 6 hours. The mixture was then cooled to room temperature, and 100 ml of water was added and thoroughly stirred. The mixture was filtered and the phthalimide precipitated out as time passed. The precipitate was washed thoroughly with water at about 50° C. and dried, whereupon 3.0 grams of the compound (VIII) was obtained in the form of a crude product consisting of cream colored crystals. These crystals were refined by recrystallization from DMF/water.
Melting point: 319°-323° C. (with decomposition).
IR (KBr): 1787, 1731, 1459, 1409, 1354, 1338, 1330, 1296, 1248, 1095, 1052, 931, 897, 874, 793, 718, and 707 cm -1 .
Mass: m/e(%) 429 (21), 428 (100, M + ), 282 (17), 281 (10) 280 (16), and 104 (33).
Elemental analysis as C 20 H 8 N 6 O 4 S Calculated: C 56.08; H 1.88; N 19.62 Found: C 55.43; H 1.64; N 19.45.
EXAMPLE 2
Preparation of Compound (IX) from Compound (VIII)
127 milligrams of the compound (VIII) (0.3 mmol) prepared in Example 1 was introduced into a 20 ml pear-shaped flask and cooled to 0° C. Five milliliters of 10% aqueous hydrazine solution at 0° C. was added to the flask and the mixture was agitated at 0° C. for a period of 3 hours and then filtered. 44 milligrams of the compound (IX) (yield 86%) was obtained as a crude product in the form of a cream colored solid. This was refined by recrystallization from ethanol.
Melting point: 312°-313° C. (with decomposition).
IR(KBr): 3400, 3330, 3250, 3090, 1673, 1660, 1620, 1590, 1530, 1485, 1336, 975, 930, 858, 800, 790, and 750 cm -1 .
Mass: m/e(%) 168 (100, M + ), and 43 (31).
Elemental analysis as C 4 H 4 N 6 S Calculated: C 28.57; H 2.40; N 49.97 Found: C 37.31; H 4.21; N 37.88.
EXAMPLE 3
Preparation of Compound (I) from Compound (IX)
300 milligrams of the compound (IX) (1.8 mmol) prepared in Example 2, 3 ml of anhydrous methylene chloride and 1 ml of pyridine were placed in a 20 ml pear-shaped flask. A solution obtained by dissolving 0.4 ml (622 mg, 5.6 mmol) of thionyl chloride in 3 ml of anhydrous methylene chloride was introduced into a dropping tube and fitted to the flask. The thionyl chloride solution was drip fed into the flask slowly while agitating the mixture at room temperature and a red solid precipitated out. The mixture was further agitated for a period of 30 minutes at room temperature after the drop-wise addition had been completed. The mixture was filtered, and 177 mg (yield 51%) of crude product was obtained in the form of a red solid. This was refined by sublimation and 165 mg (yield 47%) of bis[1,2,5]thiadiazolo[3,4-b:3',4'-e]pyrazine of formula (I) was obtained in the form of red crystals.
Melting point: 323°-329° C. (with decomposition).
IR(KBr): 1480, 1322, 1285, 1251, 960, 932, 925, and 837 cm -1 .
Mass: m/e(%) 196 (100, M + ), and 46 (15).
Elemental analysis as C 4 N 6 S 2 Calculated: C 24.49; N 42.83; S 32.68 Found: C 24.45; N 42.88; S 32.81.
UV: λmax CH 2 Cl 2 /nm (ε) 421 (2.50×10 3 ), 372 (3.34×10 4 ) and 365 (2.91×10 4 ).
Having thus described the invention in detail it will be understood that further changes and modifications thereto falling within the scope of the invention as defined by the appended claims may suggest themselves to one skilled in the art.
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The compound bis[1,2,5]thiadiazolo[3,4-b:3',4'-e]pyrazine represented by the formula (I): ##STR1## a process for preparing this compound, a method of using this compound and novel intermediate products.
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FIELD
[0001] The present disclosure relates in general to systems and methods for providing power and data communication for downhole tools, in particular to systems and methods for providing power and data communication for downhole tools in horizontal wellbores and other non-vertical wellbores.
BACKGROUND
[0002] More and more oil and gas wells are being planned and drilled as horizontal wells. It is now accepted that production and/or economics from horizontal wells can be far greater than from vertical wells in the same formations. This is a relatively new trend and a lot of the techniques, technology, and accepted valuation methods that have worked on vertical wells do not work the same for horizontal legs of deviated wellbores. The industry is slowly catching up, but the efficiency and accuracy of the new technologies for horizontal wells can be very costly and are somewhat unreliable to date. There is a need for new systems and methods for adapting known technologies to provide intervention, methods, and data specifically suited for use with horizontal wells.
[0003] Adaptations that have been developed for horizontal wells include E-coil tubing, wireline well tractors, pump-down systems, etc. These services can be very expensive and time-consuming, and can add greatly to the cost of drilling and completing a horizontal well.
[0004] For these reasons, there is a need for systems and methods for providing power, two-way communication, and operation of downhole tools in horizontal and other non-vertical wellbores that are more reliable, cheaper, easier to maintain, easier to run, and less complicated than what is currently available.
BRIEF SUMMARY
[0005] In general terms, the present disclosure teaches a system and method whereby specialized equipment such as wireline logging tools, drillstem testing equipment, pressure recorders, temperature recorders, downhole pumps, and other equipment designed for vertical oil and gas wells can be adapted to run in horizontal and other non-vertical wellbores.
[0006] Such specialized equipment often requires external power, communication, and control inputs from the surface in order to operate valves, recording devices, etc. These facilities are often provided by means of a wireline with an electrical conductor or an armored cable with internal conductors. These tools and equipment items are attached to the wireline and lowered into the wellbore to the desired depths (such as by means of a winch at surface).
[0007] In vertical wellbores, the tools or equipment can be easily lowered to the bottom of the wellbore. However, in a wellbore transitioning from a vertical leg to a horizontal leg, the tools will tend to stop at the heel (i.e., the beginning of the horizontal leg) due to increased friction against the side of the wellbore. There needs to be some external force to pull or push the tool assemblies into and along the horizontal leg. Pump-down systems and wireline well tractors have been built to accomplish this task.
[0008] The present disclosure teaches the use of a horizontal leg extension for the wireline or armored cable. For purposes of this patent document, the horizontal leg extension may be alternatively referred to as a “wireline extension”. The system taught by the present disclosure uses two “wet connects”; i.e., plug-in sockets connecting electrical power and signals in a wet downhole environment without shorting or loss of electronic communication. There are different types of wireline wet connects, but in general terms a wet connect comprises two components: a probe (male) section and an “overshot” (female) section. One example of a known wireline wet connect is disclosed in U.S. Pat. No. 5,358,418.
[0009] In accordance with the present disclosure, a first (or lower) wet connect is provided for connecting the wireline to a downhole tool or package of downhole tools, and a second (or upper) wet connect is provided for connecting the wireline extension to a primary wireline extending from surface into the vertical (or predominantly vertical) leg of a wellbore also having a horizontal (or otherwise non-vertical) leg. In one configuration of a wireline extension assembly in accordance with the disclosure, the length of the wireline extension will be slightly greater than the length of the horizontal leg of the wellbore (or greater in length than the distance that the extension needs to extend into the horizontal leg). This ensures that the male probe of the second (upper) wet connect will always be disposed (and oriented coaxially) within a lower region of the vertical leg of the wellbore (and not in the heel or in the horizontal leg), in order to facilitate connection to the primary wireline by means of the overshot section of the second wet connect.
[0010] However, wireline extension assemblies and related methods in accordance with the present disclosure are not limited or restricted to assemblies in which the male probe of the upper wet connect is always disposed within the vertical leg of the wellbore. In testing carried out by the inventor, wet connect overshots have been successfully connected to male probes that were oriented close to 30 degrees off vertical. Any limitations as to the range of angular orientations at which the male probe section of a wet connect could be successfully connected downhole to the corresponding overshot section generally will be a function of the type of wet connect used and any ancillary components for facilitating downhole mating of the male probe and overshot.
[0011] The broadest embodiments of wireline extension assemblies and related methods in accordance with the present disclosure are not intended to be limited or restricted to the use of any particular type of wet connect. Accordingly, wireline extension assemblies and related methods in accordance with the present disclosure are intended to cover embodiments using wet connects of either known or later-developed types in which the male probes and overshot sections (or analogous components) can be satisfactorily engaged when the wet connects are disposed within horizontal or otherwise non-vertical wellbore legs, or in a transition sections (e.g., heel sections) between contiguous wellbore legs of different angular orientations.
[0012] To assembly and install a wireline extension in accordance with the present disclosure into a wellbore, the first (lower) and second (upper) wet connects are run into the wellbore on a first (or lower) string of drill pipe or tubing, referred to herein as the extension string. The first (lower) wet connect is carried at the lower end of the extension string and the second (upper) wet connect is carried at the upper end of the extension string. The upper and lower wet connects are in electrical/electronic communication by means of a secondary wireline (the “wireline extension”) disposed within the extension string.
[0013] A suitable derrick or service rig is used to push the extension string downward around the heel of the wellbore and into the horizontal leg as required, by adding additional tubing sections to the upper end of the extension string, thus forming second (or upper) tubing string disposed entirely within the vertical leg of the wellbore. After the extension string is thus in a desired position, with the upper wet connect still disposed within the vertical leg of the wellbore, a primary wireline is run from a surface wireline unit (typically a mobile wireline unit) into the upper tubing string and connected to the second (upper) wet connect so as to provide power, data communication, and/or other facilities to the tool package at the lower end of the extension string.
[0014] To reposition the tool package at a location within the horizontal leg but closer to the heel, the primary wireline is disconnected from the second (upper) wet connect and withdrawn from the upper tubing string, and then the derrick or service rig removes tubing sections from the upper end of the upper tubing string and draws it upward as required to move the tool package at the end of the extension string to the desired new position within the horizontal leg. The primary wireline is then inserted back into the upper tubing string for reconnection to the upper wet connect at the upper end of the extension string.
[0015] Similarly, the tool package can be moved further toward the toe of the wellbore (if there is room to do so) by withdrawing the primary wireline from the upper tubing string, adding tubing sections to the upper tubing string as appropriate to push the upper string toward the toe, and then re-inserting the primary wireline into the upper tubing string and reconnecting it to the upper wet connect at the upper end of the extension string. This operation requires, however, that the upper tubing string remains disposed within the vertical leg of the wellbore being thus lengthened.
[0016] In accordance with a first aspect, the present disclosure teaches a method for selectively positioning a downhole tool within a wellbore, including the steps of:
providing first and second wet connects, each wet connect comprising a male probe and an overshot matingly engageable with the male probe; connecting the male probe of the first wet connect to a selected downhole tool to form a tool package; running a first tubing string into the wellbore to a selected depth, with the tool package being carried at the lower end of the first tubing string such that the male probe of the first wet connect projects into the first tubing string, and with the first tubing string having at its uppermost end a wet connect sub carrying the male probe of the second wet connect; providing a first wireline having an upper end and a lower end, and running the first wireline into the first tubing string with the overshot of the first wet connect attached to the lower end of the first wireline; latching the overshot of the first wet connect with the male probe of the first wet connect; connecting the upper end of the first wireline to the male probe of the second wet connect; running additional tubing into the wellbore to form a second tubing string of selected length contiguous with the upper end of the first tubing string; running a second wireline into the second tubing string, with the overshot of the second wet connect being attached to the lower end of the second wireline; and latching the overshot of the second wet connect with the male probe of the second wet connect, so as to effect an electrical/electronic connection between the downhole tool and the second wireline.
[0026] The method may include the additional steps of:
unlatching the overshot of the second wet connect from the male probe of the second wet connect; withdrawing the second wireline from the second tubing string; making up additional tubing onto the upper end of the second tubing string so as to increase the length of the second tubing string by a desired amount, thus correspondingly relocating the downhole tool within the wellbore; and running the second wireline back into the second tubing string, and re-latching the overshot of the second wet connect with the male probe of the second wet connect.
[0031] The method may also include the additional or alternatively additional steps of:
unlatching the overshot of the second wet connect from the male probe of the second wet connect; withdrawing the second wireline from the second tubing string; removing tubing from the upper end of the second tubing string so as to decrease the length of the second tubing string by a desired amount, thus correspondingly relocating the downhole tool within the wellbore; and running the second wireline back into the second tubing string, and re-latching the overshot of the second wet connect with the male probe of the second wet connect.
[0036] In accordance with a second aspect, the present disclosure teaches a wireline extension assembly including:
a first tubing string disposed within a wellbore, the first tubing string having an upper end and a lower end; a tool package comprising a downhole tool connected to a first wet connect probe, the tool package being connected to the lower end of the first tubing string such that the first wet connect probe projects into the first tubing string; a wet connect sub carrying a second wet connect probe, the wet connect sub being connected to the upper end of the first tubing string; a first wet connect overshot in latching engagement with the first wet connect probe; and a first wireline connecting the first wet connect overshot and the second wet connect probe.
[0042] The wireline extension assembly may also include a second tubing string contiguously extending from the upper end of the first tubing string, plus a second wireline having a lower end connected to a second wet connect overshot, and with the second wet connect overshot being in latching engagement with the second wet connect probe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] Embodiments in accordance with the present disclosure will now be described with reference to the accompanying figures, in which numerical references denote like parts, and in which:
[0044] FIG. 1 schematically illustrates a wellbore having vertical and horizontal legs, with a wireline extension in accordance with the present disclosure disposed within the vertical leg of the a wellbore.
[0045] FIG. 2 is a schematic illustration similar to FIG. 1 , showing the wireline extension disposed partially within the horizontal leg of the wellbore and connected to a primary wireline running to the surface through an upper tubing string.
[0046] FIGS. 3A and 3B illustrate the components of an exemplary prior art wet connect.
[0047] FIG. 4 illustrates the components of an alternative wet connect.
DETAILED DESCRIPTION
[0048] FIG. 1 schematically illustrates a wellbore 100 having a vertical leg 100 V having an upper end 102 , a heel section 104 , and a horizontal leg 100 H extending to a toe end 106 . In accordance with the present teachings, one or more desired downhole tools 40 may be made up at surface with the male probe of a first (or lower) wet connect 30 . This assembly of the lower wet connect probe and tool (or tool package) 40 is run into vertical wellbore leg 100 V at the lower end of a first or lower tubing string 20 (alternatively referred to herein as extension string 20 ). First (lower) wet connect 30 may be housed or carried by a suitable wet connect sub 26 incorporated into first (lower) tubing string 20 as shown in FIGS. 1 and 2 (the term “sub” being commonly used in the oil and gas industry to denote any small or secondary component in a tubing string).
[0049] A surface rig (derrick) 15 is used to lower this assembly into vertical wellbore leg 100 V to a selected depth corresponding to the distance that tool package 40 is intended to extend into horizontal leg 100 H. This is done by adding tubing sections to extension string as required until it reaches the desired length.
[0050] At this stage, a wireline extension 32 is lowered down the inside of extension string 20 by means of a wireline unit 10 associated with rig 15 , with the overshot (female) section of first (lower) wet connect 30 attached by means of a cable head to the bottom end of wireline extension 32 , until the overshot section latches onto the male probe section of first (lower) wet connect 30 on tool package 40 .
[0051] The upper end of wireline extension 32 is then connected to the male probe section of a second (or upper) wet connect 50 , which is carried by the upper end of extension string 20 . Depending on the particular type of wet connects used, it may be necessary or desirable to provide means for maintaining tension in wireline extension 32 and thus prevent inadvertent disengagement of first wet connect 30 from downhole tool(s) 40 . This would be particularly desirable for embodiments in which first (lower) wet connect 30 is held in the latched position by means of a conventional J-slot-and-pin arrangement (the details and operation of which will be familiar to persons skilled in the art). This style of wet connect requires some tension on the wireline so that it will remain latched.
[0052] Persons skilled in the art will appreciate that means for maintaining tension in wireline extension 32 could be provided in various different ways, and embodiments in accordance with the present disclosure that incorporate such means are not limited or restricted to any particular such means. By way of non-limiting example, however, means for maintain tension in the wireline extension could be provided in the form of a tensioner sub 22 near the upper end of extension string 20 , and incorporating a cable clamp (not shown) that is bolted wireline extension 32 with a stop shoulder in the bottom of tensioner sub 22 .
[0053] In some cases it may be desirable or necessary to add one or more tubing sections 24 to extension string 20 to serve as spacers (or “spacer subs”) so as to match the length of any extra length of wireline extension 32 between wet connect sub 26 and tensioner sub 22 . The need for such spacers may arise in particular in cases where wireline extension 32 comprises armored conductor cable or similarly rigid electric line.
[0054] The purposes of such spacers would be to prevent such extra length of wireline cable from becoming kinked or coming under too much stress (such as from flexure). This “space-out” provided by spacer sub(s) 24 will allow the male probe of second (upper) wet connect 50 to be held in a fixed position in wet connect sub 26 . More specifically, wet connect sub 26 holds the male probe of second (upper) wet connect 50 such that it cannot move up or down, and also substantially centers the male probe within extension string 20 and prevents it from falling over and lying against the inside diameter of a second (upper) tubing string 60 subsequently connected to extension string 20 (as described in further detail below). This facilitates easier latching and un-latching of the female overshot section of second (upper) wet connect 50 (as described in further detail below).
[0055] The above-described need or desirability for spacers could arise, for instance, where a wireline extension assembly has been prepared for use in a particular wellbore and to have a certain set length (i.e., a “set string”) and to be used in multiple wellbores of similar dimensions, and it is desired to use that assembly in a wellbore of different dimensions.
[0056] However, spacers generally should not be required if a particular wireline extension assembly is to be used in multiple wellbores of substantially similar dimensions. In that scenario, once the initial “space-out” on the first well has been done, it should typically be possible to run the same assembly into each subsequent similar well, in the same order of assembly, without the need to make corrections or compensate for any slight well variables. It would not be necessary to do a space-out procedure for each subsequent well in the series of similar wells. The tubing sections and subs that were run in below the second (upper) wet connect and making up the extension string for the first well (a “set string”) would be put aside, and if this set of tubing components is to be run again into a second similar wellbore the space-out inherently provided by the set string should be appropriate for the second wellbore.
[0057] After the wireline extension assembly comprising extension string 20 and wireline extension 32 has been assembled as described above, additional tubing can then be added to the upper end of extension string 20 to form a second (or upper) tubing string 60 , until the completed wireline extension assembly has been pushed around heel 104 of wellbore 104 and extends to toe 106 of horizontal leg 100 H of wellbore 100 as shown in FIG. 2 (or a desired distance into horizontal leg 100 H short of toe 106 , as may be dictated by operational parameters). Because the length of the wireline extension has been selected to exceed the distance to which downhole tools 40 are intended to extend into horizontal leg 100 H (as previously discussed), the male probe of second (upper) wet connect 50 will remain disposed within vertical leg 100 V of wellbore 100 after the wireline extension has been positioned within horizontal leg 100 H.
[0058] At this stage, a wireline unit 10 (of known type) at surface lowers a primary wireline 12 into upper tubing string 60 , with the overshot section of second (upper) wet connect 50 having been connected to the lower end of primary wireline 12 at surface. Lowering of primary wireline 12 continues until the overshot section of second (upper) wet connect 50 engages the male probe of second wet connect 50 , thus establishing electrical/electronic communication between primary wireline 12 and the downhole tool package 40 at the end of the wireline extension assembly. The tools can then be powered and operated, and measured data can be transmitted from the tools to the surface for recordation.
[0059] Using this system, the entire length of horizontal leg 100 H can be mapped or tested without needing to remove downhole tools 40 from wellbore 100 . Tool package 40 can be moved to a new position within horizontal leg 100 H by simply unlatching second wet connect 50 within upper tubing string 60 , withdrawing primary wireline 12 from upper tubing string 60 (by means of wireline unit 10 at surface), using surface rig 15 to remove tubing sections from upper tubing string 60 as necessary to move tool package 40 a desired distance away from the toe 106 of horizontal leg 100 H, and then running primary wireline 12 back into upper tubing string 60 string and re-latching it to second wet connect 50 . This procedure can then be repeated as many times as necessary to test or log a desired length of the horizontal leg of the wellbore.
[0060] FIGS. 3A and 3B illustrate the male probe section 80 and female overshot section 70 of a prior art wet connect using a J-slot-and-pin latching mechanism. FIG. 3A illustrates the complete male probe section 80 , aligned with the typically cylindrical lower portion of overshot section 70 . A latching pin 72 projects radially into the bore of the lower portion of overshot 70 , which typically has one or more longitudinal slots 74 . Male probe 80 has a lower end 81 adapted for connection to a wireline, an electrical contact 84 (typically copper) at its upper end, and an insulator 82 for electrically isolating contact 84 from the main body of probe 80 .
[0061] A medial region of probe 80 is machined or otherwise formed to define a generally helical “J-slot” section 86 , which will receive latching pin 72 when probe 80 is inserted into overshot 70 as illustrated in FIG. 3B . J-slot 86 is configured such that when latching pin 72 has traveled to the lower end of J-slot 86 , a tensile force applied to the wet connect assembly will cause latching pin 72 to become lodged in a pin-receiving pocket associated with J-slot 86 such that overshot 70 and probe 80 are mechanically latched. In FIG. 3B , conductor 82 can be seen through longitudinal slot 74 in overshot 80 , moving upward within overshot 80 to engage a mating electrical contact (not visible) inside overshot 80 . Probe 80 will typically be provided with a suitable swivel joint to prevent twisting of a wireline connected to the probe's lower end 81 as latching pin 82 travels within the generally helical J-slot 86 .
[0062] However, systems and methods in accordance with the present disclosure are not limited or restricted to the use of wet connects using a J-slot-and-pin latching mechanism, or to any other particular type or types of latching mechanism. By way of non-limiting example, alternative latching mechanisms could use high-strength (e.g., neodymium) magnets, friction, suction, or mechanical collets.
[0063] One non-limiting example of an alternative wet connect latching mechanism is illustrated in FIG. 4 , and comprises a female overshot section 75 and a male probe section 90 . Overshot 75 has a collet ring 77 disposed within an annular groove in the bore of overshot 75 , with collet ring 77 being in the form of a split ring with annular thread-like grooves 78 formed on its inside diameter. Male probe 90 has a lower end 91 adapted for connection to a wireline, and an electrical contact 94 and insulator 92 at its upper end. An upper medial region of probe 90 is formed with annular thread-like ridges, such that insertion of probe 90 into overshot 75 will cause elastic deformation of collet ring 77 to allow annular ridges 96 on probe 90 to engage annular grooves 78 on collet ring 77 , thus mechanically latching or locking probe 90 within overshot 75 (until such time as a sufficient tensile force is applied to unlock probe 90 from overshot 75 ).
[0064] In a variant of the mechanism shown in FIG. 4 , a suitably contoured magnet (not shown) could be housed within overshot 75 for magnet engagement with a complementarily contoured portion of probe 90 . For example, the magnet could be of generally toroidal configuration with a central opening defining a frustoconical surface for mating engagement with a frustoconical shoulder 95 as shown in FIG. 4 on probe 90 .
[0065] In another variant latching mechanism, the male probe and overshot could be connected by means of a friction lock and/or vacuum. This could be done by providing a resilient element such as an O-ring 98 disposed within a circumferential groove on probe 90 as shown in FIG. 4 . In that alternative embodiment, the size of the O-ring and the amount of interference with the bore of overshot 75 will determine the magnitude of the axial force required to push probe 90 into latching engagement with overshot 75 or to withdraw probe 90 out of engagement with overshot 75 .
[0066] Systems and methods in accordance with the present disclosure are also not limited or restricted to the use of any particular type of wireline. In some embodiments, the wireline could be a braided wireline having a single conductor cable for use as the power and communication means. In alternative embodiments, the wireline could comprise a multi-conductor cable instead of a single conductor, with the number of conductors being selected to suit the specific requirements (e.g., power and data transmission) of the downhole tool or tools being used,
[0067] Another option, depending on operational requirements, would be a wireline comprising a single conductor cable having an armored casing or shell made of stainless steel or other durable protective material.
[0068] A further alternative would be to use “E-coil” for the wireline extension instead of conventional wireline. E-coil has been around for many years, and is simply coiled tubing with either braided wireline or armored conductor cable inserted into the length of the tubing.
[0069] Each of these wireline alternatives has advantages and disadvantages. Unlike braided wireline, E-coil most likely would not require a swivel or a tensioner sub. This may also be true for armored conductor cable as well. If a set string of tubing/drill pipe is used on the horizontal leg, then a spacer system might not be required. If the wet connect latching mechanism uses collets or magnets, then a tensioner system may not be required.
[0070] It is to be understood that the scope of the claims appended hereto should not be limited by the preferred embodiments described and illustrated herein, but should be given the broadest interpretation consistent with the description as a whole. It is also to be understood that the substitution of a variant of a claimed element or feature, without any substantial resultant change in functionality, will not constitute a departure from the scope of the disclosure.
[0071] In this patent document, any form of the word “comprise” is to be understood in its non-limiting sense to mean that any item following such word is included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one such element. Any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the subject elements, and may also include indirect interaction between the elements such as through secondary or intermediary structure.
[0072] Relational terms such as but not limited to “vertical”, “horizontal”, and “coaxial” are not intended to denote or require absolute mathematical or geometrical precision. Accordingly, such terms are to be understood as denoting or requiring substantial precision only (e.g., “substantially vertical”) unless the context clearly requires otherwise. Wherever used in this document, the terms “typical” and “typically” are to be interpreted in the sense of representative of common usage or practice, and are not to be understood as implying essentiality or invariability.
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A wireline extension assembly includes a first tubing string housing a wireline extension electrically interconnecting wet connects at the upper and lower ends of the first string, with the lower wet connect being electrically connected to a downhole tool. The assembly is pushed into the horizontal leg of a deviated wellbore by forming a second tubing string extending upward from the upper end of the first string, thereby positioning the tool within the horizontal leg while leaving the upper wet connect disposed within the vertical leg. A primary wireline is then run from a surface wireline unit into the upper string and connected to the upper wet connect, thus providing electrical power, data communication, and/or other facilities to the tool. The tool can be repositioned within the horizontal leg by withdrawing the primary wireline, removing or upper string tubing sections, and then reinstalling the primary wireline.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application of International Application No. PCT/EP2008/064527 filed Oct. 27, 2008, which designates the United States of America, and claims priority to German Application No. 10 2008 003 540.8 filed Jan. 8, 2008, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
The invention relates to a method of starting an internal combustion engine according to claim 1 , a device for starting an internal combustion engine.
BACKGROUND
It is known to start an internal combustion engine without the use of a starter by injecting fuel into a cylinder, the piston of which is in a power phase, and by igniting the injected fuel.
The igniting of an internal combustion engine without the use of a starter is necessary in particular to set an engine, which is being operated with many stop phases, running again without high electrical energy. For example, in the case of fuel-economy engines, the engines are stopped during stop phases, for example at traffic lights or upon other interruptions to travel, and the internal combustion engine is restarted by actuation, for example of the clutch.
From DE 199 55 857 A1 and from DE 100 20 325 A1 corresponding methods of starting an internal combustion engine are known. Here an internal combustion engine, in particular for a motor vehicle, is described, which is provided with pistons that are movable [in] a cylinder and act upon a crankshaft. During operation of the internal combustion engine the piston runs through an induction phase, a compression phase, a power phase and an exhaust phase. A controller is further provided, by means of which fuel is injected in a first operating mode during a compression phase or in a second operating mode during an induction phase directly into a combustion chamber delimited by the cylinder and the piston. The controller is designed in such a way that in order to start the internal combustion engine in the stationary state of the crankshaft fuel is injected into the cylinder, the piston of which is in the compression phase, and ignited so that the crankshaft moves backwards. In this case, it may be disadvantageous that a cylinder can no longer be used for compression and ignition because combustion residues of a not yet exhausted combustion pre-gas are present, with the result that a combustible mixture does not exist.
It could moreover be disadvantageous if the engine is stationary for an extended period because then the pressure in the compression cylinder has dropped to such an extent that reliable ignition cannot occur. As with direct starting, the starting capability depends upon the filling volume, the state of the piston and also upon the length of time between stop and start. The pressure in the cylinder to be ignited lasts for a short time only. After a longer pause between stop and start the pressure adjusts itself to the ambient pressure. The residual volume may then have a lower oxygen content. A further drawback is that parasitic residual gases further impair the ignitability.
SUMMARY
According to various embodiments, an improved method and an improved device for starting an internal combustion engine with a low consumption of electrical energy can be provided.
According to an embodiment, in a method of starting an internal combustion engine having at least one cylinder, an inlet- and an exhaust valve and having a piston that interacts with a crankshaft and moves the crankshaft during normal operation of the internal combustion engine in a defined direction of rotation, wherein the piston is situated in a first or initial position, the piston is moved with the aid of a drive counter to the normal direction of rotation of the crankshaft into a defined start position, fuel is injected into the cylinder and the fuel is ignited.
According to a further embodiment, upon a cutting-out of the internal combustion engine an ignition provided for the cylinder is not carried out. According to a further embodiment, the first or initial position may lie in the power stroke of the piston, and the piston may be moved back in the direction of the top dead centre. According to a further embodiment, the piston is not moved back over the top dead centre. According to a further embodiment, before reaching the start position fuel may be injected into the cylinder and then the fuel may be ignited. According to a further embodiment, fuel can be injected into the first cylinder before reaching the start point and the fuel can be ignited at the start point. According to a further embodiment, the internal combustion engine may comprise at least a second cylinder having a second inlet valve, having a second exhaust valve and having a second piston that interacts with the crankshaft, wherein, as the first piston moves into the start position, the second piston is moved into a third position, during which the inlet valve of the second cylinder is opened. According to a further embodiment, the movement of the first piston upon cutting-out of the internal combustion engine can be braked in movement and may come to a standstill in a defined position. According to a further embodiment, the first piston can be moved into a region after the top dead centre but without opening of the exhaust valve. According to a further embodiment, the first piston can be moved from the first or initial position further in the normal direction of rotation of the crankshaft until the exhaust valve of the first cylinder opens, that the first piston is then moved counter to the normal direction of rotation of the crankshaft into the start position.
According to another embodiment, a device for starting an internal combustion engine may comprise a controller and a drive that is connected to a crankshaft of the internal combustion engine, wherein the controller is designed to control the drive in accordance with a method as described above.
According to yet another embodiment, a controller can be designed to carry out a method as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
There now follows a detailed description of the invention with reference to the figures. These show in
FIG. 1 a diagrammatic representation of an internal combustion having four cylinders,
FIG. 2 a diagrammatic representation of one of the cylinders and a controller,
FIG. 3 a first program run,
FIG. 4 a diagrammatic representation of part of the power strokes of the first and third cylinder, and
FIG. 5 a second program run.
DETAILED DESCRIPTION
An advantage of the method according to various embodiments is that the piston of the cylinder to be ignited is moved into a defined start position. For this purpose a drive is provided, which is workingly connected to the piston.
In a further form of implementation, upon cutting-out of the internal combustion engine an ignition provided for the cylinder is not carried out. Thus, no exhaust gases are contained in the cylinder. Furthermore, the oxygen content of the filling of the cylinder is higher than after an ignition.
In a further form of implementation the piston is moved from a power stroke back in the direction of the top dead centre. In this case, the piston is preferably not moved back over the top dead centre. This saves current because a high compression energy to a point over the dead centre is not necessary. The lower energy consumption of the starter motor has the added result that a starting-voltage dip as a result of the starter is lower. This allows the electronic equipment in the motor vehicle to be of a simpler design.
In a further form of implementation the first piston of the first cylinder is coupled to a second piston of a second cylinder and the first piston is moved back until an inlet valve of the second piston opens and lets ambient air into the second piston. This ensures that the second piston is filled with fresh air, i.e. with air containing unburnt oxygen.
In a further form of implementation, after cutting-out of the internal combustion engine the movement of the first piston is braked and hence the first piston is brought to a halt in a desired starting position. In this way the starting position of the first piston may be selected in a defined manner.
In a further form of implementation the first piston in the first cylinder is moved back in the direction of the top dead centre, without however opening the exhaust valve of the first cylinder. This ensures that the gas filling in the first cylinder is compressed.
In a further form of implementation, upon cutting-out of the internal combustion engine the first piston is braked into a starting position that lies in the power stroke or in the exhaust stroke.
In a further form of implementation, the first piston, if it is situated at a standstill in the power stroke, is moved further in the direction of rotation of the engine until the exhaust valve opens. The first piston is then moved counter to the direction of rotation of the engine into the start position. The effect thereby achieved is that the first cylinder is filled with gas through an exhaust channel.
FIG. 1 shows in a diagrammatic representation of an internal combustion engine 1 having four cylinders 2 , 3 , 4 , 5 , which are workingly connected to a crankshaft 6 . The crankshaft 6 is connected by a non-illustrated clutch and by a non-illustrated transmission to a non-illustrated drive train, for example of a motor vehicle. FIG. 1 shows an internal combustion engine that operates according to a four-stroke principle. To control the gas exchange a camshaft rotating at twice the engine speed is used, which is driven by the crankshaft. The camshaft opens the gas exchange valves, which are designed separately to push out the waste gases and take in the fresh gases, counter to the action of the valve springs. Shortly before the bottom dead centre the exhaust valve opens and, given a supercritical pressure ratio, during this preliminary exhaust ca. 50% of the combustion gases leave the combustion chamber. During the exhaust stroke the upward-moving piston ensures an almost complete removal of the combustion gases from the combustion chamber. Shortly before the top dead centre of the piston the inlet valve opens while the exhaust valve is still open. To distinguish it from the ignition TDC, at which combustion occurs, this position of the crankshaft is known as the gas exchange TDC because in this region the otherwise strictly separate intake- and exhaust processes overlap. Shortly before the gas exchange TDC the exhaust valve closes and, while the inlet valve is open, the downward-moving piston may take in fresh air. This second stroke of the gas exchange, the induction stroke, lasts until shortly after the bottom dead centre. During the following upward movement of the piston a compression process is carried out. Then, at the ignition TDC the igniting of the injected fuel occurs. During the following power stroke the combustion occurs and the piston is moved back down. Instead of a camshaft, an electric drive may be provided for opening and closing the inlet- and exhaust valves. A piston therefore executes the induction stroke, the compression stroke, the power stroke and the exhaust stroke, i.e. 4 strokes. In the case of a four-cylinder engine, for example the first and second cylinder are in phase and the third and fourth cylinder are out of phase by one stroke.
In FIG. 1 a controller 7 and a drive 8 , in particular an electric motor and/or a motor/generator unit are further provided. The drive 8 is connected to the crankshaft 6 . The four cylinders 2 , 3 , 4 , 5 are substantially identical in construction and are now described with reference to the first cylinder 2 .
FIG. 2 shows the first cylinder 2 having a first piston 9 , which is connected by a connecting rod 10 to the crankshaft 6 . On the first cylinder 2 an inlet valve 11 and an exhaust valve 12 are provided. The inlet valve 11 and the exhaust valve 12 are actuated by a non-illustrated camshaft. The inlet valve 11 is disposed in an intake channel, through which fresh air is sucked into the first cylinder 2 . The exhaust valve 12 is disposed in an exhaust channel, through which burnt exhaust gases may be discharged into the exhaust channel 14 . An ignition device 15 is further provided, which projects into the first cylinder 2 and by means of which a fuel-air mixture may be ignited. An injection valve 16 is moreover provided, which injects fuel into the first cylinder 2 .
Further represented is the drive 8 , which is connected to the controller 7 . By means of the drive 8 the position of the pistons may be adjusted via the crankshaft. The controller 7 is connected to a plurality of sensors 17 , which acquire various operating parameters of the internal combustion engine and/or of the motor vehicle, in particular a crankshaft angle of the crankshaft 6 . In the data/program memory 18 values and programs are filed, which the controller 7 uses to control the internal combustion engine 1 . For example, in the data/program memory 18 values, at which the inlet- and/or exhaust valve 11 , 12 are opened and/or closed, are filed. Further filed in the data/program memory 18 are data that determine the instant, at which an ignition by means of the ignition device 15 occurs in the cylinder. The controller 7 is moreover connected to a start/stop switch 19 . The start/stop switch 19 is used to communicate to the controller 7 whether the internal combustion engine is to be started or cut out. The start/stop switch may be designed in the form of an ignition switch or an on/off switch.
FIG. 3 shows a form of implementation for carrying out a method of starting an internal combustion engine 1 . In this case, the internal combustion engine 1 in a first program point 100 is in a stationary state, i.e. no injection and no ignition is being carried out and the pistons of the cylinders are not moving. Then, in program point 110 the information that the internal combustion engine 1 is to be started is passed to the controller 7 . This may be realized for example by means of the start/stop switch 19 or by actuation of another switch, for example by detection of the actuation of the clutch pedal. The controller 7 , which acquires the position of the individual pistons of the cylinders by means of the sensors 17 , selects the cylinder that is situated in the power stroke. This is carried out in program point 120 .
In the following program point 130 the controller 7 controls the drive 8 in such a way that the selected cylinder is moved counter to the direction of motion during normal operation of the internal combustion engine back in the direction of the top dead centre. In this case, the gas in the first cylinder 2 is compressed.
This situation is represented in FIG. 4 . In the inoperative state of the internal combustion engine the first cylinder is situated in a first position P 1 shortly before opening of the exhaust valve. The first piston is then moved by the drive 8 back in the direction of a second position P 2 until shortly before the top dead centre. Assuming that the internal combustion engine 1 has a plurality of cylinders, in particular four cylinders 2 , 3 , 4 , 5 , then for example the third cylinder is situated in the compression stroke in a third position P 3 in the inoperative state of the internal combustion engine. As the first piston is moved back into the second position P 2 , a third piston of the third cylinder is moved back in the fourth position P 4 . In the fourth position P 4 the inlet valve of the third cylinder is open, so that fresh air may flow into the third cylinder. Through the use of the drive 8 the instant and the position of the pistons during backward motion may be selected freely within specific limits. For example, the first piston of the first cylinder is reversed in the direction of the top dead centre but not beyond the top dead centre. In the second position P 2 of the first piston, in a program point 140 fuel is injected into the first cylinder and then the fuel is ignited by means of the ignition device 15 .
As a result of the combustion in the first cylinder 1 and the kinetic energy thus produced, the first piston is moved in the normal direction of motion of the internal combustion engine, wherein the air in the third cylinder is compressed. Upon reaching an optimum instant in the region of the top dead centre, in a following program point 150 fuel is injected into the third cylinder and the fuel-gas mixture is ignited. In this way it is possible for the third cylinder, directly after the first cylinder, also to execute a full power stroke. By means of these two power strokes it is possible to start the engine, without starting of the internal combustion engine with the aid of a starter being required. Compared to a starter the drive 8 may be of a markedly weaker design, as the drive has to reverse a piston of a cylinder only in the direction of the top dead centre, without having to compress air with the piston beyond the top dead centre. Thus, no compression over the top dead centre is required, nor is there any need to have to reach a minimum engine speed or carry out a plurality of ignition attempts. The drive 8 may therefore be of a markedly lighter and more economical construction than a normal starter-generator.
The first point P 1 is situated for example at a crankshaft angle of 1° to 10° before opening of the exhaust valve. The second position P 2 is situated for example at a crankshaft angle of 1° to 10° after the top dead centre for the ignition.
FIG. 5 shows a further variant of a program run for carrying out a method of starting an internal combustion engine. In this case, the internal combustion engine in a program point 200 is operating normally, i.e. fuel is being injected into the cylinders and ignited. In a following program point 210 the controller 7 receives the information that the internal combustion engine 1 is to be cut out. The controller 7 , which acquires the positions of the individual pistons of the cylinders, selects a suitable piston. For this purpose the controller 7 uses the information of a crankshaft sensor and the information of a camshaft sensor for the corresponding pistons. This is carried out in program point 220 . In a following program point 230 the controller 7 for example with the aid of the drive 8 brakes the selected piston, in the present example the first piston 9 of the first cylinder 2 , in such a way that the first piston 9 after the top dead centre stops in the power stroke, i.e. in the first position P 1 . The first position P 1 is preferably selected in such a way that the first cylinder 2 has as large an air filling as possible, i.e. that the first piston 1 is situated in a position just before opening of the exhaust valve of the first cylinder 2 . In this case, the power stroke is no longer executed, i.e. preferably no more fuel is injected and no ignition occurs.
The internal combustion engine then remains in this position until a start request occurs. The start request occurs in program point 240 . Then, in program point 250 the first piston 9 is moved counter to the normal engine running direction from the first position P 1 back in the direction of the top dead centre OT. In this case, both the inlet valve and the exhaust valve of the first cylinder are closed. Before reaching the second position P 2 , which represents the end value of the reversed piston with maximally compressed air, fuel is injected. By means of the further compression stroke a swirling of the air-fuel mixture is achieved. On reaching the second position P 2 the air-fuel mixture is ignited. The second position P 2 , as in the above example, is after the top dead centre OT, since energy to overcome the top dead centre is to be saved. The engine is moreover to start up in the direction of rotation. The fuel is injected for example at a crankshaft angle of 10° before reaching the second position P 2 .
Depending on the selected form of implementation, the second position P 2 may be selected in such a way that the inlet valve of a further cylinder, in the present example the third cylinder, is opened and the third cylinder is supplied with fresh air. Depending on the selected form of implementation, the braking of the internal combustion engine may be carried out with the aid of a starter-generator for energy recovery, for example to recover electrical energy.
In a further form of implementation, during starting the piston of the selected cylinder that is ignited first is moved further by the drive 8 initially in the normal direction of motion until fresh air flows through the exhaust channel 14 into the selected cylinder. Only then is the piston of the selected cylinder moved counter to the direction of rotation of the engine back in the direction of the top dead centre, in the manner described above. As a rule, all of the pistons are connected to the crankshaft, so that all of the pistons are simultaneously moved.
In a further form of implementation, moreover, the piston of the selected cylinder during braking is braked in such a way that the exhaust valve of the selected cylinder is already open. Furthermore, in a further form of implementation the controller 7 may select a cylinder, the exhaust valve of which shortly after the power stroke is just open.
In a further form of implementation, an eddy-current brake 20 is used to brake the engine in order to recover electrical energy, which is fed into a battery.
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In a method for starting an internal combustion engine having at least one cylinder, an inlet and an outlet valve, and having a piston interacting with a crankshaft, and the crankshaft moving in a predetermined rotational direction during normal operation of the internal combustion engine, the piston is located in an initial position, the piston is moved into a defined starting position against a normal rotational direction of the crankshaft by means of a drive, fuel is injected, and the fuel is ignited.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0001] This invention was made with government support under ARPA-E Award Number DE-AR0000278 awarded by the U. S. Department of Energy. The U. S. government has certain rights in the invention.
FIELD
[0002] The invention generally relates to batteries, and more particularly to the management of a secondary battery.
BACKGROUND
[0003] Rechargeable lithium batteries are attractive energy storage devices for portable electric and electronic devices and electric and hybrid-electric vehicles because of their high specific energy compared to other electrochemical energy storage devices. A typical lithium cell contains a negative electrode, a positive electrode, and a separator located between the negative and positive electrodes. Both electrodes contain active materials that react with lithium reversibly. In some cases, the negative electrode may include lithium metal, which can be electrochemically dissolved and deposited reversibly. The separator contains an electrolyte with a lithium cation, and serves as a physical barrier between the electrodes such that none of the electrodes are electrically connected within the cell.
[0004] Typically, during charging, there is generation of electrons at the positive electrode and consumption of an equal amount of electrons at the negative electrode. During discharging, opposite reactions occur.
[0005] During repeated charge/discharge cycles of the battery undesirable side reactions occur. These undesirable side reactions result in the reduction of the capacity of the battery to provide and store power.
SUMMARY
[0006] Traditional approaches to managing the undesirable side reactions in a battery include limiting (or otherwise controlling/regulating) the rate of charge/discharge of the battery in an attempt to minimize the undesired effects. These efforts result can results in extended charge times and peak power reduction. Thus, there is a need for a system and method for the determination of the states and parameters within a secondary battery allowing the battery management system to efficiently regulate the operation of the battery.
[0007] A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.
[0008] Embodiments of the disclosure are related to systems and methods for implementing a battery management system that estimates and predicts various states of the battery by applying, for example, an extended Kalman filter.
[0009] In some embodiments, the invention provides a method of managing a battery system. The battery system includes a battery cell and a sensor configured to measure battery cell characteristics such as, for example, voltage, current, and temperature. A state of health (SOH) and state of charge (SOC) of the battery cell are estimated at a first time by applying a physics-based battery model that applies differential algebraic equations to account for physical parameters relating to the chemical composition of the battery cell. The estimated state of health and state of charge of the battery are updated based on the battery cell characteristics measured by the sensor. The operation of the battery (e.g., the charging and discharging) are then regulated by the battery management system based on the updated state of health and state of charge.
[0010] In another embodiment, the invention provides a method of managing a battery system, the battery system including at least one battery cell, at least one sensor configured to measure at least one characteristic of the battery cell (such as voltage, current and temperature), and a battery management system including a microprocessor and a memory. At least one state of the at least one battery cell is estimated at a first time by applying a physics-based battery model that applies differential algebraic equations to account for physical parameters of a chemical composition of the at least one battery cell. At least one measured characteristic of the battery at a first time is received by the battery management system from the sensor. The at least one state of the at least one battery cell is then updated based on the at least one measured characteristic of the battery at the first time. The operation of the battery (e.g., the charging or discharging) is then regulated by the battery management system based on the at least one estimated state.
[0011] The details of one or more features, aspects, implementations, and advantages of this disclosure are set forth in the accompanying drawings, the detailed description, and the claims below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a block diagram of a battery system including a battery cell and a battery management system with sensing circuitry incorporated into the battery cell, in accordance with some embodiments.
[0013] FIG. 1B is a block diagram of another battery system with the sensing circuitry provided external to the battery cell, in accordance with other embodiments.
[0014] FIG. 2A is a functional block diagrams of a battery system that applies a combined estimation structure to jointly estimate both physical parameters of the battery cell and battery state information that are then used by a controller to regulate battery operation, in accordance with some embodiments.
[0015] FIG. 2B is a functional block diagram of a battery system that estimates physical parameters of the battery cell and battery state information separately, in accordance with some embodiments.
[0016] FIG. 3 is a flow chart of a method for operating a battery management system to estimate battery states and parameters, in accordance with some embodiments.
DETAILED DESCRIPTION
[0017] One or more specific embodiments will be described below. Various modifications to the described embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the described embodiments. Thus, the described embodiments are not limited to the embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein.
[0018] An embodiment of a battery system 100 A is shown in FIG. 1A . The battery system 100 A includes an anode tab 110 A, an anode 120 A, a separator 130 A, a cathode 150 A, a cathode tab 160 A, a sensing circuitry 170 A, and a battery management system 180 A. In some examples, the separator 130 A may be an electrically insulating separator. In some embodiments, the electrically insulating separator comprises a porous polymeric film. In various embodiments the thickness dimension of the components of a battery cell 102 A may be for the anode 120 A about 5 to about 110 micrometers, for the separator 130 A less than about 50 micrometers or in certain embodiments less than about 10 micrometers, and for the cathode 150 A about 50 to about 110 micrometers.
[0019] During the discharge of the battery cell 102 A, lithium is oxidized at the anode 120 A to form a lithium ion. The lithium ion migrates through the separator 130 A of the battery cell 102 A to the cathode 150 A. During charging the lithium ions return to the anode 120 A and are reduced to lithium. The lithium may be deposited as lithium metal on the anode 120 A in the case of a lithium anode 120 A or inserted into the host structure in the case of an insertion material anode 120 A, such as graphite, and the process is repeated with subsequent charge and discharge cycles. In the case of a graphitic or other Li-insertion electrode, the lithium cations are combined with electrons and the host material (e.g., graphite), resulting in an increase in the degree of lithiation, or “state of charge” of the host material. For example, x Li + +x e − +C 6 →Li x C 6 .
[0020] The anode 120 A may comprise an oxidizable metal, such as lithium or an insertion material that can insert Li or some other ion (e.g., Na, Mg, or other suitable ion). The cathode 150 may comprise various materials such as sulfur or sulfur-containing materials (e.g., polyacrylonitrile-sulfur composites (PAN-S composites), lithium sulfide (Li 2 S)); vanadium oxides(e.g., vanadium pentoxide (V 2 O 5 )); metal fluorides (e.g., fluorides of titanium, vanadium, iron, cobalt, bismuth, copper and combinations thereof); lithium-insertion materials (e.g., lithium nickel manganese cobalt oxide (NMC), lithium-rich NMC, lithium nickel manganese oxide (LiNi 0.5 Mn 1.5 O 4 )); lithium transition metal oxides (e.g., lithium cobalt oxide (LiCoO 2 ), lithium manganese oxide (LiMn 2 O 4 ), lithium nickel cobalt aluminum oxide (NCA), and combinations thereof); lithium phosphates (e.g., lithium iron phosphate (LiFePO 4 )).
[0021] The particles may further be suspended in a porous, electrically conductive matrix that includes polymeric binder and electronically conductive material such as carbon (carbon black, graphite, carbon fiber, etc.). In some examples, the cathode may comprise an electrically conductive material having a porosity of greater than 80% to allow the formation and deposition/storage of oxidation products such as lithium peroxide (Li 2 O 2 ) or lithium sulfide, (Li 2 S) in the cathode volume. The ability to deposit the oxidation product directly determines the maximum power obtainable from the battery cell. Materials which provide the needed porosity include carbon black, graphite, carbon fibers, carbon nanotubes, and other non-carbon materials. The pores of the cathode 150 A, separator 130 A, and anode 120 A are filled with an ionically conductive electrolyte that contains a salt such as lithium hexafluorophosphate (LiPF 6 ) that provides the electrolyte with an adequate conductivity which reduces the internal electrical resistance of the battery cell. The electrolyte solution enhances ionic transport within the battery cell 120 A. Various types of electrolyte solutions are available including, non-aqueous liquid electrolytes, ionic liquids, solid polymers, glass-ceramic electrolytes, and other suitable electrolyte solutions.
[0022] The separator 130 A may comprise one or more electrically insulating ionic conductive materials. In some examples, the suitable materials for separator 130 A may include porous polymers, ceramics, and two dimensional sheet structures such as graphene, boron nitride, and dichalcogenides. In certain examples the pores of the separator 130 may be filled with an ionically conductive electrolyte that contains a lithium salt such as lithium hexafluorophosphate (LiPF 6 ) that provides the electrolyte with an adequate conductivity which reduces the internal electrical resistance of the battery cell.
[0023] The battery management system 180 A is communicatively connected to the battery cell 102 A. In one example, the battery management system 180 A is electrically connected to the battery cell 102 A via electrical links (e.g., wires). In another example, the battery management system 180 A may be wirelessly connected to the battery cell 102 A via a wireless communication network. The battery management system 180 A may include for example a microcontroller (with memory and input/output components on a single chip or within a single housing) or may include separately configured components, for example, a microprocessor, memory, and input/output components. The battery management system 180 A may also be implemented using other components or combinations of components including, for example, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other circuitry. Depending on the desired configuration, the processor may include one or more levels of caching, such as a level cache memory, one or more processor cores, and registers. The example processor core may include an arithmetic logic unit (ALU), a floating point unit (FPU), or any combination thereof. The battery management system 180 A may also include a user interface, a communication interface, and other computer implemented devices for performing features not defined herein may be incorporated into the system. In some examples, the battery management system 180 A may include other computer implemented devices such as a communication interface, a user interface, a network communication link, and an interface bus for facilitating communication between various interface devices, computing implemented devices, and one or more peripheral interfaces to the microprocessor.
[0024] In the example of FIG. 1A , a memory of the battery management system 180 stores computer-readable instructions that, when executed by the electronic processor of the battery management system 180 A, cause the battery management system and, more particularly the electronic processor, to perform or control the performance of various functions or methods attributed to battery management system 180 A herein (e.g., calculate a state or parameter of the battery system, regulate the operation of the battery system, detect an internal short from a dendrite formation). The memory may include any transitory, non-transitory, volatile, non-volatile, magnetic, optical, or electrical media, such as a random access memory (RAM), read-only memory (ROM), non-volatile RAM (NVRAM), electrically-erasable programmable ROM (EEPROM), flash memory, or any other digital or analog media. The functions attributed to the battery management system 180 A herein may be embodied as software, firmware, hardware or any combination thereof. In one example, the battery management system 180 A may be embedded in a computing device and the sensing circuity 170 A is configured to communicate with the battery management system 180 A of the computing device external to the battery cell 102 A. In this example, the sensing circuitry 170 A is configured to have wireless and/or wired communication with the battery management system 180 A. For example, the sensing circuitry 170 A and the battery management system 180 A of the external device are configured to communicate with each other via a network. In yet another example, the battery management system 180 A is remotely located on a server and the sensing circuitry 170 A is configured to transmit data of the battery cell 102 A to the battery management system 180 A. In the above examples, the battery management system 180 A is configured to receive the data and send the data to an electronic device for display as human readable format. The computing device may be a cellular phone, a tablet, a personal digital assistant (PDA), a laptop, a computer, a wearable device, or other suitable computing device. The network may be a cloud computing network, a server, a wireless area network (WAN), a local area network (LAN), an in-vehicle network, a cloud computing network, or other suitable network.
[0025] The battery management system 180 A is configured to receive data from the sensing circuitry 170 A including current, voltage, and/or resistance measurements. Battery management system 180 A is also configured to determine a condition of the battery cell 102 A. Based on the determined condition of battery cell 102 A, the battery management system 180 A may alter the operating parameters of the battery cell 102 A to maintain the internal structure of the battery cell 102 A. The battery management system 180 A may also notify a user of the condition of the battery cell 102 A.
[0026] In other embodiments, the physical placement and configuration of various components may be modified. For example, FIG. 1B illustrates another example of a battery system 100 B that includes a battery cell 102 B, an anode tab 110 B, an anode 120 B, a separator 130 B, a cathode 150 B, a cathode tab 160 B, a sensing circuitry 170 B, and a battery management system 180 B. However, in the example of FIG. 1B the sensing circuitry 170 B is external to the battery cell 102 B and may be incorporated within the same housing as the battery management system 180 B.
[0027] In some embodiments the battery cell 102 A, 102 B may be closed system. In such a system after the battery cell 102 A, 102 B is produced the casing is sealed to prevent external elements, such as air and moisture, from entering the battery cell 102 A, 102 B and potentially causing degradation of components resulting in reduced performance and shorter life. In the discussion below, examples that refer to components in both battery system 100 A and battery system 100 B will use the reference numeral without the A or B designation (e.g., anode 120 instead of anode 120 A and anode 120 B).
[0028] However, a closed battery cell 102 presents various challenges to the battery management system 180 . The closed system does not allow the direct observation of the condition of the components of the battery cell 102 . Instead, conditions as monitored and measured by the sensing circuitry 170 may be processed or evaluated to determine various characteristics of the battery cell 102 , such as voltage, current, resistance, power, temperature and combinations thereof, during operation or while at rest, and pass those measured characteristics to a battery management system 180 which can interpret the measured characteristics in order to determine the condition of the battery cell 102 .
[0029] Various models have been developed to model the electrochemical reactions occurring within the battery cell 102 . One example, was developed by Fuller, Doyle, and Newman, (the Newman Model), ( J. Electrochem. Soc., Vol. 141, No. 1, January 1994, pp. 1-10), the contents of which are hereby incorporated by reference in their entirety. The Newman Model provides a mathematical model which can be used to estimate the electrochemical processes occurring within the battery cell 102 B based on the measured characteristics.
[0030] The charge transfer reactions at the anode 120 , and cathode 150 , may be modelled by an electrochemical model, such as the Newman Model, providing the basis to describe various battery cell 102 parameters during both the charging and discharging of the battery cell 102 . For example, the Newman Model may allow the estimation of various parameters including cathode particle radius, which can vary due to the degree of lithiation of the cathode 150 , which also may be called the state-of-charge of the battery cell 102 , anode particle radius, ion diffusion rates in the anode 120 , cathode 150 , and electrolyte, intercalation current and transference number, solution conductivity in the anode 120 , cathode 150 , and electrolyte, cell porosity of the anode 120 and cathode 150 , and equilibrium potential of the anode 120 and cathode 150 .
[0031] Physics based electrochemical models, such as the Newman Model, may include ordinary and partial differential equations (PDEs) to describe the behavior of the various parameters within the battery cell 102 . The Newman Model is an electrochemical-based model of the actual chemical and electrical processes occurring in the Li-ion batteries. However, the full Newman Model is extremely complex and requires a large number of immeasurable physical parameters to be identified. Identification of such large set of parameters involved in the nonlinear PDE and differential algebraic equations (DAEs) with current computational capacity is impractical. This gives rise to various electrochemical models that approximate the dynamics of the Newman Model.
[0032] For example, the Reduced-Order-Model (ROM), Mayhew, C.; Wei He; Kroener, C.; Klein, R.; Chaturvedi, N.; Kojic, A., “Investigation of projection-based model-reduction techniques for solid-phase diffusion in Li-ion batteries,” American Control Conference (ACC), 2014, pp. 123-128, 4-6 Jun. 2014, the contents of which are hereby incorporated by reference in their entirety, allows the model order reduction of the Newman Model of Li-ion cells while retaining the complete model structure of the of the baseline cell. The ROM of the Newman Model is able to accurately predict behavior of a truth model, compared to less realistic approximate models such as Single Particle Model, while reducing computation time and memory requirements. The Newman Model reduction by ROM, introduces a large number of states and parameters involved in highly nonlinear partial differential equations and differential algebraic equations of the ROM dynamical system. This contributes to the complexity of the parameter and state identification process. Herein we describe methods of parameter and state estimation for the highly nonlinear and complex ROM. These methods are based on online reception of measurement data and achieve a high speed of estimation.
[0033] One specific method that can be used for state and parameter is the Extended Kalman Filter (EKF). An EKF describes the process model as a nonlinear time varying model in discrete time, but uses a local linearization at each time step. The set of outputs from the electrochemical model via the EKF can include estimation of both rapidly varying states of the battery cell 102 and estimation of slowly varying parameters of the battery cell 102 . In some embodiments the state of the battery cell 102 in combination with the present input to the mathematical model allows the model to predict the present output of the battery cell 102 . States of a battery cell may for example include the state-of charge (e.g., for a lithium battery the degree of lithiation) or overpotentials. Parameters of the battery cell 102 typically vary more slowly over time than the states of the battery cell 102 . Additionally, a parameter may not be required for the model to predict the present output of the battery cell 102 . Instead knowledge of the parameters of battery cell, which may be called the state-of-health of the battery, relate to the long term functioning of the battery cell 102 . Additionally, some embodiments comprise parameters which are not directly determinable from the measurement of the current battery cell 102 characteristics. Examples of battery cell 102 parameters include the volume fractions of active materials in the anode and cathode, total cyclable lithium in the cell, electrolyte conductivity and radii of particles in the electrodes.
[0034] An embodiment of a battery system 200 A is shown in FIG. 2A . The battery system 200 includes a battery management system 205 A that includes a closed loop control module 210 A and a state and parameter estimator 220 A. The closed loop control module 210 A comprises a feedforward module 212 A and a feedback module 214 A. The battery system 200 A additionally comprises a battery 290 A which is in operable communication with the battery management system 205 A. In some embodiments the battery 290 may comprise one or more battery cells 102 . The battery system 200 A may be in operable communication with external sources of inputs to the battery system 200 A. A desired output 230 A by an external source may be input to the battery management system 205 A. An open-loop command 240 A may also be applied to the battery system 200 A via the battery management system 205 A and/or directly to the battery 290 A.
[0035] The battery management system 205 A can comprise the components previously described for the battery management system 180 of FIG. 1A . Additionally, in certain embodiments of battery system 200 A the battery management system 205 A comprises a closed loop control module 210 A which further comprises a feedforward module 212 A and a feedback module 214 A. The feedforward module 212 A is in operable communication with the state and parameter estimator 220 A as well as with external sources which can provide as inputs various commands such as desired outputs 230 A and/or open loop commands 240 A. The feedforward module 212 A may provide at least one control signal to the battery 290 A. The feedforward module 212 may also provide at least one control signal to the state and parameter estimator 220 A.
[0036] The feedback control module 214 A is in operable communication with the state and parameter estimator 220 A. The feedback control module 214 A receives the estimated states and parameters calculated by the state and parameter estimator 220 A and may provide at least one control signal to the battery 290 A. The feedback control module 214 A may also provide at least one control signal to the state and parameter estimator 220 A.
[0037] Another embodiment of a battery system 200 B is shown in FIG. 2B . FIG. 2B is identical to FIG. 2A except the state and parameter estimator 220 A of FIG. 2A is replaced by a state estimator 222 B and a parameter estimator 224 B. The state estimator 222 B and parameter estimator 224 B subsequently provide state and parameter estimates to the feedback control module 214 B in similar manner to that described for the state and parameter estimator 220 A of FIG. 2A .
[0038] The closed loop control module 210 B includes both a feedforward module 212 B and feedback module 214 B. The closed loop control module 210 B may also include set points received from open-loop sources, such as external sources. The closed loop control module 210 B supplies at least one control signal based on the feedforward module 212 B and feedback module 214 B. The feedforward component may be derived from a mathematical model, or from pre-determined set points. The feedback component is based on internal state and parameter estimates based on a physical model, such as from an electrochemical model of the battery 290 B.
[0039] In the example of FIG. 2A the state and parameter estimator 220 A may be an EKF-based estimator that simultaneously estimates the states and parameters of the battery 290 A at every time step. In order to make the overall implementation less computationally intensive, dual estimation may be employed such as in the example of FIG. 2B (i.e., where states and parameters are estimated separately). By separating the estimation into state estimation 222 and parameter estimation 224 the computational intensity may be reduced. The rate of change of the states of the battery systems 200 A and 200 B is typically faster than the rate of change of the parameters of the battery systems 200 A and 200 B. In some embodiments the frequency of updates of the parameters of the battery system 200 B is less than the frequency of updates of the states of the battery system 200 B.
[0040] In some embodiments, the separation of state and parameter estimation into separate estimators 222 B and 224 B may allow one or both of the state estimator 222 B and/or parameter estimator 224 B to be located remotely to the battery 290 B. In certain embodiments the state estimator 222 B and/or parameter estimator 224 B may be in operable communication with the other elements of the battery system 200 B by wireless communication.
[0041] An example of a method of estimating parameters and states using physics-based techniques by performing a time update and a measurement update is shown in FIG. 3 .
[0042] At the first time step, an initial estimate of the states and parameters are defined as part of the time update (step 310 ). The Jacobian of the system is evaluated (step 320 ) and an initial estimate of the noise covariance matrix is determined (step 330 ). At time t, given the current state and parameter estimates based on the most recent measurement, the time update (step 310 ) involves simulating the physics-based battery model over one time step, (t+1).
[0043] For this example, the system modelling/estimation is performed based on differential algebraic equations (DAEs)—however, the estimation may be applied to other model forms in other implementations. The DAE model can be represented by the equations:
[0000] {dot over (x)} 1 =f ( x 1 , x 2 , I, P ) (1)
[0000] {dot over (P)}=0 (2)
[0000] 0= g ( x 1 , x 2 , I, P ) (3)
[0000] y=h ( x 1 , x 2 , I, P ) (4)
[0000] where x 1 represents the differential states, x 2 represents the algebraic states, P represents the parameter vector and I represents the current inputs that are used to control battery operation.
[0044] As noted above, updating the covariance matrix (step 330 ) requires derivation of the Jacobian of the system with respect to the differential states and parameters (step 320 ). Since the model is defined in terms of a set of DAEs rather than ordinary differential equations (ODEs), a modified Jacobian is used as represented by the equation:
[0000]
J
f
=
[
f
x
1
-
f
x
2
g
x
1
g
x
2
f
P
-
f
x
2
g
P
g
x
2
0
0
]
(
5
)
[0000] where f x1 , f x2 , f P , g x1 , g x2 , and g P represent derivatives of f and g with respect to x 1 , x 2 and P. These derivatives can be obtained either analytically based on the functional forms of f and g, or numerically through simulation of the model.
[0045] After the Jacobian of the system is derived (step 320 ), the noise covariance matrix is then updated (step 330 ) as represented by the equation:
[0000] COV t+1|t =J f COV t|t J f T +Q (6)
[0000] where COV t+1|t is the covariance at t+1, J f is the Jacobian of f, J T f is the transpose of the Jacobian of f, COV t|t is the covariance at t, and Q is a positive definite matrix that can either be fixed, or time-varying.
[0046] The time-update estimate is further updated in the measurement update step based on available measurements of the characteristics of the battery 290 or battery cell 102 (step 370 ). The characteristics may include, but are not limited to, a voltage, current, resistance, temperature, or combinations thereof of the battery 290 or battery cell 102 . As subsequent measurements are obtained, the model prediction can be used to obtain a measurement error 350 (i.e., an error between a measured characteristic of the battery 340 and a corresponding value as determined by the DAE model) (step 350 ). This calculated measurement error is then used by the system to update and refine the measurement update (step 370 ) as discussed in further detail below.
[0047] Again, with a DAE based system, a modified Jacobian (J h ) is derived (step 260 ) with respect to the output equation as represented by the equation:
[0000]
J
h
=
[
h
x
1
-
h
x
2
g
x
1
g
x
2
h
P
-
h
x
2
g
P
g
x
2
]
(
7
)
[0000] where h x1 , h x2 , h P , g x1 , g x2 , and g P represent derivatives of h and g with respect to x 1 , x 2 and P. These derivatives can be obtained either analytically based on the functional forms of h and g, or numerically through simulation of the model.
[0048] During the measurement update, the covariance matrix (obtained in step 330 ) and the Jacobian (J h ) (obtained in step 360 ) are used to derive the Kalman gain (K k ), which is represented by the equation:
[0000]
K
k
=
COV
t
+
1
t
J
h
T
J
h
COV
t
+
1
t
J
h
T
+
R
(
8
)
[0000] where K k is the Kalman gain, R is a measure of the noise associated with each element. The other variables are as defined above for Equation (6).
[0049] The measurement update (step 370 ) causes the Kalman gain (K k ) to act on the measurement error to then provide up-to-date, error corrected state and parameter estimates as represented by the equation:
[0000]
[
x
^
P
^
]
t
+
1
t
+
1
=
[
x
^
P
^
]
t
+
1
t
+
1
+
K
k
y
err
(
9
)
[0050] The covariance matrix for t+1 is then updated again based on the measurements at t+1 (step 380 ), as represented by the equation:
[0000] COV t+1|t+1 =( I−K k J h ) COV t+1|t (10)
[0051] The updated states, parameters, and COV are then used as the basis (t) for the next time update 310 as the next iteration of the estimation is performed.
[0052] While the process of FIG. 3 describes the joint estimation of states and parameters such as in the example of FIG. 2A , it can be extended to a dual estimation framework of FIG. 2B where the states and parameters are estimated separately in similar fashion with two different EKFs. In the discussion below, examples that refer to components in both battery system 200 A and battery system 200 B will use the reference numeral without the A or B designation. Simulation and experimental data shows that different parameters and states of the electro-chemical model have different noise levels and different influence on the output. The noise and influence levels depend on the battery's state of operation. Various notions of state/parameter sensitivity can be used to determine which states/parameters are most critical to estimate, as well as to determine the noise covariance matrices that are used to evaluate the filter gains on each time step. For example, different notions of states and parameters' sensitivity that may be employed include a) partial derivatives of output versus states and parameters, and b) variations in the output over one drive cycle due to perturbation in states and parameters to evaluate the filter gain during each time step.
[0053] The accurate estimation of the states and parameters of a battery 290 may allow the battery management system 205 to regulate the operation of the battery 290 such that the life and performance of the battery will be enhanced. For example, the battery management system 205 by minimizing the change in parameters of the battery 290 may allow the battery 290 to undergo an increased number of charge/discharge cycles prior to replacement. In some embodiments the battery management system 205 may regulate the charging of the battery 290 to allow for the efficient intercalation of the oxidizable species rather than deposition on the surface of the electrode. This may minimize the formation of dendrites thus limiting the possibility of the formation of an internal short within the battery 290 . In other embodiments the battery management system 205 may regulate the discharge of the battery 290 in order to obtain for example, the maximum total power output from the battery 290 .
[0054] The embodiments described above have been shown by way of example, and it should be understood that these embodiments may be susceptible to various modifications and alternative forms. It should be further understood that the claims are not intended to be limited to the particular forms disclosed, but rather to cover all modifications, equivalents, and alternatives falling with the spirit and scope of this disclosure.
[0055] It is believed that embodiments described herein and many of their attendant advantages will be understood by the foregoing description, and it will be apparent that various changes may be made in the form, construction and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes.
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A method of managing a battery system, the battery system including at least one battery cell, at least one sensor configured to measure at least one characteristic of the battery cell, and a battery management system including a microprocessor and a memory, the method comprising receiving by the battery management system, from the at least one sensor at least one measured characteristic of the battery cell at a first time and at least one measured characteristic of the battery cell at a second time. The battery management system estimating, at least one state of the battery cell by applying a physics-based battery model, the physics based battery model being based on differential algebraic equations; and regulating by the battery management system, at least one of charging or discharging of the battery cell based on the at least one estimated state.
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BACKGROUND OF THE INVENTION
This invention relates to communication terminal equipment to be connected to an integrated services digital network. More particularly, this invention relates to communication terminal equipment that permits two-way communications to be performed over a complex communications network having an integrated services digital network interconnected with existing multiple communication networks and that has a capability for calling again a receiver terminal of interest when a communication trouble has occurred.
Facsimile and other types of communication terminal equipment have chiefly been connected to telephone networks and packet-switched public data networks (hereinafter abbreviated as "PSPDN"). In recent years, such communication terminal equipment is increasingly connected to an integrated services digital network which is adapted to handle digital information (which network is hereinafter abbreviated as "ISDN").
The ISDN concept refers to a communications network in which various kinds of communication machines such as telephones, facsimile equipment and telexes that are connected to data service units (DSU) through buses are designed to handle information in a standardized digital format, with all communication services to those communication machines for a particular DSU being implemented with the same number.
Various communication troubles can occur in telephone networks, PSPDNs and ISDNs as exemplified by the failure to connect a source terminal and a receiver terminal, as well as a disconnected line that occurs during communications. If a certain communication trouble occurs, disconnect information as appropriate for the situation under which the trouble has occurred is sent back to the source terminal. Each terminal equipment is provided with a repeated call management table which is descriptive of the unique correlation between disconnect information and the condition for making a repeated call. Upon receiving a certain type of disconnect information, the terminal equipment refers to that table on the basis of the received disconnect information and makes a repeated attempt to call the receiver terminal under the condition that is appropriate for that disconnect information.
Since the contents of disconnect information differ from one communications network to another, the repeated call management table in each terminal equipment also depends on which communications network it is connected to. For example, the terminal equipment connected to a PSPDN has a repeated call management table a, the terminal equipment connect to a telephone network has a repeated call management table b, and the terminal equipment connected to an ISDN has a repeated call management table c. Thus, each terminal equipment has had a single kind of repeated call management table in accordance with the communications network to which it is connected.
In the early stage of ISDN introduction, an important objective is to establish efficient interconnection between the ISDN and other existing networks. Particularly crucial is the interconnection with telephone networks and PSPDNs which are two most common communication networks.
FIG. 2 shows the basic layout for Case A which has been specified by the CCITT as regards the interconnection between ISDNs and PSPDNs. The term "Case A" as used herein means one from of services to a PSPDN that is connected to an ISDN. As shown in FIG. 2, the ISDN does not have a packet switching capability in Case A and functions only as a physical subscriber loop between a packet terminal 20 connected to the ISDN and a packet switching unit in the PSPDN. If the ISDN packet terminal 20 requests a packet-mode communication via a D-channel, the ISDN switching unit sets up a 64 kb/s unrestricted digital path between the packet terminal 20 and an ISDN access unit board (AU). As a result, a subscriber loop is completed between the ISDN packet terminal 20 and the PSPDN and, thereafter, call control from the packet terminal 20 will be performed by a procedure that is entirely the same as in the call control from the terminal directly accommodated in the PSPDN.
In the above-described configuration of Case A, the communications network to be handled is the ISDN until the packet terminal 20 is connected to the AU, so network control is performed in accordance with the procedure of ISDN call control. However, when a communication line is set up between the packet terminal 20 and the AU, the communications network to be handled is switched to the PSPDN and subsequent call control is performed in accordance with the procedure specified by CCITT's Recommendation X.25. Therefore, it a communication trouble occurs in the ISDN procedure which is followed until the packet terminal is connected to the AU, the disconnect information specified by the ISDN call control procedure is sent back and, if a communication trouble occurs in the procedure of Recommendation X.25, the disconnect information specified by the X.25 call control procedure is sent back. In the former case, the repeated call management table c must be referenced and in the latter case, the repeated call management table a must be referenced.
In fact, however, the communication terminal 20 has only the repeated call management table c and is unable to deal with the second type of disconnect information in a satisfactory manner. In short, each of the communication terminals used in the prior art communications system is equipped with only a single kind of repeated call management table, so if different types of disconnect information are sent back for different communication networks, repeated calls cannot be controlled in normal way.
SUMMARY OF THE INVENTION
The present invention has been achieved under these circumstances and has as an object providing communication terminal equipment which, irrespective of the kind of communications network to be handled, insures that a repeated attempt to call a receiver terminal of interest is made positively in response to the disconnect information that is sent back when a communication trouble has occurred.
This object of the present invention can be attained by communication terminal equipment that performs two-way communications with terminal equipment on a complex communications network that comprises an ISND interconnected with existing communication networks, which communication terminal equipment comprises: a calling unit that calls a receiver terminal by the call control procedure and under the condition of communications that comply with a specific calling condition; a call control procedure changing unit that changes the call control procedure upon detecting the switch from one communications network to another to be handled; a disconnect information detecting unit that detects the disconnect information being sent back when a communication trouble has occurred; a repeated call management table storage unit that registers a plurality of repeated call management tables each specifying the relationship between disconnect information and the condition of making a repeated call; a repeated call management table selecting unit by which a repeated call management table that complies with the call control procedure is selected from the repeated call management table storage unit; a repeated calling condition selector unit by which an appropriate condition for making a repeated call is selected from the selected repeated call management table on the basis of the returned disconnect information; and a repeated calling unit that calls again the receiver terminal of interest by the call control procedure and under the condition of communications that comply with the selected condition for making a repeated call.
In the system configuration described above, the repeated call management table selecting unit selects a repeated call management table that complies with a specific conditions of calling a receiver terminal of interest. If a communication trouble occurs during the calling operation to permit disconnect information to be sent back, the repeated call condition selecting unit selects the appropriate condition for making a repeated call from the repeated call management table in response to the returned disconnect information. The selected condition for making a repeated call corresponds to the disconnect information positively, thereby enabling a repeated call to be made in a reliable manner.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 is a functional block diagram for the communication terminal equipment of the present invention;
FIG. 2 is a diagram showing the basic configuration of Case A as specified by the CCITT;
FIG. 3 is a diagram showing an example of the composition of a repeated call management table;
FIG. 4 is a block diagram of facsimile equipment which is an embodiment of the present invention;
FIG. 5 is a diagram showing a complex communications network in which an ISDn is interconnected with a telephone network and a PSPDN;
FIG. 6 is a schematic diagram showing an example of a sequence in a normal communication procedure;
FIG. 7 is a schematic diagram showing an example of a sequence in a communication procedure in which a trouble occurs in the receiver terminal of a PSPDN; and
FIG. 8 is a flow chart showing an example of data communication in a communication system according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a functional block diagram for the communication terminal equipment of the present invention. When specific calling conditions such as the subscriber's number of the receiver terminal of interest and the condition of communications are entered, a calling unit 11 determines the call control procedure for calling on the basis of the input calling conditions and calls the receiver terminal in accordance with the thus determined call control procedure.
When the communications network to be handled is switched from one kind to another during the calling operation, a call control procedure changing unit 14 detects that event and changes the call control procedure that has been determined by the calling unit 11. A plurality of repeated call management tables are registered in a repeated call management table storage unit 15.
FIG. 3 is a diagram sowing an example of the composition of a repeated call management table. Each of the repeated call management tables registered in the storage unit 15 is composed of various kinds of disconnect information and associated parameters for repeated calling. This disconnect information contains values that correspond to CPS values, cause codes, reason indicating values and other data that are sent back, the communications network in which a communication trouble has occurred. The repeated call parameters are identifiers that help specify the conditions of making repeated calls as exemplified by the call control procedure for making a repeated call and the relevant condition of communications.
In accordance with the call procedure determined by the calling unit 11, a repeated call management table selecting unit 13 selects an appropriate repeated call management table from the repeated call management table storage unit 15. A disconnect information detecting unit 16 detects the disconnect information that is sent back from the communications network in which a communication trouble has occurred.
On the basis of the returned disconnect information, a repeated calling condition selector unit 12 selects the appropriate repeated call parameter from the selected repeated call management table. For example, if the contents of the selected repeated call management table are as shown in FIG. 3 and if the returned disconnect information is "0", "a 1 " is selected as the repeated call parameter.
On the basis of the repeated call parameter selected by the repeated calling condition selector unit 12, a repeated calling unit 10 determines the conditions of making a repeated call including the ball control procedure for repeated calling and the associated condition of communications and calls the receiver terminal again under the thus determined conditions of repeated calling.
When the operator makes a call request in the system configuration described above, the calling unit 11 determines the necessary call control procedure on the basis of the specific calling conditions. The type of the call control procedure is determined in accordance with the party to be called and the condition of communications. For example, if the call request of interest is directed to the terminal 21 shown in FIG. 2, the services to be rendered by Case A are selected and the ISDN call control procedure is first selected in order to set up a communications loop between the PSPDN and the AU that are also shown in FIG. 2.
FIG. 6 is a schematic diagram showing an example of a sequence in a normal communication procedure (Case A) whereas FIG. 7 is a schematic diagram showing an example of a sequence in a fault communication procedure in which no response occurs in the receiver terminal of the PSPDN.
If the call control procedure is selected in the ISDN, in response to the selected call control procedure, the repeated call management table selecting unit 13 selects an appropriate repeated call management table, say, table c from the repeated call management table storage unit 15.
The thus selected repeated call management table c is prepared based on the reason indication values which are defined in the ISDN.
When the call control procedure is implemented to complete a subscriber loop between the source terminal 20 and the PSPDN, the communications network to be handed is switched from the ISDN to the PSPDN.
In FIG. 6, such a switch timing is indicated as a first table switching point.
The call control procedure changing unit 14 detects that event and controls the calling unit 11 in such a way that it changes the ISDN call control procedure to the procedure specified by Recommendation X.25. When the call control procedure determined by the calling unit 11 is thus changed, the repeated call management table selector unit 13 accordingly selects an appropriate repeated call management table, say, table a, from the repeated call management table storage unit 15 to replace table c.
The selected repeated call management table c is prepared based on the cause codes defined in the PSPDN.
Thereafter, the calling unit 11 starts the calling procedure in the PSPDN to complete the connection to the receiver side packet terminal 21.
If a communication trouble occurs while the AU in the PSPDN is called, disconnect information from the ISDN is detected by the disconnect information detecting unit 16. In this instance, the repeated call management table that has been selected by the repeated call management table selector unit 14 is table c, so the repeated calling condition selector unit 12 selects an appropriate repeated call parameter on the basis of this table c and the detected disconnect information.
Similarly, if a communication trouble occurs during calling by the procedure of Recommendation X.25, disconnect information from the PSPDN is detected by the disconnect information detector unit 16. In this instance, the repeated call management table that has been selected by the repeated call management table selector unit 13 is table a, so a repeated call parameter as appropriate for the detected disconnect information is selected by referring to the repeated call management table a.
FIG. 7 is a schematic diagram showing an example of communication procedure in which the above described signal flows are indicated.
In either of the two cases described above, an appropriate repeated call parameter is selected in accordance with the disconnect information of interest and, then, the repeated calling unit 10 determines the call control procedure and communication conditions for repeated calling that comply with the selected call parameter and makes a repeated attempt to call the receiver terminal under the thus determined conditions for repeated calling.
FIG. 8 is a flow chart of the repeated calling according to the registered codes, which has been described hereinabove.
FIG. 4 is a block diagram of facsimile equipment which is an embodiment of the present invention. As shown, a bus 50 has the following units connected thereto: a main control unit 51; a G4 protocol control unit 52; a G3/G2 protocol control unit 53; a network selection processing unit 54; an image information processing unit 56; an auxiliary memory control unit 57; a network control unit (NCU) 58; a RAM 65; and an ISDN protocol control unit 55.
An operating panel 63 is connected to the main control unit 51 whereas an auxiliary memory unit 64 is connected to that auxiliary memory control unit 57. A scanner 61 and a printer 62 are connected to the image information processing unit 56 via respective interfaces 59 and 60.
The panel 53 is operated to enter various inputs including conditions of communications such as communication mode (e.g. G3 or G4 mode) and image quality mode (e.g. standard or fine), and the subscriber's number at the receiver terminal.
A plurality of the repeated call management tables described hereinabove are preliminarily registered in RAM 65. The contents of each of those repeated call management tables can be expanded or modified by the operator of the panel 63. By operating the panel 63, the contents of each repeated call management table can be output from the printer 62.
FIG. 5 is a diagram sowing schematically a complex communications network in which an ISDN having the facsimile equipment 40 connected thereto is interconnected with other communication networks which are a telephone network and a PSPDN in the case of the example under consideration. On the pages that follow, the operation of the complex communications network is described for the case where the calling condition of interest is a communication from the facsimile equipment 40 to another facsimile equipment 41 in a G4 mode.
First, the operator operates the panel 63 of facsimile equipment 40 to designate G4 mode as a condition of communications while, at the same time, he sets the calling condition by entering the subscriber's number at the receiver terminal. Then, a communication job that is appropriate for that calling condition is activated in the main control unit 51 which selects the ISDN call control procedure. The term "communication job" unit a program that manages sequence of operations from the start to the end of communication.
When the communication job is activated to start communication control, the main control unit 51 controls the network selection processing unit 54 in such a way that the G4 protocol control unit 52 is connected to the ISDN protocol control unit 55. At the same time, the main control unit 51 reads out of Ram 65 the repeated call management table that is appropriate for the selected ISDN call control procedure.
Subsequently, call control is initiated in accordance with the ISDN call control procedure. Since the receiver terminal is connected to the telephone network communication in G4 mode is impossible and the call is canceled, with disconnect information being sent back to the source terminal.
The returned disconnect information is supplied to the main control unit 51 via the ISDN protocol control unit 55 and the main control unit 51 selects an appropriate repeated call parameter in accordance with the disconnect information and the repeated call management table that has been read out of the RAM 65.
When the communication job is reactivated, the main control unit 51 references the repeated call parameter. Repeated call parameters can be preset in any appropriate manner, so if a parameter indicating "communication in G3 mode" is preliminarily registered as an alternative that is to be selected in the case where communication in G4 mode is impossible, the condition of repeated calling to be made is facsimile communication in G3 mode.
If G3 mode is designated, the main control unit 51 sets the call control procedure for the telephone network and the network selection processing unit 54 connects the G3/G2 protocol control unit 53 to the ISDN protocol control unit 55. Recognizing that the communications network to be handled has been switched to the telephone network, the main control unit 51 reads out of RAM 65 the repeated call management table that is appropriate for the call control procedure of the telephone network.
Now that repeated call control has been initiated in the manner described above, it becomes possible to establish a connection to the telephone network. Thus, communications are performed by the call control procedure of the telephone network and the image information read by the scanner 61 or the image information stored in the auxiliary memory unit 54 is sent out to the facsimile equipment 41.
In the embodiment described above, an appropriate repeated call management table is selected in accordance with the specific communications network being handled, so disconnect information from each communications network can be properly dealt with for permitting a repeated call to be made in a positive manner.
Furthermore, according to the embodiment, the contents of repeated call management tables can be expanded or modified as required, so the conditions for making a repeated call can be easily changed, which contributes to a higher operating efficiency of the system.
As is clear from the foregoing description, the communication terminal equipment of the present invention selects an appropriate repeated call management table in accordance with the specific communications network being handled and determines the proper conditions for making a repeated call on the basis of the selected repeated call management able and the disconnect information sent from the particular communications network. As a result, a repeated call can be made in a positive way even in a complex communications network consisting of many mutually interconnected networks.
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A communication terminal equipment that permits two-way communications to be performed over a complex communications network having an integrated services digital network interconnected with existing multiple communication networks and that has a capability for calling again a receiver terminal of interest when a communication trouble has occurred. The repeated call management table selecting unit selects a repeated call management table that complies with a specific conditions of calling a receiver terminal of interest. If a communication trouble occurs during the calling operation to permit disconnect information to be sent back, the repeated call condition selecting units selects the appropriate condition for making a repeated call from the repeated call management table in response to the returned disconnect information. The selected condition for making a repeated call corresponds to the disconnect information positively, thereby enabling a repeated call to be made in a reliable manner.
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PRIORITY APPLICATION
[0001] This application is a divisional of U.S. application Ser. No. 13/025,777, filed Feb. 11, 2011, which is a divisional of U.S. application Ser. No. 12/408,930, tiled Mar. 23, 2009, now issued as U.S. Pat. No. 7,888,991, which are both incorporated herein by reference in their entirety.
BACKGROUND
[0002] Many integrated circuit (IC) devices, such as processors and memory devices, often use clock signals as timing for data capture and transfer. The device may include a network to distribute clock signals from one location to other locations within the device. Clock signals in these devices are usually susceptible to variations in operating voltage and temperature, potentially causing inaccurate data capture or transfer, especially when these devices operate at high frequency, such as frequency in gigahertz range. Therefore, in some devices, designing a network to distribute clock signals may pose a challenge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 shows a block diagram of an IC device including a clock path, according to an embodiment of the invention.
[0004] FIG. 2 shows a block diagram of an IC device including a clock path having a clock distribution network (CDN), according to an embodiment of the invention.
[0005] FIG. 3 shows a block diagram of a portion of a clock path including a combination of current-mode logic (CML) based components and complementary metal-oxide semiconductor (CMOS) inverters, according to an embodiment of the invention.
[0006] FIG. 4 is a timing diagram showing clock signals having different phases and frequencies, according to an embodiment of the invention.
[0007] FIG. 5 shows a block diagram of a portion of a clock path with a converter located at local clock trees, according to an embodiment of the invention,
[0008] FIG. 6 shows a block diagram of a portion of a clock path with clock trees having different clock phases, according to an embodiment of the invention.
[0009] FIG. 7 shows a block diagram of a portion of a clock path with clock trees having the same components, according to an embodiment of the invention.
[0010] FIG. 8 shows a schematic diagram of a CML-based component, according to an embodiment of the invention.
[0011] FIG. 9 shows a schematic diagram of a divider circuit, according to an embodiment of the invention,
[0012] FIG. 10 shows a block diagram of an IC device including a bias generator, according to an embodiment of the invention.
[0013] FIG. 11 shows a block diagram of a bias generator with a current source having adjustable parallel current paths, according to an embodiment of the invention.
[0014] FIG. 12 shows a block diagram of a bias generator having multiple current sources, according to an embodiment of the invention.
[0015] FIG. 13 is a flow diagram of a method, according to an embodiment of the invention.
DETAILED DESCRIPTION
[0016] FIG. 1 shows a block diagram of an integrated circuit device 100 including a clock path 110 , according to an embodiment of the invention. IC device 100 can be a memory device or a processor. Clock path 110 of IC device 100 receives clock signals CK and CK#. The #” designation in CK# indicates that the CK# signal is inverted with respect to the CK signal. The CK and CK# signals together form a differential signal. Thus, the CK and CK# signals can be considered as components of a differential signal. The CK and CK# signals may be external to IC device 100 . Clock path 110 includes a clock distribution network (CDN) 112 to distribute the CK and CK# signals, or signals generated from the CK and CK# signals, to various locations within IC device 100 .
[0017] IC device 100 also includes a data path 120 to transfer data within IC device 100 or to transfer data to and from IC device 100 . In FIG. 1 , “DATA” presents the data transfer to and from IC device 100 . IC device 100 uses the CK and CK# signals as timing signals to transfer data, on data path 120 . Data path 120 may include components, such as data receivers, latches, and deserializers. The data receivers can be differential amplifier (e.g., sense-amp based) data receivers. Data on data path 120 includes data transferred to and from memory cells 130 .
[0018] IC device 100 also includes a bias generator 180 to generate a bias voltage V BIAS based on a bandgap reference generator 170 . IC device 100 uses bias voltage V BIAS to control gates of transistors of at least some of the components of clock path 110 .
[0019] Some of the components of IC device 100 , such as clock path 1 ] 0 and bias generator 180 , can be similar to or identical to the components described below with reference to FIG. 2 through FIG. 13 .
[0020] FIG. 2 shows a block diagram of an IC device 200 including a clock path 210 having a CDN 212 , according to an embodiment of the invention. Clock path 210 includes a receiver 232 to receive a differential clock signal formed by clock signals CK and CK#, which can have a frequency corresponding to a frequency of a clock (e.g., system clock) of a system that includes IC device 200 . Clock path 210 uses the CK and CK# signals to generate other clock signals with different phases and different frequencies for internal data capture and transfer within IC device 200 .
[0021] A buffer 234 receives the CK and CK# signals and generates a 2-phase differential clock signal that includes clock signals CK 2 and CK 2 #. The CK 2 and CK 2 # signals can be generated to have the same frequency as the frequency of the CK and CK# signals. Clock path 210 may include a duty cycle correction circuit (not shown)coupled to receiver 232 and buffer 234 to improve duty cycle of the CK 2 and CK 2 # signals.
[0022] CDN 212 includes a receiver and divider circuit 236 to receive the CK 2 and CK 2 # signals to generate 4-phase differential clock signals including a first differential clock signal formed by clock signals CK 4 A and CK 4 A #, and a second differential clock signal formed by clock signals CK 4 B and CK 4 B #. The CK 4 A , CK 4 A #, CK 4 B , and CK 4 B # signals can be generated to have a frequency that is one-half of the frequency of the CK 2 and CK 2 # signals.
[0023] CDN 212 also includes a converter 238 , which is a current-mode logic (CML) to CMOS signal (CML-to-CMOS) converter and can include a differential to single-ended signal converter. Converter 238 converts four components (CK 4 A , CK 4 B , and CK 4 B #) of the two differential clock signals into four single-ended clock signals CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 on lines 239 for distribution to a clock tree system 240 .
[0024] As shown in FIG. 2 , clock path 210 includes a combination of both CML-based and CMOS-based components. CML-based components include receiver 232 , buffer 234 , receiver and divider circuit 236 , and converter 238 . CMOS-based components include inverter circuits 250 and local clock trees 260 . In this description, a CML-based component refers to a component having input nodes to receive input differential signals and output nodes to provide output differential signals. A CMOS-based component refers to a component having an input node to receive an input CMOS-level signaling and an output node to provide a CMOS-level signaling. A differential signal and a CMOS signal can make a transition from one signal level to another signal level. The transition can be considered a “swing” of the signal. The signal levels can include supply voltage and ground potential levels, which are usually provided through conductors that are sometimes called “rails”. The signal swing of CMOS signals generated by CMOS components are generally greater than the signal swing of differential signals received at or generated by CML-based components. For example, CMOS signals can swing from supply voltage level (e.g., Nice) to ground and vice versa (or rail to rail). Differential signals associated with CML-based components generally have signal swings that are less than rail to rail.
[0025] As shown in FIG. 2 , inverter circuits 250 and local clock trees 260 are arranged in an H-tree arrangement. Inverter circuits 250 can be considered part of a global clock tree of clock tree system 240 . The global clock tree can extend a relatively long distance within IC device 200 . Local clock trees 260 can be located locally near data latches and deserializers of IC device 200 . The CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals have signal levels corresponding to CMOS signal level. Clock tree system 240 distributes the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals to inverter circuits 250 and local clock trees 260 for data capture and transfer.
[0026] Each inverter circuit 250 includes four CMOS inverters, and each of the four inverters receives one of the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals. Each local clock tree 260 can include additional inverters (not shown) to further distribute the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals. The single lines between the individual inverter circuits 250 and local clock trees 260 include multiple lines to carry multiple clock signals. FIG. 2 shows these multiple lines as single lines for simplicity.
[0027] IC device 200 also includes a bandgap reference generator 270 to generate voltage and current that are substantially constant over variations in the fabricating process, operating voltage and temperature. A bias generator 280 generates a bias voltage V BIAS based on bandgap reference generator 270 , such as based on the voltage or current from bandgap reference generator 270 . IC device 200 uses bias voltage V BIAS to control the gate of transistors in other components of IC device 200 , including CML-based components.
[0028] Some conventional clock paths may include only CMOS inverters or only CML-based components. CMOS inverters are generally more susceptible to supply voltage variation than CML-based components. CML-based components generally consume more power than CMOS-based components. Thus, some conventional clock paths may be sensitive to supply voltage variation or may consume relatively more power. In clock path 210 , however, a combination of both CML-based components and CMOS-based components can reduce power consumption, or improve sensitivity to supply voltage variation, or both.
[0029] CML-based components are generally sensitive to temperature. In some cases, variation in operating temperature can increase the temperature dependency of CML-based components. However, an appropriate value of a bias voltage, such as bias voltage V BIAS of FIG. 2 , can reduce the temperature dependency of CML-based components, such as the CML-based components in IC device 200 of FIG. 2 . Generation of bias voltage V BIAS is described in more detail below with reference to FIG. 10 through FIG. 13 .
[0030] FIG. 3 shows a block diagram of a portion of a clock path 310 including a combination of CML-based components and CMOS inverters, according to an embodiment of the invention. Components of clock path 310 can be used in clock path 210 of FIG. 2 . Clock path 310 of FIG. 3 includes additional components similar to those of clock path 210 of FIG. 1 . However, FIG. 3 shows only a portion of clock path 310 to focus on specific components shown therein.
[0031] As shown in FIG. 3 , clock path 310 includes CML-based components, such as receiver 333 and divider 335 , and CMOS-based components such as inverters 350 . Receiver 333 receives a differential dock signal (CK 2 /CK 2 #). Divider 335 receives the CK 2 and CK 2 # signals to generate two different differential clock signals, one formed by the CK 4 A and CK 4 A # signals and the other one formed by the CK 4 B and CK 4 B # signals.
[0032] Converter 338 is a CML-to-CMOS signal converter and can include a differential to single-ended signal converter. Converter 338 converts the two differential clock signals (CK 4 A /CK 4 A # and CK 4 B /CK 4 B #) into four single-ended clock signals CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 on lines 339 , which correspond to lines 239 of FIG. 2 .
[0033] A clock tree system 340 includes four inverters 350 , each receiving a corresponding clock signal CK 4 0 , CK 4 90 , CK 4 180 , or CK 4 270 . Inverters 350 provide the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals to one or more branch of clock tree system 340 for further distribution. The CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals can be used as clock signals for data latches and other components, such as deserializers, to capture and transfer data.
[0034] FIG. 4 is a timing diagram showing clock signals having different phases and frequencies, according to an embodiment of the invention. The clock signals shown in FIG. 4 correspond to the same signals shown in FIG. 1 , FIG. 2 , and FIG. 3 .
[0035] As shown in FIG. 4 , the CK and CK# signals have a cycle (period) “T” or a frequency f 1 =1/T.
[0036] The CK 2 and CK 2 # signals also have a cycle of T or a frequency f 2 =f 1 =1/T, which is equal to the frequency f 1 of the CK signal. The CK 2 and CK 2 # signals are 180 degrees (or ½ of their cycle T) relative to each other.
[0037] The CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals have a cycle of 2T or a frequency f 4 =½T, which is one-half the frequency f 2 of the CK 2 and CK 2 # signals. The CK 4 0 , CK 4 90 , CK 4 1800 , and CK 4 270 signals are 90 degrees (or ¼ of their cycle 2T) out of phase relative to each other.
[0038] The data (DATA) can have a frequency f D equal to four times the frequency f 4 of the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals (e.g., f D =4f 4 =2/T), such that during each clock cycle 1 ′, two bits of data can be captured or transferred. Data capture and transfer can occur at the edge (e.g., rising edge) of the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals. For example, as shown in FIG. 4 , four data bits B 0 , B 1 , B 2 , and B 3 of the data (DATA) can be captured or can be deserialized using four consecutive rising edges of the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals.
[0039] FIG. 5 shows a block diagram of a portion of a clock path 510 with a converter 538 located at local clock trees 560 , according to an embodiment of the invention. Clock path 510 includes a combination of CML-based components, such as CML receiver 533 , CML divider 535 , CML buffers 550 , and CMOS-based components, such as CMOS inverter 555 . FIG. 5 shows details of components within only one local clock tree 560 for clarity. Local clock trees 560 , however, have similar components.
[0040] Clock path 510 can be considered a variation of clock path 210 of FIG. 2 , with CML buffers 550 in FIG. 5 replacing CMOS inverter circuits 250 of FIG. 2 and converter 538 of FIG. 5 located at local clock trees 560 . In FIG. 2 , converter 238 is located outside local clock trees 260 and converts differential signals CK 4 A /CK 4 A # and CK 4 B /CK 4 B # into 4-phase CMOS clock signals (CK 4 0 , CK 4 90 , CK 180 , and CK 4 270 ). Then, clock path 210 distributes the 4-phase CMOS clock signals to local clock trees 260 . In FIG. 5 , however, differential signals CK 4 A /CK 4 A # and CK 4 B /CK 4 B # are distributed to local clock trees 260 by CML buffers 550 . Then, converter 538 locally converts differential signals CK 4 A /CK 4 A # and CK 4 B /CK 4 B # into the 4-phase CMOS clock signals (e.g., CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 ),
[0041] FIG. 6 shows a block diagram of a portion of a clock path 610 with clock trees 641 and 642 having different clock phases, according to an embodiment of the invention. Clock path 610 includes receivers 633 to receive a differential signal, formed by clock signals CK 2 and CK 2 #, and sends it to clock trees 641 and 642 . The CK 2 and CK 2 # signals are 2-phase clock signals that clock tree 641 uses as timing signal to capture data (DATA) at latches 621 . Clock tree 642 includes a divider 634 and inverter circuit 636 to convert the 2-phase clock signals CK 2 and CK 2 # into 4-phase clock signals CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 on lines 639 . Clock tree 642 uses the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 signals to deserialize data at deserializer 622 before the data is stored, for example, in memory cells.
[0042] FIG. 7 shows a block diagram of a portion of a clock path 710 with clock trees 741 and 742 having the same components, according to an embodiment of the invention. Clock path 710 receives a differential clock signal, formed by clock signals CK 2 and CK 2 #, at receiver 733 and sends it to clock trees 741 and 742 via CML buffers 734 . Each of clock trees 741 and 742 includes a divider 735 , a converter 738 , and a CMOS inverter circuit 750 to receive the CK 2 and CK 2 # signals to generate 4-phase CMOS clock signals CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 to capture data (DATA) at data latches 721 or 722 .
[0043] FIG. 8 shows a schematic diagram of a CML-based component 800 , according to an embodiment of the invention. CML-based component 800 has a differential amplifier configuration with a load 802 and a constant current I. CML-based component 800 includes transistors 803 and 804 to receive a differential clock signal, formed by clock signals CK IN and CK IN 4 , and generate a differential clock signal, formed by clock signals CK OUT and CK OUT #. CML-based component 800 also includes a transistor 805 having a gate controlled by an enable signal EN to activate or deactivate CML-based component 800 . CML-based component 800 further includes a transistor 806 having a gate controlled by a bias voltage V BIAS . A bias generator, similar to bias generator 280 of FIG. 1 , provides bias voltage V BIAS . CML-based component 800 with the different amplifier configuration show in FIG. 8 (or with other different amplifier configurations) can be used as receiver 232 of FIG. 2 , receiver 333 of FIG. 3 , CML buffers 550 of FIG. 5 , receivers 633 of FIG. 6 , CML buffer 637 of FIG. 6 , and CML buffers 734 of FIG. 7 . FIG. 8 shows an example of a differential amplifier configuration of CML-based component 800 . CML-based component 800 , however, can include other differential amplifier configurations.
[0044] FIG. 9 shows a schematic diagram of a divider circuit 935 , according to an embodiment of the invention. Divider circuit 935 can be used as the divider circuits described above, such as divider 335 of FIG. 3 . In FIG. 9 , divider circuit 935 is a CML latch-based divider circuit with CML latches 911 , 912 , 921 , and 922 . The circuit components, such as transistors N 1 through N 7 and resistors R 1 and R 2 of CML latches 911 , 912 , 921 , and 922 are similar and are arranged in similar ways as shown in FIG. 9 . For clarity, FIG. 9 omits details of CML latches 911 and 921 .
[0045] CML latches 911 and 912 form two stages (e.g., master and slave stages) of a first divider to receive a different clock signal that includes clock signals CK 2 and CK 2 # and generate a differential signal that includes clock signals CK 4 A and CK 4 A #. As shown in FIG, 9 , the gates of two transistors N 1 and N 2 of CML latch 912 are controlled by clock signals CK 2 and CK 2 #, and the gate of a transistor N 3 is controlled by a bias voltage V BIAS . A bias generator, which can be similar to bias generator 280 of FIG. 2 , provides bias voltage V BIAS . The CK 4 4 and CK 4 4 # signals generated by latches 911 and 912 have a frequency equal to one-half of the frequency of the CK 2 and CK 2 # signals.
[0046] CML latches 921 and 922 form two stages (e.g., master and slave) of a second divider to receive the same CK 2 and CK 2 # signals and generate a differential signal that includes clock signals CK 4 B and CK 4 B #. CML latches 921 and 922 operate in ways similar to those of CML latches 911 and 912 , except that the CK 2 and CK 2 # signals are swapped at gates of transistors N 1 and N 2 of CML latches 921 and 922 . Transistor N 3 of CML latch 922 is controlled by the same bias voltage V BIAS .
[0047] Divider circuit 935 may provide the CK 4 A , CK 4 A #, CK 4 B , CK 4 B # signals to a converter, such as converter of 238 of FIG. 2 or converter 338 of FIG. 3 , to generate 4-phase CMOS clock signals, such as the CK 4 0 , CK 4 90 , CK 4 180 , and CK 4 270 clock signals of FIG. 2 and FIG, 3 ,
[0048] FIG. 10 shows a block diagram of an IC device 1000 including a bias generator 1080 , according to an embodiment of the invention. IC device 1000 may include components similar to or identical to those of device 100 of FIG. 1 and IC device 200 of FIG. 2 . FIG. 10 shows only a portion of IC device 1000 to focus on bias generator 1080 and bandgap reference generator 1070 .
[0049] Bias generator 1080 generates a bias voltage V BIAS , which can be used as bias voltage V BIAS described above with reference to FIG. 1 through FIG. 9 .
[0050] As shown in FIG. 10 , bias generator 1080 includes generator portions 1010 and 1020 to generate voltages V INIT and V ADJ based on a current I REF from bandgap reference generator 1070 . Current I REF is a bandgap reference current that is substantially constant over variations in operating voltage and temperature. Bias generator 1080 includes a calibrating process to adjust the value of voltage V ADJ based on the relationship between voltages V INIT and V ADJ during the calibrating process. After the value of voltage V ADJ is adjusted to a selected value, bias generator 1080 stops the calibrating process to maintain the value of bias voltage V BIAS . As shown in FIG. 10 , bias generator 1080 includes a unity gain amplifier 1050 to provide voltage bias V BIAS , which is equal to voltage V ADJ . Unity gain amplifier 1050 can act as a filter to improve signal characteristic of bias voltage V BIAS .
[0051] Generator portion 1010 includes a current source 1012 and a load formed by transistors 1014 and 1016 that are coupled as a diode load and in series with current source 1012 on a circuit path between nodes 1098 and 1099 . Node 1098 can include a supply node having a supply voltage Vcc, Node 1099 can include a ground potential. Current source 1012 may include a current mirror to generate current I INIT based on current I REF , such that current I INIT can be equal to current I REF , As shown in FIG. 10 , voltage V INIT is a function of current I INIT and a resistance across the diode load formed by transistors 1014 and 1016 .
[0052] Generator portion 1020 includes a current source 1022 and a load, formed by a resistor R, coupled in series with current source 1022 on a circuit path between nodes 1098 and 1099 . Current source 1022 may include a current mirror to generate current I ADJ based on current I REF . Current I ADJ is an adjustable current. It can be adjusted using a code (represented by “CODE” in FIG. 10 ), The CODE can be a digital code having one or more bits. FIG. 11 and FIG. 12 (described below) show examples of an adjustable current source that can be used for current source 1022 of FIG. 10 , As shown in FIG. 10 , voltage Y ADJ is a function of current I ADJ and the resistance of resistor R. Thus, the value of voltage V ADJ can be adjusted by adjusting the value of current I ADJ . Further, since bias voltage V BIAS is generated based on voltage V ADJ , bias voltage V BIAS is also a function of current I ADJ and the resistance of resistor R.
[0053] As described above, bias generator 1080 includes calibrating process to adjust the value of bias voltage V BIAS based on the relationship between voltages V INIT and V ADJ . In FIG. 10 , during a calibrating process, a comparator 1030 compares the value of voltage V ADJ with the value of voltage V INIT and adjusts the value of voltage V ADJ based on the results of the comparison. The value of current I INIT and voltage are not adjusted during the calibrating process. Thus, the value of voltage V INIT can be used as a target value during the calibrating process.
[0054] Current source 1022 can be set such that the value of voltage V ADJ is set to a starting value within a voltage range (described below) and less than the value of voltage V INIT at the beginning of the calibrating process. Then, based on the comparison during a calibrating process, a controller 1040 changes the value of the CODE to change the value of current I ADJ and increase the - value of voltage V ADJ . The adjustment can repeat until the value of voltag V ADJ is at least equal to the value of voltage V INIT . Controller 1040 may include a digital counter to set the value of the CODE corresponding to a count value of the counter. Controller 1040 may use the counter to count up, increasing the value of the count value, which can correspond to an increase in the value of current I ADJ .
[0055] Current source 1022 can be alternatively set such that the value of voltage V ADJ is set to a starting value within a value range and greater than (instead of less than, as described above) the value of voltage V INIT at the beginning of the calibrating process, Then, based on the comparison during a calibrating process, controller 1040 can change the value of the CODE to change the value of current I ADJ and decrease the value of voltage V ADJ . In the alternative way, controller 1040 may use a counter to count down, decreasing the value of the count value, which can correspond to a decrement in the value of current I ADJ . The adjustment can repeat until the value of voltage I ADJ is at most equal to the value of voltage V INIT .
[0056] The voltage range of voltage V ADJ (mentioned above) can be determined by measuring its values (e.g,, during design) for different process variations. Thus, the voltage range is known before the value of voltage V ADJ is set. The voltage range of voltage V INIT can also be determined by measuring its values for different process corners. Based on the voltage ranges, the starting value of V ADJ at the beginning of the calibrating process can be set to a value within its voltage range (e.g., a lowest value in the voltage range and less than or greater than the value of voltage V INIT .
[0057] Bias generator 1080 may perform the calibrating process only one time, for example, only during a power-up sequence of IC device 1000 . After the calibrating process, for example, after the power-up sequence, IC device 1000 may switch one or more of generator portion 1010 , comparator 1030 , and controller 1040 to a lower power mode to save power. Such lower power mode may include an idle mode or an off mode.
[0058] IC device 1000 includes an operating temperature range with a first operating temperature limit lower than a second operating temperature limit. Bias generator 1080 may perform the calibrating process to adjust voltage V ADJ at a temperature that is closer to the first operating temperature limit than the second operating temperature limit. For example, IC device 1000 may have an operating temperature range from 0° C. to 100° C. and bias generator 1080 may perform the calibrating process at 25° C., Performing the calibrating process at a relatively lower temperature within operating temperature range may improve performance of device 100 .
[0059] FIG. 11 shows a block diagram of a bias generator 1180 with a current source 1122 having adjustable parallel current paths 1100 , 1101 , and 1102 , according to an embodiment of the invention. Bias generator 1180 can correspond to bias generator 1080 of FIG. 10 , FIG. 11 shows only a portion of generator 1180 to focus on current source 1122 , which can correspond to current source 1022 of FIG. 10 . In FIG. 11 , bias generator 1180 generates a voltage V ADJ , which can be used to generate a bias voltage (e,g., V BIAS =V ADJ ) similar to or identical to bias voltage V BIAS in FIG. 10 . In FIG. 11 , voltage V ADJ has a value based on the value of a current I ADJ and the resistance of a resistor R. The value of current I ADJ can be generated based on bandgap reference generator 1170 .
[0060] As shown in FIG. 11 , bandgap reference generator 1170 includes a bandgap internal circuitry 1171 , transistors P 0 , and a resistor R REF to generate a bandgap current I REF . Current source 1122 includes transistors P 1 through P 9 arranged in a current mirror configuration with transistors P 0 to generate a current I ADJ based on current I REF . The value of the current I ADJ is equal to a sum of the values of currents on current paths 1100 , 1101 , and 1102 . Each of these current paths can be configured to have different current values. For example, transistors P 1 through P 9 can have different sizes so that currents on current paths 1100 , 1101 , and 1102 can have different values.
[0061] Bias generator 1180 receives a code having bits C 0 , C 1 , and C 2 to select a combination of current paths 1100 , 1101 , and 1102 . FIG. 11 shows current source 1122 having only three current paths 1100 , 1101 , and 1102 as an example. The number of current paths can vary, The values of bits C 0 , C 1 , and C 2 can be controlled by a controller, such as controller 1040 of FIG. 10 . Depending on which combination of current paths 1100 , 1101 , and 1102 is selected, the value of current I ADJ is increased or decreased to adjust the value of voltage V ADJ .
[0062] Bias generator 1180 may adjust voltage V ADJ during a calibrating process similar to or identical to the calibrating process described above with reference to FIG. 10 . For example, bias generator 1180 can adjust voltage V ADJ by changing the values of bits C 0 , C 1 , and C 2 during a calibrating process.
[0063] FIG. 12 shows a block diagram of a bias generator 1280 having multiple current sources 1220 , 1221 , and 1222 , according to an embodiment of the invention. Bias generator 1280 can correspond to bias generator 1080 of FIG. 10 . FIG. 12 shows only a portion of generator 1280 to focus on current sources 1220 , 1221 , and 1222 . Bias generator 1280 generates a voltage V ADJ , which can be used to generate a bias voltage (e.g., V BIAS =V ADJ ) similar to or identical to bias voltage V BIAS in FIG. 10 . In FIG. 12 , voltage V ADJ has a value based on the value of a current I ADJ and the resistance of a resistor R. The value of current I ADJ can be generated based on a bandgap current I REF from bandgap reference generator 1270 .
[0064] Each of current sources 1220 , 1221 , and 1222 can include multiple parallel current paths similar to the parallel current paths of current source 1122 of FIG. 11 . Bias generator 1280 receives a code (represented by “CODE” in FIG. 12 ) to control the current on each of current sources 1220 , 1221 , and 1222 . The value of current I ADJ is equal to the sum of current from current sources 1220 , 1221 , and 1222 . Multiple current sources 1220 , 1221 , and 1222 provide bias generator 1280 with more combination of current paths to select, so that current I ADJ can be adjusted with a finer resolution and a wider range of current value.
[0065] FIG. 13 is a flow diagram of a method 1300 , according to an embodiment of the invention. Method 1300 can be used to generate a bias voltage and clock signals in an IC device.
[0066] Method 1300 includes activity 1310 to enable a bandgap reference generator. After the bandgap reference generator is settled, activity 1320 performs a calibrating process to select a value of a voltage (e.g., V ADJ ) generated based on the bandgap reference generator. The calibrating process in activity 1320 may include activities and operations of a bias generator, such as bias generators 1080 , 1180 , and 1280 of FIG. 10 , FIG. 11 , and FIG. 12 , respectively. After the calibrating process, method 1300 continues with activity 1330 to provide the bias voltage, which is based on the voltage generated during the calibrating process. The bias voltage can be similar to or identical to bias voltage V BIAS described above with reference to FIG. 1 through FIG. 12 . Activity 1330 in FIG. 13 may perform the calibrating process only one time, for example, only during a power-up sequence of the IC device.
[0067] Method 1300 also includes activity 1340 to generate clock signals for data capture and transfer. Method 1300 may use the bias voltage provided by activity 1330 to control transistors of CML-based components that method 1300 uses to generate the clock signals. Generation of the clock signals in activity 1330 may include activities and operations described above with reference to FIG. 1 through FIG. 9 to generate clock signals, such as CK 2 , CK 2 #, CK 4 A , CK 4 A ™, CKA B , CK 4 B #, CK4 0 , CK 4 90 , CK 4 180 , and CK 4 270 .
[0068] One or more embodiments described herein include apparatus and methods having a clock path with a combination of current-mode logic (CML) based and CMOS components. The apparatus and methods further include a bias generator to generate a bias voltage for use in some of the components of the clock path. Other embodiments, including additional methods and devices, are described above with reference to FIG. 1 through FIG. 13 .
[0069] The illustrations of apparatus such as IC devices 100 , 200 , and 1000 are intended to provide a general understanding of the structure of various embodiments and not a complete description of all the elements and features of the apparatus that might make use of the structures described herein.
[0070] The apparatus of various embodiments includes or can be included in electronic circuitry used in high-speed computers, communication and signal processing circuitry, memory modules, portable memory storage devices (e.g., thumb drives), single or multi-processor modules, single or multiple embedded processors, multi-core processors, data switches, and application-specific modules including multilayer, multi-chip modules. Such apparatus may further be included as sub-components within a variety of electronic systems, such as televisions, memory cellular telephones, personal computers (e.g., laptop computers, desktop computers, handheld computers, tablet computers, etc,), workstations, radios, video players, audio players (e.g., MP3 (Motion Picture Experts Group, Audio Layer 3) players), vehicles, medical devices (e.g., heart monitor, blood pressure monitor, etc.), set top boxes, and others.
[0071] The above description and the drawings illustrate some embodiments of the invention to enable those skilled in the art to practice the embodiments of the invention. Other embodiments may incorporate structural, logical, electrical, process, and other changes. In the drawings, like features or like numerals describe substantially similar features throughout the several views. Portions and features of some embodiments may be included in, or, substituted for, those of others. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. For example, the embodiments described above may also apply to a CML/CMOS CDN that uses two-phase clock signals (e.g., CK and CK# or CK 2 and CK 2 #) to capture and transfer data. In the two-phase CML/CMOS CDN, a divider (e.g., CLM divider 535 of FIG. 5 ) can be omitted.
[0072] The Abstract is provided to comply with 37 C.F.R. §1.72(b) requiring an abstract that will allow the reader to quickly ascertain the nature and gist of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to interpret or limit the claims.
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Some embodiments include apparatus and methods having a clock path with a combination of current-mode logic (CML) based and complementary metal-oxide semiconductor (CMOS) components.
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FIELD OF THE INVENTION
The present invention relates to a sidelift truck which incorporates a rotatable cab.
BACKGROUND OF THE INVENTION
In two directional sidelift trucks, the cab is conventionally disposed in a fixed forwardly-facing direction to the non-lifting side of the truck. The cab is disposed the non-lifting side of the truck to maximise the width of the load carrying platform.
The provision of a cab fixed in the conventional forwardly-facing direction does however mean that an operator has to turn and look over his shoulder when performing a loading/unloading operation. This continuous stretching is awkward and fatiguing for the operators.
In addressing this problem it has been proposed to provide a rotatable seat in the cab. However, owing to the requirement for the cab to have as narrow a width as possible, the possible angle of rotation of the seat in the cab is particularly small, typically about 15°. Thus, whilst this arrangement partially overcomes the problems experienced by an operator of a conventional sidelift truck, it still requires the operator to stretch awkwardly in his seat in order clearly to see the load when performing a loading/unloading operation.
It is an aim of the present invention to provide a sidelift truck which permits an operator when sitting comfortably in the seat of the cab, to view a load clearly while performing a loading/unloading operation.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a sidelift truck, comprising: a main body providing a load platform; a lifting assembly for handling loads to and from the load platform; and a cab mounted to the main body and rotatable about a substantially vertical axis.
In a preferred embodiment, the cab is rotatable between a substantially forwardly-facing, driving position and a substantially transversely-facing, load handling position. Preferably the angle of rotation of the cab between the two positions is limited, most preferably to around 70°.
A preferred embodiment of the present invention will now be described hereinbelow by way of example only with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of the lifting side of the front part of a sidelift truck in accordance with a preferred embodiment of the present invention, in the parked position;
FIG. 2 shows a side view of the non-lifting side of the truck of FIG. 1 in the conventional driving position;
FIG. 3 shows a front view of the truck of FIG. 1 in the conventional parked position;
FIG. 4 shows a plan view of the truck of FIG. 1 in the conventional driving position;
FIG. 5 shows a plan view of the truck of FIG. 1 with the cab in the load handling position;
FIG. 6 shows a side view of the cab rotating device of the truck of FIG. 1;
FIG. 7 shows a plan view of the cab rotating device of FIG. 6;
FIG. 8 shows an alternative cab rotating device; and
FIG. 9 shows a schematic plan view of the device of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In a conventional manner the sidelift truck 1 of the present invention comprises an elongate main body 3 which provides a load platform 5 on a major part of the upper surface thereof, a lifting assembly 7 provided midway along the longitudinal extent of the main body 3 and a cab 9 provided adjacent the front end and the non-load handling side 3a of the main body 3.
The main body 3 is mounted on two sets of wheels at the front and rear ends and includes first steps 11 in the front end to allow an operator to climb easily onto the load platform 5 and provide access into the cab 9 when in the rotated position and second steps 13 in the non-load handling side 3a of the truck 1 to provide access into the cab 9 when in the conventional driving and working position.
The lifting assembly 7 comprises a mast 15, a carriage 17 movable up and down the mast 15, and a load-engaging member 19 supported by the carriage 17. In this embodiment the load-engaging member 19 comprises a pair of forks. The lifting assembly 7, again in a conventional manner, is extendable/retractable in the direction transverse to the longitudinal axis of the main body 3 (shown by arrow A in FIGS. 4 and 5) in order that the load-engaging member 19 can be extended beyond the load handling side 3b of the main body 3 to engage a load and retracted so as to allow the load to be brought back onto the load platform 5.
The cab 9 is rotatable about a substantially vertical axis X from a forwardly-facing, driving and working position (shown in FIGS. 1 to 4) to a substantially transversely-facing, load handling position (shown in FIG. 5). The cab 9 has a substantially rectangular base, with the long side of the base being directed front-to-rear when the cab 9 is in the conventional driving and working position. The axis of rotation X of the cab 9 is disposed rearwardly of the mid-point of the long side of the cab 9 and inwardly of the mid-point of the narrow side of the cab 9 towards the load handling side 3b of the truck 1. In this way the cab 9 does not extend beyond the non-load handling side 3a of the truck 1 during rotation. It will of course be understood by a person skilled in the art that where overhang of the cab 9 beyond the non-load handling side 3a of the truck 1 can be tolerated, the axis of rotation can be located in any position. In such circumstances the axis of rotation X can be located so as to be coincident with the axis corresponding to the centre of gravity of the cab 9 when occupied such that minimum bending moments are applied.
The cab 9 is mounted to the upper surface of the main body 3 by a cab rotating device 21. FIGS. 6 and 7 show side and plan views of the cab rotating device 21. The cab rotating device 21 comprises a pair of mutually rotatable supporting plates 23, 25 which are attached respectively to the underside of the cab 9 and the upper surface of the main body 3. The supporting plates 23, 25 are rotatable in relation to one another, in this embodiment through an angle of about 70°, which limits of rotation correspond to the driving position and the load handling position. An angle of rotation of about 70° has been found to be the ideal angle of rotation from the forwardly-facing conventional driving position, which allows the operator a clear view of the load in the load handling position. The cab 9 can, however, be arranged to rotate through any other angle from the conventional driving position, such as typically 90°. In this embodiment the cab rotating device 21 is operated by a hydraulic cylinder 27. Alternatively, the cab rotating device 21 could be mechanically driven by a gear assembly with associated drive motor.
The truck 1 further comprises a control unit (not shown) which includes a sensor for detecting the lateral extension of the lifting assembly 7. The control unit actuates the hydraulic cylinder 27 in response to the detected position of the lifting assembly 7, whereby extension or retraction of the lifting assembly 7 by the operator automatically causes rotation of the cab 9 in a direction towards respectively the load handling position or the conventional driving position. This operation is such that the cab 9 is rotated at a rate relating to the rate of the extension/retraction of the lifting assembly 7. In the fully retracted position of the lifting assembly 7 (as shown in FIGS. 1 to 4) the cab 9 is required to be in the conventional forwardly-facing position in order to allow the operator an unimpeded view to drive the truck 1 and also ensure that any load carried by the lifting assembly 7 does not foul against the cab 9. As the lifting assembly 7 is laterally extended by the operator the cab 9 is progressively rotated, in this embodiment in a clockwise sense, until a point is reached where the lifting assembly 7 is fully extended and the cab 9 assumes the fully rotated, substantially laterally-facing position (as shown in FIG. 5). On retraction of the lifting assembly 7 by the operator the cab 9 is rotated correspondingly in the opposite counter-clockwise sense (as shown by arrow B in FIG. 5) to the conventional driving position, rotation ensures that the load does not foul on the cab 9.
In this embodiment an override facility is also provided whereby the cab 9 can be rotated to the load handling position with the lifting assembly 7 in the retracted position when carrying no load. This feature allows the door of the cab 9, which in this embodiment is disposed on the side of the cab 9 adjacent the non-load handling side 3a of the truck 1 when in the conventional driving position, to be located in a position where the operator can enter the cab 9 from the front end of the truck 1. This arrangement allows the operator to enter and leave the cab 9 where the truck 1 is operated in confined locations. Typical examples are in the narrow aisles of a warehouse where there is only a very limited clearance on either longitudinal side of the truck 1 and when loaded on a transporter which is only just as wide as necessary to contain the truck 1.
In use, the truck 1 is operated in every sense in a conventional manner. However, it happens that when the operator extends the lifting assembly 7 to handle a load the cab 9 rotates correspondingly towards the load handling position so as to allow the operator a full and clear view of the load to be handled. In the opposite manner, the cab 9 is automatically rotated back to the conventional driving position on retracting the lifting assembly 7. In this embodiment as shown in FIGS. 1 and 3 the load-engaging member 19 is lowered to the ground when the truck 1 is parked.
FIGS. 8 and 9 show an alternative cab rotating device. The cab 9 is rotatably mounted to the main body 3 by central pivot bearing 28 attached to the rear of the cab base (plinth) and to the upper surface of the main body. Under the cab base a load-bearing slider 29 is provided. A hydraulic cylinder is attached between the cab 9 and the body 3 rotates the cab 9 as it extends and retracts. As in the device of FIGS. 6 and 7, rotation of the cab could be limited to, e.g. around 70° or could be 90° or more.
It will be understood by a person skilled in the art that the present invention is not limited to the described embodiment but can be modified in many different ways within the scope of the appended claims.
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A sidelift truck, comprising: a main body (3) providing a load platform (5); a lifting assembly (7) for handling loads to and from the load platform (5); and a cab (9) mounted to the main body (3) and rotatable about a substantially vertical axis (X).
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This is a division, of application Ser. No. 06/652,246, filed Sept. 20, 1984 and now Pat. No. 4,785,130.
FIELD OF THE INVENTION
This invention relates to the preparation of diorganocarbonates. More particularly it relates to the preparation of dimethyl carbonate.
BACKGROUND OF THE INVENTION
Diorganocarbonates, typically dimethyl carbonate, may be prepared by the oxidative carbonylation of alcohols in the presence of a catalyst. Typically methanol is reacted with carbon monoxide and oxygen to prepare dimethyl carbonate. The reaction is carried out in the presence of a catalyst; and those skilled in the art constantly seek new catalysts to lower costs, and to improve reaction conditions, yield, rate of production, etc.
There is a substantial body of prior art relating to the production of organic carbonates. Illustrative of these references are the following:
U.S. Pat. No. 3,114,762 to Mador et al discloses as catalysts metal salts including chlorides and bromides of platinum and palladium plus an oxidizing agent such as iron or copper salts having the same anion.
U.S. Pat. No. 3,227,740 to Fenton discloses as catalyst mercuric halides or carboxylates.
Saegusa et al, J. Org Chem., 35, 2976-2978 (1970) discloses the reaction of CO with copper alkoxides including the dimethoxide, the di-allyloxide, the chloride methoxide, and the acetylacetonate methoxide.
Romano et al IEC Prod. Res. Dev. 19, 396-403 (1980) discloses as catalyst cuprous chloride/cupric chloride methoxide.
U.S. Pat. No. 4,218,391 to Romano et al discloses as catalysts salts of metals of Group IB, IIB, and VIII, preferably monovalent copper such as cuprous bromide, chloride, or perchlorate.
U.S. Pat. No. 4,318,862 to Romano et al discloses as catalyst salts of metals of Groups IB, IIB, or VIII, typically a copper salt such as CuCl.
U.S. Pat. No. 3,846,468 to Perrotti et al discloses as catalysts cuprous chloride complexes with an organic ligand such as pyridine, dipyridyl, imidazole, phenanthroline, alkyl or aryl phosphines, dimethyl sulfoxide, dimethyl formamide, quinuclidine, acetonitrile, benzonitrile, malonitrile, succinodinitrile, or adiponitrile.
U.S. Pat. No. 3,980,690 to Cipriani et al discloses as catalyst a complex of copper chloride and poly-4-vinylpyridine.
Rivetti et al, J. Organometallic Chem, 174 (1979) 221-226 discloses as catalysts palladium(II) complexes in the presence of ligands and added bases. Alkyl phosphines are said to inhibit carbonylation almost completely. The presence of tertiary amines enhances the formation of dimethyl carbonate. Low yields (6% or less) of dimethyl carbonate are obtained with Pd(OAc) 2 in the presence of ligands such as R 3 P where R is p--C 6 H 4 OCH 3 . Yield is increased to 61% in the presence of base such as diisopropylethylamine.
U.S. Pat. No. 3,952,045 to Gaenzler et al discloses as catalysts organic phosphorus compounds such as phosphine oxide, phosphite, phosphate, or phosphonate plus copper halides.
U.S. Pat. No. 4,360,477 to Hallgren et al discloses as catalysts cupric halides inter alia.
Yang et al CA 86, 171868u (1977) discloses as catalysts PdCl 2 , CuCl 2 , MnCl 2 , and LiCl.
Lapidus et al CA 93, 72328j (1980) discloses as catalysts MnCl 2 , KMnO 4 , CuCl 2 , LiCl, and Mn(OAc) 3 .
Itatani, Japanese patent publication 54-24827 pub 24 Feb. 1979 discloses as catalysts cuprous halides plus as auxiliary catalyst a halide of an alkali metal or an alkaline earth metal.
U.S. Pat. No. 4,370,275 to Stammann et al discloses as catalysts compositions containing copper, chemically bonded oxygen, and halogen and a nitrogen base. A typical catalyst contains CuO or Cu(OCl) 2 and n-butylamine inter alia. Preferred combinations include: CuCO 3 , Cu(OH) 2 ; CuCl 2 and pyridine hydrochloride etc.
U.S. Pat. No. 4,131,521 to Cipris et al discloses an electrochemical process utilizing a non-fluoride halide-containing electrolyte.
U.S. Pat. No. 4,113,762 to Gaenzler et al discloses as catalysts complexes of copper (as CuCl) with VCl 3 , CrCl 3 , FeCl 3 , CoCl 2 , AlCl 3 or SiCl 4 .
U.S. Pat. No. 4,361,519 to Hallgren discloses as catalysts (i) Bronsted bases such as a quaternary ammonium, phosphonium, or sulfonium compound or an alkoxide or hydroxide of alkali metal or alkaline earth metal or a salt of a strong base and a weak acid or amines etc. plus (ii) a Group VIIIB element Ru, Rh, Pd, Os, Ir, or Pt plus (iii) oxygen plus (IV) a redox catalyst such as a Mn or Co containing catalyst. A typical system includes (i) a pentamethylpiperidine, (ii) PdBr 2 and (iii) pyridine adduct of salicylaldehyde-ethylene diamine Co(II) complex.
European Pat. No. 0,071,286 to Drent discoses as catalysts copper compounds such as halide (in the presence of an amine) plus a sulfone such as dimethyl sulfone or a sulfolane.
It is an object of this invention to provide a method for preparation of dimethyl carbonate. Other objects will be apparent to those skilled in the art.
STATEMENT OF THE INVENTION
In accordance with certain of its aspects, this invention is directed to a method of preparing a carbonic acid ester (RO) 2 CO wherein R is a hydrocarbon group selected from the group consisting of alkyl, alkaryl, aralkyl, cycloalkyl, and aryl hydrocarbon groups which comprises reacting an alcohol ROH with carbon monoxide in the presence of a catalyst system containing:
(a) as catalyst a copper hydrocarbonoxy halide Cu(OR')X wherein R' is a hydrocarbon group selected from the groups consisting of alkyl, alkaryl, aralkyl, cycloalkyl, and aryl and X is halide; and
(b) as promoter MX, BX 3 , BR' 3 , B(OR') 3 , R'R 3 PX, or R'NR 3 X wherein M is a metal of Group I, IIA, IIB, IIIA, IIIB, IVB or VIII thereby forming product carbonic acid ester; and
recovering said product carbonic acid ester.
In accordance with certain of its other aspects, this invention is directed to a novel catalyst system containing
(a) as catalyst a copper hydrocarbonoxy halide Cu(OR')X wherein R' is a hydrocarbon group selected from the group consisting of alkyl, alkaryl, aralkyl, cycloalkyl, and aryl and X is halide; and
(b) as promoter MX, BX 3 , BR' 3 , B(OR') 3 , R'R 3 PX, or R'NR 3 X wherein M is a metal of Group I, IIA, IIB, IIIA, IIIB, IVB or VIII thereby forming product carbonic acid ester; and
recovering said product carbonic acid ester.
The charge alcohol which may be employed in practice of the method of this invention may include those characterized by the formula ROH.
In the above compound, R may be a hydrocarbon group selected from the group consisting of alkyl, aralkyl, cycloalkyl, aryl, and alkaryl, including such radicals when inertly substituted. When R is alkyl, it may typically be methyl, ethyl, n-propyl, iso-propyl, n-butyl, i-butyl, sec-butyl, amyl, octyl, decyl, octadecyl, etc. When R is aralkyl, it may typically be benzyl, beta-phenylethyl, etc. When R is cycloalkyl, it may typically be cylohexyl, cycloheptyl, cyclooctyl, 2-methylcycloheptyl, 3-butylcyclohexyl, 3-methylcyclohexyl, etc. When R is aryl, it may typically be phenyl, naphthyl, etc. When R is alkaryl, it may typically be tolyl, xylyl, etc. R may be inertly substituted i.e. it may bear a non-reactive substituent such as alkyl, aryl, cycloalkyl, ether, etc. Typically inertly substituted R groups may include 2-ethoxyethyl, carboethoxymethyl, 4-methyl cyclohexyl, etc. The preferred R groups may be lower alkyl, i.e. C 1 -C 10 alkyl, groups including eg methyl, ethyl, n-propyl, i-propyl, butyls, amyls, hexyls, octyls, decyls, etc. R may preferably be methyl.
The charge alcohol may be a phenol i.e. when R is aryl. The notation ROH is intended to include polyols such as ethylene glycol, glycerine, sorbitol, poly(oxyalkylene) polyols, etc; in these latter compounds, the formula may more typically be represented as R(OH) n wherein R is derived from an alkyl group and n is an integer, typically 2-10.
Typical charge alcohols which may be employed include:
TABLE I
methanol
ethanol
n-propanol
i-propanol
benzyl alcohol
phenol
ethylene glycol
glycerine
sorbitol
poly (oxyethylene-10) glycol etc.
Preferred are the lower (C 1 -C 3 ) alkanols; and most preferred is methanol.
The carbon monoxide charge which may be employed may be a pure gas. More commonly it may be a synthesis gas of high purity from which most of the hydrogen and carbon dioxide have been removed.
The catalyst system of this invention may contain
(a) as catalyst a copper hydrocarbonoxy halide Cu(OR')X wherein R' is a hydrocarbon group selected from the group consisting of alkyl, alkaryl, aralkyl, cycloalkyl, and aryl and X is halide; and
(b) as promoter MX n , BX 3 , BR' 3 , B(OR') 3 , R'R 3 PX, or R'NR 3 X wherein M is a metal of valence n of Group I, IIA, IIB, IIIA, IIIB, IVB, or VIII thereby forming product carbonic acid ester; and
recovering said product carbonic acid ester.
In the copper hydrocarbonoxy halide Cu(OR')X, X is fluorine, chlorine, bromine, or iodine. Preferably X is chlorine or bromine and more preferably chlorine.
R' may be selected from the same group as R; and preferably R' is lower alkyl i.e. C 1 -C 10 alkyl. Preferably R' is methyl. Typical compounds may include: ##STR1##
The promoter may be BX 3 , BR' 3 , or B(OR') 3 . It may for example be BF 3 as a BF 3 -etherate, preferably with diethyl ether i.e. BF 3 (C 2 H 5 ) 2 O. Other etherates with dimethyl ether, di-n-propyl ether, tetrahydrofuran, dioxane, etc. may be employed. BF 3 without any ether is more preferred. The promoter may be BR 3 typified by triphenyl boron or B(OR) 3 typified by B(OCH 3 ) 3 .
The promoter may be MX n wherein n is the valence of M. M is a metal of Group IA (Li, K, etc), Group IIA (Be, Mg, Ca, Sr, Ba), Group IIB (Zn, Cd, Hg), Group IIIA (B, Al, etc), Group IIIB (Sc, Y, La etc), Group IVB (Ti, Zr, etc), or Group VIII (Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt). When the metal is a Group VIII metal, it is preferably other than Fe, Co, or Ni. The preferred metals are those of Group IIA, preferably magnesium Mg or calcium Ca. The preferred MX n may be CaCl 2 . It should be noted that although M may be sodium, the results attained in terms of yield are much less satisfactory than attained eg, with calcium. When M is potassium, the initial yield is also low, but it increases if the catalyst and promoter are recycled. Others which may be employed include LiCl, MgCl 2 , KCl, PdCl 2 , etc.
The promoter may be a quaternary phosphonium salt R"R 3 PX typified by the following:
TABLE III
(C 6 H 5 CH 2 )P(C 6 H 5 ) 3 Cl
(C 4 H 9 ) 4 PBr
(CH 3 (CH 2 ) 15 )P(C 4 H 9 ) 3 Br
Preferred of these are the first two listed.
The promoter may be a quaternary ammonium halide R"NR 3 X typified by the following:
TABLE IV
(C 6 H 5 CH 2 )N(C 2 H 5 ) 3 Cl
(CH 3 ) 4 NBr
CH 3 (CH 2 ) 17 (C 6 H 5 CH 2 )N(CH 3 ) 2 Cl
(CH 3 (CH 2 ) 15 (C 6 H 5 CH 2 )N(CH 3 ) 2 Cl
(CH 3 (CH 2 ) 15 )N(C 4 H 9 ) 3 Br
The first listed is preferred.
It is a thus feature of the method of this invention that the catalyst may be ##STR2## and the promoter may be MX, BX 3 , BR' 3 , B(OR') 3 , R'R 3 PX, or R'NR 3 X. Illustrative of specific catalyst systems may be the following:
TABLE V______________________________________Catalyst Promoter______________________________________Cu(OMe)Cl LiClCu(OMe)Cl MgCl.sub.2Cu(OMe)Cl KClCu(OMe)Cl CaCl.sub.2Cu(OMe)Cl BF.sub.3Cu(OMe)Cl (C.sub.6 H.sub.5 CH.sub.2)P(C.sub.6 H.sub.5).sub.3 ClCu(OME)Cl (C.sub.4 H.sub.9).sub.4 PBrCu(OMe)Cl (Me).sub.4 NBrCu(OMe)Cl (C.sub.6 H.sub.5 CH.sub.2)N(C.sub.2 H.sub.5).sub.3 Cl______________________________________
It may be possible to prepare the catalyst system in situ. For example, in one embodiment, there may be added to the reaction mixture, CuCl 2 and Mg(OMe) 2 which react to give the catalyst system including Cu(OMe)Cl catalyst and MgCl 2 promoter.
Although Cu(II) compounds appear to be preferred, it may be possible to utilize systems containing Cu(I) typified by Cu 2 Cl 2 plus Cu(OMe)Cl or Cu(OCH 3 ) 2 ; i.e. systems in which the functioning catalyst system may be a mixed-valent Cu(I and II).
The preferred catalyst system may be those containing Cu(OMe)Cl and (C 6 H 5 CH 2 )N(C 2 H 5 ) 3 Cl; Cu(OMe)Cl and MgCl 2 or CaCl 2 ; Cu(OMe)Cl and BF 3 ; and Cu(OMe)Cl, (C 6 H 5 CH 2 )N(C 2 H 5 ) 3 Cl, and CaCl 2 or BF 3 .
It should be noted that the promoter may be present in the catalyst system in amount of 0.01-5 moles, preferably 0.5-2 moles, say 1 mole per mole of catalyst.
The catalyst system may be present in the reaction mixture in amount of 0.01-50 parts, preferably 0.01-20 parts, say 10 parts per 100 parts of charge alcohol.
Practice of the method of this invention may be carried out by adding 100 parts of the alcohol ROH, preferably methanol to the reaction mixture. The catalyst system may then be added. The system is then subjected to inert gas typically nitrogen at a partial pressure of 5-1000 psi, preferably 100-300 psi, say 100 psi and heated to 20° C.-170° C., preferably 80°-120° C., say 90° C. at a total pressure of 10-2000 psi, preferably 150-600 psi, say 150 psi over 0.25-2 hours, say 0.5 hour.
Carbon monoxide-containing gas is then admitted to a carbon monoxide partial pressure of 5-3000 psi, preferably 100-900 psi, say 350 psi over 0.25-10 hours, say 1 hour.
During this period, the following reaction occurs in the preferred embodiment:
2Cu(OMe)Cl+CO→(MeO).sub.2 CO+2CuCl.
At the end of this time, the reaction mixture may be rapidly cooled to 20° C.-90° C., say 25° C. at total pressure of 15-3000 psi, say 350 psi.
The reaction mixture may be distilled to azeotropically distill off product typically dimethyl carbonate and methanol. This product may be withdrawn as is or further treated to effect greater purification of the dimethyl carbonate.
The residual catalyst system (0.1-50 parts, say 10 parts) may be regenerated as by contacting with oxygen-containing gas, typically air at 20° C.-65° C., say 45° C. for 1-50 hours, say 6 hours in the presence of excess alcohol-typically methanol in amounts of 100 parts.
During this regeneration step, the following reaction occurs in the preferred embodiment: ##STR3##
At the end of the regeneration period the catalyst in methanol may be recycled if the water content is less than about 5 wt.%. If more water than this is present, the catalyst may be separated and then dried by heating to 30° C.-60° C., say 40° C. (under reduced pressure) for 1-10 hours, say 6 hours to yield a substantially anhydrous catalyst system which is recycled using anhydrous methanol.
Product, typically dimethyl carbonate, is recovered in yield (which varies depending on the catayst system) of 60% or more; and with the preferred catalyst systems, yields of 95%-100% may be attained. Dimethyl carbonate may be used as a solvent, a gasoline extender and octane enhancer and as a reactant in place of phosgene in the preparation of isocyanates, polycarbonates, and various agricultural and pharmaceutical intermediates.
Practice of the method of this invention will be apparent to those skilled in the art from the following wherein as elsewhere in this specification, all parts are parts by weight unless otherwise noted.
DESCRIPTION OF PREFERRED EMBODIMENTS
Example I
In this example which represents the best mode known of practicing the method of this invention, there is added to the reaction vessel 190 ml of anhydrous methanol and 18.2 g (0.14 mol) of anhydrous Cu(OMe)Cl and 16 g of anhydrous benzyltriethylammonium chloride promoter (C 6 H 5 CH 2 )N(C 2 H 5 ) 3 Cl.
The reaction mixture is pressurized to 100 psig with nitrogen, heated to 90° C. and maintained at 90° C. for 0.5 hour. The pressure is increased to 500 psig with carbon monoxide and stirring is continued for 0.5 hour. The reaction mixture is then cooled to room temperature, and depressurized. The reaction mixture is distilled with added methanol (200 ml) to recover azeotrope containing methanol and dimethyl carbonate. Analysis by Gas Chromatography indicates a yield (based on copper salt) of 101%.
Yield of dimethyl carbonate is determined (by gas chromotographic analyses using 3-pentanone as internal standard) based on copper salt added and 100% dimethyl carbonate selectivity.
Methanol is added (100 ml) and the catalyst is regenerated by bubbling air through the suspension at 45° C. for 6 hours.
In each of Examples II-X, the conditions of Example I are followed except that the promoter is different.
In Example II, no promoter is present. In Examples II, and IV-VII, after the initial run, the catalyst is regenerated by contact with air for 6 hours at 45° C. in the presence of excess methanol. In each case, the catalyst is Cu(OMe)Cl 18.2 g (0.14 mol). (Numbers in parentheses represent the yield which is attained in a subsequent run in which the catalyst used has been regenerated, the reaction conditions being otherwise the same).
TABLE VI______________________________________Example Promoter Moles % Yield______________________________________II -- 19 (22)III PdCl.sub.2 0.0014 22IV KCl 0.07 17 (28)V CaCl.sub.2 0.07 58 (67)VI CaCl.sub.2 0.0175 29 (47)VII BF.sub.3.Et.sub.2 O 0.07 51 (64)VIII C.sub.6 H.sub.5 CH.sub.2 P(C.sub.6 H.sub.5).sub.3 Cl 0.07 59IX (C.sub.4 H.sub.9).sub.4 PBr 0.07 69X (CH.sub.3).sub.4 NBr 0.07 64______________________________________
A further series of runs was carried out in excess methanol at 90° C. and 400 psig CO (initial pressure at 20° C.) for 50 minutes using Cu(OMe)Cl as catalyst 37 g (0.285 mol):
TABLE VII______________________________________Example Promoter Moles % Yield______________________________________XI -- 25XII LiCl 0.14 72XIII MgCl.sub.2 0.14 79XIV KCl 0.14 92XV CaCl.sub.2 0.14 95______________________________________
It will be noted (cf Example IV and XIV) that when potassium chloride is employed, the yield may be increased from 17% up to 92% by increasing the time of reaction from 30 minutes (Example IV) to 50 minutes (Example XIV). It should be noted that the reaction conditions for these two examples are different (Example IV: 500 psig with 70%CO-30%N 2 , measured at 90° C. and Example XIV: 400 psig with 100% CO, measured at 20° C.)
Another series of runs was carried out in excess methanol at 400 psig CO (initial pressure at 20° C.) and 90° C. for 4 hours.
TABLE VIII______________________________________Example Copper Salt Moles Promoter Moles % Yield______________________________________XV -- -- Mg(OMe).sub.2 0XVII CuCl.sub.2 0.2 Mg(OMe).sub.2 0.2 60XVIII CuCl.sub.2 0.4 Mg(OMe).sub.2 0.2 93XIX Cu(OMe)Cl 0.28 -- 76XX Cu(OMe)Cl 0.28 MgCl.sub.2 0.14 99______________________________________
From the above Tables, the following conclusions may be noted inter alia:
(i) Highest yields of dimethyl carbonate are obtained when the catalyst is Cu(OMe)Cl and the promoter is benzyltriethylammonium chloride (Ex. I) or MgCl 2 (Ex. XX) or CaCl 2 (Ex. XV).
(ii) Good yields may be attained with the catalyst systems of this invention.
(iii) High yields may be attained when the catalyst system is generated in situ (Ex. XVIII) from CuCl 2 and Mg(OMe) 2 .
(iv) Generally the use of regenerated catalyst (Ex. II and IV-VII) gives yields which are improved by a substantial factor over the use of the same catalyst in the initial run.
(v) A comparison of Examples XIX and XX indicates that the yield may be increased substantially (99%/76% or 1.3 times) by use of the system of this invention.
(vi) Comparison of Examples XVII and XVIII shows that use of increased quantities of CuCl 2 gives increased yields.
It will be apparent to those skilled in the art that the process of this invention makes it possible to obtain higher yields of dimethyl carbonate in shorter times i.e. to increase the rate of formation of desired dimethyl carbonate. Thus in Example XX, it is shown to be possible to attain 99% yield in 4 hours using MgCl 2 as promoter. Example XIII shows that it is possible to attain 79% yield after 50 minutes.
If CaCl 2 is used as promoter (Example XV), a yield of 95% is attained after 50 minutes. Thus CaCl 2 is preferred (on a basis of yield in given time) to MgCl 2 .
Generally it is possible to attain higher yield by running the reaction for a longer time or by using regenerated and recycled catalyst.
In a further series of runs, the procedure of Example I is duplicated (except that the time of reaction is only 15 minutes) with different promoters:
TABLE IX______________________________________Example Promoter Moles % Yield______________________________________XXI (C.sub.6 H.sub.5 CH.sub.2)N(C.sub.2 H.sub.5).sub.3 Cl 0.07 14XXII BF.sub.3 plus 0.035 (C.sub.6 H.sub.5 CH.sub.2)N(C.sub.2 H.sub.5).sub.3 Cl 0.035 71 1:1 mole ratioXXIII CaCl.sub.2 plus 0.035 68 (C.sub.6 H.sub.5 CH.sub.2)N(C.sub.2 H.sub.5).sub.3 Cl 0.035 1:1 mole ratio______________________________________
Although this invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made which clearly fall within the scope of this invention.
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An organic carbonate such as dimethyl carbonate is prepared by reacting an alcohol such as methanol, oxygen, and carbon monoxide in the presence of a catalyst system containing Cu(OMe)Cl as catalyst and boron trifluoride, calcium chloride, benzyltriethylammonium chloride, etc. as promoters.
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BACKGROUND OF THE INVENTION
This invention relates to an echographic suction cannula and, more specifically, to an improved medical device for liposuction.
Liposuction is a medical procedure for the aspiration and evacuation of fat from under the skin, and is performed by applying a negative pressure to a cannula, or a plain suction tube, which is moved under the skin surface through a small incision. With the devices currently available for liposuction, pinching of the skin is the only method of estimating the effect of liposuction during treatment on the thickness of fat remaining under the skin. Prior art suction cannulas for liposuction do not provide any means for precisely and continuously monitor the thickness of the remaining tissue during treatment, and the position of such cannulas within the tissue being treated can be estimated only by palpation. Consequently, surface irregularities and asymmetry were not uncommon, spoiling a large proportion of aesthetic results. This has also led to cannula malpositioning. A cannula, positioned too close to the dermis or to the muscle fascia, may cause surface dimples and furrows. If false passages are made into the deeper vital structure such as intra-abdominal organs, the consequence of cannula malpositioning can be serious enough to be life-threatening.
Tissue thickness can be measured and displayed by current medical imaging techniques, such as ultrasonography, xeroradiography or magnetic resonance imaging, but their use during liposuction would require interruptions of the operation, and contaminated heavy equipment would have to be brought to the sterile field. Moreover, the equipment would have to be retrieved before the operation can be resumed, and this would have to be repeated any number of times during an operation. As a result, such currently available imaging techniques are seldom used during liposuction and are primarily reserved for pre-operative and post-operative evaluations.
It is therefore a general object of the present invention in view of the above to provide a suction cannula which can make liposuction a safer procedure and to thereby make it possible to obtain a larger proportion of pleasant aesthetic results.
It is a more specific object of the present invention to provide a suction cannula for liposuction which will, when connected to an appropriate electronic circuitry, allow continuous, precise monitoring, visual display and recording of the thickness of fatty tissue.
It is another object of the present invention to provide such a suction cannula which also allows display and recording of the position of the cannula within the thickness of the tissue being treated.
SUMMARY OF THE INVENTION
A suction cannula, with which the above and other objects can be accomplished, may be characterized as having a handle and a suction tube longitudinally extending therefrom and containing near its tip an ultrasonic transducer. The transducer is partially exposed through a side window so as to be able not only to transmit ultrasonic pulse signals therethrough but also to receive their echoes. The suction tube is provided with suction openings through which fatty tissues are introduced into the tube to be evacuated, the window for the transducer being situated between the tip and these suction openings. A coaxial cable which connects the transducer to an external circuit passes substantially parallel to a central passage for the fatty tissues to be evacuated but within the outer casing of the suction tube so as not to obstruct the flow inside the central passage. The handle has a thumb grip indicative of the angular position of the transducer window with respect to the longitudinal axis of the suction pipe. The position of the cannula within the tissue being treated can be determined by analyzing the time delay between the electric pulse delivered to the transducer and that from the transducer in response to a received echo. The user can have this information displayed as a simultaneous and continuous image during a liposuction treatment.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is a perspective view of an echographic suction cannula embodying the present invention;
FIG. 2 is an exploded view of the tip part of the cannula of FIG. 1;
FIG. 3 is a sectional side view of the ultrasonic transducer within the tip part of FIG. 2; and
FIG. 4 is a side sectional view of the handle part of the cannula of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, an echographic suction cannula 10 according to the present invention may be made of a stainless steel, plastic or carbon material, and consists essentially of a handle 20 at its proximal (to the user's hand) end and a hollow suction tube 30 extending forward from the handle 20. The suction tube 30 has a bluntly rounded tip 32 at its forward end distal from the handle 20, its outer casing 36 having one or more suction openings 34 (only one such opening being visible in FIG. 1) on its side surface near the cannula tip 32. An ultrasonic transducer assembly 40 is contained within the suction tube 30 between the cannula tip 32 and the suction opening 34, partially exposed through a window 38 in the casing 36 such that a 3° signal aperture is provided. The assembly 40 is connected to an external electric pulse generating and processing circuit (not shown) through a coaxial cable 50 which runs longitudinally through the outer casing 36 of the suction tube 30, as more clearly shown in FIG. 2, and exits at the base of the handle 20, as shown in FIG. 1. The handle 20 is provided with a thumb grip 22 at the same angular location as the window 38 for the transducer assembly 40 around the longitudinal axis of the suction tube 30. The handle 20 is also provided at its back with a tubing grip 24 around the backward extension of the suction tube 30 for making connection to a tubing attached to an vacuum chamber (not shown) serving as a source of negative pressure.
With reference next to FIG. 2, which shows more in detail the arrangement of the ultrasonic transducer assembly 40 within the suction tube 30, the ultrasonic transducer assembly 40 is situated very close to the suction openings 34. As shown in FIG. 3, the transducer assembly 40 includes a piezoelectric element 41 connected to a live wire 52 within the coaxial cable 50. Ground terminals 42 are provided both on the outer surface of the piezoelectric element 41 and within the transducer assembly 40, both connected to the coaxial cable 50. The piezoelectric element 41 is supported by a vibration-buffering backing block 43, which is itself surrounded by an acoustic insulator 44 and a plastic case 45.
With reference next to FIG. 4, there is a central passage 26 through the suction tube 30 and the handle 20 for transporting separated fatty tissues from the suction openings 34 backward towards the back end of the handle 14. A narrower longitudinal passage 28, containing the coaxial cable 50 therein runs substantially parallel to the central passage 26, moving away therefrom as shown in FIG. 6 near the backward end of the handle 20.
When use is made of an echographic suction cannula 10 thus structured, an incision is made and the cannula tip 32 is guided through the skin into the layer of fatty tissues below. Since the tip 32 is rounded and blunt, the cannula 10 can be inserted in a non-traumatic manner. With a negative pressure applied through the central passage 26, fat is aspirated through the suction openings 34 into the central passage 26 and evacuated outside when tubing (not shown) is secured over the tubing grip 24 and connected to an external vacuum chamber (not shown) as explained above. The relative positions of the suction openings 34 and the tip 32, as well as the path of the coaxial cable 50 within the outer casing 36, provide unobstructed evacuation of the fat.
Sonar depth measurement by the echographic suction cannula 10 as described above is achieved according to the present invention by connecting the external end of the coaxial cable 50 to an external circuit (not shown) for generating and processing electric pulse signals. A first electric pulse of very short duration (say, no more than 100 nanoseconds) is delivered to the piezoelectric element 41, thereby causing a short bout of ultrasonic vibrations to be produced and propagated to the fatty tissue through the transducer window 38 providing 3° signal aperture. These ultrasonic waves travel through fatty tissues with the speed of 1460 m/sec and are reflected at the interface between echolucent fat and echogenic dermis and muscle fascia, returning and stimulating the exposed piezoelectric element 41. Thereupon, the piezoelectric element 41 produces an electric pulse signal, which is received through the coaxial cable 50, filtered and amplified by the external pulse-processing circuit.
The time lapse between the initial delivery of the pulse to the piezoelectric element 41 and the receipt of echo thereby is indicative of the tissue thickness at the position of the transducer, and this information can be displayed on a computer video screen or the like in a known manner. Since fatty tissues susceptible to liposuction treatment almost never exceeds 0.5 meters, the elapsed time almost never exceeds 1 millisecond. This means that such pulses can be delivered to the piezoelectric element 41 at a sufficiently high rate so as to provide a seemingly continuous sequence of image without the fear of interference between pulses.
With reference back to FIG. 3, the backing block 43 surrounded by the acoustic insulator 44 serves to prevent the vibrations of the piezoelectric elements 41 from causing the so-called ringing phenomenon The thumb grip 22 is on the handle 20 so as to point in the same direction as the propagation of the ultrasonic waves. Thus, by rotating the cannula 10 around its longitudinal axis, the ultrasonic waves can be directed selectably towards the superficial plane, dermis or muscle fascia by using the thumb grip 22 as visual pointer. As a practical procedure, the user may first position the tip 32 just above the muscle fascia under visual control by using the video screen, with the thumb grip 22 directed towards the depth to keep monitoring the distance to the muscle fascia. Next, the thumb grip 22 is rotated towards the surface and liposuction is carried out in that plane while the total thickness of the fatty tissues is being displayed with the cannula 10 remaining in the same position.
The invention has been described above by way of only one typical example, but this example is intended to be illustrative, not as limiting the scope of the invention. In fact, many modifications and variations are possible within the scope of the invention. For example, both the number and the shape of the suction openings 34 may be varied. The thumb grip 22 is not an indispensable component on the handle 20. It can be replaced by another surface marking or means for pointing the direction of the transducer window 38. The dimensions of the cannula 10 itself can be varied. Availability of cannulas 10 with different diameters and lengths is definitely advantageous. Smaller ones, say, with a diameter of 1.5 mm, will need a smaller ultrasonic transducer with higher frequencies up to 20 Mhz and hence shorter wave penetration, and may be suited for working just below the level of the surface of the skin. Larger ones, say, with cannula diameter of up to 10 mm or more, may have larger transducers of low frequencies of 4 Mhz or less with deeper tissue penetration and are suited for work in the depth of a thick fatty tissue layer. The piezoelectric element 41 may be provided with an acoustic lens for focusing, or may be left unfocused as in the case of the example illustrated wherein.
The external electric circuit, to which the cannula 10 of the present invention is to be connected, may be for purposes other than the thickness display Connection may be made, for example, to a circuit for automatic control of suction pressure or for regulating suction flow by opening and closing an external valve (not shown). The cannula 10 of the present invention may also be made compatible with currently available ultrasonographic equipment present at most hospitals.
It is also to be noted that this invention, with or without the handle 20, can be used on any fluid or body susceptible to be evacuated by suction, with the advantage of capability to monitor and measure fluid level and automatically regulate the suction flow according to the thus monitored or measured level. Thus, the number of ultrasonic transducers and coaxial cables within the cannula 10 may vary so as to enable continuous and simultaneous monitoring and measurements of distances in different directions. In summary, all such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of the invention.
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An echographic suction cannula has an elongated suction tube with a closed front end and an open back end. Side openings are also provided for admitting therethrough material to be evacuated and discharged. An ultrasonic transducer is encased within the suction tube and partially exposed so as to be able to transmit and receive ultrasonic waves. An electrical cable extending longitudinally within the outer casing of the suction tube connects the transducer to an external circuit for controlling the operation of the transducer, causing pulse signals to be transmitted, receiving reflected signals and calculating the thickness of the layer of fatty tissues into which the front end of the cannula has been inserted.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provisional patent application No. 60/959,960 filed on Jul. 17, 2007, the disclosure of which is incorporated herewith in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to wound closure devices and more particularly to wound closure devices having biocidal properties.
BACKGROUND
[0003] It has long been understood that any breach of the skin offers an opportunity for the entry of microbes into a body, and a consequent risk of infection. Consequently, for as long as the germ theory of disease has been accepted, first-aid givers and other medical practitioners have attempted to avoid the introduction of contaminants into a wound, and to ameliorate the effects of wound contamination. These efforts have included the application of topical cleansers, antiseptics, and antibiotics to wounds, and to surrounding skin, the localized injection of antimicrobial agents including antibiotics, and the systemic application of medicines, again including antibiotics. In addition, efforts have been made to provide sterile wound dressings and ancillary materials, as well as sterile instruments, and clothing, including sterile gloves.
[0004] Despite this effort, the contamination of wounds with biological agents remains a persistent and important problem. An important subset of this contamination problem surrounds the use of wound closure devices. When the skin is breached, either intentionally by a surgical incision, or unintentionally, as in the case of trauma, it is often necessary to use mechanical closures to close the breach. Often, these mechanical closures include sutures, ligatures, and/or surgical staples. Generally speaking, these mechanical closures operate by piercing skin and flesh adjacent to a wound or incision and applying tensile forces to pull or retain opposite edges of the wound into proximity with one another.
[0005] The process of piercing the skin and flesh to apply a mechanical closure offers a further opportunity, in addition to the wound itself, for the introduction of pathogens and other biological agents into the body of the patient. Consequently, an effort to close a wound, and thereby aid healing and exclude biological agents, may result in the contrary effect of introducing adverse biological agents. As noted above, previous efforts to avoid such contamination have included the application of antiseptic materials adjacent to a wound prior to the installation of sutures or other closures, the pre-sterilization of closure devices, and the prophylactic and remedial administration of antibiotic substances. Nevertheless, and in spite of long and concerted efforts to solve these problems, the problem of contamination of mechanical wound closure sites, and consequent infection, persists.
SUMMARY
[0006] Being aware of the long, and previously incompletely effective efforts of others to address these problems, the present inventors have arrived at a new understanding of the problem of infection related to wound closure mechanisms, and have conceived, and do here present, novel and effective solutions to these problems. In particular, it is understood that earlier efforts to sterilize the skin surrounding a wound have been inconsistently effective. This is true in a substantially sterile surgical environment, and even more true in the application of emergent medicine (i.e., first aid) to, for example, trauma victims.
[0007] The inventors have developed an important understanding that, particularly in military combat environments, where trauma is often severe and where treatment time may be constrained by ongoing fighting, it is very difficult to achieve sufficiently sterile skin conditions to avoid the introduction of infective agents through the skin during application of wound closure mechanisms (e.g., suturing).
[0008] Having developed this fundamental understanding, the inventors have created and developed wound closure mechanisms including biocidal agents adapted to suppress or destroy the activity of pathogens which are necessarily introduced into a patient's body during application of the wound closure mechanisms. Therefore, the present specification and claims disclose novel wound closure mechanisms including surgical ligatures, sutures and staples, including biocidal materials incorporated therewithin and thereupon. In various embodiments, the invention includes a suture having a metallic silver coating deposited on an external surface thereof. In certain embodiments, this silver surface coating extends inwardly of the surface into a region proximate to the surface, up to and including throughout the bulk of the material.
[0009] These and other advantages and features of the invention will be more readily understood in relation to the following detailed description of the invention, which is provided in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a wound closure device configured as a suture according to principles of the invention;
[0011] FIGS. 2A-2G show various profiles of longitudinal portions according to principles of the invention;
[0012] FIG. 3 shows a manufacturing fixturing arrangement according to principles of the invention;
[0013] FIG. 4 shows a wound closure device configured as a surgical staple according to principles of the invention;
[0014] FIG. 5 shows a wound closure device configured as a surgical staple according to principles of the invention;
[0015] FIG. 6 shows exemplary packaging for a wound closure device according to principles of the invention;
[0016] FIG. 7 shows exemplary packaging for a wound closure device according to principles of the invention; and
[0017] FIG. 8 shows a wound closure device applied to a wound on an arm of an exemplary patient according to principles of the invention.
DETAILED DESCRIPTION
[0018] The following description is provided to enable any person skilled in the art to make and use the disclosed inventions and sets forth the best modes presently contemplated by the inventors of carrying out their inventions. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known structures and devices are shown in schematic form in order to avoid unnecessarily obscuring the present invention.
[0019] FIG. 1 shows a first embodiment of the invention. In the first embodiment, a suture device 100 includes a substantially rigid needle portion 102 and a substantially flexible longitudinal portion 104 . The longitudinal portion 104 has a first end 106 substantially fixedly coupled to a second end 108 of the needle portion 102 . In various embodiments, the longitudinal portion includes one or more of a natural polymer material, a synthetic polymer material, and a metallic material. In certain embodiments, the natural polymer serial includes a natural silk material. In other embodiments, the synthetic polymer material includes a polyamide material, a polyaramid material, a polybutylene material; an acrylonitrile butadiene styrene (ABS) polymer material, a polypropylene material, a polyvinyl chloride material, a polyester material, or other synthetic or natural polymer material, including combinations thereof, as known in the art.
[0020] According to one embodiment of the invention, the substantially rigid needle portion 102 is disposed in an arcuate arrangement (as illustrated). In another embodiment of the invention, the needle portion 102 is disposed in a substantially linear arrangement. According to one embodiment, the needle portion 102 includes a region having a cutting profile, as is known in the art. In another embodiment, the needle portion 102 includes a non-cutting profile. According to one embodiment, the needle portion 102 includes a stainless steel material including, for example, a surgical stainless steel. According to a further embodiment of the invention, the needle portion 102 includes a substantially rigid polymer member. In various embodiments, the substantially rigid polymer member includes a polyamide material, a polyaramid material, a polybutylene material; an acrylonitrile butadiene styrene (ABS) polymer material, a polypropylene material, a polyvinyl chloride material, a polyester material, or other synthetic or natural polymer material, including combinations thereof, as known in the art.
[0021] According to certain embodiments of the invention, the polymer material includes a reinforcing material, or filler. In various embodiments, the reinforcing material includes one or more of carbon, silicon, and a metallic material. In certain embodiments of the invention, the reinforcing material includes a carbon fiber. In other embodiments of the invention, the reinforcing material includes a glass fiber material and in still other embodiments of the invention, the reinforcing material includes a metallic fiber material. In certain embodiments of the invention, the reinforcing material includes macroscopic scale fibers and/or particles. In other embodiments of the invention, the reinforcing material includes microscopic scale fibers and/or particles and in still other embodiments of the invention, the reinforcing material includes nanoscale fibers and/or particles.
[0022] In one embodiment of the invention, the substantially flexible longitudinal portion 104 includes a monofilament fiber portion. According to one embodiment, the monofilament portion has a substantially circular profile. In another embodiment of the invention, the monofilament portion has a substantially elliptical profile. In yet another embodiment of the invention, the monofilament portion has a substantially symmetrically grooved profile. In yet another embodiment of the invention, the monofilament portion has an asymmetrically grooved profile. In one embodiment, the grooved profile includes a deep groove. In another embodiment, the grooved profile includes a shallow groove. In still another embodiment, a combination of both deep and shallow grooves are present in the profile.
[0023] In one embodiment of the invention, a deep groove includes a groove having an aspect ratio of from at least about 50% to at least about 10%, where the aspect ratio divides an average width of the groove by an average depth of the groove. In another embodiment of the invention, a deep groove includes a groove having an aspect ratio of from at least about 60% to at least about 1%. In certain embodiments of the invention, a surface of the groove is substantially silverized throughout the depth of the groove. In certain embodiments, high capillary action is achieved by the presence of the deep groove with respect to intrinsic and/or externally introduced fluids.
[0024] In a further embodiment of the invention, the longitudinal portion 104 includes a multi-stranded fiber portion. In still another embodiment of the invention, the longitudinal portion 104 includes a portion incorporating a composite of microfibers, and in still another embodiment, the longitudinal portion 104 includes a plurality of surface microfibers forming a high-surface-area nap. In certain embodiments of the invention, the micro-fibers of the high surface area nap include up substantially uniformly silverized surface region.
[0025] FIGS. 2A-2G show various cross-sectional fiber or suture profiles, according to respective embodiments of the invention. For example, FIG. 2A shows a cross-section 202 of a region of a fiber having a substantially circular profile. FIG. 2B shows a cross-section 204 of a region of a fiber having a shallow-grooved profile. FIG. 2C shows a cross-section 206 of a region of a fiber having a plurality of substantially symmetrical deep grooves, including groove 208 . FIG. 2D show a cross-section 210 of a region of a fiber having substantially asymmetrical deep grooves 212 . FIG. 2E shows a cross-section 214 of a region of a fiber having a substantially stellate perimeter. FIG. 2F shows a cross-section 216 of a region of a fiber having a substantially elliptical perimeter, and FIG. 2G shows a cross-section 218 of a fiber having a substantially rectangular perimeter. In the illustrated embodiment, the substantially rectangular perimeter is shown as an exemplary substantially square perimeter.
[0026] It should be noted that, while the examples above have been discussed in relation to sutures, one of skill in the art will appreciate that, in other embodiments, the same forms, materials and principles are readily adapted for use in ligatures and other wound closing devices.
[0027] Referring again to FIG. 1 , in one embodiment of the invention, substantially flexible longitudinal portion 104 includes a polyamide material, and in another embodiment a polyaramid material. In still another embodiment, longitudinal portion 104 includes a polyester material, and in various other embodiments, longitudinal portion 104 includes natural and synthetic polymer materials such as would be known to one of skill in the art.
[0028] According to one embodiment of the invention the substantially flexible longitudinal portion is coated with a substantially biocidal material. In one embodiment, the substantially biocidal material includes a metallic silver material. In one embodiment, the metallic silver material comprises a 99.99% pure metallic silver region. In still another embodiment of the invention, the metallic silver material comprises a 99.995% pure metallic silver region. In one embodiment of the invention, the metallic silver material includes a metallic silver material having a purity in a range from about 99.99% to about 99.995% pure. According to one embodiment of the invention, the substantially biocidal material is disposed in a substantially uniform thickness about a profile of the substantially flexible longitudinal portion 104 .
[0029] According to one embodiment of the invention, a metallic biocidal material is combined with a further biocidal material such as, for example, one or more of an antibiotic material, an antiseptic material an antiviral material and a fungicidal material. The practitioner of ordinary skill in the art will understand that a wide variety of such biocidal materials can be applied in various embodiments and, for example, captured in grooves of fibers, as illustrated in FIG. 2 . For example, and without intending to provide a comprehensive, such biocidal materials include Acyclovir (Zovirax®), Amantadine (Symmetrel®), Aminoglycosides, Amoxicillin (generic), Amoxicillin/Clavulanate (Augmentin®), Amphotericin B, nonlipid (Fungizone®), Ampicillin (generic), Ampicillin/sulbactam (Unasyn®), Atovaquone (Mepron®), Azithromycin (Zithromax®), Cefazolin (generic), Cefepime (Maxipime®), Cefotaxime (Claforan®), Cefotetan (Cefotan®), Cefpodoxime (Vantin®), Ceftazidime (generic), Ceftizoxime (Cefizox®), Ceftriaxone (Rocephin®), Cefuroxime (Zinacef®), Cephalexin (generic), Chloramphenicol (generic), Clotrimazole (Mycelex®), Ciprofloxacin+(Cipro®), Clarithromycin+(Biaxin®), Clindamycin+(Cleocin®), Dapsone, Dicloxacillin (generic), Doxycycline (generic), Erythromycin lactobionate+(generic), Fluconazole+(Diflucan®), Foscamet (Foscavir®), Ganciclovir (Cytovene® DHPG), Gatifloxacin (Tequin®), Imipenem/Cilastatin (Primaxin®), Isoniazid (generic), Itraconazole+(Sporanox®), Ketoconazole+(generic), Metronidazole+, Nafcillin, Nitrofurantoin, Nystatin (generic), Penicillin G (generic), Pentamidine (generic), Piperacillin/Tazobactam (Zosyn®), Rifampin+(Rifadin®), Quinupristin-Dalfopristin (Synercid®), Ticarcillin/clavulanate (Timentin®), Trimethoprim sulfamethoxazole (generic), Valacyclovir (Valtrex®), Vancomycin (generic), and combinations thereof. In a further embodiment, any other appropriate medical or pharmaceutical agent can be disposed on the surface of the wound closure device.
[0030] According to one embodiment of the invention, a metallic silver material is deposited on the substantially flexible longitudinal portion 104 according to a deposition process described in U.S. Pat. No. 7,172,785 (hereinafter the '785 patent) issued Feb. 6, 2007 to G. Alan Thompson, et al., the disclosure of which is herewith incorporated by reference in its entirety. According to one aspect of the invention, a suture including a metallic needle is provided with a metallic coating about a longitudinal portion thereof, by immersing a region of the longitudinal portion in a fluid while maintaining the metallic needle outwardly of the fluid. According to certain embodiments of the invention, ultrasonic energy is applied to the suture during processing to facilitate a deposition of metallic silver material from the processing fluid onto an external surface of the suture. According to one embodiment of the invention, an additional chemical burnishing is applied to the longitudinal portion subsequent to application of the metallic coating.
[0031] In one embodiment of the invention, a portion of a needle is disposed within a substantially elastic medium during a deposition process according to the '785 patent, whereby the needle is appropriately fixtured while the substantially flexible longitudinal portion 104 is disposed within a processing fluid. In one embodiment of the invention, the substantially elastic medium includes a natural polymer material such as, for example, a natural rubber material. In another embodiment of the invention, the substantially elastic medium includes a synthetic polymer materials such as, for example, a neoprene material, and in one example a neoprene closed cell foam material. In another embodiment, the substantially elastic medium includes a polyethylene foam material. In still another embodiment of the invention, the substantially elastic medium includes a cellulose material such as, for example, a cork material.
[0032] FIG. 3 shows one arrangement for manufacturing a suture according to principles of the invention. As illustrated in FIG. 3 , a fixturing device 300 includes a support member 301 incorporating a material adapted to receive one or more needles 306 substantially elastically therewithin. Thus, as illustrated, a point 303 of a needle is lodged through a surface 308 and within a bulk region of support member 301 . An opposite end 310 of needle 306 is coupled to a proximate end 312 of a suture 314 . A distal end 316 of suture 314 is coupled, in one embodiment, to a weighted device 318 so that suture 314 is held in a substantially vertical orientation depending from needle 306 .
[0033] In certain embodiments of the invention, a clamp or clip mechanism is used to support the needle, rather than, or in combination with, having the tip of the needle 303 embedded in the material of the support member 301 . In another embodiment of the invention, a plurality of sutures 314 are mutually coupled at respective distal ends 316 to a common weighted device 318 . In certain embodiments, the weighted device includes a polymer material such as, or example, a polyvinyl chloride material. In still another embodiment of the invention, an extended more or less rigid member is coupled to distal end 316 of the suture, rather than extending the suture by weighting it.
[0034] In one exemplary embodiment, as noted above, the material of the support member 301 includes a cork material. Thus, in the illustrated embodiment, the fixturing device 300 includes a sheet of cork material formed into a curve about a longitudinal axis and coupled at adjacent edges 302 , 304 to form a substantially cylindrical support member.
[0035] In one embodiment of the invention, as illustrated in FIG. 3 , the support member 301 is disposed substantially buoyantly in a processing solution 330 . In another embodiment of the invention, the support member is suspended above an upper surface 332 of the processing solution. One of skill in the art will appreciate that in certain embodiments of the invention, deposition of a metallic silver material on the suture 314 is a achieved by moving the support member 301 , along with needles and sutures coupled thereto, successively from one bath of processing solution to another bath of processing solution until processing is complete.
[0036] One of skill in the art will also appreciate that, in other embodiments of the invention, a continuous processing methodology is employed to produce a silverized suture material, either in continuous runs or in precut lengths. Subsequently, the silverized suture material is coupled to needles by any of the various methods discussed below. In still other embodiments of the invention, a polymer piercing device, or needle, is coupled to the suture and is immersed in the processing fluid so that the polymer piercing device is metallized along with the suture material.
[0037] Making further reference to FIG. 1 , in various embodiments of the invention, a coupling between the first end 106 of the longitudinal portion 104 and the second end 108 of the needle 102 is effected by a swaging process. According to one embodiment, the second end 108 of the needle 102 includes an internal surface defining a longitudinal cavity. The first end 106 of the longitudinal portion 104 is disposed within the longitudinal cavity, and a portion of the needle 102 is compressed to bring the internal surface of the needle 102 into intimate contact with an external surface of the first end 106 , whereby the longitudinal portion is operatively affixed to the needle.
[0038] In another embodiment of the invention, a coupling between the needle 102 and the longitudinal portion 104 is achieved by a process of disposing a portion of the longitudinal portion within and through an eye of the needle, as is known in the art. According to one embodiments of the invention, a compression of the needle is employed to reduce a dimension of the eye and thereby retain the portion of the longitudinal portion within the eye of the needle. In still another embodiment of the invention, an adhesive is applied between the longitudinal portion and the needle to maintain a coupling between the longitudinal portion and the needle. In still another embodiment of the invention, a thermal welding process is employed to establish a coupling between the longitudinal portion 104 and the needle 102 . In yet another embodiment of the invention, an ultrasonic welding process is employed to establish a coupling between the longitudinal portion 104 and the needle 102 . In yet another embodiment of the invention, an electrochemical deposition is employed to establish a mutual metallic bond between a silverized surface of the longitudinal portion 104 and the needle 102 .
[0039] According to one embodiment of the invention, the longitudinal portion 104 includes a material that is substantially non-reactive and non-absorbable in the environment of a patient's body. Accordingly, subsequent removal of the non-absorbable suture allows a corresponding removal of the remaining metallic material disposed on and/or within the suture. An important and nonobvious benefit of this removability is that while silver ions are able to diffuse into surrounding tissue for their biocidal effect, substantially no bulk silver is left within the body of the patient after removal of the suture. This avoids the pigmentation that can be experienced in association with a deposition of bulk silver within a body, and other possible effects of the presence of remaining bulk silver.
[0040] In another embodiment of the invention, as shown in FIG. 4 , a wound closure device includes a surgical staple 400 . According to one embodiment of the invention, the surgical staple 400 includes a first needlelike penetrating portion 402 , and a second needlelike penetrating portion 404 . A longitudinal portion 406 is disposed between the first penetrating portion 402 and the second penetrating portion 404 . According to one embodiment of the invention, as illustrated, a flange portion 408 is disposed to provide rigidity to the first 402 and second 404 penetrating portions and the longitudinal portion 406 .
[0041] According to one embodiment, the staple 400 includes a stainless steel material including, for example, a surgical stainless steel. According to a further embodiment of the invention, the staple portion 400 includes a rigid polymer material. In one embodiment, the stainless steel material is substantially entirely enclosed within the polymer material. In another embodiment of the invention, the stainless steel material is disposed adjacent to a surface of the polymer material. In still other embodiments, no metallic portion is disposed within the polymer material. In various embodiments, the synthetic polymer material includes a polyamide material, a polyaramid material, a polybutylene material; an acrylonitrile butadiene styrene (ABS) polymer material, a polypropylene material, a polyvinyl chloride material, a polyester material, or other synthetic and natural polymer material, including combinations thereof, as known in the art.
[0042] According to one embodiment of the invention the staple 400 is coated with a substantially biocidal material. In one embodiment, the substantially biocidal material includes a metallic silver material. In one embodiment, the metallic silver material comprises a 99.99% pure metallic silver region. In still another embodiment of the invention, the metallic silver material comprises a 99.995% pure metallic silver region. In one embodiment of the invention, the metallic silver material includes a metallic silver material having a purity measurable in a range from about 99.99% to about 99.995%. According to one embodiment of the invention, the substantially biocidal material is disposed in a substantially uniform thickness about a profile of the staple 400 . In another embodiment of the invention, a further biocidal material is included on a surface of the staple or disposed within pores in the surface of the staple. According to certain embodiments of the invention, the further biocidal material includes one or more of an antibiotic and an antiseptic.
[0043] In one embodiment, the invention includes a stapling device adapted to deposit a portion of the staple 400 through a region of a patient's tissue adjacent to a wound, whereby the staple 400 is adapted to retain the wound in a substantially closed arrangement. According to one embodiment, the stapling device is adapted to fold the first 402 and second 404 penetrating portions with respect to the longitudinal portion 406 so as to substantially fix the staple 400 in place, with respect to the surrounding skin. In one embodiment of the invention, the stapling device is adapted to deposit a further biocidal material onto a surface of the patient's skin or flesh in a location where the staple 400 will penetrate. In certain embodiments, the deposited biocidal material is deposited in a liquid form, a gel form, a paste form, a powder form, a gaseous form, or any other form adapted to effectively reach and destroy pathological agents disposed in the region of penetration.
[0044] According to one embodiment, the stapling device includes a disposable stapling device, and the invention includes a method of providing a disposable stapling device which can be disposed of once a pre-loaded charge of staples is expended. In another embodiment of the invention, a rechargeable stapling device is provided, and in still another embodiment of the invention, a disposable stapling device is provided with a rechargeablity feature such that the stapling device may be used as either a disposable or a rechargeable stapling device.
[0045] FIG. 5 shows a further embodiment of the invention including a wound closure device 500 . According to one embodiment of the invention, the wound closure device 500 includes a staple having a bridge top 502 . The bridge top 502 has a notch 504 in an upper surface thereof. The notch 504 is sized and positioned to permit a practitioner to readily bend, cut or break the staple 504 removal after use of the staple is complete. In one method, according to principles of the invention, a removal tool is used to grasp, lift and cut or fracture the staple adjacent to the notch during staple removal. Also included in the invention is a removal device, such as a pliers device, adapted to remove the staple device. According to one embodiment of the invention, the removal pliers include a disposable removal pliers device.
[0046] According to one embodiment, the invention includes a surgical drain device. An exemplary surgical drain device includes a nonreactive synthetic material impregnated with a silver material. According to one embodiment of the invention the surgical drain device provides immediate and sustained antimicrobial action in surgical wounds requiring a drain by virtue of the antimicrobial properties of the silver material. According to one aspect of the invention, the surgical drain device can subsequently be removed, whereby substantially all bulk silver is removed from the body of the patient. According to one embodiment of the invention, the surgical drain device comprises a longitudinal portion like portion 104 of FIG. 1 , the longitudinal portion having a substantially hollow internal longitudinal region.
[0047] According to certain embodiments of the invention, a staple device, such as wound closure device 500 of FIG. 5 , is produced by injection molding according to methods known in the art. In certain embodiments of the invention, a plurality of staple devices are prepared including coupling members between the devices, so that chemical processing to provide silverization according to the methods discussed above can be substantially simultaneously performed on the plurality of staple devices. Thereafter, the plurality of staple devices can be separated from one another and the connecting members can be discarded or reprocessed and recycled.
[0048] According to one embodiment of the invention the devices described hereinabove are provided in substantially sterile packaging in single unit packages, and in multiple device packages. In one embodiment, the packaging includes a non-sterile outer shell having an easy-tear notch and an internal protective sterilized sleeve, pouch or envelope. According to one embodiment of the invention, color coding is applied to a package according to, and indicating, a presence of a biocidal material incorporated into a wound closure device disposed within the package. One exemplary multi-unit package according to the invention is shown in FIG. 6 . A further exemplary single-unit packet according to the invention is shown in FIG. 7 .
[0049] In certain embodiments of the invention, sterilization of the wound closure device is accomplished by irradiating the device with, for example, gamma radiation, or radiation of other effective wavelengths, after the wound closure device is enclosed in a sealed package. In other embodiments of the invention, the wound closure device is sterilized by chemical or thermal processing prior to packaging in a sterile package. For example in one embodiment of the invention, the wound closure device is heated in an autoclave prior to packaging.
[0050] In one embodiment of the invention, a wound closure device, according to one or more of the various embodiments described above, is adapted to be employed in the treatment of a human patient. In another embodiment of the invention, a wound closure device, according to one or more of the various embodiments described above, is adapted to be employed in the treatment of a non-human (veterinary) patient.
[0051] Without wishing to be bound to a theory of operation, it is believed that during use, bodily fluids including blood plasma contact the surface of the wound closure device. Consequently, biocidal material, such as ions of silver, are conveyed from the surface of the wound closure device to surrounding tissue, so as to impede or kill pathogens introduced, for example, by installation of the wound closure device. According to one embodiment of the invention, deep group fibers are particularly effective in bringing bodily fluids into contact with the biocidal material by capillary action. According to a further aspect of the invention, the described silverization process is particularly effective at providing silver within the deep grooves of deep-groove fibers.
[0052] While the exemplary embodiments described above have been chosen primarily from the field of emergency medicine, one of skill in the art will appreciate that the principles of the invention are equally well applied, and that the benefits of the present invention are equally well realized in a wide variety of other medical applications including, for example, elective and non-elective surgeries, as well as both human and veterinary medical applications. Further, while the invention has been described in detail in connection with the presently preferred embodiments, it should be understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.
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Disclosed is a wound closure device, such as a suture, including a substantially flexible tensile member, the tensile member having an external surface, the external surface including a biocidal material such as a coating of substantially pure silver. A method of applying the suture includes piercing a patient's skin adjacent to a wound using, for example, a needle and drawing a substantially flexible tensile member through a resulting aperture in the skin. By virtue of the biocidal material, pathogens and other bioactive materials drawn through the aperture are rendered less active and/or incapable of causing infection.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to caches. In particular, this invention relates to a cache coherency scheme for multiple caches in a multiprocessor system.
2. Description of the Related Art
With the shift of computing technology to the "network is the computer" paradigm, the need for a shared global memory address space and a coherent caching system in a networked computing system becomes increasingly important. FIG. 1A is a block diagram showing one such networked computer system 100 with a conventional non-uniform memory architecture (NUMA). System 100 includes a plurality of subsystems 110, 120, . . . 180, coupled to each other via a global interconnect 190. Each subsystem is assigned a unique network node address. Each subsystem includes one or more processors, a corresponding number of memory management units (MMUs) and caches, a main memory assigned with a portion of a global memory address space, a global interface and a local subsystem interconnect. For example, subsystem 110 includes processors 111a, 111b . . . 111i, MMUs 112a, 112b, . . . 112i, caches 113a, 113b, . . . 113i, main memory 114, global interface 115 and subsystem interconnect 119.
Data from main memories 114, 124, . . . 184 may be stored in one or more of caches 113a . . . 113i, 123a . . . 123i, and 183a . . . 183i. Thus, cache coherency among caches 113a . . . 113i, 123a . . . 123i, and 183a . . . 183i is maintained in order for system 100 to execute shared-memory programs correctly.
In order to support a conventional directory-based cache coherency scheme, subsystems 110, 120, . . . 180 also include directories 116, 126, . . . 186 coupled to global interfaces 115, 125, . . . 185, respectively. Referring now to FIG. 1B, each global interface, e.g., interface 115 includes a slave agent ("SA"), a request agent ("RA") and a directory agent ("DA"), e.g, SA 115a, RA 115b and DA 115c. Each DA is responsible for updating its associated directory with the status of all cached copies of its (home) main memory, including copies cached in other subsystems.
The status of cached copies in each node are recorded in directories 116, 126, . . . 186 as one of four states per node. An invalid ("I") state indicates that the node, i.e., subsystem, does not have a copy of the data line of interest. A shared ("S") state indicates that the node has an S copy, and that possibly other nodes may have S copies. An owned ("O") state indicates that the node has an O copy, and that possibly other nodes may have S copies. Note that the node with the O copy is required to perform a write-back upon replacement. Finally, a modified ("M") state indicates that the node is the sole owner of the data line, i.e., there are no S copies in the other nodes.
A RA provides a subsystem with a mechanism for sending read and write requests to the other subsystems. A DA provides access to and is responsible for updating its associated home directory. An SA is responsible for responding to requests from the DA of another subsystem.
Requests for data and responses are exchanged by the respective agents between subsystems 110, 120, . . . 180 in the form of data/control packets, thereby enabling subsystems to keep track of the states of their caches 113a . . . 113i, 123a . . . 123i, and 183a . . . 183i in directories 116, 126, . . . 186, respectively. These data/control packets are transported between subsystems via global interconnect 190. Unfortunately, since global interconnect 190 may be based on any one of a number of conventional networking protocols, e.g., a collision sense multiple access (CSMA) protocol, from the timing viewpoint, subsystems 110, 120, . . . 180 may be loosely coupled to each other at the network layer of the protocol. As such, while the arrival of packets end-to-end is guaranteed, the order of arrival of the packets is not necessarily guaranteed. The out-of-order arrival of packets at subsystems 110, 120, . . . 180 is problematic because they can result in "corner cases" which, if not detected and resolved, can disrupt cache coherency.
One such corner case is illustrated by FIGS. 2A-2D in which a data packet associated with an earlier-in-time read-to-share request (RTS -- req) arrives after the cache line is prematurely invalidated as a result of the arrival of a later-in-time read-to-own request (RTO -- req) initiated by another subsystem. In this example, initially, subsystem 110, subsystem 120 and a fourth subsystem (not shown in FIG. 1A) have shared ("S") copies of a data line from the memory space of subsystem 180.
Referring first to FIG. 2A, RA1 of global interface 115 of subsystem 110 sends a RTS -- req packet to DA8 of global interface 185 of subsystem 180. As shown in FIG. 2B, DA8 responds by initiating the transfer of a data packet to the requesting RA1.
Next, as shown in FIG. 2C, before the data packet arrives at RA1, RA2 of global interface 125 of subsystem 120 sends a read-to-own request (RTO -- req) packet to DA8.
FIG. 2D shows DA8 respond by initiating the transfer of a data packet to RA2. In addition, DA8 sends invalidate (Invld) packets to SA1 and SA4, the slave agents of subsystem 110 and the fourth subsystem, respectively.
Unfortunately, the later-in-time Invld packet arrives at SA1 before the earlier-in-time data packet arrives at RA1. As a result, SA1 receives the Invld packet first and proceeds to invalidate the old S copy of the data line of interest. Subsequently, RA1 receives the data packet, but is unable to update the value of its S copy because it has been erroneously and prematurely marked Invld.
Several conventional brute-force handshaking protocols for resolving corner cases do exist. FIGS. 3A-3F illustrate one prior art solution to the corner case described above. Again, using the same starting conditions as the example illustrated by FIGS. 2A-2D, subsystem 110, subsystem 120 and the fourth subsystem have S copies of a data line from the memory space of subsystem 180.
Referring first to FIG. 3A, RA1 of subsystem 110 sends a RTS -- req packet to DA8 of subsystem 180.
As shown in FIG. 3B, DA8 responds by initiating the transfer of a data packet to the requesting RA1. DA8 then idles while waiting for a read-acknowledgment (RTS -- ack) packet from RA1.
Next, as shown in FIG. 3C, RA2 sends a RTO -- req packet to DA8. However, DA8 is idle because it is waiting for a RTS -- ack packet from RA1 to arrive, and hence is unresponsive.
As shown in FIG. 3D, after receiving the RTS -- ack packet from RA1, DA8 is no longer idle and is now able to respond to the RTO -- req packet from RA2.
Accordingly, as shown in FIG. 3E, DA8 sends Invld packet(s) to any SAs of subsystems with S copies of the data line of interest. In this example, DA8 sends Invld packets to SA1 and SA4. DA8 is also responsible for sending a data packet together with the # -- Invld to RA2.
Subsequently, as shown in FIG. 3F, RA2 counts the number of incoming Invld -- ack from SA1 and SA4 thereby avoiding the corner case illustrated by FIGS. 2A-2D.
Unfortunately, the above-described brute-force hand-shaking solution for handling and/or reducing corner cases is inefficient because of the excessive number of handshaking control packets. These extra control packets substantially increase the network traffic. In other words, the "cure" for the infrequent but disastrous corner cases substantially degrade the efficiency of the network.
Hence, there is a need for a simple and streamlined cache coherency protocol which handles and/or reduces corner cases without substantially increasing network traffic. Advantages of the present invention include reduction of complicated race conditions resulting from the corner cases, ease of formal verification of the protocol due to the reduction of the race conditions, and increased reliability of the resulting cache coherent computer system.
SUMMARY OF THE INVENTION
The present invention provides an efficient streamlined cache coherent protocol for a multi-processor multi-cache computing system. Each subsystem includes at least one processor and an associated cache and directory. The subsystems are coupled to a global interconnect via global interfaces.
In one embodiment, each global interface includes a request agent (RA), a directory agent (DA) and a slave agent (SA). The RA provides a subsystem with a mechanism for sending read and write requests to the DA of another subsystem. The DA is responsible for accessing and updating its home directory. The SA is responsible for responding to requests from the DA of another subsystem.
Further, in accordance with the invention, each subsystem also includes a blocker. In this embodiment, each blocker is coupled to a DA and is associated with a home directory. All requests for a cache line are screened by the blocker associated with each home directory. Blockers are responsible for blocking new request(s) for a cache line until an outstanding request for that cache line has been serviced. Although counterintuitive, since blocking causes the new requests to be processed sequentially, a "locked" state managed by the blocker simplifies solutions by removing the few remaining comer cases.
In one embodiment, the blockers also include queues for storing pending requests. Variations and modifications to the blocker are also possible. For example, write-backs and read-to-own requests may be given priority for service over read-to-share requests.
DESCRIPTION OF THE DRAWINGS
The objects, features and advantages of the system of the present invention will be apparent from the following description in which:
FIG. 1A is a block diagram showing a networked computer system 100 with a conventional non-uniform memory architecture (NUMA).
FIG. 1B is a block diagram of the global interface of the computer system of FIG. 1A which includes a directory agent ("DA"), a request agent ("RA") and a slave agent ("SA").
FIGS. 2A-2D illustrate a corner case in which a data packet associated with an earlier-in-time read request arrives after the cache line is prematurely invalidated by a later-in-time read-to-own request.
FIGS. 3A-3F illustrate a conventional handshaking protocol for solving the corner case of FIGS. 2A-2D.
FIG. 4A is a block diagram showing an exemplary cache coherent networked computer system 400 of the present invention.
FIG. 4B is a block diagram of the global interface of the computer system of the present invention which includes a blocker, a directory agent ("DA"), a request agent ("RA") and a slave agent ("SA").
FIGS. 5A-5D illustrate an exemplary blocking of requests for the directory agent of FIG. 4B until an outstanding read-to-share (RTS) request has been serviced.
FIGS. 6A-6B and 6C-6D illustrate an exemplary blocking of requests for the directory agent of FIG. 4B until an outstanding read-to-own (RTO) request has been serviced.
FIGS. 6A-6B and 6E-6G illustrate an alternative way of blocking requests by the directory agent of FIG. 4B until an outstanding read-to-own (RTO) request has been serviced.
FIGS. 7A-7C illustrate an exemplary blocking of requests for the directory agent of FIG. 4B until an outstanding write-back (WB) request has been serviced.
NOTATIONS AND NOMENCLATURE
An invalid ("I") state indicates that a node/subsystem does not have a (cached) copy of a data line of interest.
A shared ("S") state indicates that the node/subsystem, and possibly other nodes, have a shared (cached) copy of the data line of interest.
An owned ("O") state indicates that the node/subsystem is the owner, i.e. this node has a "master copy". As such, this node must write the "master copy" to another node before the cache line can be reused. It is possible for other nodes to have a shared copy of the data line of interest.
A modified ("M") state indicates that the node/subsystem has the only (cached) copy of the data line of interest.
A blocked ("B") state indicates that a read/write request is outstanding for the data line of interest.
A request agent ("RA") provides a subsystem with a mechanism for requesting access to a cached data line of interest from another subsystem.
A directory agent ("DA") provides a subsystem with a mechanism for accessing its directory to track the status of copies of its main memory.
A slave agent ("SA") provides a subsystem with a mechanism for responding to a data request from another subsystem.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description, numerous details provide a thorough understanding of the invention. These details include functional blocks and an exemplary cache directory to assist a designer in implementing a cost-effective cache coherent computer system. In addition, while the present invention is described with reference to a specific cache coherent scheme for an exemplary multi-cache multi-processor computer system, the invention is applicable to a wide range of caches and network architectures. In other instances, well-known circuits and structures are not described in detail so as not to obscure the invention unnecessarily.
FIG. 4A is a block diagram showing an exemplary cache coherent networked computer system 400 of the present invention. System 400 includes a plurality of subsystems 410, 420, . . . 480, coupled to each other via a global interconnect 490. Each subsystem includes one or more processors, a corresponding number of memory management units (MMUs) and caches, a main memory assigned with portion of a global memory address space, a global interface and a subsystem interconnect. For example, subsystem 410 includes processors 411a, 411b . . . 411i, MMUs 412a, 412b, . . . 412i, caches 413a, 413b, . . . 413i, main memory 414, global interface 415 and subsystem interconnect 419. subsystems 410, 420, . . . 480 also include directories 416, 426, . . . 486 coupled to global interfaces 415, 425, . . . 485, respectively.
In accordance with the cache coherency scheme of the present invention, as shown in FIG. 4B, each global interface, e.g., interface 415, includes a slave agent ("SA"), a request agent ("RA"), a directory agent ("DA") and a blocker, e.g., SA 415a, RA 415b, DA 415c and blocker 415d. Thus there is a one-to-one correspondence between each DA and each directory.
Blockers, DAs, RAs and SAs can also be incorporated in circuits separate from the respective global interfaces. Each blocker is coupled to a DA and is responsible for holding pending request(s) for cache lines while outstanding request(s) are being serviced. Note that the "blocking" functionality can be provided by directories 416, 426, . . . 486 as described below or alternatively by adding dedicated blocking logic. The dedicated blocking logic is responsible for queuing outstanding transactions and storing a cache-line address for each of the outstanding transactions. Subsequently, the dedicated blocking logic compares the address of each outstanding transaction with all the old cache-line addresses before allowing transactions to pass to the corresponding DAs. In this alternative implementation, each completion signal only needs to clear its respective address.
DAs of each subsystem are responsible for updating its associated directory with the status of each cached-line sized portion of its (home) main memory. Accordingly, for each such portion of the main memory, the directory includes a status indicating which subsystem(s), if any, have cached copies of that particular portion. In this implementation, each directory is a home directory, i.e., local directory, for a subsystem. Thus, each directory includes entries for cached copies of data lines associated with the subsystem, describing the state of cached copies in all subsystems. DAs are also responsible for forwarding the appropriate request packets to the respective SAs.
FIGS. 5A-5D illustrate example I in which subsystem 410 needs read permission, i.e., a shared (S) copy, from a data line within the home address space of subsystem 480, but is "owned" by subsystem 420.
First, as shown in FIG. 5A, RA1 of global interface 415 of subsystem 410 sends a read-to-share request (RTS -- req) packet to blocker 485d of global interface 485 of subsystem 480. Blocker 485d responds by causing DA8 to enter a blocked (B) state (denoted by the "dotted" circle), thereby freezing new requests to DA8 for the data line of interest.
Next, as shown in FIG. 5B, DA8, now in the B state, marks its home directory 486 to reflect the requesting RA1's new status as a sharer, and forwards the RTS -- req packet to slave agent SA2 of global interface 425 of subsystem 420.
The blocked ("B") state indicates that there is a write/read request outstanding and subsequent request(s) for the same data line are blocked until the pending request has been serviced. In this implementation, blocker 485d, associated with DA8, blocks new requests for the data line by temporarily storing the requests in a local first-in-first-out (FIFO) queue or by flow controlling new requests.
SA2 responds to the RTS -- req packet by sending a data packet to RA1 and remains the "owner" of the data line, as shown in FIG. 5C.
Finally, as shown in FIG. 5D, upon receipt of the data packet from SA2, RA1 sends a RTS-completion (RTS -- compt) packet to blocker 485d. Blocker 485d causes DA8 to leave the B state. DA8 is now able to service any queued request for the data line of interest.
In example II illustrated by FIGS. 6A-6B and 6C-6D, subsystem 410 needs write permission, i.e., an owned (O) copy, from a data line whose home address space is in subsystem 480 but is owned by subsystem 420. In addition, a third subsystem and fourth subsystem (both not shown in FIG. 4A) have S copies of the data line.
First, as shown in FIG. 6A, RA1 sends a read-to-own request (RTO -- req) packet to DA8 via blocker 485d.
Next, as shown in FIG. 6B, blocker 485d causes DA8 to enter the B state and freezes new transactions to the cache line. DA8 marks its home directory to reflect the requester RA1's new status as the owner of the data line of interest, i.e., RA1's new status is owned (O). DA8 retrieves the number of sharers (# -- sharers), two sharers in this example, of this data line from its directory, appends the # -- sharers to the RTO -- req packet and forwards the RTO -- req packet to SA2. DA8 is also responsible for sending invalidate request (Invld -- req) packets to SA3 and SA4 of the third and fourth subsystems, respectively. The Invld -- req packets also include the identity of requesting RA1.
FIG. 6C shows SA2 responding to arrival of the RTO -- req packet by invalidating its copy of the data line, and sending a data packet to RA1 together with the total number of sharers. Upon receipt of the respective Invld -- req packets from DA8, both SA3 and SA4 send invalid acknowledgment (Invld -- ack) packets to RA1 and also invalidate their respective S copies.
Finally, as shown in FIG. 6D, after the arrival of the data packet from SA2 and after the arrival of the correct number of Invld -- ack packets, i.e., the # -- sharers, from SA3 and SA4, RA1 sends a RTO-completion (RTO -- compt) packet to blocker 485d. The RTO -- compt packet completes a "three-hop dirty reply" sequence. DA8 responds to the RTO -- compt packet by leaving the B state and by releasing the data line of interest.
Note that the protocol illustrated by example II can be simplified by sending # -- sharers together with the Invld -- req packet(s). Accordingly, whenever no data is required by RA1 of the requesting subsystem, the SA2 does not need to send a packet to RA1 for the sole purpose of sending the # -- shares to RA1. In other words, RA1 can obtain the # -- sharers from either SA3 or DA4, thereby reducing the network traffic by one packet.
An alternative example III is illustrated by FIGS. 6A-6B and 6E-6G. Starting with FIGS. 6A-6B as in example II, instead of sending Invld -- ack packets to the requesting RA1 as shown in FIG. 6C of example II, sharers SA3, SA4 send the Invld -- ack packets to the blocker of the home DA, i.e., blocker 485d of home subsystem 480, as shown in FIG. 6E. Consequently, home DA8 is responsible for counting the correct number of Invld -- ack packets and also responsible for receiving the RTO-compt packet from RA1 before leaving the B state. In this example, DA8 no longer needs to send # -- sharers to other nodes since SA3 and SA4 send Invld -- ack packets to blocker 485d instead of RA1.
Next, as shown in FIG. 6F, RA1 sends the RTO -- compt packet to blocker 485d after receiving the data packet from SA2. Blocker 485d is responsible for counting the Invld -- acks packets and recognizing the arrival of the RTO -- compt packet.
Finally, as shown in FIG. 6G, Blocker 285d sends a Completion -- acknowledge (Compt -- ack) packet to RA1 upon receipt of all expected Invld -- ack(s), in this example, from both SA3 and SA4. The Compt -- ack packet completes the "four-hop dirty reply" sequence and DA8 can now leave the B state and release the data line of interest.
FIGS. 7A-7C illustrate example IV in which a remote owner writes back to the host directory, e.g., subsystem 410 is the "owner" and sends a write-back request (WB -- req) to subsystem 420.
First, as shown in FIG. 7A, RA1 of global interface 415 of subsystem 410 sends a WB -- req packet to DA8 of global interface 485 of subsystem 480. DA8 responds by entering the B state and freezing new transactions to the cache line.
Next, as shown in FIG. 7B, DA8 marks its home directory to reflect the requester RA1's new status as invalid, and sends a write-back-permission (WB -- permit) back to RA1.
Finally, RA1 sends the data to DA8 via a write-back-complete (WB -- compt) packet which includes data to be replaced, as shown in FIG. 7C. Upon receiving the WB -- compt packet at DA8, the write-back transaction is complete and blocker 485d releases the data line of interest by leaving the B state. Note that RA1 only leaves the "O" state after RA1 has received the WB -- permit packet. Waiting for the WB -- permit packet from blocker 485d eliminates the corner case in which a subsequent read request to RA1 fails because RA1 replaced the cache line (using a write back) before the subsequent read request reaches RA1.
Various optimizations of the above described cache coherent mechanism are possible. For example, instead of a single FIFO queue for storing all outstanding read and write requests, RTO requests are stored in a separate queue and given priority for processing so that RTO requests are serviced first. Prioritizing write-back requests improves processor performance because typically processors of subsystems protect their respective critical code sections using a shared "key". A processor locks the key before executing its critical code section and releases the key upon completion. Thereafter, a second processor can lock the key to execute its critical code section. Hence, by giving RTO requests priority, the key can be released rapidly, allowing other processors to quickly gain access to the key.
In another embodiment, selective blocking is provided. For example, blocking is selectively activated when an RTS request or a write-back request is outstanding, but is deactivated when a RTO request is outstanding.
Subsystem 410, 420 . . . 480 of computer system 400 can be arranged in many configurations. For example, system 400 may be configured as a wide area network (WAN), such as the internet, a local area network (LAN) or a tightly coupled multiprocessor system.
Other modifications and additions are possible without departing from the spirit of the invention. For example, instead of blocking all read and write requests arriving at the DA, RTO requests whenever a request is outstanding, read-to-share requests are blocked only if there is a read-to-own or a write-back request outstanding. In addition, each subsystem may be equipped with additional circuitry to perform "local data forwarding" so that processors within a subsystem can provide data to each other without accessing the host directory of another subsystem. Hence, the scope of the invention should be determined by the following claims.
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An efficient streamlined coherent protocol for a multi-processor multi-cache computing system. Each subsystem includes at least one processor and an associated cache and directory. The subsystems are coupled to a global interconnect via global interfaces. In one embodiment, each global interface includes a request agent (RA), a directory agent (DA) and a slave agent (SA). The RA provides a subsystem with a mechanism for sending read and write request to the DA of another subsystem. The DA is responsible for accessing and updating its home directory. The SA is responsible for responding to requests from the DA of another subsystem. Each subsystem also includes a blocker coupled to a DA and associated with a home directory. All requests for a cache line are screened by the blocker associated with each home directory. Blockers are responsible for blocking new request(s) for a cache line until an outstanding request for that cache line has been serviced. A "locked" state managed by the blocker greatly reduces corner cases and simplifies solutions in the few remaining corner cases.
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PRIORITY
This application claims priority under 35 U.S.C. §119(a) to a Korean Patent Application filed in the Korean Intellectual Property Office on Jun. 22, 2006 and assigned Serial No. 2006-56417, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for maintaining uplink timing synchronization (sync) in an Orthogonal Frequency Division Multiplexing (OFDM) system and a User Equipment (UE) apparatus for the same.
2. Description of the Related Art
The mobile communication scheme can be classified into Time Division Multiplexing (TDM), Code Division Multiplexing (CDM) and Orthogonal Frequency Multiplexing (OFM) schemes according to a multiplexing method. The CDM scheme is most popularly used in the current mobile communication system, and can be subdivided into a synchronous and an asynchronous CDM scheme. Since the CDM scheme basically uses codes, it tends to suffer from a lack of resources due to a limit of orthogonal code resources. Accordingly, an OFDM scheme has emerged as an alternative to the CDM scheme.
The OFDM scheme is for transmitting data using multiple carriers, and is a type of Multi-Carrier Modulation (MCM) scheme that converts a serial input symbol stream into parallel streams, and modulates each of the parallel streams with a plurality of orthogonal sub-carriers, i.e. sub-carrier channels, before transmission. The OFDM scheme is similar to the conventional Frequency Division Multiplexing (FDM) scheme, but it maintains orthogonality between multiple sub-carriers during transmission and overlaps frequency spectra. Therefore, the OFDM scheme has high frequency efficiency, is robust against frequency selective fading and multi-path fading, and can reduce Inter-Symbol Interference (ISI) with use of a guard interval. In addition, the OFDM scheme enables simple design of a hardware equalizer and is robust against impulse noises, so it can obtain the optimal transmission efficiency during high-speed data transmission.
A Long Term Evolution (LTE) system employing the OFDM scheme is now under discussion in 3 rd Generation Partnership Project (3GPP) as the next generation mobile communication system that will replace Universal Mobile Telecommunication System (UMTS), which is the 3 rd generation mobile communication standard.
FIGS. 1A and 1B illustrate examples of a wireless mobile communication system to which reference will be made by the present invention, particularly illustrating examples of a 3GPP LTE system.
Referring to FIG. 1A , a UE 11 indicates a terminal for the 3GPP LTE system, and an Evolved Radio Access Network (E-RAN) 14 , a radio base station device directly participating in communication with a terminal in the existing 3GPP system serves as a Node B for managing cells, and also serves as a Radio Network Controller (RNC) that controls a plurality of Node Bs and radio resources. In the E-RAN 14 , an Evolved Node B (E-NB) 12 and an Evolved RNC (E-RNC) 13 can be separately implemented in the physically different nodes, or can be merged in a single node, in the manner of the existing 3GPP system. Although in the following description the E-NB 12 and the E-RNC 13 are physically merged in a single node of the E-RAN 14 , the same can be applied to when the E-RNC 13 is separately implemented in the physically different node.
An Evolved Core Network (E-CN) 15 is a node provided by merging functions of a Serving GPRS Support Node (SGSN) and a Gateway GPRS Support Node (GGSN) in the existing 3GPP system into one function. The E-CN 15 , interposed between a Packet Data Network (PDN) 16 and the E-RAN 14 , serves as a gateway for allocating an Internet Protocol (IP) address to the UE 11 and connecting the UE 11 to the PDN 16 . Definitions and functions of the SGSN and the GGSN follow the 3GPP standard, and a detailed description thereof will be omitted herein.
Referring to FIG. 1B , an Evolved UMTS Radio Access Network (E-RAN) 110 is simplified to a 2-node configuration of Evolved Node Bs (E-NBs) 120 , 122 , 124 , 126 and 128 , and anchor nodes 130 and 132 . A UE 101 , or a terminal, accesses an IP network by the E-RAN 110 . The E-NBs 120 to 128 correspond to the existing Node Bs in the UMTS system, and are connected to the UE 101 over a wireless channel. Unlike the existing Node Bs, the E-NBs 120 to 128 perform more complex functions. In LTE, because all user traffics, including real-time services such as Voice over IP (VoIP), are serviced over a shared channel, there is a need for devices for gathering status information of UEs and performing scheduling depending thereon, and the E-NBs 120 to 128 manage the devices.
Generally, one E-NB controls a plurality of cells. In addition, the E-NB performs Adaptive Modulation & Coding (AMC) that determines a modulation scheme and a channel coding rate according to channel status of a UE. Similar to High Speed Downlink Packet Access (HSDPA), High Speed Uplink Packet Access (HSUPA) and Enhanced Dedicated CHannel (E-DCH) of UMTS, even in LTE, Hybrid Automatic Repeat reQuest (HARQ) is performed between the E-NB 120 to 128 and the UE 101 . However, because LTE cannot meet various Quality of Service (QoS) requirements only with HARQ, Outer-ARQ in an upper layer can be performed between the UE 101 and the E-NBs 120 to 128 . HARQ, as is well known, refers to a technique for soft-combining previously received data with retransmitted data without discarding the previously received data, thereby increasing a reception success rate. In high-speed packet communication, such as HSDPA and EDCH, the HARQ technique is used to increase transmission efficiency. It is expected that to realize a data rate of a maximum of 100 Mbps, LTE will use OFDM as a wireless access technology in a 20-MHz bandwidth.
FIG. 2 illustrates an uplink timing synchronization procedure in a 3GPP LTE system to which OFDM is applied.
Referring to FIG. 2 , a first UE (UE 1 ) is located near an E-NB, and a second UE (UE 2 ) is located far from the E-NB. T_pro 1 indicates a propagation delay time in wireless transmission up to the UE 1 , and T_pro 2 indicates a propagation delay time in wireless transmission up to the UE 2 . Because the UE 1 is located nearer to the E-NB compared to the UE 2 , it has less propagation delay time. In FIG. 2 , T_pro 1 is 0.33 us, and T_pro 2 is 3.33 us.
In one cell (indicated by a circle in FIG. 2 ) of the E-NB, when the UE 1 and the UE 2 are powered on or are in an idle mode, uplink timing synchronization of the UE 1 , the UE 2 and of UEs in the cell, detected by the E-NB, are not matched to each other. Reference numeral 201 indicates timing synchronization for uplink transmission of an OFDM symbol of the UE 1 , and reference numeral 202 indicates timing synchronization for uplink transmission of an OFDM symbol of the UE 2 . When propagation delay times of uplink transmission of the UE 1 and the UE 2 are considered, timings at the E-NB receiving the uplink OFDM symbols are shown by reference numerals 211 , 212 and 213 . That is, the uplink symbol 201 of the UE 1 is received at the E-NB with a propagation delay time in the timing 212 , and the uplink symbol 202 of the UE 2 is received at the E-NB with a propagation delay time in the timing 213 .
Since uplink timing synchronizations for the UE 1 and the UE 2 have not been acquired (matched) yet for the timings 212 and 213 , start timing 211 in which the E-NB receives and decodes an uplink OFDM symbol, timing 212 in which the E-NB receives an OFDM symbol from the UE 1 , and timing 213 in which the E-NB receives an OFDM symbol from the UE 2 are different from each other. Therefore, the uplink symbols transmitted from the UE 1 and the UE 2 serve as interference components to each other, as they have no orthogonality, and the E-NB may not successfully decode the uplink symbols 201 and 202 transmitted from the UE 1 and the UE 2 , due to the interference and the discrepancy between the start timing 211 and the reception timings 212 and 213 of uplink symbols.
Therefore, the E-NB matches uplink symbol reception timings of the UE 1 and the UE 2 through the uplink timing synchronization procedure. After completion of the uplink timing synchronization procedure, the E-NB can match the start timing 221 in which it receives and decodes uplink OFDM symbols, the timing 222 in which it receives an uplink OFDM symbol from the UE 1 , and the timing 223 in which it receives an uplink OFDM symbol from the UE 2 . After matching the timings, the E-NB can maintain orthogonality between the uplink symbols transmitted from the UE 1 and the UE 2 , and thus can successfully decode the uplink symbols 201 and 202 transmitted from the UE 1 and the UE 2 .
FIG. 3 illustrates an example of an uplink timing synchronization procedure.
In step 311 , a UE 301 generates a preamble code to be used in the uplink timing synchronization procedure. If the UE 301 is constructed such that multiple preamble codes can be used in the uplink timing synchronization procedure, the UE 301 generates one of the multiple preamble codes. The ‘preamble code’ is a type of code sequence agreed upon between the UE 301 and an E-NB 302 , and the UE 301 transmits the preamble code over the uplink using radio resources allocated by the E-NB 302 in step 321 (UL SYNC REQ). Upon receipt of the preamble code, the E-NB 302 calculates a correlation between the preamble code and candidate preamble codes available for uplink timing synchronization during a sliding window having a certain constant interval, to find the timing and preamble code indicating the highest correlation. In addition, the E-NB 302 calculates a difference between the then-reception timing and the timing in which it should actually have received the preamble code, and provides in step 322 the UE 301 with an IDentifier (ID) of the found preamble code and information on the uplink timing difference using a response message (UL SYNC RES). In step 331 , the UE 301 changes and updates the uplink transmission timing using the information on the uplink timing difference, received through the response message. From this time one, uplink signaling and data transmission is achieved using the changed and updated uplink timing.
Steps 341 , 342 and 343 indicate a process of re-performing the uplink timing synchronization procedure in steps 311 , 321 and 322 to recheck the changed and updated timing, and can be omitted.
The uplink timing synchronization procedure shown in FIG. 3 should be periodically performed because the UE in the mobile communication system continuously moves, and thus the distance difference between the UE and the E-NB may change over time. When the periodic uplink timing synchronization procedure is performed, the UE periodically generates a preamble code used for the uplink timing synchronization procedure and transmits the preamble code to the E-NB over the uplink, and the E-NB should find an uplink timing difference by receiving and decrypting the periodic uplink preamble code, and provide the uplink timing difference information to the UE over the downlink. Therefore, overhead of the uplink signaling/downlink signaling occurs, causing inefficient use of radio resources.
SUMMARY OF THE INVENTION
An aspect of the present invention is to address at least the problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide a method of maintaining uplink timing synchronization without uplink transmission of a preamble from a UE or without transmission of uplink timing difference information from an E-NB to solve the inefficient use problem of radio resources, occurring due to periodic transmission of uplink signaling and downlink signaling during maintenance of the uplink timing synchronization, and a UE apparatus for the same.
According to the present invention, there is provided a method for maintaining uplink timing sync in a mobile communication system. The method includes transmitting to a Node B an uplink sync request message including a preamble code, receiving from the Node B an uplink sync response message in response to the request message, adjusting uplink timing according to uplink timing adjustment information included in the response message, and storing the adjusted uplink timing as reference uplink timing for uplink signaling or data transmission; after storing the reference uplink timing, periodically measuring downlink timing, and calculating a difference between the measured downlink timing and previously stored reference downlink timing, determining the uplink timing using the calculated difference of the downlink timing and the reference uplink timing, receiving a request message for readjustment of the uplink timing from a Node B that has detected discrepancy of the uplink timing, readjusting the uplink timing using uplink timing adjustment information included in the uplink timing readjustment request message, updating the reference uplink timing with the readjusted uplink timing, and storing the updated reference uplink timing, and when updating the reference uplink timing, updating the last measured downlink timing as the reference downlink timing, and storing the reference downlink timing.
According to the present invention, there is provided a user equipment apparatus for maintaining uplink timing sync. The user equipment apparatus includes a message transceiver for receiving a message including uplink timing adjustment information from a Node B, and transmitting uplink data and signaling to the Node B according to uplink timing, a message decrypter for decrypting a message received from the message transceiver to acquire the uplink timing adjustment information, a reference timing manager for setting reference uplink timing according to the acquired uplink timing adjustment information, and setting the reference downlink timing according to the downlink timing, an uplink timing adjuster for periodically adjusting the uplink timing using a difference between the downlink timing and the reference downlink timing, and the reference uplink timing, a timer for counting a period for which the uplink timing is adjusted, and a downlink measurer for measuring the downlink timing according to the period, and providing the measured downlink timing to the uplink timing adjuster and the reference timing manager.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings in which:
FIGS. 1A and 1B illustrate conventional configurations of an OFDM mobile communication system to which reference will be made by the present invention;
FIG. 2 illustrates an uplink timing synchronization procedure in an OFDM mobile communication system;
FIG. 3 illustrates an example of an uplink timing synchronization procedure;
FIG. 4 illustrates a method of maintaining UL timing synchronization in an OFDM system according to the present invention;
FIG. 5 illustrates an operation of a UE according to the present invention; and
FIG. 6 illustrates a UE apparatus according to the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will now be described in detail with reference to the annexed drawings. In the following description, a detailed description of known functions and configurations incorporated herein has been omitted for the sake of clarity and conciseness.
In the present invention, when a UE acquires UpLink (UL) timing synchronization with an E-NB through an initial UL timing synchronization procedure, the UE sets DownLink (DL) timing during corresponding UL transmission before DL transmission including UL timing difference information from the E-NB, or DL timing during DL transmission including the UL timing difference information, as Reference DL timing, and sets and maintains the then-UL timing adjusted using the UL timing difference information as Reference UL timing. The UE periodically acquires DL timing through measurement on a DL channel, finds a DL timing difference by comparing it with the Reference DL timing, and finds the then-UL timing by applying the DL timing difference to the Reference UL timing. The period can be short, and can be configured by the E-NB.
When the UL timing has discrepancies due to abrupt unstableness of the DL channel, the discrepancy is detected by the E-NB and UL timing difference information can be signaled to the UE over the DL. Upon receipt of the UL timing difference information transmitted over the DL, the UE changes/updates Reference UL timing to the UL timing adjusted using the UL timing difference information, and changes/updates Reference DL timing to DL timing during corresponding UL transmission before DL transmission including the UL timing difference information, or to DL timing during DL transmission including the UL timing difference information.
To prevent the discrepancy of UL timing due to abrupt unstableness of the DL channel, the UE finds a difference between an average value of DL timing, calculated through measurement for the period, and the Reference DL timing, or finds a difference between the DL timing and the Reference DL timing through periodic measurement on the DL channel. When the difference between the average value of DL timing, calculated through measurement on the DL channel for the period, and the Reference DL timing has an abnormally large value, it can be disregarded.
The term ‘UL timing’ used throughout the specification, which is the timing in which the UE transmits signaling/data over the UL, can be indicated as a timing offset (in units of actual time such as μs, or in such units as slots, symbols, subframes or frames) with respect to a DL frame to which the UE has matched a DL sync channel, and the ‘DL timing’ indicates DL frame timing acquired through a DL sync channel.
FIG. 4 illustrates generally a method of finding UL timing according to the present invention, and more particularly a method of finding UL timing by applying a difference between DL timing and Reference DL timing to Reference UL timing.
Referring to FIG. 4 , steps 411 , 421 and 422 indicate execution of an initial UL timing synchronization procedure. That is, in step 411 , a UE 401 generates a preamble code to be used for a UL timing synchronization procedure. If the UE 401 is constructed such that multiple preamble codes can be used in the UL timing synchronization procedure, the UE 401 generates one of the multiple preamble codes. The ‘preamble code’ is a type of code sequence agreed upon between the UE 401 and an E-NB 402 , and the UE 401 transmits the preamble code over the uplink using radio resources allocated by the E-NB 402 in step 421 (UL SYNC REQ). Upon receipt of the preamble code, the E-NB 402 calculates a correlation between the received preamble code and candidate preamble codes available for UL timing synchronization during a sliding window having a constant interval, to find the timing and preamble code indicating the highest correlation. In addition, the E-NB 402 calculates a difference between the then-reception timing and the timing in which it should actually have received the preamble code, and provides in step 422 the UE 401 with an ID of the preamble code and information on the UL timing difference using a response message (UL SYNC RES).
In step 431 , the UE 401 adjusts UL timing using the UL timing difference information received through the response message, and sets it as Reference UL timing. In addition, the UE 401 sets DL timing in step 412 as Reference DL timing.
Here, an operation order of step 431 is subject to change. That is, if steps 411 , 421 and 422 are re-performed in the manner of steps 341 , 342 and 343 of FIG. 3 to recheck UL timing adjusted according to the UL timing difference information received in step 422 , Reference DL timing is reset to the DL timing during the re-performed UL preamble code transmission, and Reference UL timing is reset to the UL timing adjusted according to the newly received UL timing difference information.
After completion of the UL timing adjustment in step 431 , the UE 401 performs in step 432 UL signaling/data transmission with the adjusted UL timing.
In FIG. 4 , for the DL timing measurement of step 412 for Reference DL timing setting, although when the UL timing difference information was received over the DL in step 422 , DL timing for the DL at the time (step 421 ) that the UL transmission has occurred before the DL reception is measured herein by way of example, the present invention does not exclude any other possible time for which the DL timing for setting Reference DL timing is measured. For example, DL timing for the DL at the time (step 422 ) that UL timing difference information was received over the DL, can be set as Reference DL timing.
In steps 441 and 451 , the UE 401 measures DL timing at each time through measurement for a period T, calculates a difference between the measured DL timing and the Reference DL timing, and calculates/adjusts the UL timing by applying the DL timing difference to the Reference UL timing. That is, without signaling exchange with the E-NB 402 , the UE 401 finds DL timing through periodic measurement, finds a timing difference between the DL timing and Reference DL timing by comparing the DL timing with Reference DL timing, and then finds UL timing by applying the timing difference to the Reference UL timing.
When UL timing is discrepant due to abrupt unstableness of the DL channel, the E-NB 402 detects the discrepancy in step 471 , and transmits UL timing difference information to the UE 401 using a message in step 481 , thereby sending a request for readjustment of the UL timing to the UE 401 . Upon receipt of a UL timing readjustment instruction, the UE 401 resets the DL timing for the corresponding UL transmission time (step 461 in FIG. 4 ) as Reference DL timing, and resets the UL timing adjusted using the UL timing difference information received through a message in step 481 , as Reference UL timing.
Although not shown in FIG. 4 , a difference between an average value of DL timing measured for the period T and the Reference DL timing can be applied to the Reference UL timing in steps 441 and 451 . In addition, when the average value of DL timing measured for the period T is used for finding a difference from the Reference DL timing as described above, the abnormally great difference can be disregarded without application. Even when the DL timing measured in steps 411 and 451 of FIG. 4 , other than the average value of DL timing measured for the period T, is used for finding the difference with the Reference DL timing, the abnormally great difference can be disregarded without application. In this case, the previously acquired UL timing can be used as it is.
FIG. 5 illustrates an operation of a UE to which an embodiment of the present invention is applied.
Referring to FIG. 5 , in step 501 , the UE receives UL timing difference information (UL timing adjustment info or UL timing advance info) from an E-NB. In step 511 , the UE sets or updates DL timing during UL transmission as Reference DL timing before reception of the UL timing difference information of step 501 , and stores the DL timing. In step 512 , the UE adjusts the UL timing using the UL timing difference information received in step 501 . In step 513 , the UE sets or updates the UL timing adjusted in step 512 as Reference UL timing, and stores the Reference UL timing. In step 521 , the UE determines whether a period of adjusting UL timing has arrived.
If the UL timing adjustment period has arrived, the UE measures DL timing through measurement in step 531 , calculates a difference between the measured DL timing and the Reference DL timing in step 532 , and then adjusts UL timing by applying the calculated difference to the Reference UL timing in step 533 . However, if the adjustment period of the UL timing has not arrived, the UE maintains the last adjusted UL timing in step 541 .
Although not shown in FIG. 5 , as described above, the UE does not exclude any other possible time for which it sets Reference DL timing in step 511 . For example, the UE can set, as Reference DL timing, the DL timing for which it has received UL timing difference information over the DL.
FIG. 6 illustrates a UE apparatus to which an embodiment of the present invention is applied.
Referring to FIG. 6 , the UE includes a message transceiver 601 , a message decrypter 611 , a Reference UL/DL timing manager 621 , a DL measurer 631 , a timer 641 and a UL timing adjuster 651 .
The message transceiver 601 receives signaling including UL timing difference information from an E-NB. The message decrypter 611 decrypts a message received from the message transceiver 601 to detect UL timing difference information, and the UL timing difference information is delivered to the UL timing adjuster 651 via the Reference UL/DL timing manager 621 . The UL timing adjuster 651 adjusts UL timing using the UL timing difference information received via the Reference UL/DL timing manager 621 , and updates the adjusted UL timing as Reference UL timing. The updated Reference UL timing is used for later setting the timing for UL message transmission via the message transceiver 601 .
Upon receipt of the UL timing difference information via the message transceiver 601 and the message decrypter 611 , the Reference UL/DL timing manager 621 updates the DL timing measured by the DL measurer 631 as Reference DL timing. The DL timing measured by the DL measurer 631 is DL timing when the UE transmitted the corresponding UL message before it receives a message including UL timing difference information. The timer 641 manages a UL timing update period for matching UL timing synchronization, at which period the timer 641 reports arrival of the period to the DL measurer 631 and the UL timing adjuster 651 . The DL measurer 631 acquires the DL timing, and the UL timing adjuster 651 calculates a timing difference by comparing the acquired DL timing with the Reference DL timing stored in the Reference UL/DL timing manager 621 , and adjusts UL timing by applying the timing difference to the Reference UL timing stored in the Reference UL/DL timing manager 621 .
As is apparent from the foregoing description, according to the present invention, the UE stores UL timing and DL timing for the time at which it has acquired initial UL timing synchronization, as Reference UL timing and Reference DL timing, respectively, periodically finding DL timing, calculating a difference by comparing the DL timing with the Reference DL timing, and maintaining UL timing by applying the difference to the Reference UL timing. By doing so, the number of signaling transmissions between the UE and the E-NB is reduced, thereby reducing overhead of UL/DL signaling and enabling efficient use of radio resources.
While the invention has been shown and described with reference to a certain preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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Disclosed is a method for maintaining uplink timing synchronization by a User Equipment (UE) in a mobile communication system, without uplink transmission of a preamble from a UE or without transmission of uplink timing difference information from an Evolved Node B (E-NB) to solve the inefficient use problem of radio resources, occurring due to periodic transmission of uplink signaling and downlink signaling during maintenance of the uplink timing synchronization, and a UE apparatus for the same.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a US National Stage of International Application No. PCT/GB2009/002678, filed 16 Nov. 2009, which claims the benefit of GB 0820984.3, filed 17 Nov. 2008, both herein fully incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a bottle with a tamper-proof cap.
BACKGROUND OF THE INVENTION
[0003] Many tamper-proof caps are known in the art which are designed to demonstrate to a user whether or not a cap has previously been removed. The most common tamper-proof cap is a screw-on lid, the lower lip of which is attached to a collar via a frangible element. The collar is prevented from rotating with the cap so that, when the cap is rotated, the frangible elements break to separate the collar from the lid thereby providing a visual indication that the cap has previously been opened.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention is directed to a bottle with a tamper-proof cap with an outlet in the cap for dispensing the liquid from the bottle. The bottle is designed, in particular, for use in an inverted configuration, namely with the outlet lowermost in normal use, in a device for dispensing liquid soap or the like. The bottle is designed to be a refill which sits above a base which houses a mechanism for selectively dispensing a liquid such as soap from the dispenser, either by a hand operated pump, or by an automated system which detects the proximity of a user's hands and activates a pump to automatically dispense the liquid. Once the refill is empty, if the user could remove the cap and refill the bottle, there is a danger that they would fill the bottle with a product which was incompatible with the dispensing device, or would fail to replace the cap properly resulting in leakage into the base which would at best be messy and at worst would damage the device.
[0005] According to the present invention, there is provided a bottle with a tamper-proof cap with an outlet therethrough, the bottle having a neck that is attached to the cap, a retaining shoulder adjacent to the end of the neck and facing away from the open end of the neck, the cap comprising at least one retaining member having a retaining shoulder complementary to the shoulder on the bottle, the retaining member being attached to the cap by a frangible member, whereby insertion of the bottle into the cap causes the retaining member to deflect so that the shoulder on the bottle passes the retaining member, whereupon the retaining member is resiliently biased back to its normal position so that its retaining shoulder co-operates with the retaining shoulder on the bottle to hold the bottle and cap together, and whereby pulling the cap from the bottle causes the shoulder on the bottle to bear against the shoulder on the retaining member and distort or break the frangible member thereby moving the retaining member to a position which prevents the cap from being subsequently retained on the bottle.
[0006] Thus, the user is able to use the bottle as normal to dispense liquid from the outlet. Once the bottle is empty, if the user removes the cap, they will distort or break the frangible member so that the retaining member will no longer be effective. This will prevent them from re-securing the lid to the bottle.
[0007] There may be a single arcuate retaining member which may either fully encircle the neck of the bottle, or may extend around a substantial proportion of the neck. However, preferably, there are a plurality of arcuate retaining members spaced around the circumference of the neck. Having a plurality of such members makes it easier for them to deflect as the bottle is inserted into the cap.
[0008] The plurality of retaining members may extend all the way around the cap. However, preferably, the retaining members are spaced intermittently around the cap. If this is the case, a frangible member is preferably attached at each end of the retaining member. Alternatively, there may be a plurality of frangible members connected between the cap and the surface of the retaining member which faces the cap. Between the intermittent retaining members, there may be a plurality of support members to complete the circle.
[0009] Preferably, a tapered surface is provided on at least one of the end of the neck and the retaining member to assist in deflecting the retaining member when the bottle is inserted into the cap.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A bottle with a tamper-proof cap will now be described with reference to the accompany drawings, in which:
[0011] FIG. 1 is a cross-section through a dispenser;
[0012] FIG. 2 is a cut-away perspective view of the refill being introduced into the dispenser but not yet being engaged;
[0013] FIG. 3 is a view similar to FIG. 2 showing the refill in an intermediate position;
[0014] FIG. 4 is a view similar to FIGS. 3 and 4 showing the refill in its fully engaged position;
[0015] FIG. 5 is a perspective view of the cap assembly prior to assembly;
[0016] FIG. 6 is a perspective view of the cap assembly after assembly;
[0017] FIG. 7 is a cross-section showing the engagement between the bottle neck and cap assembly;
[0018] FIG. 8 is a perspective view of the cap with the frangible members intact;
[0019] FIG. 9 is a view similar to FIG. 7 after the bottle has been removed from the cap;
[0020] FIG. 10 is a view similar to FIG. 8 after the frangible members have broken off;
[0021] FIG. 11 is an exploded perspective view of a cap of a second refill unit;
[0022] FIG. 12 is a view similar to FIG. 11 showing the assembled cap;
[0023] FIG. 13 is a cross-sectional view through the pressure relief valve of the second example; and
[0024] FIG. 14 is a view similar to FIG. 13 showing the pressure relief valve in an open configuration to allow the flow of air.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The dispenser is a hands-free dispenser which is generally suitable for domestic use. The dispenser is primarily intended to dispense liquid soap, but may also be used to dispense other liquid or semi-liquid products (ideally with a viscosity greater than water), such as hand cream, body lotion, moisturiser, face cream, shampoo, shower gel, foaming hand wash, shaving cream, washing up liquid, toothpaste or a sanitising agent such as alcohol gel.
[0026] The dispenser comprises two main parts, namely a refill 1 and a base unit 2 . The refill 1 provides a reservoir of liquid to be dispensed and is fitted to the base unit 2 as set out below.
[0027] The base has an interface 3 into which liquid is dispensed from the refill unit. The interface 3 is in fluid communication with a dispensing tube 4 . A pump 5 is selectively operable to pump a metered dose of the liquid along dispensing tube 4 and out of dispensing head 6 .
[0028] The base has an infrared transmitter 7 A which transmits an infrared beam through a window 8 to a receiver 7 B to sense the presence of a user's hands in the vicinity of the dispenser.
[0029] Control circuitry reacts to a signal from the proximity sensor to activate the pump. The illustrated sensor is a break beam sensor, but may also be a reflective sensor. Although an infrared sensor is shown, any known proximity sensor such as a capacitive sensor may be used. The device may be mains powered or battery powered. Alternatively, it may be a manually operated pump device in which a user pushes a lever to displace the product.
[0030] The interface between the refill 1 and base unit 2 will now be described in greater detail with reference to FIGS. 2 to 10 .
[0031] The base unit 2 comprises a cowling 10 which forms a cup-shaped housing surrounding a significant portion of the refill to protect and support it. A spigot 11 projects through the base of the cowling 10 and is sealed to the cowling 10 by an O-ring seal 12 . The spigot has a plurality of castellations 13 in its top surface. A second O-ring seal 14 surrounds the spigot 11 beneath the castellations 13 .
[0032] The refill 1 comprises a bottle 20 to which a cap 21 is fixed. The bottle 20 has a neck 22 which fits over and seals with an annular flange 23 within the cap 21 . The cap 21 has an upwardly depending skirt 24 (when in the inverted orientation shown in the drawings) which forms the outer surface of the cap. Working inwardly from the skirt 24 , the next feature of the cap is an outer annular wall 25 which is generally co-axial with the skirt 24 .
[0033] This is shown in detail in FIGS. 5 to 10 .
[0034] The outer annular wall 25 consists of a pair of retaining members 26 and a pair of support members 27 which alternate with one another and each extend for approximately a quarter of the circle as shown in FIGS. 5, 6 , 8 and 10 . The profile of the support members 27 is as shown in FIG. 2 . These members extend directly up from the lower wall of the cap, are parallel sided and have an inclined upper surface 28 . The profile of the retaining members 26 is shown in FIGS. 7 and 9 . Unlike the support members 27 , these are not fixed to the wall of the cap. Instead, they are fixed at either end to the support members 27 by frangible members 29 as best shown in FIGS. 6 and 8 . The retaining members 26 are parallel sided and have an inclined upper surface 35 as shown in FIGS. 7 and 9 .
[0035] As shown in FIGS. 7 and 9 , the neck 22 of the bottle has an inclined outer surface 36 which is complimentary to the inclined surfaces 28 and 35 of the annular wall 25 . Behind the inclined outer surface 36 is a shoulder 37 which faces the main body of the bottle 20 . This inclined outer surface 36 and shoulder 37 is only present in the vicinity of the retaining members 26 and not in the vicinity of the support members 27 . Adjacent to the support members 27 , the neck 22 has a parallel sided configuration as shown in FIG. 2 .
[0036] In order to insert the bottle 20 into the cap 21 , the bottle 20 is pushed down with its neck fitting over the annular flange 23 . The inclined outer surface 36 of the bottle co-operates with the inclined surfaces 28 , 35 to displace the retaining members 26 radially outwardly until the shoulder 37 snaps into place behind the retaining members 26 as shown in FIG. 7 . When the bottle 20 is pulled off of the cap 21 , the shoulders 37 bear against the retaining members 26 , thereby breaking frangible members 29 so that the retaining members 26 become detached from the cap 21 as shown in FIGS. 9 and 10 . Once this has happened, it is no longer possible to retain the cap on a bottle, thereby preventing subsequent use of the refill 1 .
[0037] It should be noted that it is not necessary for both of the retaining members 26 to become fully detached from the lid. It is possible that only one of these becomes detached, or that one or both are simply displaced to a location at which they can no longer engage with the neck of the bottle.
[0038] Returning now to FIGS. 2 to 4 , the liquid outlet and associated valve will now be described.
[0039] The liquid outlet from the reservoir is provided by an annular wall 30 surrounding a central opening 31 . At the top of the annular wall 30 is an inclined surface 32 (see FIG. 4 ) which provides a valve seat for outlet valve element 33 . This is shown in the form of a U-shape cup-like member, but may equally be a solid member or a hollow ball-like member. The outlet valve element 33 is biased into its closed position by a plurality of biasing elements 34 . These are attached at their upper end towards the top of the valve element 33 and are attached at their lower ends at a location radially outward of the annular wall 30 and below the top of the annular wall 30 . They are preferably formed integrally with the valve element 33 .
[0040] As shown in FIGS. 2 to 4 , when the refill 1 is lowered into the base unit 2 , the spigot 11 engages with the lower surface of the valve element 33 as shown in FIG. 3 . Further downward movement of the refill causes the valve element 33 to be lifted from its seat, and also brings the O-ring 14 into sealing engagement with the annular wall 30 . The valve element 33 is lifted to the position shown in FIG. 4 . In this position, liquid in the bottle 20 can flow around the biasing elements 34 , and enter the spigot via the castellations 13 and hence flow into the base unit 2 . Liquid is prevented from escaping between the spigot 11 and annular wall 30 by the O-ring seal 14 . This arrangement offers a simple and mess-free way for a consumer to insert a refill regardless of the fill level of the refill.
[0041] In order to remove a refill, the consumer lifts it out of the base whereupon the biasing elements 34 cause the valve element 33 to return to the seat 32 . During this movement, the seal between the spigot 11 and annular wall 30 is maintained by the O-ring seal 14 . A spent refill is then replaced by a new one following the above procedure.
[0042] The cap is provided with a pair of pressure relief valves 40 . Each is formed by an annular boss 41 integral with the cap 21 . A pressure relief valve element 42 is seated on the top of the annular boss 41 and is biased in place by a pair of biasing elements 43 (as shown, for example, in FIG. 5 ). The biasing force is such that, under normal conditions, the pressure relief valve element 42 forms an air tight seal on the boss 41 . However, when the pressure within the bottle 20 drops below a certain level, the pressure differential across the relief valve element 42 is sufficient to overcome the force exerted by biasing elements 43 and to allow air into the bottle 20 . This reduces the pressure differential thereby restoring the air tight seal without leakage of fluid.
[0043] Each pressure relief valve 40 is surrounded by an annular barrier 44 which extends axially to a level axially above the level of the top of the annular wall 30 . Thus, when the valve element 33 is open, any air entering the relief valve 40 will not become entrained in the outgoing liquid stream. In practice, this means that the relief valve can be placed closer to the outlet, thereby resulting in a more compact cap. Although two relief valves are shown, a single valve, or more than two valves could be provided if necessary.
[0044] The manner in which the cap is assembled is illustrated in FIGS. 5 and 6 .
[0045] The assembly is a three-part structure consisting of the cap 21 , a valve plate 45 and a fixing plate 46 . The cap has a number of moulded features including the annular flange 23 , annular wall 25 and annular bosses 41 . In addition, the cap 21 has a plurality of fixing posts 47 .
[0046] The valve plate 45 is an elastomeric material and is integrally formed with the valve element 33 , biasing elements 34 , relief valve element 42 and biasing elements 43 . The valve plate has a plurality of locating holes 48 which correspond to the fixing posts 47 .
[0047] The fixing plate 46 is made of a rigid plastics material and is integrally formed with the annular barrier 44 . As with the valve plate 45 , the fixing plate 46 is also provided with a plurality of locating holes 49 which correspond to the fixing posts 47 .
[0048] To assemble the cap, the three components are placed on top of one another as shown in FIG. 6 with the fixing posts entering the locating holes to ensure that the components are correctly aligned. Heat or adhesive is then applied to the top of the fixing posts 47 to secure the fixing posts to the fixing plate 46 . The elastomeric valve plate 45 is thereby sandwiched between the cap 21 and fixing plate 46 which holds the valve elements 33 and 42 in position.
[0049] A second example of a cap for a refill unit will now be described with reference to FIGS. 11 to 14 .
[0050] The structure of the outlet valve element 33 in the second example is essentially the same as the first example, and will not be described again in relation to the second example.
[0051] As can be seen from FIG. 11 , the cap 21 is integrally molded with a number of features, such as the annular walls 25 and 30 and a conical part 50 of the pressure relief valve which will be described below. A resilient lip 53 (described in more detail below) for the pressure relief valve is provided integrally molded with the valve plate 45 . The fixing plate 46 is also provided with a shield 57 for the relief valve. This is equivalent to the barrier 44 in FIG. 2 , but only extends around the side of the relief valve facing the outlet valve element 33 . The barrier 44 and shield 57 could be used interchangeably in the two examples.
[0052] The cap assembly is assembled in the same manner as in the first example.
[0053] The pressure relief valve 60 is illustrated in FIGS. 13 and 14 .
[0054] The valve has the conical part 50 which is an integral part of the cap 21 as mentioned above. At the top of the conical part 50 is a cylindrical post 61 . The resilient lip 53 is effectively a hollow frustoconical extension of the valve plate 52 of resilient material which extends along the conical part 50 from which it diverges slightly and is a tight fit against the post 61 . At least one air inlet 62 (also shown in FIG. 11 ) passes through the wall of the conical part 50 and is normally covered by the resilient lip 53 as shown in FIG. 11 . When the pressure in the bottle 20 falls as liquid is emptied the pressure differential across the resilient lip 53 will eventually become sufficient to displace the lip 53 to a sufficient degree to allow air A into the bottle 20 as shown by the arrows in FIG. 8 . It should be noted that the degree to which the resilient lip 53 lifts from the conical element 50 has been exaggerated in FIG. 8 and that, in practice, this will be almost imperceptible.
[0055] Instead of sealing against the post, the resilient lip 53 may seal against the conical part 50 . In this case, the lip will not diverge from the conical part as shown. Instead, it would actually have an angle of incline less than the angle of the conical part 50 so as to be naturally biased onto the conical part.
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The present invention is directed to a bottle with a tamper-proof cap with an outlet in the cap for dispensing the liquid from the bottle. The bottle is designed, in particular, for use in an inverted configuration, namely with the outlet lowermost in normal use, in a device for dispensing liquid soap or the like.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to N-benzylindole- and benzopyrazole derivatives having anti-asthmatic, anti-allergic, anti-inflammatory and immunomodulating effects.
2. Background Information
Indole derivatives have many uses as synthetic building blocks for the synthesis of drugs, for example the drugs indomethacin and acemethacin have an N-substituted indole skeleton.
Indomethacin is the prototype of compounds having a predominantly anti-inflammatory and anti-rheumatic effect.
An indazole derivative that can be cited is the substance bendazac which has an anti-inflammatory effect; the synthesis of the substance, IUPAC name [(1-benzyl-1H-indazole-3-yl)oxy]acetic acid, is described in US PS 3 470 194.
DE-OS 42 25 756 and EP 392 317 describe benzimidazoles which constitute angiotensin antagonists, in particular angioterlsin-II antagonists.
DE-OS 27 31 647 describes 1,3-benzothiolanes and their pharmaceutically useful salts.
Colantti (Chim. Ther 6(5), 367-79) describe indole derivatives which have coccidiostatic properties.
Clark et al (J. Med. Chem, 36 (18), 264-57) describe 1H-indole-3-carboxamides substituted by quinuclidyl radicals and derivatives at the acid amide nitrogen. These compounds are 5HT 3 antagonists and can, for example, be used as anti-emetics.
EP 490 263 describes N-methyl-indole derivatives as 5-HT-antagonists.
EP 485 962 describes N-methyl-indole derivatives as S 3 -receptor antagonists.
WO 88/5432 describes N-alkyl substituted 3-indole-carboxylic acid derivatives as diuretics and cardiovascularly active substances.
WO 93/2062 also describes N-alkyl-substituted 3-indole carboxylic acid amides, in which the amide nitrogen is substituted by a heterocyclic system, such as a tetrazole ring or a substituted tetrazole ring.
EP 580 502 describes 3-(hydroxybenzylidenyl)-indoline-2-one-derivatives with an anti-inflammatory, analgesic, anti-arteriosclerotic and anti-asthmatic effect. The compounds, which can be present as an E/Z-isomer mixture, inhibit LTB 4 synthesis.
The compounds carry various substituents at the indoline nitrogen; there is a keto- or thioketo group at the 2-carbon atom of the indoline ring.
SUMMARY OF THE INVENTION
It is the object of the invention to provide novel compounds which have an anti-asthmatic, anti-allergic, anti-inflammatory and immunemodulating effect; processes are also described for the preparation of the compounds and of drugs that can be obtained from the compounds.
The object of the invention therefore comprises compounds of the general formula 1 ##STR2## having the following meanings: R 1 =hydrogen, (C 1 -C 6 )alkyl, where the alkyl group can be straight-chained or branched and can be substituted once or several times by halogen, phenyl, which for its part can be substituted once or several times by halogen, (C 1 -C 6 )alkyl, (C 3 -C 7 )cycloalkyl, carboxyl groups, esterified carboxyl groups, trifluoromethyl groups, trichloromethyl groups, hydroxyl groups, methoxy groups, ethoxy groups, benzyloxy groups, benzyl groups or benzoyl groups, 2- or 3-thienyl, 2-quinolyl, 2-, 3- or 4-pyridyl which, for its part, can be substituted once or several times by halogen, (C 1 -C 4 )alkyl groups or (C 1 -C 4 )alkoxy groups, (C 3 -C 7 )cycloalkyl, aryl, for example phenyl or naphthyl, heteroaryl, for example 2-, 3- or 4-pyridyl, 2- or 8-quinolyl, 2-thienyl or 1,3 or 8 isoquinolyl, where aryl or heteroaryl can be substituted once or several times by halogen, (C 1 -C 4 )alkyl, (C 1 -C 4 )alkoxy, hydroxy, thiol groups, thioether groups (C 1 -C 4 )alkanoyl groups, CN, --COOH, --CF 3 , NO 2 , (C 1 -C 3 )alkoxycarbonyl, an amino group of the general formula ##STR3## or aroyl, with aryl in the meaning stated. R 2 and R 3 can be the same or different and can represent hydrogen, (C 1 -C 6 )alkyl, straight-chained or branched, (C 3 -C 7 )cycloalkyl, (C 1 -C 6 )alkanoyl, (C 1 -C 6 )alkoxy, halogen, benzyloxy, hydroxy, in addition R 2 and R 3 can represent the nitro group, the amino group, which can be substituted as herein before described, the methoxy group and carbamic acid esters, which are linked to the aromatic ringsystem by the N-atom,
W can represent CH or N,
Y can represent O, S or a single bond in such a manner that the heterocyclic system is directly associated with the group ##STR4## X can represent CH or N, furthermore, when Y stands for a single bond in such a way that the heterocyclic system is directly associated with the group ##STR5## X can represent a >C═ group, where a single bond from the group >C═, which is only saturated by one hydrogen atom in formula 1, is now linked via a methylene group to the nitrogen atom of the group NR 6 R 7 of R 5 , and where furthermore, if R 6 and R 7 are equal with hydrogen, this hydrogen is replaced
G can be(i)= ##STR6## or (ii)= ##STR7## or (iii)=R 14 where, in the case of G=(i)
R 4 =hydrogen, (C 1 -C 6 )alkyl, where the alkyl group can be straight-chained or branched, (C 3 -C 7 )cycloalkyl,
n=1-6
m=0 or 1 ##STR8## R 5 can represent N-(C 1 -C 6 )alkyl-2-pyrrolidinyl or the radical ##STR9## where R 6 and R 7 can be the same or different and can either represent H, (C 1 -C 6 )alkyl, quinolyl, phenyl which can be substituted with pyridylmethyl or the pyridine skeleton, where the pyridine can optionally be linked to one of the ring carbon atoms and be substituted with the radicals R 8 and R 9 which can be the same or different and as substituents R 8 and R 9 can have the the meaning (C 1 -C 6 )alkyl, where the alkyl group can be straight-chained or branched, (C 3 -C 7 )cycloalkyl, (C 1 -C 6 )alkoxy, NO 2 , NH2, ethoxycarbonylamino or phenoxycarbonylamino,
In addition, R 6 1 , R 7 and the N-atom to which they are link, can form a piperazine ring-system of formula 2 ##STR10## where R 10 can represent the groups (C 1 -C 6 )alkyl, where the alkyl group can be straight-chained or branched, (C 3 -C 7 )cycloalkyl, and phenyl which can be substituted with alkyl, alkoxy, halogen, the benzylhydryl and the bis-F-benzylhydryl group, furthermore
R 5 can represent a 2-, or 4-pyrimidinylamino ring, which can be substituted several times with a methyl group or a 4-piperidylamino ring, where the N-atom of the piperidine ring can be substituted in each case with H, (C 1 -C 6 )alkyl, where the alkyl group can be straight-chained or branched, (C 3 -C 7 )cycloalkyl, aralkyl, phenyl or the pyridine ring substituted with the groups NH 2 , NO 2 , OCH 3 and NHCOOEt,
R 5 also represents the 3- or 4-tetrahydropyridylamino ring, the N-atom of which can be substituted by H, (C 1 -C 6 )alkyl, where the alkyl group can be straight-chained or branched, (C 3 -C 7 )cycloalkyl and aralkyl,
Z can represent O or S or two hydrogen atoms
for G=(ii)
R 11 can have the same meaning as R 1 ,
R 12 and R 13 can be the same or different and independently of one another occupy all the carbon positions at the (non-aromatic) heterocyclic system and have the meaning given above for R 1 and
o can be 1-4
for G=(iii)
R 14 can represent benzyl that can be substituted once or several times by halogen, (C 1 -C 6 )-alkyl, where the alkyl group can be straight-chained or branched, (C 1 -C 6 )alkoxy or benzyloxy, or the group ##STR11## where R 15 can be hydroxy, 2,3- or 4-pyridylamino, that can be substituted with an amino, nitro (C 1 -C 4 )alkoxycarbonyl or (C 1 -C 4 )alkoxy-carbonylamino, 4-quinolylamino, that can be substituted with (C 1 -C 4 )alkyl or 2-pyridylmethoxy.
The compounds of the invention can also be present as acid addition salts, for example as salts of mineral acids such as hydrochloric acid, sulfuric acid, phosphoric acid, salts of organic acids, such as acetic acid, lactic acid, malonic acid, maleic acid, fumaric acid, glucuronic acid, citric acid, gluconic acid, embonic acid, methan-sulfonicacid, trifluoracetic acid.
The designation "straight-chained alkyl group" is understood to mean for example radicals such as methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, "branched alkyl group" is understood to mean radicals such as isopropyl or tert.-butyl. The designation "alkyl groups" is understood to mean both "straight-chained" and also "branched" alkyl groups. "Cycloalkyl" is understood to mean radicals such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl or cycloheptyl. The designation halogen stands for fluorine, chlorine, bromide or iodine. The designation "alkoxy group" constitutes radicals such as methoxy, ethoxy, propoxy, butoxy, isoproloxy, isobutoxy or pentoxy.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the invention display a good effect in pharmacological models for the release of histamine according to the following instructions:
Inhibition of allergically-induced histamine release in-vitro (CHIR)
The method described herein below was carried out after Jasani & Stanworth, 1979, J. Immunol. Meth. 30, 55. Sprague-Dawley rats were sensitised against egg albumin (EA) by subcutaneous injection of 30 mg EA with killed Bordetella pertussis bacteria as adjuvant. Four weeks later, the mast cells of the peritoneal and pleura cavities were isolated from these animals. The cells were washed, resuspended in tris gel CM (the composition of tris gel CM buffer is as follows:
______________________________________tris 25 mMol/l NaCl 120 mMol/l CaCl.sub.2 0.5 mMol/l gelatin 0.01% (% by weight)______________________________________
the rest is water, the pH value of the solution is 7.6) buffer and pre-incubated with the test substances for 15 minutes at 37° C. The cells were then stimulated at 37° C. by adding the antigen EA to release histamine. After 30 minutes the cells were centrifuged off and the histamine released was determined in the cell supernatant using a fluorometric method (Shore et al. 1959, J. Pharmacol. Exp. Ther. 127, 182).
The compounds also displayed effects in inhibiting the anti-CD3-induced release of interleucin-4 and interleucin-5 according to the following instructions:
Inhibition of anti-CD3-induced release of interleucin (IL)-4 (CIL4TC) and IL-5-release (CIL5TC) in vitro
The method described hereinbelow was carried out after Munoz et al. 1990, J. Immunol. 144, 964. Murine T-helper cells (D10.G4) were used as IL-4/IL-5-producing cells. These cells were pre-incubated with the test substances for 30 minutes at 37° C. The cells were then stimulated at 37° C. to produce interleucins by adding a monoclonal antibody against the T-cell receptor domain CD3 (anti-CD3). After 16 hours, the cells were centrifuged off and the released interleucins were quantified in the cell supernatant with ELISAs for murine IL-4 and IL-5.
______________________________________Table of pharmacological experimental results Compound CHIR [μmol/l] CIL4TC [μmol/l] CIL5TC [nmol/l]______________________________________D-22558 IC50-0.016 IC50-7967 IC50-1521 D-22559 IC50-3.4 51% with IC50-6601 10 000 nmol/l D-22561 15% with 10 IC50-5683 IC50-3214 D-22685 33% with 10 IC50-8577 IC50-6887 D-22686 IC50-0.20 41% with IC50-7314 10 000 nmol/l D-22693 IC50-0.4 48% with IC50-2702 10 000 nmol/l D-22697 --,-- IC50-7287 IC50-2881 D-22698 --,-- 38% with IC50-7765 10 000 nmol/l D-22992 IC50-0.68 IC50-9734 IC50-6237 D-22993 IC50-0.54 IC50-8973 IC50-6935______________________________________ CHIR = Inhibition of allergicallyinduced histamine release in vitro effec Concentration unit: 10,000 nmol/l Effect: % inhibition
The in vitro investigations with D-22557 and D-22558 were continued in vivo (late phase eosinophilia model) in sensitised guinea pigs
Method:
Male guinea pigs (Pirbright White, 200-250 g. Charles River Wiga, Sulfeld) were actively sensitised using a s.c. injection cf ovalbumin (10μg+100 mg aluminium hydroxide) and boosted 2 weeks later. One week after the booster injection the animals were exposed for 30 seconds to an aerosol made from 0.5% ovalbumin solution. 24 hours later brochoalveolar lavage (BAL) was carried out with 2×5 ml physiol. salt solution in animals sacrificed using an overdose of pentobarbital sodium and desanguinated. The lavage fluid was pooled, centrifuged for 10 minutes at 400×g and the cell pellet resuspended in 1 ml physiological salt solution. The eosinophiles were counted in a Neubauer chamber after staining by using a Becton Dickinson eosinophile test kit. Percentage Inhibition of the eosinophilia in the lavage was calculated in percent by comparing the eosinophile count of the groups treated with substance with the eosinolphile count of normal (unchallenged) and challenged control groups not treated with the substance. Each group numbered 10 animals. Test substances were either given prophylactically 2 hours before allergen challenge (-2 h) or therapeutically 4 hours after challenge (+4 h). When the therapeutic application was investigated, the animals (all groups) received azelastin (10 μg/kg po) 2 hours before allergen challenge to avoid deaths arising due to the onset of early phase bronchoconstriction.
Results:
______________________________________ Dose (mg/kg) + Time of Substance Route treatment % Inhibition______________________________________D-22557 0.5 ip -2 h 59% 1 ip -2 h 42% 5 ip -2 h 50% D-22558 5 ip -2 h 41% D-22558 10 po -2 h 23% 30 po -2 h 35% D-22558 10 ip +4 h 59%______________________________________
The processes for preparing the compounds of the invention are described by way of example in the following reaction diagrams I-VI and in general instructions. All the compounds can be prepared as described or by analogous means.
The compounds of general formula 1 with G=(i)
W=CH
X=CH
Y=single bond, such that the heterocyclic ring system is directly associated with the group ##STR12## Z=O may be obtained according to the following diagram:
DIAGRAM 1 ##STR13##
In accordance with the above diagram I, the 4-aminopyridine compound was obtained as well as the 3-aminopyridine compound.
N-(4-pyridyl)-[1-(4-fluorobenzyl)indole-3-yl]acetamide (D-22558)
Variant 1 for the Preparation of the Compound N-(4-Pyridyl)-[1-(4-fluorobenzyl)indole-3-yl]acetamide
1st step
[1-(4-fluorobenzyl)indole-3-yl]acetic acid-(4-fluorobenzyl)ester
100 ml dimethylsulfoxide (DMSO) are added to a three-necked flask under an N 2 atmosphere, 2.1 g sodium hydride (mineral oil suspension) are added with vigorous stirring and treated dropwise with a solution of 5 g (17.8 mmol) indole-3-acetic acid in 50 ml DMSO. 2.58 g (35.6 mMol) 4-fluorobenzyl chloride are added with further stirring. After 12 hours at 25° C. the reaction mixture is added to 300 ml water and extracted with ether. The organic phase is dried and the solvent is removed under reduced pressure. The residue is purified by column chromatography on silica gel.
Eluting mixture: methylene chloride/petroleum ether (80:20). Yield: 78% of theory.
2nd step
[1-(4-fluorobenzyl)indole-3-yl]acetic acid
8.7 g (22.2 mMol) [1-(4-fluorobenzyl)indole-3-yl]acetic acid (4-fluorobenzyl)ester are dissolved in 50 ml ethanol. 110 ml 1N sodium hydroxide solution are added and the mixture heated for 1 hour at reflux. After cooling, the aqueous phase is washed with ether, acidulated with concentrated hydrochloric acid and the precipitate filtered.
Yield: 6 g
3rd step
Preparation of the compound N-(4-pyridyl)-[1-(4-fluorobenzyl)indole-3-yl]acetamide (D-22558)
3.5 g (12.3 mMol) [1-(4-fluorobenzyl)indole-3-yl]acetic acid are dissolved in 100 ml anhydrous tetrahydrofuran. To this solution are added 2.54 g (12.3 mMol) dicyclohexylcarbodiimide and 1.16 g (12.3 mMol) 4-aminopyridine. After stirring for 24 hours at 0° C., the formed dicyclohexyl urea is separated off. After mixing in the solvent, the residue is purified by column chromatography on silica gel. Eluting agent:
methylene chloride/ethanol: 95:5 (V/V). Yield: 65% of theory; Melting point: 55-60° C.
Elementary analysis:
______________________________________calc. C 73.52 H 5.05 N 11.69 found C 73.18 H 4.95 N 11.45______________________________________
General Instructions for the Preparation of the Compounds of General Formula 1 According to Diagram I
1st step:
The indole carboxylic acid derivative is added to a protic, dipolar aprotic or unpolar organic solvent such as isopropanol, THF, DMSO, DMA, dioxan, toluene, DMF, N-methylpyrrolidone or methylene chloride and added dropwise under N 2 atmosphere to a double molar suspension of a base prepared in a three-necked flask, such as sodium hydride, pulverised KOH, tert. BuOK, dimethylaminopyridine or sodium amide (mineral oil suspension) in a suitable solvent. The desired alkylaralkyl-, heteroaralkyl or aryl halide is added to the mixture, optionally in addition of a catalyst, such as Cu, and under stirring, for example in a range of 30 minutes to 3 hours, the temperature being maintained within a range from 0° C. to 120° C., preferably 30° C. to 80° C., particularly at 50° C.-60° C. When the reaction is completed, the reaction mixture is added to water, extracted for example with diethyl ether dichloromethane, methyl-tert.-butyl ether or tetrahydrofuran and the collected organic phase is dried with anhydrous sodium sulfate. The solvent is removed under reduced pressure, the residue crystallised by milling, or the oily residue is purified by recrystallisation, by column chromatography or by flash chromatography on silica gel or aluminium oxide. The eluting mixture is for example dichloromethane and diethylether in a ratio of 8:2 (Vol/Vol) or a mixture of dichloromethane and ethanol in a ratio of 9:1 (Vol/Vol).
2nd step:
The N-substituted indole carboxylic acid ester obtained according to the above instructions (1st step) is dissolved in ethanol and treated with 1N sodium hydroxide solution. The saponification reaction is carried out between 20° C. and 100° C., preferably between 40° C. and 80° C., particularly between 50° C. and 60° C. After 1-2 hours the mixture is cooled to room temperature, acidulated with hydrochloric acid or concentrated hydrochloric acid and the precipitated N-substituted indole acetic acid is isolated by filtration.
3rd step:
The acid obtained according to the above instructions (2nd step) is dissolved in anhydrous tetrahydrofuran. Dicyclohexyl carbodiimide is added as condensation agent followed by the substituted primary or secondary amine. After stirring for 24 hours at a temperature of 0° C.-50° C., preferably from 0° C.-30° C., particularly between 0° C. and -200° C., the formed urea is filtered. After evaporation of the solvent, the residue is recrystallised or purified chromatographically over silica gel. The eluting solvent used is, for example, a mixture of dichloromethane and ethanol (95:5 Vol/Vol).
Instead of dicyclohexylcarbodiimide (DCC) as condensation agent in the condensation reaction in step 3 it is also possible to use diisopropylcarbodiimide (DIC) as condensation agent.
The condensation reaction of step 3 can, however, also be carried out using triphenylphosphine and bromotrichloromethane in THF at a temperature of 30° C.-70° C. instead of using DCC/THF or DIC/THF. Furthermore, the combinations carbonyldiimidazole in anhydrous THF were used for the condensation reaction (step 3) at a temperature of 0° C. to 60° C., preferably at a temperature of 10° C.-30° C., particularly at 25° C. As an additional condensation agent used in the condensation reaction in step 3, the combination 1-methyl-2-chloropyridinium iodide with triethylamine was used in dichloromethane at a temperature of 0° C.-80° C., preferably between 30° C. and 70° C., particularly between 50° C. and 60° C.
According to these general instructions for steps 1-3, the following compounds were synthesised and are listed in the following summary, quoting their code numbers (D-number) and the corresponding chemical designation. The following table 1 shows, the structures of these compounds, their melting points and R F values as well as the coupling reagents used for their preparation in the condensation reaction (step 3) from the general formula 1 and the substituents Y-G, X, R 1 , R 2 , R 3 and W:
A: dicyclohexylcarbodiimide or diisopropylcarbodiimide solvent:anhydrous tetrahydrofuran (DCC(DIC)/THF)
B: triphenylphosphine/bromotrichloromethane (Ph 3 P/BrCCl 3 /THF)
C: carbonyldiimidazole/TMF(CDI)THF)
D: 1-methyl-2-chloropyridinium iodide/triethylamine in the solvent methylene chloride
______________________________________D-22553 N-(3-pyridyl-yl)-(1-methylindole-3-yl)acetamide D-22560 N-(4-pyridyl-yl)-(1-benzylindole-3-yl)acetamide D-22680 N-(3-pyridyl-yl)-(1-benzylindole-3-yl)acetamide D-22681 N-(3-pyridyl-yl)-1-[(4-fluorobenzylindole-3- yl]propionamide D-22684 N-(3-pyridyl-yl)-3-(1-methylindole-3- yl]propionamide D-23198 1-(3-(1-(4-fluorobenzyl)indole-3-yl)propionamide)- 4-(4-chlorophenyl)piperazine D-23245 N-(4-pyridyl-yl)-4-(1-(4-fluorobenzyl)indole-3- yl)butyramide D-23496 N-(2,6-dimethylpyridine-2-yl)-2-[1-(4-fluoro- benzyl)indole-3-yl]acetamide D-22682 N-(3-pyridyl-yl)-3-(1-benzylindole-3- yl)propionamide D-22683 N-(4-pyridyl-yl)-3-(1-benzylindole-3- yl)propionamide D-22689 N-(4-pyridyl-yl)-3-(1-methylindole-3- yl)propionamide D-22690 N-(4-pyridyl-yl)-3-[1-(4-fluorobenzyl)indole-3- yl]propionamide D-22691 N-(4,6-dimethylpyridine-2-yl)-3-[1-(4-fluoro- benzyl)indole-3-yl]propionamide D-22693 N-(4-pyridyl-yl)-2-(1-ethylindole-3-yl)acetamide D-22694 N-(4,6-dimethylpyridine-2-yl)-2-(1-ethylindole-3- yl)acetamide D-22695 N-(4,6-dimethylpyridine-2-yl)-2-(1-benzylindole-3- yl)acetamide D-23489 N-(3-pyridyl)-4-(1-benzylindole-3-yl)butyramide D-23490 N-(4-pyridyl)-4-(1-benzylindole-3-yl)butyramide D-23495 N-(3-pyridyl)-2-[1-(4-fluorobenzyl)indole-3- yl]acetamide D-23705 N-(2-pyridyl)-3-(1-benzylindole-3- yl)propionamide D-23725 N-(2-pyridyl)-2-(1-benzylindole-3-yl)acetamide D-23728 N-(2-pyridyl)-3-[1-(4-fluorobenzyl)indole-3- yl]propionamide D-22552 N-(4-pyridyl)-4-(indole-3-yl)butyramide D-22701 N-(4,6-dimethylpyridine-2-yl)-3-(benzylindole-3- yl)propenamide D-23200 (N-(4,6-dimethylpyridine-2-yl)-3-[1-(4- fluorobenzyl)indole-3-yl]propionamide D-22940 1-[2-(indole-3-yl)acetamide]-4-(4-chlorophenyl) piperazine D-22941 1-[2-(indole-3-yl)acetamide]-4-(4,4'- bisfluorobenzhydryl)piperazine D-22943 1-[2-(indole-3-yl)acetamide]-4-methylpiperazine D-23197 1-[3-(indole-3-yl)propionamide]-4-(4,4'-bisfluoro- benzhydryl)piperazine D-23247 N-(4-pyridyl)-3-(1-benzyl-5-methoxyindole-3- yl)propionamide D-23246 N-(4-pyridyl)-3-[1-(4-fluorobenzyl)-5- fluoroindole-3-yl]propionamide D-23244 N-(4-pyridyl)-3-(1-benzyl-5-fluoroindole-3- yl]propionamide D-22946 1-[3-(indole-3-yl)propionamide]-4-(4-chlorophenyl)- piperazine D-22945 1-[3-(indole-3-yl)propionamide]-4-(4-methoxy- phenyl)piperazine D-22944 1-[3-(indole-3-yl)propionamide]-4-methylpiperazine D-22942 1-[2-(indole-3-yl)acetamide]-4-(4-methoxyphenyl) piperazine D-23243 N-(4-pyridyl)-3-(1-benzylindole-3-yl)acrylamide D-23242 N-(4-pyridyl)-3-(5-chloroindole-3- yl)propionamide D-23241 N-(4-pyridyl)-3-(5-chloroindole-3- yl)propionamide D-23240 N-(4-pyridyl)-3-(5-methoxyindole-3-yl)propion- amide D-23239 N-(4-pyridyl)-3-[1-(4-fluorobenzyl)-5-iso- propyl-indole-3-yl]propionamide D-23238 N-(4-pyridyl)-3-(5-isopropylindole-3- yl)propionamide D-23488 N-(4-pyridyl)-2-(5-chloroindole-3-yl)acetamide D-23491 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-2-methyl-5- isopropylindole-3-yl]acetamide D-23492 N-(4-pyridyl)-2-(1-benzyl-5-fluoroindole-3-yl) acetamide D-23493 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-5- chloroindole-3-yl]acetamide D-23494 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-5- fluoroindole-3-yl]acetamide D-23497 N-(4-pyridyl)-2-(2-methyl-5-isopropylindole-3- yl)acetamide D-23498 N-(4-pyridyl)-3-[1-(4-fluorobenzyl)-5- methoxyindole-3-yl]propionamide D-23499 N-(4-pyridyl)-2-(2-methyl-5-chloroindole-3-yl)- acetamide D-23500 N-(4-pyridyl)-3-(1-benzyl-5-isopropylindole-3- yl)propionamide D-23501 N-(4-pyridyl)-2-(1-benzyl-2-methyl-5-fluoro- indole-3-yl)acetamide D-23502 N-(4-pyridyl)-2-(2-methyl-5-methoxyindole-3- yl)-acetamide D-23703 N-(4-pyridyl)-2-(5-methoxy-1H-indole-3-yl)- acetamide D-23721 N-(4-pyridyl)-3-[5-chloro-1-(4-fluorobenzyl)- indole-3-yl]propionamide D-23735 N-(4-pyridyl)-2-(1-benzyl-5-chloroindole-3- yl)acetamide D-23727 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-5- isopropyl-indole-3-yl]acetamide D-23707 N-(4-pyridyl)-2-(5-fluoro-2-methylindole-3- yl]acetamide D-223712 N-(4-pyridyl)-2-(1-(4-fluorobenzyl)-2-methyl-5- fluoroindole-3-yl]acetamide D-23708 N-(4-pyridyl)-2-(1-benzyl-2-methyl-5- isopropylindole-3-yl]acetamide D-23729 N-(4-pyridyl)-3-(1-benzyl-5-chloroindole-3- yl)propionamide D-23702 N-(4-pyridyl-yl)-2-[1-(4-fluorobenzyl)-2-methyl-5- methoxyindole-3-yl]acetamide D-23718 N-(4-pyridyl-yl)-2-[1-(4-fluorobenzyl)-2-methyl-5- chloroindole-3-yl]acetamide D-23722 N-(4-pyridyl-yl)-3-[1-(4-fluorobenzyl)indole-3- yl]acrylamide D-23724 N-(4-pyridyl-yl)-2-(1-benzyl-5-isopropylindole-3- yl]acetamide D-23701 N-(2-pyridyl-yl)-2-[1-(4-fluorobenzyl)indole-3- yl]acetamide D-23711 N-(4-pyridyl-yl)-2-(5-isopropyl-1H-indole-3- yl]acetamide D-23726 N-(4-pyridyl-yl)-2-(5-fluoro-1H-indole-3- yl]acetamide D-23698 N-(4-pyridyl-yl)-2-[1-benzyl-5-methoxyindole-3- yl]acetamide D-23700 (E)-N-(4,6-dimethylpyridine-2-yl)-3-(1-methyl- indole-3-yl)acrylamide D-23719 N-(4-pyridyl-yl)-2-[1-(4-fluorobenzyl)-5- fluoro(indole-3-yl)]acetamide D-23732 N-[2,6-dimethyl-(4-pyrimidyl]-2-[1-(4- fluorophenyl)-5-fluoro(indole-3-yl]acetamide D-23717 N-(4-pyridyl-yl)-2-[1-(4-fluorophenyl)-indole-3- yl]acetamide D-23733 N-[2,6-dimethyl-(4-pyrimidyl]-2-[1-(4- fluorophenyl)-indole-3-yl]acetamide D-23734 N-(4-pyridyl-yl)-2-[1-(4-fluorophenyl)-5-methoxy- indole-3-yl)acetamide D-23730 N-(4-pyridyl)-3-[(5-benzyloxy-1H-(indole-3- yl]propionamide D-23720 N-(4-pyridyl)-2-[1-(4-fluorophenyl)-6-methoxy- indole-3-yl]acetamide D-24034 N-(4-pyridyl)-2-[(1-n-butyl-(indole-3- yl))acetamide D-24035 N-(4-pyridyl)-2-[1-(4-chlorobenzyl)-(indole-3- yl)]acetamide D-24036 N-(4-pyridyl)-2-[1-(3-fluorobenzyl)-indole-3- yl]acetamide D-24040 N-(4-pyridyl)-2-[1-(2-fluorobenzyl)-indole-3- yl)acetamide D-24041 N-(4-pyridyl)-2-[1-(3-trifluoromethylbenzyl)- indole-3-yl]acetamide D-24042 N-(2-pyridyl)-ethyl)-2-[1-(4-fluoro- benzyl)indole-3-yl]acetamide D-24236 N-[(2-pyridyl)-methyl]-{1-(4-fluorobenzyl)- indole-3-yl]acetamide D-24244 N-[4-(4-pyridyl)-methyl)phenyl]-2-[1-(4- fluorobenzyl)indole-3-yl]acetamide D-24238 N-[(3-pyridyl)-methyl]-[1-(4-fluoro- benzyl)indole-3-yl]acetamide D-24239 N-[(4-pyridyl)-methyl]-[1-(4-fluoro- benzyl)indole-3-yl]acetamide D-23714 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-6- hydroxyindole-3-yl]acetamide______________________________________
TABLE 1 - New indole derivatives according to reaction diagram 1 ##STR14## 1 D X R.sup.1 R.sup.2 R.sup.3 W Fp[° C.] CR Y--G 22553 ##STR15## 2 CH CH.sub.3 H H CH 152 A 22560 ##STR16## 3 CH ##STR17## 4 H H CH 40-60 (deliquesce) A 22680 ##STR18## 2 CH ##STR19## 4 H H CH 160 A 22681 ##STR20## 5 CH ##STR21## 6 H H CH 116 A 22684 ##STR22## 5 CH CH.sub.3 H H CH 129 A 23198 ##STR23## 7 CH ##STR24## 6 H H CH oil D 23245 ##STR25## 8 CH ##STR26## 6 H H CH oil D 23496 ##STR27## 9 CH ##STR28## 6 H H CH 132 D 22682 ##STR29## 0 CH ##STR30## 4 H H CH 120 A 22683 ##STR31## 1 CH ##STR32## 6 H H CH 154 A 22689 ##STR33## 1 CH CH.sub.3 H H CH 118 A 22690 ##STR34## 1 CH ##STR35## 6 H H CH 125 A 22691 ##STR36## 2 CH ##STR37## 6 H H CH 40-60 (deliquesce) B 22693 ##STR38## 3 CH CH.sub.2 CH.sub.3 H H CH 130-132 A 22694 ##STR39## 9 CH CH.sub.2 CH.sub.3 H H CH 159 B 22695 ##STR40## 9 CH ##STR41## 4 H H CH 40-60 (deliquesce) B 23489 ##STR42## 3 CH ##STR43## 4 H H CH 110 D 23490 ##STR44## 8 CH ##STR45## 4 H H CH 93 D 23495 ##STR46## 2 CH ##STR47## 6 H H CH 145 D 23705 ##STR48## 2 CH ##STR49## 4 H H CH 116-118 D 23725 ##STR50## 2 CH ##STR51## 4 H H CH 118-120 D 23728 ##STR52## 2 CH ##STR53## 6 H H CH 104-105 D 22552 ##STR54## 8 CH H H H CH 91 A R Y--G 22701 ##STR55## 4 CH ##STR56## 4 H H CH 174 B 23200 ##STR57## 4 CH ##STR58## 6 H H CH oil B 22940 ##STR59## 5 CH H H H CH 236-238 C 22941 ##STR60## 6 CH H H H CH 162-164 C 22943 ##STR61## 7 CH H H H CH 152-154 C 23197 ##STR62## 8 CH H H H CH 190-192 D Y --G 23247 ##STR63## 1 CH ##STR64## 4 5-OCH.sub.3 H CH 60-70 (deliquesce) D 23246 ##STR65## 1 CH ##STR66## 6 5-F H CH 60-70 (deliquesce) D 23244 ##STR67## 1 CH ##STR68## 4 5-F H CH 185 D 22946 ##STR69## 9 CH H H H CH 189-191 C 22945 ##STR70## 0 CH H H H CH 170-172 C 22944 ##STR71## 1 CH H H H CH 154-156 C 22942 ##STR72## 2 CH H H H CH 174-176 C 23243 ##STR73## 3 CH ##STR74## 4 H H CH 239-240 D 23242 ##STR75## 1 CH H 5-Cl H CH 189 D 23241 ##STR76## 1 CH H 5-F H CH 150-160 D 23240 ##STR77## 1 CH H 5-OCH.sub.3 H CH 142 D 23239 ##STR78## 1 CH ##STR79## 6 ##STR80## 4 H CH 45-55 (deliquesce) D 23238 ##STR81## 1 CH H ##STR82## 4 H CH 70-78 (deliquesce) D 23488 ##STR83## 3 CH H 5-Cl H CH 200 (disint.) D 23491 ##STR84## 3 CH.sub.3 ##STR85## 6 ##STR86## 4 H CH 174 D 23493 ##STR87## 3 CH.sub.3 ##STR88## 6 5-Cl H CH 150-156 D 23494 ##STR89## 3 CH ##STR90## 6 5-F H CH 70-76 (deliquesce) D 23497 ##STR91## 3 C--CH.sub.3 H ##STR92## 4 H CH 209 D 23492 ##STR93## 3 CH ##STR94## 4 5-F H CH 130-137 D 23498 ##STR95## 1 CH ##STR96## 4 5-OCH.sub.3 H CH 144 D 23499 ##STR97## 3 C--CH.sub.3 H 5-Cl H CH >250 D 23500 ##STR98## 1 CH ##STR99## 4 ##STR100## 4 H CH 50 (deliquesce) D 23501 ##STR101## 3 C--CH.sub.3 ##STR102## 4 5-F H CH 85-90 D 23502 ##STR103## 3 C--CH.sub.3 H 5-OCH.sub.3 H CH 203 D 23703 ##STR104## 3 CH H 5-OCH.sub.3 H CH 166-167 D 23721 ##STR105## 1 CH ##STR106## 6 5-Cl H CH 58-60 (deliquesce) D 23735 ##STR107## 3 CH ##STR108## 4 5-Cl H CH 138-140 D 23727 ##STR109## 3 CH ##STR110## 6 ##STR111## 4 H CH 88 D 23707 ##STR112## 3 C--CH.sub.3 H 5-F H CH 200 (disinte.) D 23712 ##STR113## 3 C--CH.sub.3 ##STR114## 6 5-F H CH 95-105 (deliquesce) D 23708 ##STR115## 3 C--CH.sub.3 ##STR116## 4 ##STR117## 4 H CH 164 D 23729 ##STR118## 1 CH ##STR119## 4 5-Cl H CH 160 D 23702 ##STR120## 3 C--CH.sub.3 ##STR121## 6 5-OCH.sub.3 H CH 162 D 23718 ##STR122## 3 C--CH.sub.3 ##STR123## 6 5-Cl H CH 145 D 23722 ##STR124## 5 CH ##STR125## 6 H H CH >250 D 23724 ##STR126## 3 CH ##STR127## 4 ##STR128## 4 H CH 67-68 D 23701 ##STR129## 6 CH ##STR130## 6 H H CH 110-111 D 23711 ##STR131## 3 CH H ##STR132## 4 H CH 174 D 23726 ##STR133## 3 CH H 5-F H CH 200 (disinte.) D 23698 ##STR134## 3 CH ##STR135## 4 5-OCH.sub.3 H CH 145-146 D 23700 ##STR136## 4 CH CH.sub.3 H H CH 162-163 D 23719 ##STR137## 3 CH ##STR138## 7 5-F H CH 186 D 23732 ##STR139## 8 CH ##STR140## 7 5-F H CH 55 (deliquesce) D 23717 ##STR141## 3 CH ##STR142## 7 H H CH 152 D 23733 ##STR143## 8 CH ##STR144## 7 H H CH 55 (deliquesce) D 23734 ##STR145## 3 CH ##STR146## 7 5-OCH.sub.3 H CH 218 D 23730 ##STR147## 1 CH H ##STR148## 9 H CH 170 D 23720 ##STR149## 3 CH ##STR150## 7 6-OCH.sub.3 H CH 152 D 24034 ##STR151## 3 CH CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3 H H CH oil D 24035 ##STR152## 3 CH ##STR153## 0 H H CH 153 D 24036 ##STR154## 3 CH ##STR155## 1 H H CH 161 D 24040 ##STR156## 3 CH ##STR157## 5 H H CH 146 D 24041 ##STR158## 3 CH ##STR159## 2 H H CH 127 D 24042 ##STR160## 3 CH ##STR161## 6 H H CH 87 D 24236 ##STR162## 4 CH ##STR163## 6 H H CH 75 D 24244 ##STR164## 5 CH ##STR165## 6 H H CH 118 D 24238 ##STR166## 6 CH ##STR167## 6 H H CH 163 D 24239 ##STR168## 7 CH ##STR169## 6 H H CH 139-140 D 23714 ##STR170## 3 CH ##STR171## 8 6-OH H CH 213 -- 23635 ##STR172## 3 CH ##STR173## 9 H H CH 79 (disint.) D 23644 ##STR174## 0 CH ##STR175## 9 H H CH 54 (disint.) D 23681 ##STR176## 1 CH ##STR177## 9 H H CH 156-161 D 23767 ##STR178## 2 CH ##STR179## 9 H H CH 118-120 D 23784 ##STR180## 2 CH ##STR181## 2 H H CH 144-145 D 23785 ##STR182## 0 CH ##STR183## 2 H H CH 111-112 D 23841 ##STR184## 3 CH ##STR185## 2 H H CH 181-183 (oxalate) D
Starting compounds for the compounds of general formula 1, prepared according to synthesis diagram I, which emerge from table 1 (intermediate syntheses):
Final synthesis steps
(D-compounds) of general formula 1 from table I and their primary steps
A) 22558, 22560, 22680, 22693, 22694, 22695, 22940, 22941, 22943, 22942, 22944, 22945, 23495, 23496, 23699 23701, 23725, 23635, 23644, 23681, 22553, 23767
(N-alkylation agent: CH 3 ) instead of 4-fluorobenzylchloride in diagram 1)
from (indole-3-yl)acetic acid (commercially available);
B) 24035, 24040, 24041, 24042, 24236, 24244, 24238, 24239, 23784, 23785, 23841
from (indole-3-yl)acetic acid ethyl ester (commercially available);
C) 22681, 22682, 22683, 22684, 22689, 22690, 22691, 22946, 23197, 23198, 23728, 23705,
from (indole-3-yl)acetic acid ethyl ester (commercially available);
D) 22552, 23245, 23489, 23490
from (indole-3-yl)butyric acid (commercially available);
E) 23492, 23494, 23726
from (5-fluoro-indole-3-yl)acetic acid (commercially available);
Continuation of the intermediate syntheses for the compounds of the general formula of table 1
F) 23703, 23698
from (5-methoxyindole-3-yl)acetic acid (commercially available);
G) 23238, 23239, 23240, 23241, 23242, 23244, 23246, 23247, 23498, 23500, 23730
The C-5-substituted (indole-3-yl)propionic acids are synthesised by analogy with the following literature reference:
L. Kalb, F. Schweizer, Chem. Ber. 59, 1860 (1926)
H) 23488, 23491, 23493, 23497, 23499, 23501, 23502, 23721, 23735, 23427, 23707, 23712, 23708, 23729, 23702, 23718, 23724, 23727, 23711, 23720
The C-2-, C-5- and C-6-substituted indole-3-yl acetic acid derivatives that were needed as primary steps were synthesised according to the following literature instructions:
a) S. Findlay and G. Dougherty,
J. Org. Chem. 13, 560 (1948)
b) H. Yao and P. Resnick, J. Amer. Chem. 84, 3514 (1962)
c) H. Plieninger, Chem.Ber. 87. 228 (1954)
d) Houben-Weyl E6bl "Hetarene I--Part 2a", p. 716-720, Georg Thieme Publishers, Stuttgart--New York (1994)
Continuation of the intermediate syntheses for the compounds of table 1
I) 23243, 23722, 22701
(N-benzyl-3-yl)acrylic acid or N-[4-(fluorobenzyl)indole-3-yl]acrylic acid were prepared according to the synthesis path described hereinbelow and the corresponding synthesis instructions:
Synthesis instructions:
1-benzyl-(indole-3-yl)carboxaldehyde
To a solution of 10 g (68.9 mMol) indole-3-carboxaldehyde in 50 ml dioxan are added 13.5 g K 2 CO 3 and 9 ml (75 mMol) benzylbromide. After stirring 12 hours at room temperature 200 ml water are added and the mixture is extracted with methylene chloride. The organic phase is washed with water, dried with sodium sulfate and concentrated in vacuum. After purification by column chromatography (eluting solvent: dichloromethane), 14.2 g of the desired compound are obtained. Yield: 88% of theory
(1-benzylindole-3-yl)acrylic acid methylester
8 g (34 mMol) 1-benzyl(indole-3-yl)carboxaldehyde and 25 g (74.8 mMol) triphenylphosphoranylide acetic acid methyl ester in 200 ml dioxan are refluxed for 48 hours. The dioxan is evaporated and under reduced pressure the residue is purified by column chromatography in silica gel with a mixture of dichloromethane/hexane 80:20. 8.9 g of yellow crystals are obtained.
Yield: 90% of theory. (
1-benzylindole-3-yl)acrylic acid
43 ml (87 mMol) sodium hydroxide solution are added to a solution of 8.5 g (29,2 mMol) of the above ester in 50 ml ethanol. The mixture is refluxed for 1 hour. After cooling, 200 ml water are added, and the mixture is acidulated with conc. HCl. The (1-benzylindole-3-yl)acrylic acid precipitates in the form of white crystals. Yield: 88% of theory
Continuation of the intermediate syntheses for the compounds of table 1
K) 23719, 23732, 23717, 23733, 23734
The final products were prepared from [N-(4-fluorophenyl)-5-fluoro-(indole-3-yl)acetic acids according to the following synthesis scheme and the following syntheses instructions:
Synthesis of the intermediate of compound D 23719: ##STR186##
[N-( 4 -fluorophenyl)-5-fluoro-(indole-3-yl)]acetic acid ethyl ester
A mixture of 3.9 g (17.6 mMol) [5-fluoro-1H-(indole-3-yl)]acetic acid ethyl ester, 4.04 ml (35 mMol) 4-iodide-fluorobenzene, 17.6 potassium carbonate, 9.6 g copper powder and 73 ml bromobenzene are refluxed for 48 hours. The mixture is then filtered, the solvent removed under reduced pressure and the residue purified by column chromatography on silica gel with mixtures of dichloromethane/petroleum ether (4:1, v/v) to give 4.4 g of the compound as beige crystals.
Yield: 79% of theory.
[N-(4-fluorophenyl)-5-fluoro-(indole-3-yl)]acetic acid ethyl ester
4.4 g (14 mMol) [N-(4-fluorophenyl)-5-fluoro-(indole-3-yl)]acetic acid ethyl ester are dissolved in 39 ml ethanol and mixed with a solution of 1.67 g (42 mMol) NaOH in 8 ml water. The mixture is refluxed for 1 hour, the solvent removed under reduced pressure, the residue neutralised with 1n hydrochloric acid and then extracted with ethyl acetate. The organic phase is dried with sodium sulfate and the solvent is evaporated under reduced pressure.The residue is crystallized in isopropyl ether as yellow crystals.
Yield: 3.1 g (77% of theory). Melting point: 141° C.
Continuation of the intermediate syntheses for the compounds of table 1
L) 23714
The final product D-23714 is obtained from D-23720 by methylether cleavage with BBr 3 or NaCN in DMSO according to the following literature instructions:
a) H. Ulrich et al., J. Org. Chemistry 39, 2437 (1974)
b) J. R. McCarthy et al., Tetrahedron letters 52, 5183 (1978)
c) A. D. Fraser et al., J. Org. Chemistry 41, 170 (1976)
M) 24034
Syntheses of the intermediates of D-24034.
[N-(n-butyl)-(indole-3-yl)]acetic acid ethyl ester
A solution of 0.66 g (27.5 mMol) NaH in 200 ml DMSO is added under nitrogen atmosphere dropwise to a solution of 5.1 g commercially available (25 mMol) (indole-3-yl)acetic acid ethyl ester in 30 ml DMSO at room temperature. After 30 minutes 3.2 ml (27.6 mMol) n-butyliodide are added. The mixture is stirred for 3 hours, the reaction mixture is diluted with water and extracted with ether. After drying, the solvent is removed under reduced pressure and the residue is purified by column chromatography on silica gel. Eluting solvent: dichloromethane (petroleum ether (7:2, v/v). 4.4 g of a yellow oil are obtained.
Yield: 68% of theory.
[N-(n-butyl)-indole-3-yl)]acetic acid
The synthesis is carried out according to the saponification instructions for the primary step [N-(4-fluorophenyl)-5-fluoro-(indole-3-yl)]acetic acid ethyl ester of compound D-23719.
Yield: 96% of theory.
In addition, the compounds of the general formula 1 with G=(i) can be obtained according to the following synthesis Scheme of diagram II, wherein
W=CH
X=CH
Y=a single bond, such that the heterocyclic ring system is associated directly with the group ##STR187## Z=2 hydrogen atoms.
DIAGRAM II ##STR188##
According to the above diagram II the compound N-(pyridine-3-yl)-2-[1-(4-fluorobenzyl)indole-3-yl]ethylamine maleate (D-22557) was obtained.
D-23495 was used as educt. Yield: 83% of theory related to D-23495 used. Elementary analysis:
______________________________________C calc. 67.67 found 67.62 H calc. 5.24 found 5.39 N calc. 9.1 found 8.92______________________________________
According to the above diagram II the compound N-(3-pyridyl)-3-[1-methylindole-3-yl]propylamine maleate (D-22554) was obtained.
Instructions:
To a solution of 1.2 g (4.3 mMol) of the basic amide D-22684 in 150 ml anhydrous tetrahydrofuran in a three-necked flask are added a suspension of 0.8 g (21 mmol) LiAlH 4 in 10 ml THF under nitrogen atmosphere and vigorous stirring. The mixture is refluxed for 2 hours and cooled to 15° C. The excess LiAlH 4 is hydrolysed by slow addition of 10 ml iced water. The obtained mixture is extracted several times with methylene chloride, the organic phase is dried with anhydrous sodium sulfate and the solvent is removed under reduced pressure. The residue is dried and transferred to the maleate as follows:
Maleate synthesis:
The base of D-22554 obtained as set out above is dissolved in a little anhydrous ethyl acetate and mixed with a concentrated solution of maleic acid used in equivalent amount to the base in ethyl acetate, the mixture is left to stand over night at 4° C and the crystalline compound obtained--D-22554--is filtered.
MP: 118° C.; Yield: 83% of theory related to the maleate. Elementary analysis: C calc. 66.13 found 65.92;
______________________________________C calc. 66.13 found 65.92 M calc. 6.08 found 6.21 N calc. 11.02 found 10.94______________________________________
General instruction for preparing compounds of general formula 1 by analogy with diagram II
The indole-3-yl carboxylic acid amide is added in a nitrogen atmosphere to a three-necked flask with stirrer, dropping funnel and reflux cooler into an anhydrous organic solvent such as diethyl ether, THF, dioxan or toluene. After adding 2-5 times, preferably 3-times the molar excess of reducing agent, such as lithium aluminium hydride, sodium cyanoborohydride or sodium borohydride/activator the mixture is heated at reflux for 1-2 hours, then cooled to approx. 10° C. and the excess reducing agent hydrolysed with excess water. The reaction mixture is extracted several times with an organic solvent, preferably methylene chloride, chloroform or also ethyl acetate, the combined extracts are dried with anhydrous sodium sulfate and then concentrated to dryness in a vacuum. The base obtained in this manner can be converted to the maleate by the following path.
The base obtained in the above manner is dissolved in an organic solvent, preferably an alcohol, such as methanol, ethanol or isopropanol or also in an aprotic solvent such as ethyl acetate or methylene chloride and treated with the equivalent amount of maleic acid which is dissolved in a little ethyl acetate or isopropanol. When left at room temperature or at 0-5° C., the corresponding maleate crystallises, is filtered and dried under reduced pressure.
According to this general instruction for the synthesis of new indole derivatives according to diagram II, the following compounds were synthesised which are listed in the following summary, quoting their code numbers (D-numbers) and the corresponding chemical designation. The following table 2 shows the structures of these compounds and their melting points from the general formula I and the substituents Y-G, W, X, R 1 , R 2 and R 3 :
______________________________________D-22551 N-(4-pyridyl-yl)-2-(1-methylindole-3- yl)ethylamine maleate D-22685 N-(4-pyridyl-yl)-2-(1-benzylindole-3-yl)ethyl amine maleate D-22688 N-(4-pyridyl-yl)-4-(indole-3-yl)butylamine oxalate D-22696 N-(4-pyridyl-yl)-3-(1-methylindole-3-yl)propyl amine maleate D-22697 N-(4-pyridyl-yl)-3-(1-methylindole-3-yl)propyl amine D-22554 N-(3-pyridyl-yl)-3-(1-methylindole-3-yl)propyl- amine D-22555 N-(3-pyridyl-yl)-3-(1-benzylindole-3-yl)propyl amine D-22557 N-(3-pyridyl-yl)-2-[1-(4-fluorobenzyl)indole-3- yl]ethylamine maleate D-22561 N-(4-pyridyl-yl)-2-[1-(4-fluorobenzyl)indole-3- yl]ethylamine maleate D-23699 N-(2-(4,6-dimethylpyridyl))-2-[1-(4- fluorobenzyl)indole-3-yl]ethylamine maleate D-23704 N-(2-pyridyl-yl)-3-[1-(4-fluorobenzyl)indole-3- yl]propylamine D-23710 N-(3-pyridyl-yl)-2-(1-benzylindole-3-yl)ethyl- amine maleate D-23713 N-(2-pyridyl-yl)-2-[1-(4-fluorobenzyl)indole-3- yl]ethylamine D23723 N-(2-pyridyl-yl)-2-(1-benzylindole-3-yl)- ethylamine D-24045 N-(4-pyridyl-yl)-2-[1-butyl-indole-3-yl]ethyl- amine D-24038 N-(4-pyridyl-yl)-2-[1-(4-chlorobenzyl)indole-3- yl]ethylamine D-24043 N-(4-pyridyl-yl)-2-[1-(2-fluorobenzyl)indole-3- yl]ethylamine D-24044 N-(4-pyridyl-yl)-2-[1-(3-trifluoromethyl- benzyl)indole-3-yl]ethylamine D-23709 N-(4-pyridyl-yl)-4-[1-(4-fluorobenzyl)indole-3 yl]butylamine D-22698 N-(4-pyridyl-yl)-3-[1-(4-fluorobenzyl)indole-3 yl]propylamine D-22686 N-(3-pyridyl-yl)-3-3[1-(4-fluorobenzyl)indole-3- yl]propylamine D-23731 N-(4-pyridyl-yl)-4-(1-benzylindole-3-yl)butyl- amine______________________________________
TABLE 2__________________________________________________________________________New indole compounds according to reaction diagram II1 STR189##D Y--G X R.sup.1 W R.sup.2 R.sup.3 Fp[° C.]__________________________________________________________________________ 22551 (Maleat) 3 CH CH.sub.3 CH H H 119 - 22685 (Maleat) 3 CH 191## 4 CH H H 140 - 22688 (Oxalat) 4 CH H CH H H 60 (deliquesce) - 22696 (Maleat) 5 CH CH.sub.3 CH H H 126-128 - 22697 5 CH 195## 4 CH H H oil - 22554 6 CH CH.sub.3 CH H H 118 - 22555 6 CH 198## 4 CH H H 76 (deliquesce) - 22557 (Maleat) 7 CH 200## 6 CH H H 142 - 22561 (Maleat) 8 CH 202## 6 CH H H 111 - 23699 (Maleat) 9 CH 204## 6 CH H H 104-105 - 23704 0 CH 206## 6 CH H H 112-113 - 23710 (Maleat) 7 CH 208## 4 CH H H 122-124 - 23713 1 CH 210## 6 CH H H 110 - 23723 1 CH 212## 4 CH H H 116-117 - 24045 8 CH CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3 CH H H 51 (deliquesce) - 24038 8 CH 215## 0 CH H H 49 (deliquesce) - 24043 8 CH 217## 2 CH H H 153 - 24044 8 CH 219## 3 CH H H oil - 23709 4 CH 221## 6 CH H H 80-90 - 22698 5 CH 223## 6 CH H H 126-128 - 22686 (Maleat) 6 CH 225## 6 CH H H 136 - 23731 4 CH 227## 4 CH H H 60-65 (deliquesce)__________________________________________________________________________
Starting material for the compounds of general formula 1 which emerge from table 2 prepared according to synthesis diagram II
Final synthesis products (D-compounds)intermediates of general formula 1 from table 2 (correspond to final according to synthesis diagram II products from Tab. 1)
______________________________________ D-22554 D-22684 D-22561 D-22558 D-22555 D-22682 D-22557 D-23495 D-22685 D-22560 D-22688 D-22552 D-22696 D-22689 D-22697 D-22683 D-22698 D-22690 D-24038 D-24035 D-24043 D-24040 D-24044 D-24041 D-24045 D-24034 D-23710 D-22680 D-23699 D-23496______________________________________
Final synthesis products (D-compounds)intermediates of general formula 1 from table 2 (correspond to final according to synthesis diagram II products from Tab. 1)
______________________________________ D-23713 D-23701 D-23723 D-23725 D-23709 D-23245 D-23704 D-23728 D-23731 D-23490______________________________________
The compounds of general formula 1 with X═ C═, where a single bond of C=, which is saturated by hydrogen in formula 1 and which is linked via a methylene group to the N-atom of the group --NR 6 R 7 of R 5 and in the event that R 6 and R 7 are equal to hydrogen, this hydrogen is replaced, are obtained according to the following DIAGRAM III:
DIAGRAM III ##STR229##
The compound N-(3-ethoxycarbonylamino-6-methoxypyridine-2-yl)-1,2,3,4-tetrahydro-β-carboline-(D-22550) was obtained according to diagram III:
1st step
1,2,3,4-tetrahydro-β-carboline
In an Erlenmeyer flask 10 g (50 mMol) of tryptamine hydrochloride are dissolved with stirring at 45° C. in 160 ml H 2 O. The mixture is cooled at room temperature and a solution of 5.3 g (56 mMol glyoxylic acid monohydrate in 12 ml water and then, slowly, a cold solution of 2.8 g (48 mMol) KOH in 14 ml water is added. After stirring for 1 hour the precipitate formed is filtered and washed with 40 ml H 2 O. The isolated compound is transferred to a beaker with 96 ml water. Under stirring 13.6 ml conc. hydrochloric acid is added slowly to the product. The mixture is refluxed for 30 minutes, treated again with conc. HCl and kept at boiling temperature for 15 minutes. After cooling to room temperature the precipitate is filtered, washed with 12 ml water, dissolved in 160 ml H 2 O and heated to approx. 55° C. under stirring. The solution is adjusted to pH 12 with 20 percent KOH. The resultant solid compound is then filtered, washed with 160 ml water and dried in vacuum.
MP: 205° C.; Yield: 75% of theory
2nd step:
N- (3-nitro-6-methoxy-2-pyridyl-yl)-1,2,3,4-tetrahydro-β-carboline
200 ml acetonitrile and 3.01 g K 2 CO 3 are filled into a flask. The mixture is cooled with an ice-sodium chloride mixture and 2.5 g (14.5 mMol) 1,2,3,4-tetrahydro-β-carboline and 2.71 g (14.5 mMol) 2-chloro-3-nitro-methoxypyridine are added. This is allowed to come to room temperature with stirring and heated to reflux temperature for 2 hours. The reaction mixture is evaporated in vacuum and the residue is treated with 150 ml H 2 O. The insoluble residue is recrystallised from ethanol.
MP: 218-220° C.; Yield: 89% of theory
3rd step:
N-(3-ethoxycarbonylamino-6-methoxypyridine-2-yl)-1,2,3,4-tetrahydro-β-carboline
4 g (12.3 mMol N-(3-nitro-6-methoxypyridine-2-yl-1,2,3,4-tetrahydro-β-carboline are added with stirring to a three-necked flask with 200 ml anhydrous ethanol. 2 g sodium borohydride and 0.5 g palladium charcoal are added under a nitrogen atmosphere. The mixture is refluxed for 2 hours with further nitrogen gassing. It is then cooled to 10° C. and 4.07 g (37 mmol) chloroformic acid ethyl ester are added dropwise. This is stirred for 2 hours at 30° C., then cooled to 15° C., filtered and concentrated. The residue is purified by column chromatography on silica gel with a mixture of petroleum ether/diisopropyl ether 50/50 (V/V). The residue recrystallised from petroleum ether/dichloromethane (95:5 (V/V)).
MP: 125° C.; Yield: 42% of theory.
General instructions for the preparation of compounds of general formula 1 according to diagram III
Tryptamine hydrochloride is dissolved in water in a flask with heating. Glyoxylic acid monohydrate and a solution of an inorganic base such as NaOH, KOH, LiOH or Ba (OH) 2 are added. After the reaction the precipitate formed is filtered off and washed. The precipitate is heated in an inorganic acid such as hydrochloric acid or sulfuric acid, more conc. hydrochloric acid is added and the mixture is refluxed for some time. After cooling, the precipitate formed is filtered, washed and dissolved again in H 2 O with stirring. The pH is adjusted to pH 12 with 20 percent KOH and the formed 1,2,3,4-tetrahydro-β-carboline is filtered.
The 1,2,3,4-tetrahydro-β-carboline formed in this manner is heated under reflux for 1-3 hours with commercially available 2-chloro-3-nitro-6-methoxypyridine and a base, for example alkali metal carbonates or alkali hydrogen carbonates in an organic solvent, such as acetonitrile, propionitrile, THF, diethylether or dioxan. After evaporation of the solvent, the residue is diluted with water and the insoluble residue is recrystallised from ethanol.
Product obtained according to the above instructions is reduced in a manner known per se; here: N-(3-nitro-6-methoxy-pyridine-2-yl)-1,2,3,4-tetrahydro-β-carboline is dissolved in absolute ethanol and treated in a nitrogen atmosphere with sodium borohydride and Pd-C as catalyst. The mixture is refluxed for 1-4 hours. After cooling, the chloroformic acid ester is added, in this case chloroformic acid ethyl ester, and stirred for further 1-4 hours. After filtration and evaporation of the solvent the residue is purified by column chromatography on silica gel with a mixture of petroleum ether/diisopropyl ether 50:50 (V/V) and recrystallised from petroleum ether/dichloromethane.
The following examples were synthesised according to the above instructions:
N-(6-amino-5-ethoxycarbonylamino-(-2-pyridyl))-1,2,3,4-tetrahydro-β-carboline (D-22559)
MP: 191° C.; Yield: 40% of theory
Elementary analysis
______________________________________C calc. 64.94 found 65.05 H calc. 6.02 found 6.01 H calc. 19.93 found 19.79______________________________________
1-methyl-N-(3-nitro-6-methoxy-(2-pyridyl))-1,2,3,4-tetrahydro-β-carboline (D-23716)
MP: 178-179° C.; Yield: 61% of theory;
1-methyl-N-(5-nitro-6-amino-(2-pyridyl))-1,2,3,4-tetrahydro-β-carboline (D-23706)
MP: 192-194° C.; Yield: 65.5% of theory
The synthesis of the intermediate 1-methyl-1,2,3,4-tetrahydro-β-carboline is carried out according to the conventional method of the Pictet-Spengler reaction from tryptamine and acetaldehyde according to the following literature:
Lit.
A. M. Jackson, A. H. Smith, Tetrahedron 24, 403 (1968) and G. Buchi, K. B. Matsumoto, H. Nishimura, J. Aver. Chem. Soc. 93, 3299 (1971):
Spath and Lederer, Chem. Ber. 63, 2101 (1930): Hahn et al. Ann. 520, 107 (1935); Chem. Ber. 71, 2163 (1938), 2192 (1938)
The compounds of general formula 1 with G=(i) can also be obtained according to the synthesis scheme of diagram IV, where:
W=CH
X=CH
Y=a single bond,
in such a manner that the heterocyclic system is directly associated with the group ##STR230##
DIAGRAM IV ##STR231##
The compound N-(5-ethoxycarbonylamino-6-amino-(2-pyridyl))-2-(indole-3-yl)ethylamine (D-22191) was, for example, obtained according to the above diagram IV.
Instructions for reaction:
1st step: 3 g (18.7 mMol) tryptamine, 3.25 g (18.7 mMol) 2-amino-3-nitro-6-chloropyridine and 2.6 g K 2 CO 3 are heated in 300 ml acetonitrile in a flask for 1 hour under reflux. The solvent is removed under reduced pressure, the residue is diluted with water and extracted with dichloromethane. The dichloromethane extracts are dried with anhydrous sodium sulfate, filtered and concentrated. The residue is purified by column chromatography on silica gel with a mixture of dichloromethane/ethanol 95:5 (V/V). and recrystallised in absol. ethanol. MP: 196° C., yield 72% of theory.
2nd step: The reduction of the nitro group and the subsequent reaction with chloroformic acid ethyl ester or chloroformic acid phenyl ester is carried out according to the general synthesis instructions to prepare compounds of general formula 1 according to diagram III (step 3) on p. 71.
Apart from acetonitrile it is also possible to use dioxan, THF, dimethylformamide and isopropanol as solvents for the 1st step. Apart from K 2 CO 3 it is also possible to use Na 2 CO 3 , NaHCO 3 , triethylamine or basic ion exchanges as acid catchers.
Apart from EtOH it is also possible to use methanol, isopropanol or dioxan as solvents in the 2nd step (reduction step).
In a variant of diagram IV, 2-chloro-3-nitro-6-methoxypyridine was used for the condensation with corresponding "indole-3-yl-alkylamines" (1st step) instead of 2-amino-3-nitro-6-chloropyridine, which is explained in connection with the preparation of the final compound D-23202 on the basis of the following synthesis Scheme. ##STR232##
The condensation reaction of 2-(l-methylindole-3-yl)isopropylamine with 2-chloro-3-nitro-6-methoxypyridine in acetonitrile (1st step) and K 2 CO 3 was carried out by analogy with the instructions on page 69 (there step 2) applying to the compound D-22550. The 2nd step with NaBH 4 /Pd-C and the subsequent reaction with chloroformic acid ethyl ester occurred by analogy to the instructions for the synthesis of D-22550 according to step 3 therein.
According to the above general instructions for the synthesis of new indole derivatives according to diagram IV the following compounds were synthesised which are listed in the following summary, quoting their code numbers (D-numbers) and the corresponding chemical designation.
The following table 3 shows the structures of these compounds, their melting points from general formula 1 and the substituents Y-G, W, X, R 1 , R 2 and R 3 :
______________________________________D-22192 N-(3-ethoxycarbonylamino-6-methoxy(2-pyridyl))-2- (indole-3-yl)ethylamine D-22556 N-(3-phenoxycarbonylamino-6-methoxy(2-pyridyl))-2- (indole-3-yl)ethylamine D-22702 N-(3-ethoxycarbonylamino-6-methoxy(2-pyridyl))--3- (indole-3-yl)propylamine D-22706 N-(3-ethoxycarbonylamino-6-methoxy(2-pyridyl))-2- (1-benzyl-indole-3-yl)isopropylamine D-22948 N-(3-ethoxycarbonylamino-6-methoxy(2-pyridyl))-2- [1-(4-fluorobenzyl-indole-3-yl)ethylamine D-22949 N-(5-ethoxycarbonylamino-6-amino(2-pyridyl))-2- [1-(4-fluorobenzyl-indole-3-yl)ethylamine maleate D-22950 N-(5-ethoxycarbonylamino-6-amino(2-pyridyl))-3- (indole-3-yl)propylamine maleate D-23203 N-(5-ethoxycarbonylamino-6-amino(2-pyridyl))-2- (1-benzylindole-3-yl)ethylamine maleate D-23201 N-(3-nitro-6-methoxy(2-pyridyl))-2-(1-benzyl- indole-3-yl)ethylamine D-23205 N-(5-ethoxycarbonylamino(2-pyridyl))-2-(1- benzylindole-3-yl)isopropylamine D-23204 N-(5-ethoxycarbonylamino-6-amino(2-pyridyl))-3- [1-(4-fluorobenzyl)indole-3-yl]propylamine D-23715 N-(5-ethoxycarbonylamino-6-amino(2-pyridyl))-2- (5-chloroindole-3-yl)ethylamine maleate D-22193 N-[1-(3-ethoxycarbonylamino-6-methoxy-(2-pyridyl)) piperidine-4-yl]-3-(indole-3-yl)propionamide D-22194 N-[1-(3-ethoxycarbonylamino-6-methoxy-(2-pyridyl))-2- piperidine-4-yl](indole-3-yl)acetamide D-22987 N-(5-ethoxycarbonylamino-6-amino-(2-pyridyl))-2- (1-methylindole-3-yl)isopropylamine maleate D-22988 N-(3-ethoxycarbonylamino-6-amino-(2-pyridyl))-2- (-methylindole-3-yl)ethylamine D-22989 N-(3-ethoxycarbonylamino-6-methoxy-(2-pyridyl))-2- (5-chloroindole-3-yl)ethylamine D-22990 N-(5-ethoxycarbonylamino-6-amino-(2-pyridyl))-2- (1-methylindole-3-yl)ethylamine D-22991 N-(5-nitro-6-amino-(2-pyridyl))-2-(1-benzylindole- 3-yl)ethylamine D-22992 N-(3-ethoxycarbonylamino-6-methoxy-(2-pyridyl))-2- (1-benzylindole-3-yl)ethylamine D-22993 N-(3-ethoxycarbonylamino-6-methoxy-(2-pyridyl)-3- [1-(4-fluorobenzyl)indole-3-yl)propylamine D-23202 N-(3-ethoxycarbonylamino-6-methoxy-(2-pyridyl))-2- (1-methylindole-3-yl]isopropylamine D-22195 N-[1-(5-ethoxycarbonylamino-6-amino-(2-pyridyl))-4- piperidyl]-2-(indole-3-yl)propionamide D-24325 N-[1-(5-ethoxycarbonylamino-6-amino-(2-pyridyl))-4- piperidyl](indole-3-yl]acetamide D-22188 N-(5-nitro-6amino-(2-pyridyl))-2-(indole-3- yl)ethylamine D-22189 N-[1-(5-nitro-6-amino-(2-pyridyl))-4-piperidyl]-3- (indole-3-yl)propionamide D-22190 N-[1-(5-nitro-6-amino-(2-pyridyl))-4-piperidyl]-(indole- 3-yl)acetamide D-22699 N-(3-nitro-6-methoxy-(2-pyridyl))-3-(indole-3- yl)propylamine D-22700 N-(5-nitro-6-amino-(2-pyridyl))-3-(indole-3- yl)propylamine D-22703 N-(3-nitro-6-methoxy-(2-pyridyl))-2-(1-benzyl- indole-3-yl)isopropylamine D-22704 N-(3-nitro-6-methoxy-(2-pyridyl))-2-[1-(4- fluorobenzyl)indole-3-yl]ethylamine D-22705 N-(3-nitro-6-amino-(2-pyridyl))-2-[1-(4-fluoro- benzyl)indole-3-yl]ethylamine D-22707 N(5-nitro-6-amino-(2-pyridyl))-2-(1-methylindole- 3-yl)isopropylamine D-22984 N-(3-nitro-6-methoxy-(2-pyridyl))-2-(1-methyl. indole-3-yl)ethylamine D-22947 N(5-nitro-6-amino-(2-pyridyl))-2-(1-methylindole- 3-yl)ethylamine D-22985 N-(3-nitro-6-methoxy-(2-pyridyl))-2-(5- chloroindole-3-yl)ethylamine D-22986 N-(5-nitro-6-amino-(2-pyridyl))-2-(5-chloroindole- 3-yl)ethylamine______________________________________
TABLE 3__________________________________________________________________________Novel indole compounds according to reaction diagram IV1 STR233##New indole derivatives according to reaction diagram IVD Y--G W X R.sup.1 R.sup.2 R.sup.3 Fp[°C.]__________________________________________________________________________ 22191 2 CH CH H H H 46 (deliquesce) - 22192 3 CH CH H H H 184 - 22193 4 CH CH H H H 92 - 24325 5 CH CH H H H 232-234 - 22194 6 CH CH H H H 144 - 22195 7 CH CH H H H 208 - 22556 8 CH CH H H H 131 - 22702 9 CH CH H H H 53 (deliquesce) - 22706 0 CH CH ## 2 H H 166 - 22948 1 CH CH ## 3 H H 113 - 22949 4 CH CH ## 3 H H 175 - 22950 (Maleat) 5 CH CH H H H 138 - 22987 (Maleat) 6 CH CH CH.sub.3 H H 110 - 22988 7 CH CH CH.sub.3 H H 120-122 - 22989 7 CH CH H 5-Cl H 90 (deliquesce) - 22990 (Maleat) 8 CH CH CH.sub.3 H H 168-170 - 22992 9 CH CH ## 2 H H 114-116 - 22993 0 CH CH ## 3 H H 90-92 (deliquesce) - 23202 1 CH CH CH.sub.3 H H 50 (deliquesce) - 23203 (Maleat) 2 CH CH ## 2 H H 168-170 - 23205 (Maleat) 3 CH CH ## 2 H H 144-146 - 23204 (Maleat) 4 CH CH ## 3 H H 90 (deliquesce ) - 23715 4 CH CH H 5-Cl H 182-184 - 22991 5 CH CH ## 2 H H 158-160 - 23201 6 CH CH ## 2 H H 116-118 - 22188 7 CH CH H H H 196 - 22189 8 CH CH H H H 192 - 22190 9 CH CH H H H 200 - 22699 0 CH CH H H H 113 - 22700 1 CH CH H H H 120 - 22703 2 CH CH ## 2 H H 128 - 22704 3 CH CH ## 3 H H 138 - 22705 5 CH CH ## 3 H H 149 - 22707 4 CH CH CH.sub.3 H H 50 (deliquesce) - 22984 5 CH CH CH.sub.3 H H 244-246 - 22947 5 CH CH CH.sub.3 H H 140 - 22985 5 CH CH H 5-Cl H 180-182 - 22986 5 CH CH H 5-Cl H 218-220 - 22687 6 CH CH ## 3 H H 133#__________________________________________________________________________
Starting material for the compounds of general formula 1 (intermediate synthesis) synthesised in table 3 according to reaction diagram IV:
______________________________________Final compound Starting material [D]______________________________________D-23715 22986 D-23203 22991 D-22705 22949 D-22990 22947 D-22950 22700 D-22987 22707 D-22191 22188 D-22993 22704 D-22988 22984 D-22556, D-22192 22985 D-22992 23201 D-22702 22699 D-22195 22189 D-24325 22190______________________________________
The 2-(1-methylindole-3-yl)isopropylamine used, for example, for the final compound D-23202 can be synthesised according to the following reaction scheme: ##STR287## Instructions:
1st step: A solution of 9 g (56.5 mMol) 1-methyl-indole-3-carbaldehyde and 6.1 g (79 mMol) ammonium acetate in 200 ml nitroethane is refluxed with stirring for 2 hours. After substantial evaporation of the solvent an orange-coloured precipitate of 1-(1-methyl-1H-indole-3-yl)-2-nitropropene precipitates out after cooling.
Yield: 86% of theory; MP: 132-134° C.
2nd step: A suspension of 3.6 g LiAlH 4 in 200 ml anhydrous tetrahydrofuran (THF) is mixed dropwise with a solution of 5.4 g 1-(1-methyl-1H-indole-3-yl)-2-nitropropene in 100 ml THF. The mixture is heated to reflux for 1 hour, then cooled, excess of lithium aluminium hydride is slowly destroyed by adding 150 ml iced water and the resultant mixture is extracted with dichloromethane. The organic phase is dried with anhydrous sodium sulfate and evaporated in vacuum. A yellow oil is obtained that is dried in vacuum and immediately used for the condensation reaction with 2-chloro-3-nitro-6-methoxypyridine.
Yield: 85% of theory.
The compounds of general formula 1 from the 1H-indazole series with G=(i) can also be prepared according to the following diagram V:
DIAGRAM V: ##STR288##
According to the above diagram V, the compound N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-1H-indazole-3-yloxy]acetamide (D-23591) was for example obtained as follows:
A suspension of 1.0 g (3.33 mol) [[1-(4-fluorophenylmethyl)-1H-indazole-3-yl]oxy]-acetic acid in 20 ml methylene chloride was mixed with stirring with a suspension of 0.85 (3.33 mMol) 2-chloro-1-methylpyridinium-iodide, 1.2 ml triethylamine and 0.31 g (3.33 mMol) 4-aminopyridine in 30 ml methylene chloride and heated to reflux for 4 hours. After cooling, the reaction mixture is extracted three times with 50 ml H 2 O and the methylene chloride solution is dried over anhydrous sodium sulfate. Evaporation the solution yields a precipitate which is purified on a silica gel column (column chromatography on silica gel with a mixture toluene (chloroform/methanol 2:1:0.5).
Yield: 0.82 g (65.4% of theory); Melting point: 136° C.-139° C.
New 1H-indazole derivatives were synthesized according to the above instructions and by analogy with the general method of procedure according to diagram I, these are listed in the following summary, quoting their code numbers (D-numbers) and the corresponding chemical designation. The following table 4 shows the structures of these compounds and their melting points from the general formula 1 and the substituents Y-G, W, X, R 1 , R 2 and R 3 :
______________________________________D-23557 N-(4-pyridyl)-2-[1-(4-chlorobenzyl)-5-methoxy- 1H-indazole-3-yloxy]acetamide D-23590 N-(4-pyridyl)-2-[1-(4-chlorobenzyl)-1H-indazole 3-yloxy]acetamide D-23592 N-(3-pyridyl)-2-[1-(4-chlorobenzyl)-5-methoxy- 1H-indazole-3-yloxy]acetamide D-23593 N-(2-methyl-4-quinolyl)-2-[1-(4-chlorobenzyl)-5- methoxy-1H-indazole-3-yloxy]acetamide D-23686 N-(3-pyridyl)-2-[1-(4-fluorobenzyl) 1H-indazole-3-yloxy]acetamide D-23687 N-(2-nitro-3-pyridyl)-2-[1-(4-fluorobenzyl)-1H- indazole-3-yloxy]acetamide D-23758 N-(3-pyridyl)-2-[1-(4-chlorobenzyl)-1H- indazole-3-yloxy]acetamide D-23760 N-(3-pyridyl)-2-[1-(4-fluorobenzyl)-5-methoxy- 1H-indazole-3-yloxy]acetamide D-23761 N-(6-amino-2-pyridyl)-2-[1-(4-chlorobenzyl)-1H- indazole-3-yloxy]acetamide D-23778 N-(2-nitro-3-pyridyl)-2-[1-(4-chlorobenzyl)-1H- indazole-3-yloxy]acetamide D-23779 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-5-methoxy- 1H-indazole-3-yloxy]acetamide D-23781 N-(4-pyridyl)-2-[1-(4-fluorobenzyl)-5-nitro-1H- indazole-3-yloxy]acetamide D-23782 N-(5-methoxycarbonyl-2-pyridyl)-2-[1-(4- fluorobenzyl)-1H-indazole-3-yloxy]acetamide D-23783 N-(6-amino-2-pyridyl)-2-[1-(4-fluorobenzyl- indazole-3-yloxy]acetamide D-23828 N-(4-pyridyl)-2-[1-(4-chlorobenzyl)-5-nitro-1H- indazole-3-yloxy]acetamide D-23829 N-(6-amino-2-pyridyl)-2-[1-(4-chlorobenzyl)-5- methoxy-1H-indazole-3-yloxy]acetamide D-23830 N-(5-methoxycarbonyl-2-pyridyl)-2-[1-(4- fluorobenzyl-5-methoxy-1H-indazole-3- yloxy]acetamide D-23861 N-(6-amino-2-pyridyl)-2-[1-(4-fluorobenzyl)-5- methoxy-1H-indazole-3-yloxy]acetamide D-23874 N-(5-methoxycarbonyl-2-pyridyl)-2-[1-(4- chlorobenzyl-5-methoxy-1H-indazole-3- yloxy]acetamide D-23915 N-(2-nitro-3-pyridyl)-2-[1-(4-fluorobenzyl)-5- methoxy-1H-indazole-3-yloxy]acetamide D-23930 N-(5-methoxycarbonyl-2-pyridyl)-2-[1-(4- chlorobenzyl-1H-indazole-3-yloxy]acetamide______________________________________
TABLE 4__________________________________________________________________________Novel 1H-indazole derivatives according to diagram V7 STR289##D --Y--G R.sup.1 X W R.sup.3 R.sup.2 Fp.__________________________________________________________________________ 23557 8 STR290## 9 N CH H 5-O--CH.sub.3 97-99° C. - 23590 8 STR292## 9 N CH H H 158-161.degree . C. - 23591 8 STR294## 3 N CH H H 136-139.degree . C. - 23592 0 STR296## 9 N CH H 5-O--CH.sub.3 177-178° C. - 23593 1 STR298## 9 N CH H 5-O--CH.sub.3 152-160° C. - 23686 0 STR300## 3 N CH H H Ol - 23687 2 STR302## 3 N CH H H 158-160.degree . C. - 23758 0 STR304## 9 N CH H H 148-150.degree . C. - 23760 0 STR306## 3 N CH H 5-O--CH.sub.3 159-160° C. - 23761 3 STR308## 9 N CH H H 170-171.degree . C. - 23778 2 STR310## 9 N CH H H 154-156.degree . C. - 23779 8 STR312## 3 N CH H 5-O--CH.sub.3 157-158° C. - 23781 8 STR314## 3 N CH H 5-NO.sub.2 176-178° C. - 23782 4 STR316## 3 N CH H H 160.5-161.5.de gree. - 23783 3 STR318## 3 N CH H H 193.5-194.5.de gree. - 23828 8 STR320## 9 N CH H 5-NO.sub.2 207.5-208° C. - 23829 3 STR322## 9 N CH H 5-O--CH.sub.3 178-180° C. - 23830 4 STR324## 3 N CH H 5-O--CH.sub.3 160-160.5° C. - 23861 3 STR326## 3 N CH H 5-O--CH.sub.3 157.5-158° C. - 23874 4 STR328## 9 N CH H 5-O--CH.sub.3 159-160° C. - 23915 2 STR330## 3 N CH H 5-O--CH.sub.3 180-181° C. - 23930 4 STR332## 9 N CH H H 169-170.degree . C.__________________________________________________________________________
Starting compounds for reactions according to diagram V
The starting substances according to the reactions described for diagram V can be prepared from the 1-benzyl-1H-indazole-3-ols published by L. Baiochchi et al. Synthesis 1978, 633 and thus known to the literature by reaction with chloroacetic acid ethyl ester in DMF with K 2 CO 3 and also in aqueous sodium hydroxide solution at room temperature or elevated temperature up to 80° C. The (1-benzyl-1H-indazole-3-yl)oxyacetic acid ethyl esters primarily formed thereby are reacted with sodium hydroxide solution at 50° C. in an ethanol/water solvent mixture and the corresponding (1-benzyl-1H-indazole-3-yl)oxyacetic acids precipitated out by acidulation with dilute hydrochloric acid.
In addition, the compounds of general formula 1 with G=(ii) can be obtained according to the synthesis path of diagram VI, where
W=CH
X=N
Y=O
DIAGRAM VI ##STR334##
The compounds 1-(4-chlorobenzyl)-3-[2-(1-methylpyrrolidine-2-yl)-ethoxy]-1H-indazole (D-22591) and 1-(4-chlorobenzyl)-3-(1-methyl-azepan-4-yloxy)-1H-indazole (D-22175) were obtained according to the above diagram VI:
Instructions:
4,1-(4-chlorobenzyl)-3-[2-(1-methylpyrrolidine-2-yl)-ethoxy]-1H-indazole(1) and 1-(4-chlorobenzyl)-3-(l-methyl-azepan-4-yloxy)-1H-indazole (2)
A solution of 3.75 g (29 mMol) 1-methylazepan-4-ol in 15 ml anhydrous THF was added dropwise to a solution of 5 g (19 mMol) 1-(4-chlorobenzyl)-1H-indazole-3-one in 150 ml anhyclrous THF at 23° C. with stirring. After stirring for approx. 10 min. at room temperature 7.6 g (29 mMol) triphenylphosphine and a solution of 5.1 g (29 mMol) azodicarboxylic acid ethyl ester in 10 ml anhydrous THF was then immediately added dropwise. After stirring for 5 hours at room temperature the solvent was removed at reduced pressure. The residue was purified by flash chromatography in the first with a mixture of CH 2 Cl 2 /aceton (80:20), whereby triphenylphosphine oxide and small amounts of unreacted 1-(4-chlorobenzyl)-1H-indazole-3-one were eluted. Elution with a mixture of CH 2 Cl 2 /methanol (80:20) yielded a mixture consisting of the two title compounds 1 and 2: 1-(4-chlorobenzyl)-3-[2-(1-methylpyrrolidine-2-yl)-ethoxy]-1H-indazole (1) and 1-(4-chlorobenzyl)-3-[(1-methylazepan-4-yl)oxy]-1H-indazole (2). ##STR335## General instructions for the preparation of compounds of general formula 1 for G=(ii)
A solution of the amine is added dropwise at room temperature to a stirred solution of the indazole derivative in an organic solvent, such as THF, dioxan, DMF or DMA. This mixture is briefly stirred before adding triphenylphosphine and azodicarboxylic acid ester in THF. After the end of the reaction the solvent is removed under reduced pressure. The residue is purified by column chromatography with a mixture of methylene chloride/acetone (80:20).
The following compounds were synthesized according to the above instructions for the synthesis of novel indazole derivatives according to diagram VI and according to the example set out as well as to the General Instructions, these are set out in the following summary, quoting their code numbers (D-numbers) and the corresponding chemical designation. The following table 5 shows the structures of these compounds and their melting points from the general formula 1 and the substituents Y-G, W, X, R 1 , R 2 , R 3 :
______________________________________D-21963 1-(4-fluorobenzyl)-3-(1-methylazepan-4-yloxy)- 1H-indazole D-22055 1-(4-fluorobenzyl)-3-(1-methyl-4- piperidyloxy)-1H-indazole D-22105 1-(4-chlorobenzyl)-3-(1-methyl-4-piperidyl- oxy)-1H-indazole D-23172 1-(4-chlorobenzyl)-3-[2-(1-methylpyrolidine-2- yl)-ethoxy]-5-nitro-1H-indazole D-23173 1-(4-chlorobenzyl)-3-(1-methylazepan-4-yloxy)- 5-nitro-1H-indazole D-22453 1-(4-fluorobenzyl)-3-[3-(N-diethyl amino)- propoxy]-1H-indazole D-22470 1-(3-pyridylmethyl)-3-[3-(N-diethylamino)- propoxy]-1H-indazole D-22585 1-(4-fluorobenzyl)-3-[3-(N-dimethylamino)- propoxy]-1H-indazole hydrochloride D-22627 1-(2-quinolylmethyl)-3-[3-(N-dimethylamino)- propoxy]-1H-indazole D-22634 1-(2-quinolylmethyl)-3-[3-(N-dimethylamino)- propoxy]-1H-indazole hydrochloride D-22768 1-(4-fluorobenzyl)-3-[3-(N-dimethylamino)- propoxy]-1H-indazole maleate D-22814 1-(4-chlorobenzyl)-3-[3-(N-dimethylamino). propoxy]-1H-indazole D-22890 1-(4-chlorobenzyl)-3-[3-N-diethylamino)- propoxy]-5-nitro-1H-indazole hydrochloride D-22895 1-(4-chlorobenzyl)-3-[3-(N-diethylamino)- propoxy]-1H-indazole D-22952 1-(4-chlorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-[(4-methoxyphenyl)-methylcarbonyl- amino]-1H-indazole hydrochloride D-22953 1-(4-chlorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-[(4-methoxyphenyl)-carbonylamino]- 1H-indazole hydrochloride D-22954 1-(4-chlorobenzyl)-3-[3-(N-diethylamino)- propoxy)-5-[(4-bromophenoxy)-carbonylamino]-1H- indazole hydrochloride D-23097 1-(4-fluorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-(ethoxycarbonylamino)-1H-indazole hydrochloride D-23174 1-(4-fluorobenzyl)-3-(3-(N-dimethylamino)- propoxy]-5-nitro-1H-indazole hydrochloride D-23225 1-(4-chlorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-(cyclohexyloxycarbonylamino]-1H- indazole hydrochloride D-23236 1-(4-fluorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-(cyclohexyloxycarbonylamino)-1H- indazole hydrochloride D-23308 1-(4-fluorobenzyl)-3-[3-N-dimethylamino)- propoxy]-5-methoxy-1H-indazole D-23309 1-(4-chlorobenzyl)-3-(3-(N-diethylamino)- propoxyl-5-(ethoxycarbonylamino)-1H-indazole hydrochloride D-23517 1-(4-fluorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-(fluoroenylmethyloxycarbonylamino)- 1H-indazole hydrochloride D-23584 1-(4-fluorobenzyl)-3-[3-(N-diethylamino)- propoxy]-5-(cyclopentyloxycarbonylamino)-1H- indazole hydrochloride______________________________________
TABLE 5__________________________________________________________________________Novel indazole derivatives according to diagram VI4 STR336##D --Y--G R.sup.1 X W R.sup.3 R.sup.2 Fp.__________________________________________________________________________ 21963 5 STR337## 3 N CH H H oil - 22055 6 STR339## 3 N CH H H 140- 144° C. - 22105 7 STR341## 9 N CH H H 82° C. - 23173 5 STR343## 9 N CH H 5-NO.sub.2 75-78° C. - 23172 8 STR345## 9 N CH H 5-NO.sub.2 171- 174° C. - 22175 5 STR347## 9 N CH H H oil - 22591 9 STR349## 9 N CH H H oil - 22453 0 STR351## 3 N CH H H 102° C. - 22470 0 STR353## 1 N CH H H oil - 22585 2 STR355## 3 N CH H H 103° C. - 22768 3 STR357## 3 N CH H H 85° C. - 22814 4 STR359## 9 N CH H H oil - 22890 5 STR361## 9 N CH H 5-NO.sub.2 134- 138° C. - 22895 0 STR363## 9 N CH H H oil - 22952 5 STR365## 9 N CH H 6 147- 149.degre e. C. - 22953 5 STR368## 9 N CH H 6 170- 172.degre e. C. - 22954 5 STR371## 9 N CH H 7 178- 0 C. - 23097 5 STR374## 3 N CH H 8 99-102.degree . C. - 22627 5 N CH H H 175° C. - 22634 9 N CH H H 152° C. - 23174 5 STR379## 3 N CH H 5-NO.sub.2 150- 153° C. - 23225 5 STR381## 9 N CH H 0 181° C. - 23236 5 STR384## 3 N CH H 0 159° C. - 23308 0 STR387## 3 N CH H 5-O--CH.sub.3 89° C. - 23309 5 STR389## 9 N CH H 8 95° C. - 23517 5 STR392## 3 N CH H 1 142° C. - 23584 5 STR395## 3 N CH H 2 oil397##__________________________________________________________________________
|
The N-benzylindole- and benzopyrazole derivatives of the general formula 1 ##STR1## possess anti-asthmatic, anti-allergic, anti-inflammatory and immunomodulating effect and are suitable for the preparation of medicaments.
| 2
|
This is a continuation of application Ser. No. 359,814 filed May 14, 1973, which in turn is a continuation-in-part of application Ser. No. 282,217 filed Aug. 21, 1972. Both applications are now abandoned.
PERTINENT PRIOR ART
In the Journal of Heterocyclic Chemistry, 7, 1173 (1970) the preparation of 5-phenyl-1,4-benzodiazepines utilizing hexamethylenetetramine is disclosed.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides the art with a procedure for the preparation of compounds of the formula ##STR1## wherein D is selected from the group consisting of ##STR2## R 1 is selected from the group consisting of hydrogen, halogen, nitro and trifluoromethyl, R 2 is selected from the group consisting of hydrogen and lower alkyl and R 3 is selected from the group consisting of hydrogen and halogen
Which comprises reacting a compound of the formula ##STR3## wherein D, R 1 and R 2 are as above and X is selected from the group consisting of chlorine, bromine and iodine (preferably chlorine) with hexamethylenetetramine, the improvement residing in the performance of the reaction in the presence of ammonia.
By the term "lower alkyl" as utilized hence herein, there is intended straight or branched chain aliphatic hydrocarbon groups such as methyl, ethyl, propyl, butyl and the like. When R 2 is lower alkyl, it is preferably methyl. By the term "halogen" as utilized herein, all four forms thereof are contemplated, i.e. chlorine, bromine, fluorine and iodine, unless otherwise specified. When R 1 is halogen, preferred are the halogens, chlorine or bromine, with chlorine being especially preferred. When R 3 is halogen, preferred are the halogens, chlorine and fluorine, with fluorine being especially preferred.
Preferred compounds whose preparation is effected by the procedure described herein include:
7-CHLORO-1,3-DIHYDRO-5-PHENYL- 2H-1,4-benzodiazepin -2-one;
7-CHLORO-5-(2-CHLOROPHENYL)-1,3-DIHYDRO-2H-1,4-benzodiazepin-2-one;
1,3-DIHYDRO-7-NITRO-5-PHENYL- 2H-1,4-benzodiazepin-2-one;
7-CHLORO-1,3-DIHYDRO-5-(2-FLUOROPHENYL)-2H-1,4-benzodiazepin-2-one;
1,3-dihydro-7-nitro-5-(2-fluorophenyl)-2H-1,4-benzodiazepin-2-one;
5-(2-chlorophenyl)-1,3-dihydro-7-nitro-2H-1,4-benzodiazepin-2-one;
7-bromo-1,3-dihydro-5-(2-pyridyl)-2H-1,4-benzodiazepin-2-one
and the 1-methyl derivatives of these compounds.
The prior art discloses the preparation of benzodiazepines of the formula I utilizing hexamethylenetetramine and a compound of the formula II. Such prior art procedures do result in good yields when certain starting materials of the formula II are utilized, e.g. when in the formula II R 2 is lower alkyl. However, for example, when R 2 is hydrogen consistently good yields are not obtained.
It has been discovered by the present applicant, that if ammonia is present in the reaction zone during the reaction of a compound of the formula II with hexamethylenetetramine, better yields of the compounds of the formula I result generally when compared with the procedure disclosed in the Journal of Heterocyclic Chemistry, 7, 1173 referred to above regardless of the character of the starting material utilized. Hence, the present invention improves upon the prior art as reflected in the aforementioned article by providing a general approach to the class of compound illustrated in formula I utilizing a compound of the formula II and hexamethylenetetramine which is simple and facile and which results in higher yields than with the aforementioned prior art process. Furthermore, a compound of the formula I of good purity is obtained when following the techniques described herein.
When proceeding from the compound of the formula II to the corresponding compound of the formula I utilizing hexamethylenetetramine, the reaction is effected in the presence of any inert organic solvent, which is suitable for the purposes of the present invention. Among the many such inert organic solvents so suitable, there can be included lower alkanols, such as methanol, ethanol, n-butanol and the like, dimethylformamide and similar inert organic solvents as well as aqueous mixtures of these, e.g. aqueous ethanol (95%), aqueous butanol. All this is required of the solvent is that the starting materials be soluble therein and that the solvent does not interfere with the ensuing reaction. Preferred are lower alkanols, such as methanol or ethanol. Furthermore, the character of the solvent should be such that it possesses the propensity to solubilize ammonia in the form that it enters the reaction zone.
While temperature and pressure are not critical to a successful performance of the process described herein, it is preferred to perform the reaction at a temperature of from about room temperature to about the reflux temperature of the reaction medium. Most preferably, elevated temperatures are utilized, most suitably, a temperature at about the reflux temperature of the reaction medium. Furthermore, in one embodiment, the reaction is performed under pressure to increase the concentration of ammonia present in the reaction zone.
Preferably, the ammonia is added to the reaction medium in such amounts as to saturate the inert organic solvent. As noted above, it is preferable to carry out this reaction at the reflux temperature of the solvent, since in general less ammonia will be required to saturate the solvent when elevated temperatures are employed. Usually, only minor molar amounts of ammonia are required to effect a successful performance of the desired reaction of a compound of the formula II above with hexamethylenetetramine. Thus, in a preferred aspect, a solvent is selected which will solubilize the starting materials but will become supersaturated with ammonia when relatively minor molar amounts of it are added thereto.
For example, in one preferred embodiment, ethanol is utilized. It is saturated when about a 1% molar quantity of ammonia is present in the reaction zone; such percentile being determined by a ratio, the numerator of which is the molar amount of ammonia required to supersaturate the solvent medium and the denominator of which is the sum of the molar amounts of hexamethylenetetramine, a compound of the formula II and ammonia present in the reaction zone. The solubility of ammonia in any inert organic solvent useable for the purposes of the present invention can be easily determined by reference to conventional texts. From this determination, the appropriate inert organic solvents can be readily ascertained. The use of pressure, as is noted above, will increase the concentration of ammonia present in the reaction zone over that required to normally saturate the inert organic solvent. Thus, in one aspect, the reaction is performed under a pressure of from about 1 to about 2 atms. Higher amounts of ammonia can be provided to the reaction zone by the simple expedient of using appropriate aqueous inert organic solvents.
As should be apparent from the above, the invention resides in adding ammonia to a reaction medium in which hexamethylenetetramine and a compound of the formula II are to be present. The manner of adding ammonia to the reaction zone is not critical. However, ammonia must be present before both hexamethylenetetramine and a compound of the formula II are present in the reaction zone. Thus, the hexamethylenetetramine can be added to an inert organic solvent of the type referred to above and the ammonia can then be added to the reaction zone prior to the addition of the compound of a formula II above. Alternatively, the ammonia can be dissolved in an inert organic solvent and subsequently a compound of the formula II above and hexamethylenetetramine can be added to the reaction zone.
Furthermore, the manner by which ammonia is introduced into the reaction zone is not critical. In one preferred process aspect, ammonia is provided to the reaction zone simply by bubbling gaseous ammonia therethrough. The ammonia can also be provided to the reaction zone in a less preferred embodiment by utilizing an ammonia generating reagent, e.g. ammonium carbonate which dissociates into ammonia when present in a solvent medium such as ethanol which is heated to reflux. Yields are not usually as good when an ammonia generating reagent is utilized instead of ammonia per se.
A particularly noteworthy feature of the process of the present invention resides in the fact that large molar excesses of hexamethylenetetramine are not required for a successful performance thereof. For example, by the present invention, for every one mole of the starting material of the formula II utilized, if as little as 0.10 moles is utilized, most preferably, if as little as 0.50 moles of hexamethylenetetramine is utilized, the desired compound of the formula I above is obtained. Thus, the present invention achieves an additional and particularly surprising and noteworthy end in that the amount of hexamethylenetetramine utilized is minimized and as a consequence of this, the cost of raw materials utilized in performing the process described herein is reduced without a corresponding diminution of yield. This particularly salient feature of the present invention therefore further provides a particularly commercially viable process. It should be noted that yields do begin to diminish when less than 0.50 moles of hexamethylenetetramine are utilized. However, when 0.50 moles of hexamethylenetetramine are utilized, the desired compound of the formula I is obtained in very good yields and of high quality.
It has been observed that when performing the process of the present invention with hexamethylenetetramine, there is obtained an intermediate of the formula ##STR4## wherein R 1 , R 2 , X and D are above. This reaction product can be reacted with ammonia with or without isolation from the reaction medium in which it is prepared to obtain the desired compound of the formula I above.
Thus, a compound of the formula IV, particularly wherein R 2 is lower alkyl can be isolated from the reaction medium containing the reaction product of hexamethylenetetramine with a compound of the formula II and the so-obtained compound of the formula IV can be isolated and treated with ammonia whereby to obtain the corresponding compound of the formula I. Alternatively, a compound of the formula II above and hexamethylenetetramine can be added to a reaction medium and there can be provided ammonia thereto without isolating a compound of the formula IV. In a preferred embodiment, the intermediate of the formula IV is not isolated but is reacted with ammonia without isolation from the reaction medium in which it is prepared. This is particularly true when R 2 in formula IV above is hydrogen.
A compound of the formula IV can be prepared by techniques other than that described herein. For example, as in the Journal of Heterocyclic Chemistry article identified above, a compound of the formula II above can be added to a solvent of low polarity such as acetonitrile with stirring at room temperature. A compound of the formula IV above can be isolated. The so-obtained compound of the formula IV after isolation from the solvent in which it is prepared, can be reacted with ammonia whereby a compound of the formula I above results in good yields and of high purity. The reaction of a compound of the formula IV with ammonia proceeds under the same reaction conditions as ascribed hereinabove to the preparation of a compound of the formula I via the treatment of a compound of the formula II with hexamethylenetetramine and ammonia as should be obvious to one of ordinary skill in the art. Thus, all of the reaction conditions and solvents specified above in connection with the preparation of a compound of the formula I with the use of hexamethylenetetramine apply with equal efficacy to the treatment of the intermediate of the formula IV with ammonia, except that hexamethylenetetramine is not added to the reaction zone.
When following the preparative procedure described above, particularly when utilizing a starting material of the formula II wherein R 2 is hydrogen, it has been observed that the reaction of hexamethylenetetramine with the aforementioned compound of the formula II results in the evolution of formaldehyde. The ammonia that is present reacts with the formaldehyde so-formed to regenerate hexamethylenetetramine.
It was further discovered by the present inventors that the desired compound of the formula I can be prepared by treating a compound of the formula II with formaldehyde in the presence of excess ammonia.
In the last-mentioned reaction, there can be utilized anhydrous formaldehyde (paraformaldehyde) or aqueous formaldehyde (38% formalin). Temperature and pressure are not critical to a successful performance of this process but it is preferred to perform the reaction at elevated temperatures, e.g. at about the reflux temperature of the reaction medium. The reaction is preferably effected in the presence of an inert organic solvent and among the many suitable organic solvents, there can be included those identified above in connection with the formation of a compound of the formula I from a compound of the formula II with hexamethylene and ammonia. Therefore, among the many inert organic solvents suitable for the purposes of the present invention, there can be included methanol, ethanol, n-butanol and the like, dimethylformamide and similar inert organic solvents as well as aqueous mixtures of these, e.g. aqueous ethanol or methanol. Here again all that is required of the solvent is that the starting materials be soluble therein and that the solvent does not interfere with the ensuing reaction. Preferred is methanol and/or ethanol.
It can be stated therefore that in this process aspect, the formaldehyde reacts with ammonia which is present in molar excessive amounts to form hexamethylenetetramine whereby a compound of the formula IV results which with or without isolation, preferably without isolation, is converted into a compound of the formula I. The manner in which ammonia is introduced and the amount introduced is the same as described above when a compound of the formula I is prepared utilizing hexamethylenetetramine and ammonia. Thus, in a preferred aspect, the reaction solvent in this process variation is saturated with ammonia, preferably simply by bubbling ammonia through the reaction solvent.
This application is a continuation-in-part of application Ser. No. 282,217 filed Aug. 21, 1972.
The following examples are illustrative but do not limit the present invention. All temperatures are stated in degrees Centigrade.
EXAMPLE 1
To a 2 liter, 4-necked flask equipped with a stirrer, reflux condenser and an inlet for ammonia, there was added 600 ml. of ethanol and 31.7 gm. of hexamethylenetetramine. Ammonia was then bubbled through the resultant reaction medium with stirring until the medium was saturated with ammonia. The saturated solution was heated to reflux, while continuing the bubbling of ammonia through the reaction medium. Thereafter, 78 gm. of 2-bromo-2'-(2-fluorobenzoyl)-4'-nitroacetanilide was carefully added over a period of two hours while maintaining refluxing conditions. The reaction mixture was refluxed for three hours longer and then was concentrated in vacuo to dryness at 50° C. To the residue there was added 300 ml. of toluene and 0.4 gm. of p-toluene sulfonic acid. The resultant medium was heated to reflux for 1 hour. The mixture was then cooled to about 70° C. and washed with water. The toluene layer was then permitted to cool to room temperature. 7-Nitro-5-(2-fluorophenyl)-3H-1,4-benzodiazepin-2-(1 H)-one crystallized out. It was isolated by filtration, then washed with toluene and dried.
EXAMPLE 2
To a 2-liter, 4-necked flask equipped with a stirrer, reflux condenser and inlet for ammonia, there was added 600 ml. of ethanol and 31.2 gm. of hexamethylenetetramine. With agitation, ammonia was bubbled through the resultant reaction medium until the ethanol was saturated with ammonia. The resultant medium was heated to reflux. While maintaining the reaction under refluxing conditions and bubbling ammonia therethrough, there was carefully added 40 gm. of 2-bromo-4'-chloro-2'-(2-chlorobenzoyl)acetanilide over a period of two hours. The reaction mixture so obtained was then evaporated to dryness. To the residue, there was added 300 ml. of toluene and then 0.3 gm. of para-toluene sulfonic acid. The toluene solution was heated to reflux. The reaction medium was permitted to cool to 70° C. After cooling, it was washed with hot water. The toluene extract was permitted to cool to room temperature. After cooling to 10° C., the crystalline product which formed was filtered off, washed with toluene and petroleum ether, dried overnight under vacuum at 100° to give 7-chloro-5-(2-chlorophenyl)-1,3-dihydro-2H-1,4-benzodiazpin-2-one, m.p. 200°-200.5° C.
EXAMPLE 3
To a 2-liter, 4-necked flask equipped with a reflux condenser, an ammonia addition tube and a stirrer, there was added 600 ml. of ethanol and 30.4 gm. of hexamethylenetetramine. Ammonia was bubbled through the reaction medium until the ethanol became supersaturated. The reaction mixture was heated to reflux while 40 gm. of 2-bromo-2'-(2-chlorobenzoyl)-4'-nitroacetanilide was carefully added to the resultant medium over a period of 31/2 hours. The refluxing and bubbling of ammonia through the reaction medium was continued for three hours longer and then it was evaporated to dryness. To the residue was added 250 ml. of toluene and 0.4 gm. of para-toluene sulfonic acid. The mixture was refluxed for 1 hour. The toluene layer was cooled to 70° C. The resultant medium was washed with water. The toluene layer was then cooled to room temperature. The product crystallizes from the reaction medium. The crystals were filtered off, and washed once with toluene and once with petroleum ether and dried, yielding 5-(2-chlorophenyl)-1,3-dihydro-7-nitro-2H-1,4-benzodiazepin-2-one, m.p. 203°-204° C.
EXAMPLE 4
Into a 12-liter, 3-necked flask equipped with a condenser and an ammonia addition tube, there was added 7.2 liters of ethanol and 470.4 gm. of hexamethylenetetramine. The ammonia was bubbled through the resultant reaction medium with stirring until the medium become supersaturated. With refluxing, 480.0 gm. of 2-chloroacetamido-5-chlorobenzophenone was carefully added over a period of 4 hours. The resultant mixture was heated at reflux for an additional 2 hours while bubbling ammonia there through. The resultant medium was then left to stand overnight and then concentrated to dryness in vacuo. To the concentrate was added 2.4 liters of toluene and the resultant medium was heated to reflux. 0.5 Gm. of para-toluene sulfonic acid was then added. The refluxing was continued for a period of one hour. After cooling the medium to 70° C., 1.5 liters of hot water was added. The product which separated was cooled to 20° and isolated by filtration, washed and dried in vacuo. The product obtained was 7-chloro-1,3-dihydro-5-phenyl-2 H-1,4-benzodiazepin-2-one.
In a similar manner as described above, there can be prepared 7-bromo-1,3-dihydro-5-(2-pyridyl)-2H-1,4-benzodiazepin-2-one melting at 225°-235° C. from 2-(2-chloroacetamido-5-bromo benzoyl)pyridine.
EXAMPLE 5
A 12-liter, 3-neck flask equipped with a sealed stirrer, reflux condenser, and ammonia addition tube is charged with 7.2 liters of ethanol. The alcohol is heated to reflux with stirring on a steam bath. The solvent is then saturated with ammonia to a concentration of about 0.6 to 0.7% by weight. While the heating bath is momentarily removed, 493 grams of hexamethylenetetramine is added. Heating is resumed, and 480 grams of 2-chloroacetamido-5-chlorobenzophenone, is slowly added in small increments. Ammonia is steadily bubbled into the refluxing solution. The addition of the chloroacetamido compound is done over a 3 to 4-hour period. The reaction mixture is the heated under reflux for an additional 2 hours. The flow of ammonia is interrupted and the alcohol is removed by vacuum distillation.
The reaction flask is transferred to a heating mantle and the residue is slurried and heated to reflux in 2.4 liters of toluene. At reflux temperature, 2 × 0.5 grams of p-toluenesulfonic acid is added about 15 minutes apart. A small amount of water (ca. 1 to 2 ml.) separates. The slurry of crystals is then cooled to 70° C. and the water-soluble material is dissolved by the addition of 1.5 liters of hot (70° C.) water. The heterogenous mixture is stirred overnight while cooling to room temperature. 7-Chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one which separates is isolated by filtration and washed once with 250 ml. of cold tap water and once with 250 ml. of cold (0° C.) toluene. The product is then dried to constant weight at 80° C.
EXAMPLE 6
To a 2-liter, 4-necked flask equipped with a stirrer, a reflux condenser and an ammonia tube, there was added 600 ml. of ethanol and 37.9 g. of hexamethylenetetramine with stirring. Ammonia was bubbled through the resultant reaction medium with stirring until reflux temperature was reached. Then there was carefully added to the refluxing solution 40.0 g. of 2-chloroacetamido-5-nitro benzophenone. Ammonia is steadily bubbled into the reaction mixture while continuing to reflux for three hours. The resultant solution was cooled, evaporated to dryness at 50° C. The residue was dissolved in 300 ml. of toluene. 0.3 G. of paratoluene sulfonic acid was added to the resultant solution. The solution was heated to reflux. The refluxing was continued for 1 hour. The reaction medium was then permitted to cool to room temperature. The product which separated was filtered off, washed with water and dried. This material was taken up in 435 ml. of methylene chloride. It was then filtered through Hyflo. Upon the addition of 90 ml. of 3N nitric acid to the filtrate, crystals appeared. They were filtered off, washed with methylenechloride and dried for 15 minutes. The crystals were added to 1 liter of water with stirring. Ammonium hydroxide was then carefully added to the resultant medium until a pH of about 8 was reached. After stirring the resultant medium for 1/2 hours, the crystalline precipitate which formed were filtered off, washed with cold water and dried at 80° for 8 hours yielding 1,3-dihydro-7-nitro-5-phenyl-2H-1,4-benzodiazepin-2-one of melting point 217°-219° .
EXAMPLE 7
To 1350 ml. of ethanol there was added 90 gm. of 2-chloroacetamido-5-chlorobenzophenone and 92.5 gm. of hexamethylenetetramine. Ammonia was bubbled through the resultant medium under a pressure. The resultant medium was heated to reflux. The resultant reaction medium was evaporated in vacuum to dryness. It was triturated then with 250 ml. of hot water twice on a steam bath. The aqueous phase was removed by decantation. The crystalline residue was heated for 30 minutes in 250 ml. of toluene on a steam bath and then cooled to room temperature. The crystals which formed were filtered, washed twice with 25 ml. of toluene and 25 ml. of petroleum ether and dried to constant weight yielding 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one melting point 213°-215° C.
EXAMPLE 8
13.5 liters of 95% ethanol, 900 gms. of 2-chloroacetamido, 5-chlorobenzophenone and 925 gms. of hexamethylenetetramine were charged to a stirred pressure vessel. The medium was saturated with ammonia gas at ch. 15# gauge of pressure with stirring. The ammonia supply was turned off. The resultant medium was heated for three hours at 78°-80° C. After cooling and venting the ammonia, the batch was removed from the pressure vessel to a vacuum still. The batch was concentrated to dryness in vacuo from a steam bath. The the residue was added 21/2 liters of toluene and 5.0 g. of p-toluenesulfonic acid and the resultant mixture was heated to reflux. Ca. 5 mls. of water formed, removed by azeotropism. After cooling to 70° C. three liters of water at 70° C. were added. The crystal slurry so obtained was cooled for one hour at +10° to +15° C. After filtering, washing the product with 2 × 250 ml. of tap water and once with 250 ml. of cold (+10° C.) toluene and drying to constant weight, 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one was obtained.
EXAMPLE 9
A mixture of hexamethylenetetramine (17.5 g., 0.125 mol), methanol (135.5 ml) and 2(2-chloro-N-methylacetamido)-5-chlorobenzophenone (80.5 g., 0.25 mol) was saturated with ammonia. Heat the stirred mixture slowly to reflux with a steady stream of ammonia flowing through the mixture. During the course of the reaction ##STR5## was prepared. The product was not isolated. Hold at reflux for 6 hours. Stop the flow of ammonia and remove the solvent under vacuum. Take up the residue in a mixture of toluene (500 ml.) and hot water (500 ml). Separate the toluene phase and add to it, with stirring, 3N nitric acid (169 ml). The crystals which separate are filtered, wash with toluene (50 mls) and resuspended in a mixture of toluene (250 ml) and water (250 ml). Concentrated ammonia (30 ml) is added to pH 8. The toluene phase is separated, washed with water (250 ml) and then distilled to dryness in vacuo yielding 96.09% of 7-chloro-1-methyl-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one, melting point 125° to 127° C.
EXAMPLE 10
A mixture of ethanol (600 ml) and hexamethylenetetramine (39.1 g., 0.279 mol) was stirred and saturated with ammonia. With ammonia bubbling into the mixture it was slowly heated to reflux. Over a period of 41/2 hours, 2-(2-chloro-N-methylacetamido)-5-chlorobenzophenone (40 g., 0.124 mol) was added in increments yielding ##STR6## which was not isolated. Refluxing was continued for 2 hours longer. The reaction mixture was then distilled to dryness in vacuo at 50° C. The residue was stirred with toluene (250 ml), heated to reflux and heated with two increments of para-toluene sulfonic acid. Reflux was continued for one hour. After cooling to 70° C., the toluene was washed with hot water to remove soluble salts and distilled to dryness in vacuo. The residue was dissolved in hot ethanol (111 mol) and the solution cooled at -10° C. for one hour. The crystalline 7-chloro-1,3-dihydro-1-methyl-5-phenyl-2H-1,4-benzodiazepin-2-one obtained was isolated and weighed 29 g., melting point 129° to 131° C. Concentration of the mother liquor by ca. 50% gave a second crop weighing 2.0 g. melting at 127° C.
EXAMPLE 11
A mixture of ethanol (1100 ml), hexamethylenetetramine (70.0 g., 0.5 mol), 26% ammonium hydroxide (58 ml) and 2-chloroacetamido-5-chlorobenzophenone (308.2 g., 1.0 mol) was stirred and slowly heated to reflux with ammonia bubbling into the mixture. Reflux was continued for 5 hours, the flow of ammonia was interrupted, and the reaction mixture distilled to dryness in vacuo. The residue was heated to reflux for 30 minutes in a mixture of toluene (500 mls) and water (500 mls) and then allowed to cool slowly to room temperature. The crystalline material was filtered, washed with toluene (100 mls) and hot water (2 × 250 mls) and dried to constant weight. The product, 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (226 g) obtained corresponded to a yield of 83.5%, melting point 210° C.
EXAMPLE 12
A mixture of ethanol (1100 mls), hexamethylenetetramine (35 g., 0.25 mol), 26% ammonium hydroxide (58 ml), and 2-chloroacetamido-5-chlorobenzophenone (308.2 g., 1.0 mol) were permitted to react as described in Example 11 except that the reflux period was increased from 5 to 7 hours. The reaction product, 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (221 g.) isolated in a manner identical with Example 11, was obtained in 81.6% yield, melting point 208.5° to 209° C.
EXAMPLE 13
A mixture of methanol (550 mls), hexamethylenetetramine (14.1 g., 0.1 mol) and 2-chloroacetamido-5-chlorobenzophenone (308.2 g., 1.0 mol) was stirred and saturated with ammonia at room temperature. The mixture was heated slowly to reflux with a steady stream of ammonia bubbling through the solution. Refluxing was continued for 24 hours. The flow of ammonia was interrupted and the crystal slurry obtained was cooled to room temperature. The product, filtered, washed with methanol (2 × 125 ml) and hot water (4 × 500 ml), and dried gave 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (169 g., 62.3%) melting at 213° to 215° C.
EXAMPLE 14
A mixture of ethanol (300 ml) and hexamethylenetetramine (20 g., 0.143 mol) was stirred, heated to reflux, and saturated with ammonia. 2-Chloroacetamidobenzophenone (18.1 g., 0.066 mol) was added in small increments over 3 to 4 hours while a steady stream of ammonia was bubbled into the reaction mixture. Refluxing was continued for 3 hours after complete addition of 2-chloroacetamidobenzophenone. The flow of ammonia was interrupted and the ethanol removed by distillation in vacuo. The residue obtained was taken up in chloroform (200 ml), and washed with water (100 ml) at 50° C. The chloroform layer was evaporated to dryness at 30° C. and the oily solid obtained was recrystallized from toluene (100 ml) to give 1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (13.2 g., 86%), melting at 184°-186° C.
EXAMPLE 15
A mixture of methanol (275 ml.) and 2-chloroacetamido-5-chlorobenzophenone (154.2 g., 0.5 mol) was heated to reflux with a steady stream of ammonia bubbling in. At reflux 37% formaldehyde solution (237 ml) was fed in over ca. 40 minutes. The reaction mixture was then heated under reflux for 5 hours. The flow of ammonia was stopped and the slurry of crystals was cooled to room temperature, filtered, washed with methanol (2 × 125 ml), hot water (4 × 500 ml) and dried. There was obtained 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (104.6 g., 77.3%), melting at 211.5° to 214.5° C.
EXAMPLE 16
A mixture of paraformaldehyde (147.2 g.) and methanol (550 ml.) was stirred and heated to reflux with a steady stream of ammonia bubbling in. The crystal slurry of hexamethylenetetramine which formed was cooled to room temperature and 2-chloroacetamido-5-chlorobenzophenone (308.2 g., 1.0 mol) was added in one portion. With ammonia bubbling in, the reaction mixture was heated at reflux for 10 hours. The flow of ammonia was interrupted and the reaction mixture was cooled to room temperature, filtered, washed with methanol (2 × 125 ml.) and hot water (4 × 500 ml) and dried. There was obtained 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (220.4 g., 81.4%) melting at 212.5° to 215° C.
EXAMPLE 17
Paraformaldehyde (200 g., 91% flake) is placed in a stirred reactor equipped with a reflux condenser, decanter, and ammonia addition tube. Methanol (575 mls.) is added and then gaseous ammonia below the surface of the reaction mixture. 2-Chloroacetamido-benzophenone (273.7 g.) is then added. With a slow, continuous flow of ammonia to the reaction zone, the mixture is heated at reflux for 5 hours. The crystal slurry obtained is distilled to recover the methanol. Toluene (1350 mls.) is now added to the crystal residue and residual water is removed by azeotropic distillation through the decanter. When dry, the hot toluene solution is filtered, the filtrate is cooled for crystallization, and the product obtained isolated to give 1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one (200 g., 84.7%) m.p. 180°-181° C. (uncorr.).
EXAMPLE 18
Paraformaldehyde (147.2 g., 91% flake) is placed in a stirred reactor equipped with an ammonia addition tube and a reflux condenser. Methanol (550 mls.) is added, along with 2-chloroacetamido-5-chloro-2'-fluorobenzophenone (326.2 g.) at room temperature. The reaction mixture is stirred and ammonia gas bubbled in below the surface of the reaction mixture. The reaction mixture was then heated at reflux for 10 hours with a steady flow of ammonia gas. Cool to room temperature and filter the crystalline product obtained. Wash product with cold methanol (2 × 125 mls. at -10° C.), followed by hot water (4 × 500 mls at 60° C.). When dry, there was obtained 7-chloro-1,3-dihydro-5-(2-fluorophenyl)-2H-1,4-benzodiazepin-2-one (205 g., 71%) m.p. 205.5°-207° C. (uncorr.).
EXAMPLE 19
250 g. of 2-chloroacetamido-5-chlorobenzophenone, 122.5 g. of hexamethylenetetramine were added to 2.5 liters of acetonitrile in a 5 l., 3-neck flask, equipped with a stirrer and calcium chloride drying tube. The reactants were stirred for 72 hrs. at room temperature. All reactants went into solution. The product which was ##STR7## crystallized out. The product was filtered, washed with a small amount of fresh solvent and dried yielding 328 gms. or 91.4% (crude yield) of product, m.p. 169°-170° C.
EXAMPLE 20
89.7 gms. of product obtained in Example 19 was dissolved in ammonia ethanol. The so-obtained reaction mixture was heated and gaseous ammonia was bubbled into the reaction mixture continuously during the heat-up and for a 5-hour period of reflux yielding 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one which was isolated according to conventional procedures. Yield, 86.6%, m.p. 212°-214° C.
EXAMPLE 21
In a one liter, stirred flask equipped with a reflux condenser was placed 89.7 gms. of ##STR8## 61.6 gms. of 2-chloroacetamido-5-chlorobenzophenone, 22.4 mls. of 26% ammonium hydroxide and 425 mls. of ethanol. Ammonia was bubbled into the reaction mixture while it was stirred and heated to reflux. Refluxing was continued for 5 hrs. thereafter with stirring. The reaction mixture was distilled to dryness in a Swissco evaporator. The residue was then heated at reflux for one hour in a mixture of 100 mls. of toluene and 100 mls. of water and cooled to room temperature yielding 7-chloro-1,3-dihydro-5-phenyl-2H-1,4-benzodiazepin-2-one. The product was filtered, washed with 20 mls. of water and 20 mls. of toluene and dried. It weighed 92.5 gms. or 85.4%. The crude product melted at 210°-213° C.
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1,4-Benzodiazepin-2-ones are prepared via the reaction of a haloacetamidophenyl ketone with hexamethylenetetramine in the presence of ammonia. The 1,4-benzodiazepin-2-ones so prepared are known compounds useful as muscle relaxant and anti-convulsant agents.
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FIELD OF THE INVENTION
This invention relates generally to graphics processing systems and, in particular, to methods of rendering objects for display upon a display monitor.
BACKGROUND OF THE INVENTION
In computer graphics applications it is frequently desirable to draw lines, curves and points in three dimensional space that are spatially coincident with a surface in three dimensional space, and which are required to be visible on the surface. Such objects may be characterized as "surface markings," and occur in a wide range of applications.
It has been found that a conventional method of drawing lines, curves and points in a computer graphics system induces inaccuracies. These inaccuracies often result in portions of the surface markings disappearing "behind" the surface and, thus, not being displayed in the desired manner.
FIG. 2 illustrates a representative scene consisting of a triangle, suspended in space, that is to be rendered for display together with a surface marking. In FIG. 2 the surface marking has the form of a line that lies on the surface of the triangle. A standard depth buffer (z-buffer) method for rendering this scene employs an area of memory referred to as an image buffer. The image buffer contains one entry for each display monitor pixel center point (represented by + in FIG. 2). Each entry of the image buffer includes a red, green, and blue (RGB) value representing a color for that pixel, and a depth (z) value to represent the distance, from a viewer or viewplane, of the frontmost object processed thus far for that pixel. Before rendering a scene, each image buffer pixel entry is typically initialized to a specified background color and to a z value representing a greatest possible representable distance from the viewer.
For each object in the scene (for example the triangle and the line in FIG. 2), the set of pixels covered by that object are enumerated. For each pixel, the RGB color of the object, at that pixel's center point, is calculated. For example, the calculation may be made by interpolating the colors at the vertices (PQR) of the triangle or at the endpoints (ST) of the line. Furthermore, a z value representing the distance of the object from the viewer at the pixel center point is calculated. Each computed z value is compared with the z value already stored in the corresponding entry of the image buffer for that pixel, and if the computed z value at the pixel center is closer to the viewer than the z value currently in the image buffer for that pixel, then for that pixel the current object obscures the closest object processed thus far. As a result, the computed RGB color value and the computed z value replace the values currently stored in the image buffer. When all of the objects are thus processed, the image buffer stores RGB and z values that correspond only to points on objects that lie closest to the viewer, and that are not obscured by a "nearer" object.
Generally the z-buffer approach works well. However, when it is applied to surface markings such as lines, curves and points that are coincident with a surface (such as the line and the triangle in FIG. 2), it is observed that a significant proportion of the pixels of the surface marking may be hidden by the surface and, as a result, not displayed.
Similar problems with two coincident surfaces (as opposed to lines, curves and points coincident with a surface) have been observed to be caused by numerical roundoff errors resulting from a limit on the precision of the computer representation of the z values. However, it has further been determined by the inventors that this is not the cause of the problem in the case of surface markings. As a result, methods that have been devised to deal with roundoff errors in the z values do not solve the problem of obscured surface markings. By example, a method that employs toleranced depth tests to overcome roundoff errors is disclosed in commonly assigned U.S. patent application Ser. No. 07/672,058, filed Mar. 12, 1991, entitled "Direct Display of CSG Expression by Use of Depth Buffers" by D. A. Epstein, J. R. Rossignac, and J. W. Wu.
It is thus an object of this invention to provide a method to render surface markings so that a portion or portions of the surface markings are not obscured by the surface which they are intended to mark.
SUMMARY OF THE INVENTION
The foregoing and other problems are overcome and the object of the invention is realized by a method for execution by a graphics processing system for rendering objects for display to a viewer upon a display having a plurality of display pixels. The method includes the steps of, for a surface to be displayed having a surface marking coincident therewith, (a) moving or displacing the surface marking towards the viewer or, alternatively, moving the surface away from the viewer, by an amount that is function of a parameter (S) and also a scale factor that expresses a relationship between viewer eye coordinate units and display pixel units. The parameter (S) determines a maximum slope for the surface, relative to a viewing plane, such that the step of moving will not cause a portion of the surface marking to be obscured by the surface. The step of moving includes a step of (b) applying a predetermined transformation (T' e ) from a viewer eye coordinate system to a modified viewer eye coordinate system.
The parameter (S) may equal |Δz/Δx|, or |Δz/Δy|, or a combination of |Δz/Δx| and |Δz/Δy|, in an (x, y, z) viewer coordinate system. In the case of a perspective transformation, T' e also compensates for the movement of the surface marking towards the viewer.
The predetermined transformation T' e is selected as a function of whether a perspective projection or an orthographic projection of the surface and the surface marking upon a viewing plane is performed.
For the orthographic projection, it is shown that the scale factor K is given by ##EQU1##
It is also shown that the amount of movement is given by S/2K, and therefore that a modified viewer coordinate system z-axis distance value z' e is given in terms of an unmodified viewer coordinate system z-axis distance value z e as
z'.sub.e =z.sub.e +S/2K.
Therefore, for the orthographic projection the predetermined transformation T' e is given by: ##EQU2##
For the perspective projection it is shown that the scale factor K is given by ##EQU3##
It is also shown that the amount of movement is given by z e S/2K, where z e is a distance along an unmodified viewer coordinate system z-axis. It is further shown that a modified viewer coordinate system z-axis distance value z' e is given in terms of the unmodified viewer coordinate system z-axis distance value z e as:
z'.sub.e =z.sub.e -z.sub.e S/2K=z.sub.e (1-S/2K).
Therefore, for the perspective projection the predetermined transformation T' e is given by: ##EQU4##
That is, the method of this invention modifies the eye coordinates [x e y e z e ] to obtain in their place modified eye coordinates [x' e y' e z' e ]. This is achieved by moving a surface marking closer to the viewer, or by moving the surface further from the viewer, prior to applying a screen transform T s . One preferred method for accomplishing this operation is by inserting the additional transform T' e into the set of transformations that transform from object coordinates, to world coordinates (T w ), to eye coordinates (T e ), and finally to screen coordinates (T s ). Using a conventional 4×4 homogenous coordinate system notation, one suitable expression for this improved transformation is:
[wx.sub.s wy.sub.s wz.sub.s w]=[x.sub.o y.sub.o z.sub.o 1]T.sub.w T.sub.e T'.sub.e T.sub.s.
BRIEF DESCRIPTION OF THE DRAWING
The above set forth and other features of the invention are made more apparent in the ensuing Detailed Description of the Invention when read in conjunction with the attached Drawing, wherein:
FIG. 1a is a simplified block diagram of a first embodiment of a graphics rendering system that is constructed and operated in accordance with the invention;
FIG. 1b is a simplified block diagram of a second embodiment of a graphics rendering system that is constructed and operated in accordance with the invention;
FIG. 2 illustrates a scene consisting of a triangle PQR and a line ST, wherein pixel centers are indicated by (+), the line is approximated by pixels designated ⊕, and wherein approximating pixels A, B, C are one-half pixel from the line ST; and
FIGS. 3a and 3b illustrate a perspective projection and an orthographic projection, respectively, and both illustrate a top view with a viewer at an origin O of a viewer coordinate system.
DETAILED DESCRIPTION OF THE INVENTION
The inventors have determined that the source of the problem of the obscured surface markings is not intuitively obvious, and that an understanding of the problem requires a careful analysis of the method used to draw lines, curves, and points in a computer graphics system, such as one shown in FIG. 1a.
Before describing the method of the invention in detail, reference is made to FIG. 1a wherein there is depicted a computers graphics system 10 that is suitable for implementing the method of the invention. The system 10 includes a digital bus 12 that couples together a data processor 14, a memory 16, a frame buffer 18 that is coupled to a display monitor 20, and an I/O controller 22 having a user entry device, such as a keyboard 24, coupled thereto. Preferably the display 20 is a high resolution color graphics display. The processor 14 processes image data that is provided thereto over the bus 12 to create a displayable image in an image buffer 26, and executes a program to implement the method of the invention that is described in detail below. The contents of image buffer 26 are subsequently moved across the bus 12 to the frame buffer 18 for display on the display monitor 20.
FIG. 1b illustrates another computer graphics system that is suitable for practicing the invention. In FIG. 1b the processor 14 provides graphics commands and data, including predetermined transformations, to a graphics display subsystem 28. Graphics display subsystem 28 includes a dedicate display processor 30 having an output coupled to a frame buffer 32. The display processor 30 operates on the graphics commands, such as Display a Triangle, in accordance with the predetermined transformations (described below), to render objects for display. Pixels representing surfaces of objects, including surface markings as appropriate, are stored within the frame buffer 32. The output of the frame buffer 32 provides display pixel data to the display 20.
Consideration is again made of the line ST shown in FIG. 2. In that, in general, a line drawn between any two given endpoints does not pass exactly through pixel centers, it is necessary to approximate the line by illuminating the pixels (indicated by ⊕ FIG. 2) whose centers are closest to the desired geometric line. However, the centers of the approximating pixels may be as far as one-half of a pixel width away from the desired geometric line.
It is noted that a similar one-half pixel error is possible in the case of curves and points. However, the remainder of this discussion treats only the case of lines, it being realized that the problem for curves and points is analogous, and that the solution provided by the invention is exactly the same. These objects (lines, curves and points) are collectively referred to herein as "surface markings".
The above mentioned pixel approximation has been determined by the inventors to be the cause of the non-displayed surface marking pixels. That is, some pixels of the line will not be visible if the line is coincident with a surface (such as the triangle PQR in FIG. 2) and if the surface is sloped. This is because the z values that are used for the pixels that approximate the line ST are derived from the z values on the geometric line; but when these z values are applied to nearby approximating pixel centers that are not on the geometric line, the resulting pixel may be hidden by the surface, because the surface has a different z value at the position of the approximating pixel than it has on the geometric line. For example, if the bottom of the triangle PQR is sloped toward the viewer (but the triangle PQR is nevertheless still coincident with the line ST), then the triangle PQR will obscure all of the line's pixels that are below the geometric line, such as the pixels marked A, B and C in FIG. 2.
It is noted that the triangle PQR may be one face of a larger object, and may in some cases represent the result of a tessalation of an object's surface during the rendering process.
The solution provided by the method of the invention can generally be stated as follows: (a) the surface markings are moved toward the viewer by a small amount before rendering, thus bringing the hidden surface marking pixels back into view, or, alternatively, (b) the surface is moved away from the viewer by a small amount before rendering, thus bringing the hidden surface marking pixels back into view. Case (a) is achieved by specifying a positive value for a surface slope (S) parameter. Case (b) is achieved by specifying a negative value for the (S) parameter. Both case (a) and case (b) are considered to be equivalent, and the remainder of the description of the invention is made generally only for the case (a).
It should be noted that moving the surface markings forward could potentially cause them to be visible in front of another surface which should hide them. Therefore, the amount by which the surface markings are moved must be carefully selected. In addition, a perspective projection requires additional compensation for the fact that moving the surface markings toward the viewer makes the surface markings appear larger. The approach that is taken is illustrated in FIGS. 3a and 3b. FIGS. 3a and 3b illustrate a perspective projection and an orthographic projection, respectively, and both illustrate a top view with a viewer at an origin O of a viewer coordinate system (x, y, z). Surface marking A, which is coincident with plane PQ having a slope parameter S, where S=|Δz/Δx|, projects onto the image plane IJ at position B. In FIGS. 3a and 3b, the term Δz is the line segment DF, and the term Δx is the line segment AD. The nearest pixel location is C, one-half pixel away, which therefore makes the surface feature appear to be located at D, behind the plane. The apparent spatial error is given by AD=δ/2. As will be shown, and in accordance with the invention, by moving A forward to E, a z distance of DF=Sδ/2, the new apparent position G is no longer obscured by the plane PQ. In general, the term δ is a distance in the viewer coordinate system that corresponds to a pixel error distance, in the viewing plane, in drawing the surface marking against the surface.
It is noted that this example assumes that there is no slope of the surface in the y-dimension. However, the method of the invention applies as well to a slope in y, given by |Δz/Δy|, and to a slope in both x and y. In all cases, the slope parameter (S) is referenced to the image plane IJ, and a slope parameter having a value of zero is considered to be parallel to the image or viewing plane. The value of S may be specified by a user through, by example, the keyboard 24 of FIG. 1a, or may be regarded as a constant.
In greater detail, in FIGS. 3a and 3b it should be observed that a distance of one pixel on the screen corresponds to some distance δ in eye coordinates, and a one-half pixel error on the screen corresponds to a distance δ/2 in eye coordinates. Therefore, moving the surface markings toward the viewer by some multiple S of δ/2 compensates for the one-half pixel error in drawing a surface marking against a surface that has a slope as large as S, relative to the viewing direction. The value of the slope parameter S is selected so as to minimize the number of pixels missing from surface markings, after applying a transformation T' e that is described in detail below. The value of the slope parameter S is also selected so as not to create a possibility for surface markings to be visible when they should be hidden by another surface. The inventors have determined that a value for S of approximately eight provides satisfactory results for many applications, although the exact value of S is not critical, so long as a satisfactory display results. In this regard it is noted that errors against highly sloped surfaces are less noticeable in that, in general, highly sloped surfaces cover less display screen area.
There is now described a method that solves the problem of hidden surface markings by modifying the standard transformations used in computer graphics systems, for two commonly used projections, orthographic (FIG. 3b) and perspective (FIG. 3a). In both the orthographic and perspective projections, the standard coordinate transformation process starts with a collection of objects each described in terms of a set of object coordinates [x o y o z o ] in its own object coordinate system. Each object is placed into a common world coordinate system by a transform T w that depends on the relationship between the object coordinate system and the world coordinate system. Next, world coordinates are transformed to "eye" (or "camera" or "viewer") coordinates [x e y e z e ] relative to the frame of reference of the viewer by a transform T e . T e depends on the position and orientation of the viewer relative to the world coordinate system. Finally, eye coordinates are transformed into screen coordinates [x s y s ], measured in pixels, by a transform T s that depends on the type of projection (orthographic or perspective), and on the details of the camera. Using a standard 4×4 homogeneous coordinate system notation this transformation is expressed by:
[wx.sub.s wy.sub.s wz.sub.s w]=[x.sub.o y.sub.o z.sub.o 1]T.sub.w T.sub.e T.sub.s.
The derivation and use of these standard transformations is well known to these skilled in the art. By example, reference in this regard is made to the text "Computer Graphics: Principles and Practice", 2nd Edition J. Foley, A. Van Dam, S. Feiner, and J. Hughes (Addison Wesley 1990). It is noted that the above described set of transformations represent but one suitable approach, and that other approaches can be employed to yield the same result.
The method of this invention modifies the eye coordinates [x e y e z e ] to obtain in their place modified eye coordinates [x' e y' e z' e ]. This is achieved by moving the surface marking closer to the viewer or, as described above, by moving the surface farther from the viewer, prior to applying the screen transform T s . One preferred method for accomplishing this operation is by inserting an additional transform T' e into the above equation before T s , resulting in:
[wx.sub.s wy.sub.s wz.sub.s w]=[x.sub.o y.sub.o z.sub.o 1]T.sub.w T.sub.e T'.sub.e T.sub.s. (1)
The details of the transform T' e depend on whether the screen projection described by T s is an orthographic or a perspective projection. Both of these projections are now described in detail.
Orthographic projection (FIG. 3b)
In an orthographic projection, screen coordinates [x s y s ] are obtained by taking eye coordinates [x e y e z e ] and scaling x e and y e by some scale factor K:
x.sub.s =Kx.sub.e, y.sub.s =Ky.sub.e. (2)
The value of the scale factor K is a function of the width of the field of view in eye-space units, and on the horizontal resolution of the camera in pixels: ##EQU5## Consider the distance δ in the x or y direction in eye space that corresponds to an apparent distance of one pixel on the screen. The maximum error of one-half pixel that occurs in drawing a surface marking is just compensated for, when the surface marking is drawn against a surface of slope S, by moving the surface marking toward the viewer by a distance of Sδ/2, as shown in FIGS. 3a and 3b.
From equation (2) it can be concluded that the eye-space equivalent δ of a screen pixel, in the case of an orthographic projection (FIG. 3b), is given by
δ=1/K
Thus, the amount by which a surface marking is moved towards the viewer to avoid "burying" the surface marking behind a surface of slope S is
Sδ/2=S/2K.
Accordingly, the modified eye space z coordinate z' e is given by
z'.sub.e =z.sub.e +Sδ/2=z.sub.e +S/2K. (3)
As described above in equation (1), the transformation from eye coordinates [x e y e z e ] to modified eye coordinates [x' e y' e z' e ] is accomplished in the graphics system 10 by inserting a transform T' e into the conventional transformation process. Equation (3) for the modified eye coordinate z' e implies that, for an orthographic projection T' e is given by ##EQU6##
Expressed in this form, it can be appreciated by those having skill in the art that the method of the invention is readily incorporated into many graphics systems that allow arbitrary 4×4 homogeneous transformations in the process of converting object coordinates to screen coordinates.
Perspective projection (FIG. 3a)
For a perspective projection, the relationship between screen coordinates [x s y s ] and eye coordinates [x e y e z e ] is given by
x.sub.s =Kx.sub.e /z.sub.e' y.sub.s =Ky.sub.e /z.sub.e' (5)
where K is a parameter of the camera and is a function of the angle of view and the resolution (number of pixels) of the camera: ##EQU7## where the 1 unit is expressed in the viewer coordinate system.
Considering the distance δ in the x or y direction in eye space that corresponds to an apparent distance of one pixel on the screen; the maximum error of one-half pixel that occurs in drawing a surface marking is compensated for when the surface marking is drawn against a surface of slope S by moving the surface marking toward the viewer by a distance of Sδ/2, as shown in FIG. 3a.
From equation 5 it can be concluded that the eye-space equivalent δ of a screen pixel, in the case of a perspective projection, is given by
δ=-z.sub.e /K.
It is noted that the minus sign results from the fact that in the conventional eye-space coordinate system the z e values increase towards the viewer, with z e =0 at the viewer, so that the z e values for visible objects in front of the camera are negative. It is further noted that in some approaches the opposite convention for z e is adopted. For these approaches, the minus sign is eliminated from the foregoing equation and from the subsequent equations appearing below.
Thus, the amount by which the surface marking is moved toward the viewer to avoid "burying" the surface marking behind a surface of slope S is given by:
Sδ/2=z.sub.e S/2K.
As a result, the modified eye space coordinate z' e is given by
z'.sub.e =z.sub.e +Sδ/2=z.sub.e -z.sub.e S/2K=z.sub.e (1-S/2K).(6)
However, in a perspective projection (unlike an orthographic projection) , the screen coordinates [x s y s ] depend on z e . As a result, modifying z e to z' e causes the size and position of the object on the screen to shift, resulting in object to appear misregistered relative to other objects. Fortunately, the modification of z e to obtain the term z' e is purely multiplicative (by a factor of 1-S/2K as shown in equation (6)). In that x s and y s are proportional to 1/z e , as shown in equation (5), the misalignment is avoided by similarly multiplying x e and y e by a factor of 1-S/2K:
x'.sub.e =x.sub.e (1-S/2K), y'.sub.e =y.sub.e (1-S/2K). (7)
As described in equation (1), the transformation from eye coordinates [x e y e z e ] to modified eye coordinates [x' e y' e z' e ] is accomplished in the graphics system 10 by inserting the transform T' e into the standard transformation process. Equations (6) and (7) for the modified eye coordinates [x' e y' e z' e ] imply that, for a perspective projection, T' e e is given by ##EQU8##
Expressed in this form, it can further be appreciated by those having skill in the art that this method of the invention is also readily incorporated into many graphics systems that allow arbitrary 4×4 homogeneous transformations in the process of converting object coordinates to screen coordinates.
In summary, the inventors have identified a cause of a problem of missing pixels when rendering surface markings such as lines, curves, and points that are coincident with a surface. The problem has been determined to result from pixel-location inaccuracies in drawing the surface markings. The inventors have also provided methods for solving the problem by moving the surface markings toward the viewer, as summarized by equations (1), (4) and (8). The methods of the invention are widely applicable, in that they are readily incorporated into many conventional graphics systems. The methods provide for the user to select a parameter S that represents a maximum surface slope, relative to the viewer, for which the missing pixels will be completely avoided. Too large a value for S may result in the opposite error of surface markings being visible when they should be obscured by another surface. A value for S of approximately eight has been shown to provide good results, although the exact value of S is not critical.
If, by example, triangle PQR is one face of a geodesic sphere, and if each face includes surface markings, then some large subset of faces will be inclined with a slope of less than eight and will thus not hide the surface markings. For those faces that are inclined with a slope of greater than eight, their projection upon the view plane IJ will generally encompass a small area and, as result, any missing surface marking pixels will not be as visually apparent.
Although described in the context of a planar surface (triangle PQR) it should be understood that the methods described herein are applicable in general to situations wherein pixel-location inaccuracies exist in the rendering of a surface marking against either a planar or a curved surface.
Thus, while the invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that changes in form and details may be made therein without departing from the scope and spirit of the invention.
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A method, for execution by a graphics processing system (10), for rendering objects for display to a viewer upon a display (20) having a plurality of display pixels. The method includes the steps of, for a surface to be displayed having a surface marking coincident therewith, (a) moving the surface marking towards the viewer or, alternatively, moving the surface away from the viewer, by an amount that is function of a parameter (S) and also a scale factor (K) that expresses a relationship between viewer eye coordinate units and display pixel units. The parameter (S) determines a maximum slope for the surface, relative to a viewing plane, such that the step of moving will not cause a portion of the surface marking to be obscured by the surface. The step of moving includes a step of (b) applying a predetermined transformation T' e from a viewer eye coordinate system to a modified viewer eye coordinate system. The predetermined transformation T' e is selected as a function of whether a perspective projection or an orthographic projection of the surface and surface marking upon a viewing plane is performed. For the perspective projection, the transformation T' e is shown to also compensate for the movement of the second object towards the viewer.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present multi-compartment container relates in general to a container for storing therapeutic agents and more specifically to a multi-compartment container for securely storing therapeutic agents such as pills, vitamins, etcetera, to be taken on a periodic basis.
BACKGROUND OF THE INVENTION
[0002] In simple form, a pill container holds a given amount of medication in a cylindrical container with a screw-on threaded lid. Such a container is generally of a size that can easily be placed in a medicine cabinet with several other similar pill containers. Such a container may also be readily carried in a purse, or in the pocket of a pair of pants.
[0003] Generally, a pill container is designed such that the lid is not easily removable, as is the case with many pill containers having a screw-on threaded lid. In other words, pill containers tend to be “child resistant.” Some child resistant pill containers require the pill taker to push down on the cap and then turn the lid in order to access the pill contained therein. Others are designed such that the pill taker must squeeze on opposite ends of the cap in order to be able to turn the cap and access the pills. Yet others are designed such that both the container and the lid of the container must be perfectly aligned before the cap may be removed and access to the contents may be gained.
[0004] More complex pill containers allow for several medications, various dosages of medications, vitamins, and other therapeutic agents, to be stored in one container separated by various compartments. Medications, for example, may be stored in various compartments or cavities labeled by the day of the week or month to correspond with a concomitant cycle. The problem with these types of multi-compartment containers however, is that they lack safety mechanisms, including the types of safety mechanisms as described above. These types of containers and their contents may be easily accessed by children and others for whom the contents were not meant to be used.
[0005] There is a need in the art for a multi-compartment container that is able to store various therapeutic agents and is child resistant. It is to these ends that the present multi-compartment container has been developed.
BRIEF SUMMARY OF THE INVENTION
[0006] To minimize the limitations in the prior art, and to minimize other limitations that will be apparent upon reading and understanding the present specification, the present multi-compartment container describes a container for storing therapeutic agents that may comprise a lower portion having one or more lower cavities for storing said therapeutic agents, an upper portion having one or more upper cavities for storing said therapeutic agents, a child resistant mechanism, such that said therapeutic agents stored in said lower portion and said upper portion are secured from tampering, at least one hinge connecting said lower portion and said upper portion, one or more lower walls in said lower portion, wherein said one or more lower walls is placed such that said one or more lower walls create said one or more lower cavities, and one or more upper walls in said upper portion, wherein said one or more upper walls is placed such that said one or more upper walls create said one or more upper cavities.
[0007] Said container may further one or more lower portion covers, placed upon and releasably attached to said lower portion such that said therapeutic agents within said one or more lower cavities are secured within said one or more lower cavities, one or more upper portion covers, placed upon and releasably attached to said upper portion such that said therapeutic agents within said one or more upper cavities are secured within said one or more upper cavities, and labels for said one or more lower cavities and said one or more upper cavities.
[0008] It is an objective of the present multi-compartment container to safely and securely store a variety of therapeutic agents.
[0009] Is another objective of the present multi-compartment container to efficiently organize a variety of therapeutic agents.
[0010] These and other advantages and features of the present multi-compartment container are described herein with specificity so as to make the present multi-compartment container understandable to one of ordinary skill in the art.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] Elements in the FIGS. have not necessarily been drawn to scale in order to enhance their clarity and improve understanding of these various elements and embodiments of the multi-compartment container. Elements that are known to be common and well understood to those in the industry are not depicted in order to provide a clear view of the various embodiments of the multi-compartment container. Furthermore, reference numerals have been repeated throughout the FIGS. to indicate sufficiently corresponding elements and to simplify the disclosure.
[0012] FIG. 1 is a three dimensional view of a multi-compartment container.
[0013] FIG. 2 is a three dimensional view of said multi-compartment container in FIG. 1 , said multi-compartment container being slightly ajar.
[0014] FIG. 3 is a three dimensional view of said multi-compartment container in FIG. 1 , said multi-compartment container being in a substantially open position.
[0015] FIG. 4 is a three dimensional view of an alternative embodiment of a multi-compartment container.
[0016] FIG. 5A is a three dimensional view of said multi-compartment container in FIG. 4 , said multi-compartment container being slightly ajar.
[0017] FIG. 5B is a close-up three dimensional view of an alternative embodiment of male connecting threads.
[0018] FIG. 6 is a three dimensional view of said multi-compartment container in FIG. 4 , said multi-compartment container being in a substantially open position.
[0019] FIG. 7 is a three dimensional view of another alternative embodiment of a multi-compartment container.
[0020] FIG. 8 is a three dimensional exploded view of said multi-compartment container in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0021] In the following discussion that addresses a number of embodiments and applications of the present multi-part container, reference is made to the accompanying drawings that form a part thereof, where depictions are made, by way of illustration, of specific embodiments in which the multi-compartment container may be practiced. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the multi-compartment container.
[0022] FIGS. 1-3 depict an embodiment of multi-compartment container 101 . In particular, FIG. 1 is a three dimensional view of multi-compartment container 101 . Multi-compartment container 101 may generally be comprised of lower portion 102 , upper portion 103 , cap 104 , and hinge 106 . Multi-compartment container 101 may also be constructed out of various materials including plastic, metal, or other natural or synthetic materials, or any combination of the above mentioned materials.
[0023] As depicted, lower portion 102 may be comprised of two primary sections 107 . Each section 107 of lower portion 102 may run the length of multi-compartment container 101 . Each section 107 of lower portion 102 may also be parallel to one another. It may also be noted that sections 107 comprising lower portion 102 have flat bottoms. Said flat bottoms may make storing multi-compartment container 101 on a shelf, for example, more practicable and stable as compared to a rounded bottom.
[0024] It may also be noted that the ends of sections 107 are also flat as depicted in FIG. 1 . Similar to the flat bottoms of sections 107 , flat ends may allow for multi-compartment container 101 to be more efficiently stored, as multi-compartment container 101 may be placed flush against the wall in a medicine cabinet, for example, allowing for maximal space to be utilized both within said medicine cabinet and multi-compartment container 101 . Although FIG. 1 depicts each section 107 of lower portion 102 as curving upward on each side except for the ends, this is not to limit the scope of multi-compartment container 101 . Rather than being somewhat rounded in shape, multi-compartment container 101 may be of a substantially rectangular shape, having no curved edges. Multi-compartment container 101 may also be more curved in shape. For example, it is within the scope of multi-compartment container 101 to have ends that are of a curvy nature rather than completely flat. Other shapes and styles may be utilized without departing from the scope of multi-compartment container 101 .
[0025] Upper portion 103 may be an exact replica of lower portion 102 . Thus, upper portion 103 may also be comprised of two partially curved and partially flat sections 107 as described above. Because upper portion 103 may mimic lower portion 102 , this may allow for multi-compartment container 101 to rest upon a shelf, for example, upside down, and yet still be stable.
[0026] The four sections 107 depicted in FIG. 1 are not to limit the scope of multi-compartment container 101 . In another embodiment, for example, lower portion 102 may be comprised of a single section 107 , and upper portion 103 may also be comprised of a single section 107 . In another embodiment, lower portion 102 and upper portion 103 may be comprised of a disproportionate number of sections 107 , yet still be within the spirit of multi-compartment container 101 .
[0027] Cap 104 may be employed to securely close multi-compartment container 101 . As depicted in FIG. 1 , this may be accomplished by male connecting threads 105 located on multi-compartment container 101 , and female connecting threads (not shown) located on cap 104 .
[0028] Cap 104 may also be of a child resistant nature. For example, when cap 104 is secured to the entirety of multi-compartment container 101 , cap 104 may be removed from multi-compartment container 101 by pressing down on cap 104 and then turning such that cap 104 is removed. In another embodiment, cap 104 may be removed from multi-compartment container 101 by pressing simultaneously on both sides of cap 104 and then turning. In yet another embodiment, cap 104 may be of a nature such that it cannot be removed unless it is aligned in a certain configuration. Other similar caps may be employed by multi-compartment container 101 . In another embodiment, however, another child resistant device may be used that would make it difficult for access to be gained. This may include a combination lock, or design such that the multi-compartment container may be opened by pressing on either end first.
[0029] Hinge 106 may be of a nature such that it solidly connects upper portion 103 and lower portion 102 along the length of the rear side of multi-compartment container 101 . Although not fully depicted in FIG. 1 , hinge 106 may run the entire length of multi-compartment container 101 . In another embodiment, hinge 106 may be a series of one or more separate connectors, similar to the hinges found on a typical household door. In yet another embodiment, hinge 106 may not be employed at all. Rather, lower portion 102 may be configured to receive upper portion 103 such that upper portion 103 merely snaps into place onto lower portion 102 or vice versa. In this embodiment, a security feature may be added such that a button or a lever may be engaged in order to separate said upper portion 103 and lower portion 102 , such that multi-compartment container 101 retains child resistant properties.
[0030] FIG. 2 is a three dimensional view of multi-compartment container 101 , said multi-compartment container 101 being slightly ajar. FIG. 2 reveals additional features that may comprise multi-compartment container 101 , i.e. cavities 201 and walls 202 . It is within said cavities 201 that various therapeutic agents may be stored. As shown in FIG. 2 the front section 107 of lower portion 102 is comprised of seven cavities 201 aligned side by side and separated by walls 202 . In another embodiment a different number of cavities 201 may be employed. For example, it is within the spirit of the invention that front section 107 of lower portion 102 may be comprised of as little as one cavity 201 while upper portion 103 is comprised of a concomitant number. In another embodiment, lower portion 102 and upper portion 103 may be comprised of a disproportionate amount of cavities 201 .
[0031] It may also be noted that the member comprising male connecting threads 105 may be divided into separate parts during the manufacturing process with one hemisphere located on lower portion 102 and another hemisphere located on upper portion 103 . This “broken” design may allow strategic placement of cap 104 .
[0032] FIG. 3 is a three dimensional view of multi-compartment container 101 in a substantially open position. As noted above, each section 107 in FIG. 3 contains seven cavities 201 , however, this is not to limit the scope of multi-compartment container 101 . Again, each section 107 may contain more or less cavities 201 depending on the type and duration of therapeutic agents employed by the particular multi-compartment container 101 .
[0033] FIG. 3 further depicts section covers 301 . Section covers 301 may serve to help keep therapeutic agents contained in cavities 201 secured in place when opening and closing multi-compartment container 101 . Section covers 301 may be of a transparent nature in order to see the actual therapeutic agents contained in multi-compartment container 101 . However, in another embodiment, section covers 301 may be designed such that they serve as a visual block to the therapeutic agents contained in multi-compartment container 101 . Thus, although as depicted in FIG. 3 section covers 301 are clear, this is why it may be more accurate to depict cavities 201 as being represented by a dotted line in the event that an opaque cover 301 were to be employed by multi-compartment container 101 .
[0034] Furthermore, section covers 301 and/or cavities 201 themselves may be labeled. One form of labeling may include days of the week, such as Sunday through Saturday. Utilizing the embodiment depicted in FIG. 3 , each cavity 201 may correspond to each day of the week, and being as there are four sections 107 each having seven cavities 201 , four weeks, or twenty-eight days of therapeutic agents may be stored in multi-compartment container 101 . Other embodiments may utilize fewer or more cavities 201 and sections 107 . Thus, it is within the scope of multi-compartment container 101 to be comprised of two cavities 201 or 365 cavities 201 . Said cavities 201 may correspond to a cycle, such as a treatment cycle using varying doses of medication, or a calendar cycle such as hours of the day, days of the week, days of a month, months of a year, etc.
[0035] FIGS. 4-6 depict an alternative embodiment of multi-compartment container 101 . FIGS. 4-6 are of substantially the same nature as FIGS. 1-3 , with some minor differences in the configuration of cap 104 and male connecting threads 105 . As shown in FIG. 4 , the circular configuration of male connecting threads 105 may be located entirely on lower portion 102 . FIG. 4 additionally depicts tab 401 , which may be solidly connected to upper portion 103 , and extend toward lower portion 102 . When multi-compartment container 101 is closed, as shown in FIG. 4 , tab 401 may come to rest and be secured in aperture 501 (not shown) located on an upper portion of male connecting threads 105 .
[0036] After tab 401 is secured in aperture 501 , cap 104 may be attached. As discussed above, cap 104 may comprise a variety of child resistant designs. In FIG. 4 however, the child resistant design of tab 401 secured within male connecting threads 105 may not necessitate further child resistant safety measures, however this is not to limit the spirit of multi-compartment container 101 . In another embodiment, several different child safety designs may be employed on a single multi-compartment container 101 to further secure therapeutic agents from tampering.
[0037] FIG. 5A is a three dimensional view of multi-compartment container 101 shown in FIG. 4 , said multi-compartment container 101 being slightly ajar. FIG. 5A depicts further detail of the alternative embodiment utilizing tab 401 , lip 502 , and aperture 501 . From this perspective, it may be noted how tab 401 may be placed in or taken out of aperture 501 . Tab 401 may further be comprised of lip 502 and a spring mechanism (not shown). Lip 502 may be a slight protrusion from tab 401 , such that when tab 401 is inserted into aperture 501 , more force may be necessary to fully close and secure multi-compartment container 101 . Conversely, when opening multi-compartment container 101 , it may be necessary to depress lip 502 which may be held up by said spring mechanism in order to open multi-compartment container 101 .
[0038] FIG. 5B is a close-up three dimensional view of an alternative embodiment of male connecting threads 105 . In this embodiment it may be noted that rather than having aperture 501 , male connecting threads may utilize opening 503 to achieve a similar result. Rather than aperture 501 receiving tab 401 , opening 503 may alternatively receive tab 401 in a similar manner, namely tab 401 may come to rest in opening 503 rather than be placed in a hole, as depicted by aperture 501 depicted in FIG. 5A . Cap 104 may thereafter be placed on male connecting threads 105 to secure the contents of multi-compartment container 101 . Cap 104 may be placed such that when fully in place, multi-compartment container 101 may not be opened, as lip 502 , which may protrude from tab 401 , may catch cap 104 . As such multi-compartment container 101 may not be opened unless cap 104 is removed after which lip 502 may not be blocked by cap 104 .
[0039] FIG. 6 is a three dimensional view of multi-compartment container 101 shown in FIG. 4 in a substantially open position. It may be noted that FIG. 6 is representative of one embodiment of multi-compartment container 101 . Other embodiments may include multi-compartment-container sans covers 301 . Another embodiment may include the alternative male connecting threads 105 and opening 503 as discussed in FIG. 5B , rather than the embodiment disclosing aperture 501 in FIG. 6 .
[0040] FIG. 7 is a further alternative embodiment of multi-compartment container 101 . Unlike the embodiments discussed thus far having both upper portions 103 and lower portions 102 , the embodiment depicted in FIG. 7 is comprised of a singular base portion 701 . This embodiment further comprises an alternative cover 301 , which may be placed over base portion 701 such that the contents of base portion 701 are secured in the event that multi-compartment container 101 were to be jostled or flipped. Multi-compartment container 101 may then be further secured with cap 104 . Cap 104 may be of the same child resistant designs as discussed above. Other child resistant techniques may be utilized, however, to keep therapeutic agents contained in said multi-compartment container 101 safe.
[0041] FIG. 7 depicts seven cavities 201 which comprise base portion 701 which may logically correspond to the days of the week. In other embodiments, however, base portion 701 may be comprised of more cavities 201 or less cavities 201 , and said cavities 201 may correspond to other cycles as discussed above. Furthermore, the shape of multi-compartment container 101 may vary. As such, another embodiment similar to that depicted in FIG. 7 may be of a substantially square shape. Such other embodiments do not digress from the essence of multi-compartment container 101 .
[0042] FIG. 8 is an exploded view of said multi-compartment container 101 in FIG. 7 . In this exploded view, it may be noted how cap 104 may be secured to multi-compartment container 101 , i.e., male connecting threads 105 and female connecting threads on cap 104 (not shown). It may also be noted that an additional cavity 201 may be utilized immediately beneath where cap 104 is placed.
[0043] A multi-compartment container for the secure storage of therapeutic agents has been described. The foregoing description of the various exemplary embodiments of the multi-compartment container has been presented for the purposes of illustration and disclosure. It is not intended to be exhaustive or to limit the multi-compartment container to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit of the multi-compartment container.
DESCRIPTION OF THE REFERENCE SYMBOLS
[0000]
101 : multi-compartment container
102 : lower portion
103 : upper portion
104 : cap
105 : male connecting threads
106 : hinge
107 : section
201 : cavity
202 : wall
301 : cover
401 : tab
501 : aperture
502 : lip
503 : opening
701 : base portion
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A multi-compartment container for the secure storage of therapeutic agents comprises at least a base portion having at least two cavities, said at least two cavities serving as the location where said therapeutic agents are stored, and a child resistant device. Said child resistant device allows for the secure storage of said therapeutic agents. Said child resistant device may be in the form of a typical prescription pill container cap or may be more complex, such as a combination lock. Other features may include covers to keep said therapeutic agents in place, hinges to open said multi-compartment container, and labels corresponding to related cycles for said therapeutic agents.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. application Ser. No. 07/521,553, filed May 10, 1990, U.S. Pat. No. 5,102,903.
BACKGROUND OF THE INVENTION
Glaucoma is an ocular disease complex associated with an elevated pressure within the eye, i.e., elevated intraocular pressure (IOP). As a result of the elevated IOP, damage to the optic nerve, resulting in irreversible loss of visual function, may ensue. Untreated, this condition may eventually lead to blindness. Ocular hypertension, i.e., a condition of elevated IOP, without optic nerve damage or characteristic glaucomatous visual field loss, is now believed by the majority of ophthalmologists to represent the earliest phase in the onset of glaucoma. Glaucoma is among the leading causes of blindness in the U.S. today.
Drugs currently available for the control of the symptoms of glaucoma and to halt the progressive optic nerve damage are only marginally effective (Yorio (1985) J. Ocular Pharmacol. 1:397-422). Recently, the renin-angiotensin system (RAS) has been suggested as possibly playing a role in the maintenance of intraocular pressure, as the angiotensin-converting enzyme (ACE) inhibitors, captopril and SCH 33861, have been shown to lower IOP in ocular normotensive rabbits (Watkins et al. (1987) J. Ocular Pharmacol. 3:295-307) and in humans with elevated intraocular pressures (Constad et al. (1988) Am. J. Opthalmol. 105:674-677). More recently, a renin inhibitor identified as Abbott-64662 was found to decrease aqueous humor formation and lower the IOP in rabbits following topical application (Stein et al. (1989) The Pharmacologist 31:124).
The use of certain angiotensin-AII receptor antagonists in the treatment of elevated intraocular pressure and glaucoma has been disclosed in South African Patent Application 871653, to Schering, filed Mar. 6, 1987.
Conventional therapy for glaucoma has involved topical administration of pilocarpine and/or epinephrine, and more recently beta-blockers, such as Timolol, administered to the eye several times daily. For example, beta-blockers useful as antiglaucoma agents are disclosed in commonly-assigned U.S. patent application Ser. No. 07/285007, filed Dec. 15, 1988 (CC-0747).
SUMMARY OF INVENTION
According to the present invention there is provided a method of treating glaucoma and intraocular hypertension in a mammal comprising administering to the eye of the mammal, in an amount effective to reduce intraocular pressure, an angiotensin-II antagonist compound having the formula (I): ##STR1## or pharmaceutically suitable salts thereof, wherein
X, Y and Z are independently N or CR 2 with the proviso that
1) when R 2 ≠H, then only one of X, Y or Z can be CR 2 ;
2) when Z═N, then Y and X≠CR 2 ; or
3) when Y═N, then Z and X≠CR 2 ; and
4) when X═Y═N, then Z≠N;
5) when X═N, Y═Z═CR 2 , then with respect to Y, R 2 ═C 3-4 alkyl or C 4 alkenyl and with respect to Z, R 2 ═H or Cl and R 1 ═(CH 2 ) n OR 4 where n=1 and R 4 ═C 1 alkyl, A═carbon-carbon single bond, R 3 ═CO 2 H and R 5 ═H.
A is a carbon-carbon single bond, CO, O, NHCO, or OCH 2 ;
R 1 is alkyl of 2 to 6 carbon atoms, alkenyl or alkynyl of 3 to 6 carbon atoms or (CH 2 ) n OR 4 then R 2 is provided that when R 1 is (CH 2 ) n OR 4 then R 2 is H, alkyl of 2 to 6 carbon atoms, alkenyl or alkynyl of 3 to 6 carbon atoms;
R 2 is H, alkyl of 2 to 6 carbon atoms, alkenyl or alkynyl of 3 to 6 carbon atoms, ##STR2##
R 3 is --CO 2 H, --NHSO 2 CF 3 , ##STR3##
R 4 is H or alkyl of 1 or 4 carbon atoms;
R 5 is H, halogen, NOX 2 , methoxy, or alkyl of 1 to 4 carbon atoms;
R 6 H, alkyl of 1 to 6 carbon atoms; cycloalkyl of 3 to 6 carbon atoms, (CH 2 ) m C 6 H 5 , OR 7 or NR 8 R 9 ;
R 7 is H, alkyl of 1 to 5 carbon atoms, cycloalkyl of 3 to 6 carbon atoms, phenyl or benzyl;
R 8 and R 9 independently are H, alkyl of 1 to 4 carbon atoms, phenyl, benzyl or NR 8 R 9 taken together form a ring of the formula ##STR4##
Q is NR 10 , O or CH 2 ;
R 10 is H, alkyl of 1 to 4 carbon atoms or phenyl;
R 11 is alkyl of 1 to 6 carbon atoms or perfluoroalkyl of 1 to 6 carbon atoms, (CH 2 ) p C 6 H 5 ;
R 12 is H, alkyl of 1 to 4 carbon atoms; or acyl of 1 to 4 carbon atoms;
m is 0 to 6;
n is 1 to 6;
p is 0 to 3;
r is 0 to 1;
t is 0 to 2.
Preferred in the method of the invention are compounds of formula (I) wherein:
A is a carbon-carbon single bond, or NHCO;
R 1 is alkyl, alkenyl or alkynyl each of 3 to 5 carbon atoms;
R 2 is H, alkyl, alkenyl or alkynyl each of 3 to 5 carbon atoms, ##STR5##
R 3 is --CO 2 H, --NHSO 2 CF 3 , or ##STR6##
R 4 is H or CH 3 ;
R 5 is H;
R 6 is H, alkyl of 1 to 6 carbon atoms, OR 7 , or NR 8 R 9 ;
R 7 is alkyl of 1 to 6 carbon atoms;
R 8 and R 9 independently are H, alkyl of 1 to 4 carbon atoms, or taken together with the nitrogen form the ring ##STR7##
R 11 is CF 3 , alkyl of 1 to 4 carbon atoms or phenyl;
m is 0 to 3;
n is 1 to 3; and pharmaceutically suitable salts thereof.
Included in the above-described preferred compounds are pyrroles of the formula ##STR8## wherein R 1 , R 2 , R 3 , R 5 and A are defined as above.
More preferred in the method of the invention are compounds of the above formulae wherein
A is a carbon-carbon single bond;
R 1 is alkyl or alkenyl of 3 to 5 carbon atoms or CH 2 OR 4 ; provided that when R 1 is CH 2 OR 4 then R 2 is alkyl or alkenyl of 3 to 5 carbon atoms;
R 2 is alkyl or alkenyl of 3 to 5 carbon atoms, CH 2 OR 4 , COR 6 , ##STR9##
R 6 is H, OH, alkyl of 1 to 4 carbon atoms;
R 7 is alkyl of 1 to 4 carbon atoms; and pharmaceutically acceptable salts.
Specifically preferred compounds in the method of the invention are:
5-n-Propyl-1-[(2'-(1H-tetrazol-5-yl)-biphenyl-4-yl)methyl]pyrrole-2-carboxylic acid, ethyl ester
5-n-Butyl-1-[(2'-(1H-tetrazol-5-yl)-biphenyl-4-yl)methyl]pyrrole-2-carboxylic acid, ethyl ester
5-n-Butyl-1-[(2'-1H-tetrazol-5-yl)-biphenyl-4-yl)methyl)pyrrole-2-carboxylic acid
5-n-Propyl-1-[(2'-carboxybiphenyl-4-yl)methyl]pyrrole-2-carboxylic acid;
5-n-Propyl-1-[(2'-(1H-tetrazol-5-yl)-biphenyl-4-yl)methyl]pyrrole-2-carboxaldehyde;
5-n-Butyl-1-[(2'-(1H-tetrazol-5-yl)-biphenyl-4-yl)methyl]pyrrole-2-carboxaldehyde;
2-(Acetyloxymethyl)-5-(1'-butenyl)-1-[(2'-(1H-tetrazol-5-yl)-biphenyl-4-yl)methyl]pyrrole;
and pharmaceutically suitable salts thereof.
Pharmaceutically suitable salts include both the metallic (inorganic) salts and organic salts; a list of which is given in Remington's Pharmaceutical Sciences, 17th Edition, page 1418 (1985). It is well known to one skilled in the art that an appropriate salt form is chosen based on physical and chemical stability, flowability, hydroscopicity and solubility. Preferred salts of this invention for the reasons cited above include potassium, sodium, calcium and ammonium salts.
Throughout the text when an alkyl substituent is mentioned, the normal alkyl structure is meant (i.e., butyl is n-butyl) unless otherwise specified.
In the foregoing structural formulae, when a substituent can be present in more than one position it can be selected independently at each occurrence. For example, if R 4 is present as part of both the definition of R 3 and A and/or B it need not be defined as the same substituent, but can be selected independently for R 3 , A, and B.
DETAILED DESCRIPTION OF THE INVENTION
The compounds useful in this invention are described in and prepared by methods set forth in copending and commonly-assigned U.S. patent application U.S. Ser. No. 07/279,193, filed Dec. 6, 1988 (BP-6360-A) which issued as U.S. Pat. No. 5,015,651 on May 14, 1991 (page 13, line 1 through page 117, line 22), and corresponding European published application EPA 0 323 841, published Jul. 12, 1989 (page 8, line 20 through page 59, line 18), the disclosures of which are hereby incorporated by reference.
The compounds of this invention are advantageously administered topically to the eye in the form of a solution, ointment, or solid insert, such as is described in U.S. Pat. No. 4,195,085. Formulations may contain the active compound, preferably in the form of a soluble acid addition salt, in amounts ranging from about 0.01% to about 10% by weight, preferably from about 0.5% to about 5% by weight. Unit dosages of the active compound can range from about 0.001 to about 5.0 mg, preferably from about 0.05 to about 2.0 mg. The dosage administered to a patient will depend upon the patient's needs and the particular compounds employed.
Carriers used in the preparations of the present invention are preferably nontoxic ophthalmologically acceptable pharmaceutical organic or inorganic compositions such as: water; mixtures of water and water-miscible solvents, such as lower alcohols; mineral oils; petroleum jellies; ethyl cellulose; polyvinylpyrrolidone; and other conventional carriers. In addition, the pharmaceutical preparations may also contain additional components such as emulsifying, preserving, wetting, and sterilizing agents. These include: polyethylene glycols 200, 300, 400, and 600; Carbowaxes® 1,000, 1,500, 4,000, 6,000, and 10,000 (polyethylene glycol, Union Carbide, Danbury, Conn.); bacteriocidal components, such as quaternary ammonium compounds; phenylmercuric salts known to have cold sterilizing properties and which are non-injurious in use; thimerosal; methyl and propyl paraben; benzyl alcohol; phenyl ethanol; buffering ingredients such as sodium chloride, sodium borate, sodium acetates, gluconate buffers; and other conventional ingredients such as sorbitan monolaurate, triethanolamine, oleate, polyoxyethylene sorbitan monopalmitylate, dioctyl sodium sulfosuccinate, monothioglycerol, thiosorbitol, ethylenediamine tetraacetic acid, and the like. Additionally, suitable ophthalmic vehicles can be used as carrier media for the present purpose including conventional phosphate buffer vehicle systems, isotonic boric acid vehicles, isotonic sodium chloride vehicles, isotonic sodium borate vehicles, and the like.
The method of treatment of this invention advantageously involves the topical administration of eye drops containing the active compound. Formulations for eye drops preferably include the active compound as a soluble acid addition salt in a properly buffered, sterile, aqueous isotonic solution.
The effect of compounds of formula (I) on intraocular pressure can be demonstrated in comparison to the ACE inhibitor captopril in the following Conscious Rabbit Model:
Adult New Zealand white rabbits are placed in a restrainer and their IOP measured using an Alcon Applanation Pneumatonagraph, which has both a digital output and recorder for maintaining permanent records. Three consecutive readings per eye are made (duration 10 sec. each) until a constant IOP is recorded. In some instances the peripheral ear artery is cannulated and systemic blood pressure recorded on a physiograph.
Test drugs are applied locally to one eye, either in topical form, or through intracameral administration. Measurements of IOP are made on both the treated eye and vehicle control. A dose comparable to the ocular hypotensive action found in a pilot study is selected as the starting dose and the dose is increased or decreased logarithmically and the effects on IOP is observed. Two to four log doses are tested in order to construct a log dose effect curve, which provides information on efficacy as well as potency. A time course for the drug effect is monitored by measuring the IOP of untreated animals for 60 minutes at 15 minute intervals, to obtain a baseline, and following drug addition (single dose), the IOP is measured at 30 minute intervals for six hours, or until recovery of the IOP. In addition, once a dose-effect curve is generated, the effects of agents on systemic blood pressure (BP) following topical administration are assessed by selecting the ED50 dose for testing. Thus, both changes in IOP and BP are monitored for each agent.
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Substituted pyrrole, angiotensin-II receptor antagonists and pharmaceutically acceptable salts thereof are useful for treating glaucoma and ocular hypertension.
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[0001] This application is related to and claims priority from European Patent Application No. 16 152 932.6, filed Jan. 27, 2016, the entire contents of which are fully incorporated herein by reference for all purposes.
[0002] The present invention relates to autofocusing-based correction of Bo fluctuation-induced ghosting.
[0003] Long-TE gradient-echo images are prone to ghosting artifacts. Such degradation is primarily due to magnetic field variations caused by breathing or motion. The effect of these fluctuations amounts to different phase offsets in each acquired k-space line. In fact, phase artifacts, regardless of the chosen TE parameter, affect all scans. The longer TE, the more severe the artifacts are. A common remedy is to measure the problematic phase offsets using an extra non-phase-encoded scan before or after each imaging readout.
[0004] Brockstedt et al. (“High resolution diffusion imaging using phase-corrected segmented echo-planer imaging”, MAGNETIC RESONANCE IMAGING; ELSEVIER SCIENCE, vol. 18, no. 6, 1 January 2000, p. 649-657) use navigator echo phase corrections, performed after a one-dimensional Fourier transform along the frequency-encoding direction in order to reduce motion artifacts. The navigator echoes are acquired together with the image. However, the use of navigators requires longer repetition duration, reducing the effective time during which relevant image data is acquired.
[0005] It is therefore an object of the present invention to develop a postprocessing method for gradient-echo scans, which is capable of removing Bo fluctuation-induced ghosting artifacts-, wherein the entire duration of the sequence repetition may be used to acquire image data.
[0006] The object is achieved by a method and a system according to the independent claims. Advantageous embodiments are defined in the subclaims. Particularly, the invention estimates the phase offsets directly from the raw image data by optimization-based search of phases that minimize an image quality measure. This eliminates the need for any sequence modifications and additional scan time.
[0007] In contrast to Brockstedt et al., the method of the invention is navigator free, which allows using the entire duration of the sequence repetition to acquire the image data. The image data alone may be used to estimate the unknown phase offsets.
[0008] The optimization problem is formulated and solved where one seeks the latent phase offsets in the Fourier domain that are associated with a minimal value of an image quality measure that is evaluated in the spatial domain. This way, the need for extra non-phase-encoded navigator scans and the related increase in sequence complexity and scan time may be avoided. The experimental results demonstrate that the inventive method is capable of removing the ghosting artifacts, and that the quality of the outcome images is similar to navigator-based reconstructions. To conclude, the proposed method is a valid alternative to using navigators with only a slight increase in post processing time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0010] These and other aspects of the present invention will be described in more detail in the following detailed description, in relation to the annexed drawing in which:
[0011] FIG. 1 shows a comparison between uncorrected images with images corrected for Bo fluctuations using a conventional navigator-based approach as well as the proposed autofocusing-based method;
[0012] FIG. 2 shows the differences between the autofocusing and navigator-based approaches; and
[0013] FIG. 3 shows the differences between the autofocusing and navigator-based approaches.
DETAILED DESCRIPTION
[0014] According to an embodiment of the invention, equation 1 shows a navigator-less reconstruction formulated as an optimization problem, which involves finding the minimum value of the objective function:
[0000]
Φ
^
=
argmin
Φ
ϕ
(
(
G
x
+
G
y
)
SOS
(
F
H
A
Φ
Q
)
)
+
λ
G
Φ
2
(
1
)
[0015] The matrix F H denotes the inverse Fourier transform matrix and Q the acquired multi-coil raw data.
[0016] The unknown phase values Φ are searched that are associated with low values of the image quality measure or metric φ. More precisely, one computes the entropy φ(•) of the spatial intensity variations in the SOS-combined image (sum of squares).
[0017] The described embodiment of the invention proposes to use an entropy φ(•) of the image gradients as an image metric. Before computing the entropy, an edge-detection filter is applied to the image. More specifically, the differences between the neighboring voxels in spatial domain are computed in both X (readout) and Y (phase encode) directions, while skipping the Z (partition) direction. The matrices that are used to perform the finite difference operations in the x and y direction are denoted by G x and G y , respectively.
[0018] Their effect can be seen as a convolution of the image with a high pass filter [1-1] in both X and Y direction. The result is an image gradient, which emphasizes sharp structures such as edges.
[0019] Computing an image-metric on the spatial gradients rather than determining it on the raw pixel intensities is advantageous in the context of MRI, where an image not corrupted by phase artifacts has clean sharp transitions between the tissues (i.e. fat layer of the skull/air surrounding the head transition). Whenever, i.e. due to field distortions, an image is corrupted by ghosting artifacts, the edges become blurry and smeared out. This has an effect of increasing the variance in the gradient domain representation, and thus, increasing the entropy. Although the entropy evaluated on raw pixel intensities is also sensitive to ghosting and blurring artifacts, the inventors observed in experiments that the entropy of the gradients is associated with better reconstruction outcomes. The choice of the gradient entropy for MR image quality estimation was also found to be highly effective in a specialized study that evaluated and compared various image quality metrics—Kiaran McGee et al (“Image Metric-Based Correction of Motion Effects”).
[0020] As an alternative image metric, a total variation or L 1 norm of the gradient image may be used instead of an entropy.
[0021] The phase values Φ are applied to the acquired images Q (for each coil element) using the diagonal matrix A, whose elements are the complex exponentials exp(iΦ t ), with t being the repetition index, i.e. the number of the repetition as counted from the start of the acquisition.
[0022] In this formulation, the objective function is invariant to circular shifts of the image in the phase-encoding direction because such circular shifts amount to phase ramps—composed of recovered phases Φ—in the frequency domain. The problem of unnecessary circular shifts can be avoided by adding a regularization term, which penalizes strong variations of the recovered phases.
[0023] The parameter λ controls the strength of the regularization and may be set to 0.1.
[0024] The resulting non-linear optimization problem may be solved in 80 iterations of the LBFGS algorithm (Byrd R H, Lu P, Nocedal J, Zhu C. A limited memory algorithm for bound constrained optimization. SIAM Journal on Scientific and Statistical Computing 1995; 16:1190-1208). The operations were implemented from Eq. 1 on the GPU in CUDA, bringing the computation time for each slice down to a few seconds.
[0025] To evaluate the performance of the proposed method long-TE gradient-echo images were acquired of the brain of a healthy volunteer after obtaining informed consent and approval by the local ethics committee. Data was acquired at 9.4 T using a custom-built head coil (16 transmit/31 receive channels). 9 slices were acquired of the ventral portions of the brain where field variations are relatively severe, mainly due to breathing-related motion. The GRE sequence included a non-phase-encoded navigator (or phase-stabilization) scan after each imaging readout. The sequence parameters were as follows: TR=356 ms, TE=30 ms, nominal flip angle=45°, matrix=512×512, resolution=0.4×0.4 mm 2 , slice thickness=1 mm.
[0026] FIG. 1 shows a comparison between uncorrected images with images corrected for Bo fluctuations using a conventional navigator-based approach as well as the proposed autofocusing-based method. Ghosting artifacts in the uncorrected data are more severe in slice 6 shown on the bottom, which is positioned lower than slice 3 (top). In both slices, autofocusing and navigator-based correction techniques are able to improve image quality significantly.
[0027] Apart from some flow-related artifacts, ghosting is completely removed and the images resulting from both techniques are practically indistinguishable from one another. In fact, the differences between the autofocusing and navigator-based approaches amount to the minute high-frequency details as illustrated in FIG. 2 . FIG. 3 compares the phase offsets retrieved a method according to an embodiment of the invention with the navigator-based measurement.
[0028] Since there is a sign as well as a global phase offset ambiguity, the sign was adjusted and the mean was subtracted from both phase series before plotting them. Although there are a few differences in the recovered phase values, the general pattern of oscillations caused by breathing is the same.
[0029] According to a second embodiment of the invention, the phase artifact correction technique of the invention can be naturally extended to cover the problem of even-odd ghosting artifacts in [EPI] scans. There, the ghosts are displaced by N/2 voxels in phase encode direction due to asymmetry between the odd and even echoes. The asymmetry arises because of field inhomogeneities, eddy currents, or imperfect gradient waveforms. The ghosting artifacts are caused by relative shifts of even and odd k-space segments and in the spatial domain can be modeled by linear phase ramps:
[0000] q=M odd F ( p a,b *u )+ M even F ( u ) (2)
[0030] Here, q is the single-coil phase-corrupted image in Fourier domain, F is discrete Fourier transform matrix, p a,b is a linear phase ramp in spatial domain, u is phase-artifact free image in the spatial domain, and M odd and M even are diagonal matrices that extract odd and even segments in the frequency domain. The operator * denotes component-wise multiplication. The field distortions make the segments acquired in the frequency domain translated against the origin in read direction. The amount of translation depends on the strength of the field distortions. According to the present embodiment of the invention, such translations are modeled in the spatial domain with phase ramps i.e. the spatial dual of Fourier translations. The parameter a controls the slope of the ramp, and b determines the offset. Thus, p a,b (x)=exp(iax+b), where x is the spatial coordinate, and i is imaginary unit The problem of finding unknown ramp parameters can be formulated in the following way:
[0000] a,b =argmin a,b φ(( G x +G y )SOS( p a,b *F H M odd Q+F H M even Q )) (3)
[0031] Here, SOS is sum-of-squares coil combination method, φ is an image quality estimator, and Q is the matrix that contains coil images in frequency domain representation. Once the parameters a and b are recovered, they can be used to correct the image for even-odd ghosting artifacts.
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A method for correcting B o fluctuation-induced ghosting artifacts in long-TE gradient-echo scan images, comprising the steps of: acquiring an image (u); determining phase offsets (Φ); and applying the phase offsets (Φ) to the image (u); such that an entropy of the spatial intensity variations in the corrected image (u) decreases.
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[0001] The present invention relates to a safety strap buckle, in particular for automotive child safety seats, as well as for push-chairs or prams.
BACKGROUND OF THE INVENTION
[0002] Safety strap buckles for automotive child safety seats are known, e.g. as described in European Patent Application EP-A-0 867 131, comprising:
[0003] a buckle body connected to a first strap portion; and
[0004] a click-on lock mechanism housed inside the buckle body and designed to releasably lock two tongues connected to a second and third strap portion.
[0005] In the embodiment described in the above patent application, the lock mechanism comprises a release button which is maintained, by a return spring, in an upper lock position in which the tongues are retained inside the buckle body by a rodlike retaining member engaging corresponding retaining seats defined by the two tongues.
[0006] The release button is movable, in a direction perpendicular to the insertion direction of the tongues and in opposition to the elastic force of the spring, into a lower release position, in which the retaining member is released from the seats on the tongues to permit expulsion of the tongues from the buckle body.
[0007] In the above known embodiment, the rodlike retaining member is supported by the release button, and so moves with the button between the two lock and release positions. As a result, when the tongues are inserted into the buckle body, thus moving the retaining member into the retaining seats, the release button is also moved with it and produces undesired noise.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a safety strap buckle designed to eliminate the above drawback of the known art.
[0009] According to the present invention, there is provided a safety strap buckle as claimed in the attached Claims.
[0010] Very briefly, the basic idea underlying the invention is to provide a lock mechanism for a buckle of the above type, wherein the retaining member is a separate component part from the release button. Consequently, the lock stage only involves the retaining member, which engages the retaining seats on the tongues in the usual way, while the release buttons remains stationary in the rest position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present invention will now be described in detail, purely by way of a non-limiting example, with reference to the accompanying drawings, in which:
[0012] FIG. 1 shows an exploded view in perspective of a first embodiment of a safety strap buckle in accordance with the present invention;
[0013] FIG. 2 shows a schematic, partly cross sectioned view in perspective of a detail of the lock mechanism of the FIG. 1 buckle;
[0014] FIG. 3 shows a schematic cross section of the FIG. 2 detail;
[0015] FIG. 4 shows a schematic cross section of a portion of a second embodiment of a safety strap buckle in accordance with the present invention;
[0016] FIG. 5 shows a section along line V-V of the buckle portion in FIG. 4 ;
[0017] FIG. 6 shows an exploded view in perspective of a release button and a rodlike retaining member of a third embodiment of a safety strap buckle in accordance with the present invention;
[0018] FIG. 7 shows a view in perspective, with parts removed for clarity, of a fourth embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] In the following description and accompanying drawings, only the part of the buckle containing the innovative lock mechanism is described and illustrated. For any other details, the reader is referred to the known art referred to in the introduction.
[0020] With reference to FIG. 1 , number 10 indicates as a whole a safety strap buckle in accordance with the invention, in particular for automotive child safety seats, as well as for push-chairs or prams. Buckle 10 comprises a hollow body or shell 12 in turn comprising: a substantially flat bottom wall 12 a ; a substantially flat top wall 12 b ; two lateral walls 12 c ; a front wall 12 d ; and a fastening portion 16 on the opposite side to front wall 12 d and having a slot 18 by which to attach body 12 to a first strap portion (not shown).
[0021] Two known tongues 20 and 21 are insertable inside body 12 through an opening 14 in front wall 12 d and in a direction substantially perpendicular to front wall 12 d (hereinafter referred to as the longitudinal direction).
[0022] Tongues 20 and 21 are attached respectively to a second and third strap portion (not shown) by means of respective slots 22 and 23 , and each comprise, in known manner, a stem portion 24 , 25 having a downward-facing recess 26 , 27 which acts as a retaining seat. As will be clear from the following description, a buckle in accordance with the invention may obviously also be used in retaining systems employing a different number of tongues (typically one or three).
[0023] Hollow body 12 houses the buckle click-on lock mechanism, which substantially comprises a rodlike retaining member 28 and a release button 29 , both shown in detail in FIGS. 2 and 3 .
[0024] With particular reference to FIGS. 2 and 3 , retaining member 28 comprises a rod 30 which extends in a direction (hereinafter referred to as the transverse direction) parallel to the plane of bottom wall 12 a of body 12 and perpendicular to the insertion direction of tongues 20 and 21 , and engages retaining seats 26 and 27 in tongues 20 and 21 to retain tongues 20 and 21 inside body 12 . In the example shown, rod 30 has a rectangular cross section, but may obviously have a differently shaped, preferably circular, cross section.
[0025] Retaining member 28 also comprises two guide members 31 and 32 fixed to the ends of rod 30 , and which slide, in a direction perpendicular to the plane of bottom wall 12 a (hereinafter referred to as the vertical direction), inside an appropriately shaped guide seat 34 formed in body 12 . Alternatively, one guide member—in this case, annular in shape—may be provided.
[0026] The two guide members 31 , 32 (or one guide member) are preferably made of plastic material. Rod 30 may be made of plastic material—in which case, it is formed in one piece with guide members 31 and 32 —or of metal material—in which case, the two guide members are advantageously molded onto it.
[0027] Retaining member 28 is movable, in the vertical direction defined above, between a lowered position, in which tongues 20 and 21 can be inserted and released inside body 12 , and a raised position (shown in FIGS. 2 and 3 ), in which, once tongues 20 and 21 are inserted inside body 12 , rod 30 engages retaining seats 26 and 27 to prevent release of the two tongues.
[0028] Retaining member 28 is maintained in the raised lock position by a spring 35 —in the example shown, a leaf spring, the ends of which press on guide members 31 and 32 , on one side, and the central portion of which presses on bottom wall 12 a of body 12 , on the other side.
[0029] Spring 35 may obviously be a different type, e.g. a helical compression spring; in which case, two springs are preferably used, and press on the two guide members 31 and 32 at the ends of rod 30 .
[0030] Button 29 comprises, in known manner, a top portion 36 , e.g. disk-shaped, which is pressed by the user to release the strap; and two guide members 38 and 39 joined to (e.g. formed in one piece with) top portion 36 and mounted to slide inside guide seat 34 .
[0031] The two guide members 38 , 39 of button 29 advantageously comprise respective stop teeth 40 , 41 , which slide in respective vertical grooves 42 , 43 ( FIG. 3 ) in guide seat 34 , and cooperate with respective stop surfaces 44 , 45 at the top ends of grooves 42 , 43 to define a top limit position (lock position) of the button.
[0032] Button 29 is maintained in the lock position by a spring 46 —in the example shown, in the form of a cylindrical helical spring—interposed between disk-shaped portion 36 and a supporting surface 48 (shown schematically in FIG. 3 ) defined by buckle body 12 .
[0033] Operation of the lock mechanism of the buckle according to the invention will now be described briefly.
[0034] When inserted inside buckle body 12 at the lock stage, tongues 20 , 21 interact in known manner with rod 30 of retaining member 28 , so that rod 30 engages retaining seats 26 , 27 on the tongues to retain the tongues inside the buckle. Retaining member 28 being a separate component part from button 29 , the button remains stationary in the lock position during the above operation, thus generating no noise. When button 29 is pressed at the release stage, on the other hand, guide members 38 , 39 of the button push retaining member 28 into the lowered position, in which rod 30 disengages the retaining seats on the tongues, which are expelled in known manner from buckle body 12 by an ejector spring 50 (shown in FIG. 1 ).
[0035] FIGS. 4 and 5 show a second embodiment of a safety strap buckle in accordance with the present invention, and in which parts identical or corresponding to those in FIGS. 1 to 3 are indicated using the same reference numbers.
[0036] The second embodiment substantially differs from the first by the rodlike retaining member only comprising rod 30 , with no guide members. The ends of rod 30 slide inside respective guide seats 52 formed in hollow body 20 beneath guide seat 34 of button 29 . Rod 30 is moved downwards, to release the lock mechanism, by two bottom appendixes 54 (only one shown in FIG. 5 ) formed by guide members 38 , 39 and also sliding inside guide seats 52 of rod 30 .
[0037] FIG. 6 shows a third embodiment of a safety strap buckle in accordance with the present invention, and in which parts identical or corresponding to those in FIGS. 1 to 5 are indicated using the same reference numbers.
[0038] The third embodiment substantially differs from the second by retaining rod 30 sliding inside two guide seats 56 , 57 defined by slots in respective guide members 38 , 39 of release button 29 .
[0039] In the second and third embodiment too, spring 35 acting on retaining rod 30 may be a leaf spring or any other suitable type. For example, two cylindrical helical springs pressing on the two ends of the rod may be used.
[0040] FIG. 7 shows a fourth embodiment of a safety strap buckle in accordance with the present invention, and in which parts identical or corresponding to those in FIGS. 1 to 6 are indicated using the same reference numbers.
[0041] The fourth embodiment differs from the FIG. 2 embodiment by two helical springs 35 , as opposed to one leaf spring, acting on the ends of rod 30 to keep rod 30 in the raised lock position; and each tongue 20 , 21 (only one is shown in its entirety) is formed by molding plastic material onto a respective metal reinforcing insert 60 (only one shown in FIG. 7 , without plastic material). Inserts 60 are embedded completely in the plastic material, and terminate, at one end, with respective annular portions 61 surrounding slots 22 , 23 , and, at the other end, with respective appendixes 62 embedded in the teeth defining respective retaining seats 26 , 27 .
[0042] Body 12 is also formed by molding plastic material onto a metal reinforcing insert 65 (shown partly).
[0043] Metal insert 65 is embedded completely in the plastic material, and comprises : an annular end portion 66 embedded in portion 16 about slot 18 ; a load-transfer portion 67 defined by two arms (only one shown) and extending, from portion 66 , along lateral walls 12 c and beneath guide seats 52 (not shown in FIG. 7 but similar to those to FIG. 5 ) and therefore beneath rod 30 in the vertical or release direction; and two appendixes 68 , which define the ends of said arms, are aligned with the ends of rod 30 in the longitudinal direction, and are located opposite guide seats 52 (i.e. on the opposite side with respect to the retaining seats 26 , 27 when tongues 20 , 21 engage body 12 ) to assist in retaining rod 30 in the event of pull on buckle 10 in the longitudinal direction.
[0044] Clearly, changes may be made to the embodiments and details described and illustrated herein purely by way of non-limiting examples, without, however, departing from the scope of the invention as defined in the accompanying Claims.
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The buckle has a buckle body, and a lock mechanism for releasably locking two tongues insertable inside the buckle body in a longitudinal insertion direction; the lock mechanism includes a retaining rod movable, in a release direction perpendicular to the longitudinal insertion direction, between a lock position engaging retaining seats formed in the two tongues, and a release position disengaging the two tongues to permit expulsion of the tongues from the buckle body; the lock mechanism also includes a release button movable in the release direction to move the retaining rod into the release position; and the retaining rod is movable in the release direction independently of the release button, and is maintained in the lock position by a spring.
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BACKGROUND OF THE INVENTION
The technical area of the invention is the area of spinning mill machines such as draw frames, carding machines, and so forth, and therein a process to control a group of spinning machines consisting of several spinning machines ("spinning machine group") and a control network for the construction of a system control for the spinning machine group.
A spinning machine is an example of a spinning mill machine and consists of a plurality of spinning stations, at this time approximately 280 spinning station assembled into one spinning machine. For many applications, it is however necessary to interconnect several spinning machines, so that the control center becomes very important. Based on the spinning machine R1 of Rieter AG according to Prospectus 1431 d of November 1992, up to 32 rotor spinning machines can be connected to their SCC II control center. Each of these rotor spinning machines may have up to 280 spinning stations. The complexity and size that such a system may assume becomes apparent if, in addition, several machine groups of the size mentioned are interconnected in large spinning plants in order to form a large combination.
From the above-mentioned state of the art it can be seen that a spinning machine group in a combination of several spinning machines can be controlled and monitored only if network technology is used. FIGS. 4a, 4b are examples of possible networks in the state of the art in which two topologies are shown in graphic simplification. These topologies function with the Ethernet network, which is the state of the art protocol and is called CSMA/CD (Carrier Sense Multiple Access with Collision Detect). It functions so that a station (a "node") transmits a data or information package when it has first checked whether another node is already active. If another node (node or station) is active, the first mentioned node waits until the network cable is free. In the case that two or more stations transmit simultaneously by coincidence (so-called collisions), they recognize this through active comparison of the transmitted data and from the data measured on the cable. If the measured data does not match the transmitted data, the transmission is interrupted and is repeated only after a waiting period. In the protocol used, the waiting period is determined by means of a random generator which delivers exponentially increasing delay values in repetitions. This can prevent two stations from using repeatedly the same waiting period and from thus being set for continuous collision. Collisions result in time loss. In addition to the time loss due to collisions, it can be also seen in the known topology that a coupling between two stations (e.g. node 1 and node 2 or node 1.1 and node 1.2) blocks the network for all other stations which cannot use the network during the communication of two stations. The shown "router" (communication from the lower network to the higher network in FIG. 4b) to which the host (also several hosts) is coupled, places a load on the network.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to improve the operability of the spinning machine controls (with network) described in the state of the art and to accelerate the direct interaction of all the elements of the network which are connected together in a combination. Additional objects and advantages of the invention will be set forth in part in the following description, or will be obvious from the description, or may be learned through practice of the invention.
The present invention proposes that the data communications protocol for the exchange and the transmission of operation data and measured values of the higher communications level also be used for the lower communications level. To carry out this simplification of network protocols it is proposed to use a bus backplane on which several components, in particular several CPUs (central processing units) are coupled together. Each single bus backplane can stand for a spinning machine with its plurality of spinning stations in the case where the spinning mill machine is, for example, a rotor spinning machine.
Data communication makes it possible to improve the control of the machine group; the communication can be used without difficulty also to monitor the machine group.
The previously mentioned bus backplane hardware is not tied to any specific architecture, and bus backplanes of Intel (multibus I,II) or Motorola (VME) or others can be used. The bus backplane is, on the one hand, closely related to the machine controls and, on the other hand, closely related to the network. The tight coupling by the hardware structure is assisted by the selected software coupling, in which the communications protocol on the bus backplane and the communications protocol on the higher communications plane is the same, in particular a standardized protocol.
The bus system with the backplane can accept interface circuits (interfaces) of the most different types.
According to the invention, a non-deterministic bus is brought very close down to the spinning machine, and with respect to hardware closer than a conventional network (e.g. according to the Ethernet principle) would reach. On the other hand, the spinning machine must also be able to carry out deterministic tasks which are time-critical. For this purpose, suitable processors are connected to the bus backplane, making deterministic control, adjustment, and equidistant acquisition of scanned values possible. The bus backplane is therefore constructed advantageously as a multiprocessor bus backplane. If a multiprocessor bus backplane is used, the appertaining standard protocol is also suitable for multiprocessing, corresponding for example to the TCP/IP protocol.
The operativeness of the spinning machine controls is considerably improved with respect to time. However, improved speed is not the only advantage of the invention. Better structure and more flexible connection of the bus system components become possible, even when bus backplanes of different origin are used. In spite of the existing difficulties, the invention can avoid the initially mentioned access conflicts as well as be maintenance-friendly, so that programming costs are lowered considerably. The network also requires fewer overhead expenses.
The bus backplanes which can be assigned to each spinning machine may be interconnected in a local network so that a first group of spinning machines are connected together via this local bus. Several local busses can be connected via respective routers to a higher-rank network so that the host has access to all routers on all subnets which in turn are structured in several bus backplanes. Bus backplane and subnet have the same topology (i.e. the same data communications protocol), and this accelerates communication and structurally simplifies the system a considerable extent.
A network design which would be sufficient for most network controls of spinning machines consists of three levels, level j, level j+1, and level j+2. Level j is the level of the bus backplanes. It contains several bus backplanes BPi and these are connected via a network access to a local bus consisting of a cable. The local bus is the higher level j+1. The data communications protocol on level j+1 and that in the bus backplane BPi (of level j) is the same. From level j+1 a router leads to a superimposed level j+2 to which the control center (the host) is coupled. There are thus three levels, the level of the bus backplane, the level of the local bus which has a higher rank bus, and the level of the host which is coupled to the higher-rank bus. Between the superimposed level j+2 and the level j+1 directly below, the data communications is not the same; only between level j+1 and the level below (the level j of the bus backplane) is there identity of protocol.
The utilization of the general index j indicates that this configuration can be shifted up and down in more strongly hierarchically broken-down systems, but generally three levels are necessary to be able to use the invention in a purposeful manner, one level of these operating with the protocol of a typical network application and the two levels below with another protocol which, although still network-applicable, is however very narrowly oriented towards deterministic busses.
The enclosed figures through which several examples of embodiments shall be explained facilitate the understanding of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example with three bus backplanes BP1, BP2 and BP3, and with three hierarchically staggered network busses, level j, level j+1 and level j+2, in the example j=1;
FIG. 2 illustrates a bus backplane of FIG. 1, the BP1, which contains an access module Cl allowing access from the bus backplane to the network-oriented bus of the level j+1 (or, in another embodiment, to the bus of level j+2 above it);
FIG. 3 shows in a schematic view a VME bus backplane which is coupled downwards via a processor (a CPU) to an AT bus and which is able to access the local TCP/IP bus of level j+1 of FIG. 1 via VCOM upwards. In this example the BP1 stands for one single machine with e.g. 280 spinning stations. The communications level represented by this figure is therefore "within the spinning machine" while the couplings to the outside (to the local bus) and to the other center units are regarded as "outside the machine"; and
FIGS. 4a and 4b are diagrammatic representations of state of the art networks in which two topologies are shown in graphic simplification.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are shown in the drawings. Each example is provided by way of explanation of the invention, and not as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield still a further embodiment.
FIG. 1 shows an example of a combination of three bus backplanes BP1, BP2, BP3 which are switched together on a local bus (level j+1). A router R leads from the local bus to a superimposed bus which is designated by "level j+2" in FIG. 1. A host system M is connected to bus j+2 and takes over the central control of all routers R potentially coupled to the superimposed bus of level j+2. The multiple routers R may be found in an expanded system through the addition of the four components R, BP1, BP2, BP3 on the superimposed bus j+2. The system of FIG. 1 is insofar not limited. The system is however not limited to the number of backplanes BPi connected to the local bus in level j+1, but a plurality of these backplanes can be connected there. All these backplanes have however the same data communications protocol which is selected for TCP/IP in the example. UDP/IP is also possible.
A backplane is selected in FIG. 2, backplane 1 (BP1) being selected as an example. On it can be recognized that several central units (CPU's) are connected to the backplane, and in the example of FIG. 2 there are three CPUs, P1, P2 and P3. One of these CPUs, here CPU P1, is connected via backplane BP1 to the Ethernet Controller C1 which couples the BP1 backplane on the network level. The level j+1 of FIG. 1 which lies directly (logistically) above the backplane BP1 can be taken as network level; but level j+2 of FIG. 1 which can be coupled directly to the backplane BP1 via a corresponding controller C is also a possible level. The single coupling, as well as the two couplings, can be switched as a function of the application at the moment; if both couplings are used, two network control systems (Ethernet Controller) C are used, one coupling the backplane BP1 to level j+2, the other coupling the backplane BP1 to the level j+1.
Backplane BP1 is schematically a hardware data bus and an address bus with an appertaining number of control circuits. Overall it is called bus B1.
By looking at FIGS. 1 and 2 together, the network topology clearly appears. In vertical direction three levels j, j+1 and j+2 are shown, whereby j may generally represent integral numbers from 1 to m. In horizontal direction the level j consists of several backplanes BPi, where i can assume integral numbers from 1 to n. Each backplane BPi may in turn contain a plurality of central units Pk, where K represents integral numbers from 1 to p. P is therefore representative of a multiprocessor system which is installed on a backplane.
A backplane is understood to be a board having a plurality of layers in which the plug-in points installed on it are connected to circuits. It can be compared roughly to a typical AT bus plate which is however not multiprocessor-capable like the backplane BP of FIGS. 1 and 2. Only the multiprocessor capability makes it possible for the communications protocol on the network of level j+1 to correspond to the communications protocol on the backplane.
By contrast with FIGS. 1 and 2, as well as with the FIG. 3, yet to be discussed, representing examples of embodiments of the invention, circuits of the state of the art are explained in FIGS. 4a and 4b. Concerning FIG. 4a, it was already explained in the beginning why this topology is time-intensive, collision-prone, and has little structure. The network topology of FIG. 4b, which would be a possible alternative of that of FIG. 4a, leaves unsolved tasks and non-calculated load problems between the different functional units (called node 1.1 to node n.3). This results from the fact that many functional units (nodes) are not made by the same manufacturer and are therefore of different design. Each of these nodes may have a different architecture, so that no unity exists in the common network bus leading via the router to the host system, except if each of the systems were to be given a suitably adapted network coupling card. This coupling card slows down the system and increases the probability of collision, especially if the nodes 1.1, 1.2 and 1.3, which may belong to one machine for example, communicate with each other whereby the entire remaining bus is functionally blocked.
Instead of this, the network topologies with the backplane and the common data communications make it easy to survey backplane and higher-rank network connections, and they avoid collisions and increase speed. This is also made clear in FIG. 3 in which the backplane BP1 of FIG. 2 is shown schematically through a VME bus. A coupling card PC 80386 SX constitutes a connection in an AT bus which is deterministic. The plug-in card VCOM constitutes the coupling C1 of FIG. 2 which leads from the backplane BP1 to the local bus of level j+1 of FIG. 1.
In order to avoid misunderstandings in the designation of the busses, it is pointed out that the local bus is that of level j+1, not that of the backplane BP1. This bus is located on level j, a level below the network level j+1. Level j+2 is superimposed over the first network j+1 and cannot be seen in FIG. 3 but can be recognized if several VCOMs are switched together on the network level j+1 and if a router couples this local bus j+1 to the superimposed bus j+2.
In addition of the variant outlined above it is also possible to use VCOM of FIG. 3 together with VM30, which represents the CPU P1 of FIG. 2 in the drawing according to FIG. 3, as direct router R to the superimposed bus of level j+2. The router R is then physically contained in two separate cards, VM30 and VCOM.
The technical area of the invention is the area of spinning mill machines, such as spinning machines, and in it the control of a large number of spinning mill machines through one or several networks. The invention proposes that, in order to accelerate and improve direct interaction of all the stations controlled in the network combination, the data communications protocol of a bus made in the form of a backplane (BPi) and the data communications protocol (TCP/IP) of the higher communications level (those which are located logically above the backplane) be made identically.
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 and spirit of the invention. For example, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. It is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents.
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A process and control system are provided for controlling a combination of spinning mill machines. The system includes the process of exchanging operational data and measured values between the machines on a plurality of different communication levels which are arranged in a hierarchy. The same communication protocol is used on all of the communication levels to improve the speed and ease of control of the combination of spinning mill machines.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a container for granular substances and includes a pour spout which is opened diagonally and upwardly into a triangular shape. More particularly, this container has a pour spout which is opened diagonally and upwardly into a triangular shape at an upper part of a left side board. While the spout is closed, it ensures sealing, namely, granular substances do not spill from any part of the container other than the spout. This container can be manufactured mechanically on a mass production basis.
2. Description of the Prior Art
A container of this type having a spout which is opened diagonally and upwardly was disclosed in the Japanese Utility Model Registration Application Publication No. 52-35216 (devised by the inventor of the present invention). This container has a spout which is opened diagonally and upwardly into a triangular shape and comprises an upper part of a left side board and a sliding board connected to a side edge of the upper part of the left side board. The sliding board is guided into and slides between a front side board and an inserting piece contiguous to a ceiling board. However, since the inserting piece is merely contiguous to the ceiling board through a fold line, the sliding board opening cannot be held satisfactorily between the inserting piece and the front side board and it is difficult to maintain the opened and closed state of the spout due to the restoring force of a fold line for the upper part of the left side board. Moreover, while the spout is open, the sliding board must be supported by hand and this results in a force acting inwardly of the container on the sliding board. Thus, the sliding board is shifted inwardly and as a result a gap is caused between the sliding board and the front side board and granular substances in the container spill through the gap. In addition, when the spout is closed, it cannot be closed perfectly.
SUMMARY OF THE INVENTION
The present invention has for its object the elimination of the disadvantages of a container with a pour spout to be opened diagonally and upwardly as mentioned above.
According to the present invention, satisfactory holding of a sliding board can be obtained and the opened and closed state of the spout are stabilized by providing a sliding board integral with the upper end of a pasting piece which contacts the inner surface of a left side board and by interposing and sliding the sliding board between a front side board and a tongue piece partitioned off the front side board and connected to a ceiling board. The pasting piece is formed such that the upper end thereof is slightly higher than the front side board and a rear side board, a small cut is made at an upper end portion of a folding line connecting the pasting piece to the rear side board and a fold line extends downward and diagonally from a lower end of the cut. The sliding board has an arcuate portion which is described by a lower end of the diagonal folding line as the center and the length to the upper end of the pasting piece as the radius and a flap piece contiguous to the circumferential edge of the arcuate portion. The circumferential edge of the arcuate portion of the sliding board always projects above the ceiling board and therefore, even if a force of acts on the sliding board inwardly of the container, the sliding board does not shift from the inner surface of the front side board and no gap is caused between the sliding board. the front side board and granular substances in the container are thus prevented from spilling from any part other than the spout.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings show an embodiment of the present invention, in which:
FIG. 1 is a perspective view of a container according to the present invention when closed;
FIG. 2 is a perspective view of a container according to the present invention when opened;
FIG. 3 is a plan view of a container blank according to the present invention;
FIG. 4 is a plan view showing the blank of FIG. 3 partially assembled;
FIG. 5 is a plan view showing the blank of FIG. 3 partially assembled; and
FIG. 6 is a perspective view of an upper end of a container.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention has attained the above-mentioned object and is described below, with reference to the accompanying drawings showing a preferred embodiment.
As shown in FIG. 3, a left side board 2 and a right side board 3 are contiguous to respective sides of a front board 1, through a fold line 2a and a fold line 3a, respectively. A rear board 4 is contiguous to the right side board 3 through a fold line 42. A pasting piece 5 which will be adhered to the entire inner surface of the left side board 2 is contiguous to the rear board 4 through a fold line 5a. An upper end 6 of the pasting piece 5 extends slightly higher than the front side board 1 and the rear board 4, and a small cut 7 (about 5 mm from an upper end 6 of the pasting piece 5) is made between the rear board 4 and the pasting piece 5. A downward and diagonal fold line 9 starts at a lower end 8 of the cut 7 and crosses the pasting piece 5. A power spout A (FIG. 2) of triangular shape is composed by a part of the pasting piece 5 (above the folding line 9) and a sliding board 14 (to be described later). This spout is opened as shown by FIG. 2. A fold line 10 is provided at the side end (above the folding line 9) of the pasting piece 5. The sliding board 14 comprises an arcuate portion 12 which is a quadrant describe with a lower end 11 of the folding line 10 as the center and the length of the folding line 10 as the radius and a flat piece 13 contiguous to the circumference of the arcuate part 12. An arcuate slit 10a with both ends thereof on the folding line 10, is made in the sliding board 14 and thus a projection 22 contiguous to the pasting piece 5 is formed. With this arrangement, the spout A can readily be opened by laying a finger on the projection 22 projecting from the sliding board 14. A ceiling board 15 is provided at the upper end of the front side board 1 through a fold line 15a. As will be stated later, an upper end open part 29 of the container 21 is blocked by the ceiling board 15. A notch part 16 is made in the left side board 2 to correspond to the fold line 9. When the pasting piece 5 above the fold line 9 is folded outwardly at the fold line 9 as shown in FIG. 2, the upper part of the pasting piece 5 can be folded without any trouble. A lower end 17 of the notch part 16 and an intermediate part 18, near the left side board, on the folding line 15a are connected together with a cut 19, and a tongue piece 20 having rectangular shape is formed at the upper part of the front board 1 through the medium of the ceiling board 15 and the fold line 15a.
In manufacturing a container according to the present invention, as shown in FIG. 4, the pasting piece 5 is folded at the fold line 5a, together with the sliding board 14 for opening, toward the inner surface of the rear board 4. Adhesive is applied to an outer surface of the pasting piece 5 at the part below the folding line 9. Then, as shown in FIG. 5 the front board is folded at the folding line 3a, together with the left side board 2, toward the inner surfaces of the right side board 3 and the rear board 4. The inner surface of the left side board 2 is adhered to the outer surface of the pasting piece 5. By pressing the folding line 3a and 5a on a diagonal line, the front board 1, the right and left boards 2, 3 and the rear side board 4 are formed into a rectangular prism shape. Inserting pieces 25 and 26 at the lower end of the right side board 3 and pasting piece 5 are folded inwardly of the bottom surface of the prism shape. The inserting piece 24 of bottom board 23 is inserted into the inner surface of the lower end of the rear board 4 so as to block the bottom surface of the prism shape and thus a rectangular container 21 with its upper end opened is formed.
As shown in FIG. 6, when the ceiling board 15 is brought down, the tongue piece 20 near the left side board 2 and connected to the ceiling board 15 extends over the circumferential edge of the arcuate part 12 of the sliding board 14 beyond the inner surface of the arcuate part 12. When the ceiling board 15 is restored to its original position, the sliding board 14 interposed between the front side board 1 and the tongue piece 20.
A folding-in piece 28 contiguous to the upper end of the right side board 3, an inner ceiling board 27 contiguous to the upper end of the rear board 4 and the ceiling board 15 are folded in order, inwardly of the upper end opened part 29 of the container 21. The ceiling board 15 and the inner ceiling board 27 are adhered together to block the upper end opened part 29. Thus, the container is completed.
In opening a finished container shown in FIG. 1, fingers are applied to the projection 22 which is connected to the upper part of the pasting piece 5 and projects from the sliding board 14 and the projection 22 is pulled outwardly, whereupon the pasting piece 5 at the part above the folding line 9 rotates about the folding line 9 while sliding the sliding board 14 between the inner surface of the front board 1 and the outer surface of the tongue piece 20 and opens in a triangular shape, as shown in FIG. 2. The opened state of the spout A of triangular shape is maintained stably. To close the spout A the upper part of the pasting piece 5 is pressed by a finger, rotates about fold line 9 and slides the sliding board 14 to block the container as shown in FIG. 1. The closed state of the spout A is maintained stably.
As stated above, in manufacturing a container according to the present invention the pasting piece 5 is folded at the fold line 5a, together with the sliding board 14, toward the inner surface of the rear board 4, as shown in FIG. 4. Adhesive is applied to the outer surface of the pasting piece 5 at the part below the fold line 9. As shown in FIG. 5, the front board 1 is folded, together with the left side board 2, toward the inner surfaces of the right board 3 and the rear board 4 and the inner surface of the left side board 2 is adhered to the outer surface of the pasting piece 5. Thus, the front board 1, the right and left boards 2, 3 and the rear board 4 are formed into a rectangular shape, as shown in FIG. 6, and the bottom is blocked by conventional means. When the ceiling board 15 is brought down in a frontward direction, the tongue piece 20 extends over the circumferential edge of the arcuate part 12 of the sliding board 14 beyond the inner surface of the arcuate part 12. When the ceiling board 15 is restored to its original position, the upper end is blocked by conventional means. Therefore, no difficulty is found in manufacturing these containers mechanically and these containers can be manufactured on a mass production basis, using a conventional box making machine.
As the sliding board 14 is held between the inner surface of the front board 1 and the outer surface of the tongue piece 20 by means of the restoring force of the tongue piece 20, and slides between the front side board 1 and the tongue piece 20, the opened and closed state of the spout A are maintained stably. Therefore, it is easy to dispense granular substances while the spout A is opened and the spout A is never opened accidentally after it is closed. When the container contains granular candies or the like, it is difficult to enter for dust the container and therefore the present invention provides sanitary containers.
As the arcuate portion 12 of the sliding board 14 is designed as a quadrant which is described with the folding line 10 as the radius and with the point 11 as the center, the circumferential edge of the arcuate part 12 always projects above the ceiling board 15, irrespective of whether it is closed or opened. Thus even if force is applied to the sliding board 14 inwardly of the container, the sliding board 14 will not shift inwardly of the front board 1. This means that no gap is formed between the sliding board 14 and the front board 1 and there is no fear that granular substances exit down through any part other than the spout.
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A container for granular substances, having a mouth which opens diagonally and upwardly into a triangular shape at an upper part of a left side board. The mouth comprises a pasting piece, which is slightly higher than a front board and a rear board and a sliding board, consisting of an arcuate part and a flap piece contiguous to the circumference of the arcuate part. The sliding board is supported and slides between the inner surface of the front board and the outer surface of a tongue piece formed at the front board. The circumferential edge of the arcuate part always projects above a ceiling board, whether the mouth is opened or closed. The container ensures perfect sealing of granular substances contained therein while the mouth is closed.
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STATEMENT REGARDING GOVERNMENT FUNDING
This invention was made, in part, with government support under Grants No. R43 MH067488-01 and R01 GM57484 awarded by the National Institutes of Health, and Grants No. DAMD 17-03-2-0019 and W81XWH-06-C-0013 awarded by the United States Army Medical Research and Material Command NETRP. The government has certain rights in the invention.
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage application under 35 U.S.C. §371 of PCT/US2012/043813, filed on Jun. 22, 2012, which claims the benefit of PCT/US2011/041866 filed Jun. 24, 2011 and U.S. Provisional Application No. 61/501,207 filed, Jun. 25, 2011, the contents of each of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD
The field generally relates to organic compounds that act as nicotinic receptor antagonists. The field further relates to the use of nicotinic receptor antagonists for use as a prophylaxis and/or treatment for both small and non-small cell lung cancer, HIV, cognitive disorders, Alzheimer's disease, smoking cessation, Schizophrenia, and mammalian exposure to various neurological toxins.
BACKGROUND OF THE INVENTION
Nicotinic acetylcholine receptors (nAChRs) belong to the Cys-loop subfamily of pentameric ligand-gated ion channels and can be classified into muscle-type and neuronal subtypes. The neuronal nAChRs comprise twelve subunits (α2-α10 and β2-β4) with different arrangements, while the muscle-type is consisted of four subunits in a single arrangement of α1γα1β1δ (γ is replaced by ε in the adult). (Lukas, R. J. et al., Pharmacol. Rev. 1999, 51, 397) Two major neuronal receptors α4β2 and α7 have been identified in the central nervous system. (Flores, C. et al., Mol. Pharmacol. 1992, 41, 31; Lindstrom J. et al., Prog. Brain Res. 1996, 109, 125) The neuronal α7 nAChR has been proposed as a potential therapeutic target for a broad range of neurodegenerative and psychiatric diseases, including Alzheimer's disease, schizophrenia, anxiety, and epilepsy. A variety of selective partial and full agonists have been developed for the α7 nAChR as potential therapeutics. (Jensen A. et al., Prog., Brain Res. 1996) Several α7 nAChR selective agonists (e.g., TC-5619 and MEM-3454) have advanced to clinical trials for Alzheimer's disease and schizophrenia. (Arneric, S. P. et al., Biochem. Pharmacol. 2007, 74, 1092; Mazurov A. et al., Curr. Med. Chem. 2006, 13, 1567; Olincy A., Arch. Gen. Psychiatry 2006, 63, 630) Although extensive efforts have been taken to identify selective α7 nAChR agonists, the development of α7 selective antagonists is relatively limited. Some studies have reported that certain naturally derived compounds may be incorporated as α7 selective antagonists. For example, the krait Bungarus multicinctus derived peptide toxin α-bungarotoxin (α-BTX) and the seeds of Delphinum isolated nonpetide toxin methyllycaconitine (MLA) are two frequently used α7 selective antagonists. (Chang, C. C., et al. J. Biomed. Sci. 1999, 6, 368; Davies, A. R., et al. Neuropharmacology 1999, 38, 679)
Unfortunately, α-BTX is a potent antagonist for muscle-type nAChRs as well, and both compounds also inhibit nAChR subtypes α9 and α9α10. (Jensen, A. A., et. al. J. Med. Chem. 2005, 48, 4705) Nevertheless, subtype-selective antagonists may possess intrinsic value as tools to define the roles played by α7 nAChRs in the physiological and pathophysiological processes.
Indeed, and along these same lines, nicotinic acetylcholine receptors have been implicated as possible drug targets in a myriad of various disease states and for use as a possible measure for counter-terrorism purposes.
For example, with regards to various disease states, nAChRs have for some time now been studied in an attempt to find a possible nexus between targeting of the receptor and treatment of small cell lung carcinoma (SCLC). (Sciamanna, J. Neurochem. 69, 2302-2311 1997). While SCLC is a neuroendocrine neoplasm that accounts for a minority of newly diagnosed lung cancers, roughly a quarter, it is quite deadly and patients generally die within a mere year of being diagnosed. Thus, there is a pertinent need for the development of treatments, or means of prophylaxis, that can be administered to a patient in order to mitigate, or achieve complete ablation of, the SCLC disease state.
Despite the attendant need, few, if any, specific treatments are available for SCLC. However, the most current data available in the field indicates that two types of nAChRs can regulate NA and CA influx. Such regulation of calcium and sodium influx has biological and therapeutic ramifications in the treatment of neuroendocrine neoplasms. Thus, in light of the paucity of compounds available that can effectively and specifically target such channels, there still remains a glaring need for rationally based compounds that have the ability to target such receptors.
In addition to developing a more efficacious means for treating SCLC, there is also an attendant need for compounds that may be used to treat the more widespread dilemma of non-small cell lung cancer (NSCLC). In this regard it has been observed that mesothelioma and non-small cell lung cancer express functional nAChR. (Paleari, et al. Int. J. Cancer: 125, 199-211 2009) Thus, there has been speculation that nicotine may play some heretofore-unknown role in contributing to lung cancer pathogenesis via activation of such cellular proliferation pathways as Akt signaling or by inhibiting other natural cellular apoptotic machinery. (Id) However, some studies have indicated that nicotine acts on nAChRs, expressed in NSCLC tumor cells, by activating a proliferative response in such cells. (Id)
Next, despite their distinct disease pathology, it has been discovered that disease states such as cancer and AIDS have a common link via nAChRs. In addition to the need to develop treatments for both small and non-small cell lung cancer, however, there is also a need for compounds or treatment mechanisms that have the ability to effectively combat HIV and AIDS, disease states that also pose a very serious threat to public health worldwide. In fact more than 40 million people are infected worldwide with HIV-1 and an estimated 14,000 new infections occur every day. Since the first cases of AIDS were identified in 1981 the deaths of over 25 million people have been attributed to HIV/AIDS.
As mentioned, alpha-7 nAChRs has been found in lung cancer cells where activation by either natural molecules or compounds in tobacco smoke are shown to promote cancer growth. It has been found that those same alpha-7 nAChRs are upregulated in immune cells in AIDS. This suggests that over activation of alpha-7 receptors in macrophages by the AIDS virus protein, may cause premature cell death. Thus, and at the very least, antagonists to nAChRs are needed to continue to exploit the relationship between cancer, AIDS and nAChR activity, and thus provide treatments for these disease states.
Additionally, nicotinic acetylcholine receptors have been also been implicated to play a role in neurodegenerative diseases and cognitive disease or disorders. For example, nicotinic acetylcholine receptors have been implicated in disease such as Alzheimer's disease. Buckingham et al., Pharmacological Reviews March 2009 vol. 61 no. 1 39-61. Moreover. α7 nAChR have specifically been identified as playing a some type of role in the etiology and/or pathology of Alzheimer's disease. Jones I W, et al., J Mol Neurosci. 2006; 30 (1-2):83-4.
Nicotinic acetylcholine receptors have been also been suggested to play a role in certain neurodegenerative and cognitive disorders. The alpha7 nicotinic acetylcholine receptor (nAChR) has been thought of as a target for treatment of cognitive dysfunction associated with Alzheimer's disease and schizophrenia. J Pharmacol Exp Ther, 2009 May; 329(2):459-68. Epub 2009 Feb. 17.
However, despite these suggested links to a number of disparate diseases and disorders, there are attendant issues with nicotinic acetylcholine receptors. For example nicotinic acetylcholine receptors represent a comp ex and diverse set of receptor subtypes. Additionally, prolonged use may lead to desensitization of the receptor. Papke, et al., Journal of Pharmacology and Experimental Therapeutics , May 2009 vol. 329 no. 2 791-807.
These latter factors have made it difficult to work with nicotinic acetylcholine receptors and to develop compounds that are efficacious both in the short and long term.
SUMMARY OF THE INVENTION
It is an object of the present invention that the novel nicotinic receptor antagonists disclosed herein may be used in a broad array of clinical or medicinal facets. For example, it is a contemplated use of the present invention that the novel nicotinic receptor antagonists be used to inhibit the growth cycle of non-small cell lung cancer cells.
Without being bound by theory, it is an object of the present invention that the nicotinic receptor antagonists disclosed herein are believed to possess reversible binding properties. Moreover, the compounds of the present invention are selective for α7 nAChR. For example, the compounds of the present invention are not believed to bind to α4β2 nAChR neuromuscular receptors.
It is also contemplated that the nicotinic receptor antagonists of the present invention will be used as a counter measure to treat exposure, or potential exposure, to a wide array of potential neurotoxins. The AChRs are activated by acetylcholine (ACh), which is hydrolyzed to choline by acetylcholineesterase (AChE). When AChE is irreversibly inhibited by organophosphorus nerve agents like DFP and sarin, the uncontrolled accumulation of ACh at peripheral and central muscarinic AChRs (mAChRs) and nAChRs causes the cholinergic syndrome. This syndrome is characterized by sweating, pupillary constriction, convulsions, tachycardia, and eventually death.
The currently acknowledged treatment for nerve agent intoxication is the mAChR antagonist atropine used in concert with an oxime reactivator of AChE (e.g., pralidoxime). However, while this treatment regimen does not directly target nicotinic receptors both mAChRs and nAChRs are involved in nerve agent toxicity. It has been shown that, for example, nAChR antagonists 1i and 2, when tested in a DFP toxicity animal model to investigate their anti-seizure activity, (Peng et al.; Racine, R. J. Electroencephalogr. Clin. Neurophysiol. 1972, 32, 269.) that pretreatment with compounds 1i and 2 antagonized DFP-induced seizure-like behaviors over a 2 h period post-injection by 93.4% and 91.2%, respectively. These results suggest that the compounds of the present invention could provide neuroprotection against seizure-like behaviors induced by DFP and, therefore, may be useful for treatment of organophosphus nerve agent intoxication. Moreover, it is also contemplated that the compounds disclosed herein provide a means of discerning between the physiological roles of neuronal α7 nAChR under normal and diseased states, and as diagnostic tools used for discovering potential therapies for organophosphorus nerve agent intoxication.
As well, it is also contemplated that the nicotinic receptor antagonists of the present invention could be used as means for prophylaxis or treatment of HIV and/or AIDS. In a preferred aspect, novel α7 nAChR selective antagonists are administered in an effective therapeutic dose causing some measure of reduced symptomology or total ablation of the disease state.
However, while not bound by any theory, it is also believed that while the compounds of the present invention are selective α7 nAChR antagonists, that this does not also mean that the compounds activity is overall anticholinergic. Again, while not bound by any theory, it is surprising that these selective antagonists enhance cognition. Without being bound by theory, it is theorized that at lower doses or over extended periods, that the compounds disclosed herein may reduce desensitization in response to acetylcholine, which thereby enhances the effects of endogenous acetylcholine.
In yet another aspect of the present invention the novel nicotinic receptor antagonists disclosed herein could be used to have a protective effect on patients in order to prevent sepsis.
In still another aspect of the present invention the novel nicotinic receptor antagonists disclosed herein could be used, either alone or combination with another pharmaceutical, to treat Alzheimer's disease. It is contemplated that the present invention may also treat the symptoms of Alzheimer's disease. In one aspect it is contemplated the present invention may be used to treat at least one symptom of Alzheimer's disease.
It is contemplated by the present invention that the nicotinic receptor antagonists disclosed herein may also treat at least one symptom of Alzheimer's disease wherein that symptom of Alzheimer's disease relates to cognitive impairment.
In another aspect of the present invention it is contemplated that the novel nicotinic receptor antagonists disclosed herein could be used to treat or prevent relapse of opioid, cocaine, nicotine, and methamphetamine use. For example, it is contemplated that the novel nicotinic receptor antagonists disclosed herein could be used to in treatments directed toward smoking cessation.
In yet anther aspect, it is contemplated that the novel nicotinic receptor antagonists disclosed herein could be used to treat and/or improve cognition and/or cognition related diseases or disorders.
It is further contemplated that the compounds of the present invention may be used to treat dementia. In one embodiment the compounds of the present invention may be used to treat psychosis, e.g., in schizophrenia, schizoaffective disorder, schizophreniform disorder, psychotic disorder, delusional disorder, mania or bipolar disorder.
It is also contemplated that the compounds of the present invention may be used to treat cognitive impairment wherein cognitive impairment is a result and/or symptom of psychosis, e.g., in schizophrenia, schizoaffective disorder, schizophreniform disorder, psychotic disorder, delusional disorder, mania or bipolar disorder.
In another aspect of the present invention, it is further contemplated that novel α7 nAChR selective antagonists may be used as research or diagnostic tools. It is further contemplated that novel α7 nAChR selective antagonists could be used as a research tool in elucidating signal transduction in neuronal tissue. It is also contemplated that novel α7 nAChR selective antagonists could be used as a research tool in elucidating signal transduction pathway in non-neuronal tissue as well.
It is further contemplated that the compounds disclosed herein may be used to treat cognitive impairment that is the symptom of a medication used to treat cognitive related disease/disorder, e.g., Alzheimer's disease, schizophrenia.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a depiction of a representative dose response curves of Compound 1 and Compound 2 on the native neuronal alpha-7 nAChR in rat brain membranes.
FIG. 2 is a depiction of the inhibition of human α7 AChR responses expressed in Xenopus oocytes.
FIG. 3 is a depiction of the binding selectivity of Compound 1 and Compound 2.
FIG. 4 a and FIG. 4 b depict brain and plasma concentrations for Compounds 1 and 2, respectively.
FIG. 5 demonstrates the alpha-7 selective ligands that may be used for pharmacophore development.
FIG. 6 depicts a six-point pharmacophore model may be obtained based on the unified scheme within MOE.
FIG. 7 a depicts the results of the Novel Object Recognition test wherein the compound was administered 15 min prior to the first trial.
FIG. 7 b depicts the results of the Novel Object Recognition test wherein the compound was administered 1 hour following the first trial.
DETAILED DESCRIPTION OF THE INVENTION
The examples provided in the detailed description are merely examples, which should not be used to limit the scope of the claims in any claim construction or interpretation.
The present invention contemplates nicotinic acetylcholine receptor antagonists of Formula I:
Wherein R 1 may be a benzyl, phenethyl, 2-methoxyethyl, isobutyl, or cyclopentyl group.
Wherein R 2 may be a hydrogen or methyl group.
Wherein R 3 may be a chlorine, methoxyethyl, methyl, flourine or cyclopentyl group.
The present invention contemplates nicotinic acetylcholine receptor antagonists of Formula II:
Wherein R 1 may be a benzyl, methyl, or hydrogen group
Wherein R 2 may be H or methyl.
Wherein R 3 may be a propyl, methyl, cyclopropyl, and 4-tolyl group.
Wherein R 4 may be a hydrogen, fluorine, chlorine or furyl group.
The treatment of patients with the novel α7 nAChR selective ligands as described above addresses the immediate, and increasing, need for safer and more efficacious compounds to treat patients who suffer from diseases or disorders correlated with the activation of the nicotinic acetylcholine receptors pathways associated with the aforementioned disease states.
Accordingly, the present invention provides Method I for the treatment or prophylaxis of a disease or disorder characterized by the activation of an acetylcholine receptor pathway, comprising administering to the patient an effective amount of a α7 nicotinic acetylcholine receptor antagonists according to Formula I or Formula II in a free or pharmaceutically acceptable salt form, for example:
1.1 Method I, wherein said disease or disorder is small cell lung cancer. 1.2 Method I wherein said disease or disorder is non-small cell lung cancer. 1.3 Method I, wherein said disease or disorder is organophosphorus nerve agent intoxication 1.4 Method I, wherein said disease or disorder is infection via the human immunodeficiency virus (HIV). 1.5 Method I, wherein said disease or disorder is the result of autoimmune deficiency syndrome (AIDS). 1.6 Method I, or any of methods 1.1-1.5, wherein the patient is a human. 1.7 Method I, or any of methods 1.1-1.2, wherein the disease or disorder is characterized by metastatic cancerous cells. 1.8 Method I, or any of methods 1.1-1.2, wherein the disease or disorder is characterized by benign cancerous cells. 1.9 Method I, or any of methods 1.1-1.2, 1.7, 1.8, wherein said disease or disorder characterized by the presence of cancerous cells may be selected from the following group of diseases or disorders: squamous cell carcinoma, adenocarcinoma, large cell carcinoma, and pleuroa mesothelioma. 1.10 Method I, or any of methods 1.1-1.2, 1.7-1.9, wherein said disease or disorder is a solid tumor carcimona. 1.11 Method I, or any of methods 1.1-1.2, 1.7-1.10, wherein a patient is suffering from or at risk for developing cancer. 1.12 Method I, or any of methods 1.1-1.2, 1.7-1.10, wherein a novel α7 nicotinic acetylcholine receptor antagonist of Formula I is administered simultaneously with a second treatment for cancer selected from the group consisting of: capecitabine, trastuzumab, pertuzumab, cisplatin and irinotecan. 1.13 Method I, wherein the disease or disorder is a cognitive impairment and/or a disease or disorder related to cognitive impairment. 1.14 Method I or 1.13, wherein the cognitive related disease or disorder is mild cognitive impairment 1.15 Method I or 1.13-1.14, wherein the α7 nicotinic acetylcholine receptor antagonists according to Formula I or Formula II are used to treat at least one of the symptoms of cognitive impairment, e.g. impaired auditory processing and attention, impaired spatial organization, impaired verbal learning, impaired semantic and verbal memory, impaired executive functions. 1.16 Method I or any of 1.13-1.15 wherein the disease or disorder is Alzheimer's disease. 1.17 Method I or any of 1.13-1.16, wherein the effective amount of an α7 nicotinic acetylcholine receptor antagonist is used to treat at least one symptom of Alzheimer's disease. 1.18 Method I or 1.17, wherein the symptom of Alzheimer's disease is cognitive impairment, e.g., impaired auditory processing and attention, impaired spatial organization, impaired verbal learning, impaired semantic and verbal memory, impaired executive functions. 1.19 Method I, wherein the treatment is directed toward smoking cessation in a patient. 1.20 Method I or any of methods 1.13-1.15 wherein the α7 nicotinic acetylcholine receptor antagonist is used to treat psychosis, e.g., in schizophrenia, schizoaffective disorder, schizophreniform disorder, psychotic disorder, delusional disorder, mania or bipolar disorder. 1.21 Method I, or 1.20 wherein cognitive impairment is any of the following, e.g., impaired auditory processing and attention, impaired spatial organization, impaired verbal learning, impaired semantic and verbal memory, impaired executive functions. 1.22 Method I, or 1.20, 1.21, wherein the cognitive impairment is a symptom of the psychosis, e.g., schizophrenia, schizoaffective disorder, schizophreniform disorder, psychotic disorder, delusional disorder, mania or bipolar disorder. 1.23 Method I or any of the preceding methods wherein the patient is administered an effective amount of an α7 nicotinic acetylcholine receptor antagonist according to Formula I. 1.24 Method I or any of the preceding methods wherein the patient is administered an effective amount of an α7 nicotinic acetylcholine receptor antagonist according to Formula II. 1.25 Method I, or any the preceding methods, wherein a patient is administered an effective amount of a novel α7 nicotinic acetylcholine receptor antagonist of Formula I in a pharmaceutically acceptable carrier. 1.26 Method I, or any of the preceding methods, wherein administration of an effective amount of an novel α7 nicotinic acetylcholine receptor antagonist of Formula I or II improves cognition. 1.27 Method I, or any of the preceeding methods, wherein the administration of an effective amount of an novel α7 nicotinic acetylcholine receptor antagonist of Formula I or II is used to treat Alzheimer's disease and/or a symptom of Alzheimer's disease. 1.28 Method I, or any of the preceeding methods, wherein the administration of an effective amount of an novel α7 nicotinic acetylcholine receptor antagonist of Formula I or II is used to treat schizophrenia and/or a symptom of schizophrenia. 1.29 A pharmaceutical composition comprising a compound according to claim 1 or 2 in admixture with a pharmaceutically acceptable diluent or carrier.
In accordance with this detailed description, the following abbreviations and definitions apply. It must be noted that as used herein, the singular forms “a”, “and”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a compound” includes a plurality of such compounds and reference to “the dosage” includes reference to one or more dosages and equivalents thereof known to those skilled in the art, and so forth.
The term “treating”, “treatment”, and the like are used herein to generally mean obtaining a desired pharmacological and physiological effect. The novel α7 nAChRs described herein which are used to treat a subject with cancer generally are provided in a therapeutically effective amount to achieve any one or more of the following inhibited tumor growth, reduction in tumor mass, loss of metastatic lesions, inhibited development of new metastatic lesions after treatment has started, or reduction in tumor such that there is no detectable disease (as assessed by, e.g., radiologic imaging, biological fluid analysis, cytogenetics, fluorescence in situ hybridization, immunocytochemistry, colony assays, multiparameter flow cytometry, or polymerase chain reaction). The term “treatment”, as used herein, covers any treatment of a disease in any mammal, particularly a human, known to those that are skilled in the art
The term “subject” or “patient” as used herein is meant to include a mammal. In a preferred aspect of the present invention the mammal is a human. In another preferred aspect of the present invention the mammal is a domestic animal.
The term “pharmaceutically effective” as used herein refers to the effectiveness of a particular treatment regime. Pharmaceutical efficacy can be measured based on such characteristics, for example, as inhibition of tumor growth, reduction of tumor mass or rate of growth, lack of detectable tumor associated antigens, and any other diagnostic measurement tool that is known in the field. Pharmaceutical efficacy can also be measured based on such characteristics, for example, as inhibition of the HIV virus and/or reduction and eradication of AIDS related symptoms. Moreover, pharmaceutical efficacy can also be measured based upon the reduction of the onset of symptoms that are related to the induction of organophosphorus nerve agent intoxication.
By “pharmaceutically effective amount” as used herein refers to the amount of an agent, reagent, compound, composition, or combination of reagents disclosed herein that when administered to a mammal that are determined to be sufficiently effective against cancer that is the object of the treatment or HIV/AIDS. A pharmaceutically effective amount will be known to those skilled in the art.
By the term “tumor” is meant to include both benign and malignant growths or cancer. The term “cancer,” is meant to encompass, unless otherwise stated, both benign and malignant growths. In preferred aspects of the invention the tumor referred to is malignant. The tumor can be a solid tissue tumor such as a melanoma, or a soft tissue tumor such as a lymphoma, a leukemia, or a bone cancer. By the term “primary tumor” is meant the original neoplasm and not a metastatic lesion located in another tissue or organ in the patient's body. By the terms “metastatic disease,” “metastases,” and “metastatic lesion” are meant a group of cells which have migrated to a site distant relative to the primary tumor.
By “AIDS” is meant HIV infection: AIDS, ARC (AIDS related complex), both symptomatic and asymptomatic, and actual or potential exposure to HIV. Accordingly, the treatment of AIDS refers to the inhibition of HIV virus, the prophylaxis or treatment of infection by HIV and the prophylaxis, treatment or the delay in the onset of consequent pathological conditions such as AIDS. The prophylaxis of AIDS, treating AIDS, delaying the onset of AIDS, the prophylaxis of infection by HIV, or treating infection by HIV is defined as including, but not limited to, treatment of a wide range of states of HIV infection: AIDS, ARC (AIDS related complex), both symptomatic and asymptomatic, and actual or potential exposure to HIV.
The term “nicotinic acetylcholine receptor” refers to the endogenous acetylcholine receptor having binding sites for acetylcholine which also bind to nicotine. The term “nicotinic acetylcholine receptor” includes the term “neuronal nicotinic acetylcholine receptor.”
The terms “subtype of nicotinic acetylcholine receptor,” and “nicotinic acetylcholine receptor subtype” refer to various subunit combinations of the nicotinic acetylcholine receptor, and may refer to a particular homomeric or heteromeric complex, or multiple homomeric or heteromeric complexes.
The term “agonist” refers to a substance which interacts with a receptor and increases or prolongs a physiological response (i.e. activates the receptor).
The term “partial agonist” refers to a substance which interacts with and activates a receptor to a lesser degree than an agonist.
The term “antagonist” refers to a substance which interacts with and decreases the extent or duration of a physiological response of that receptor.
The terms “disorder,” “disease,” and “condition” are used inclusively and refer to any status deviating from normal.
The term “central nervous system associated disorders” includes any cognitive, neurological, and mental disorders causing aberrant or pathological neural signal transmission, such as disorders associated with the alteration of normal neurotransmitter release in the brain.
EXAMPLES
Example 1
The structures of Compound 1 and 2 were confirmed by UPLC-HRMS and found to have purities of 98% and 97%. Several analogs of Compounds 1 and 2, with different substitutions at positions of R1, R2, R3, and R4, were identified by substructure searches or chemical synthesis (Tables 1 and 2). Structure-activity relationships (SARs) were developed for both compounds using the binding assay. For example, substitution (e.g., methyl and chlorine) at R3 is tolerated for analogs of Compound 1. Both benzyl (1i) and isobutyl (1k) at R1 were more favorable than the more flexible phenethyl (1d).
For analogs of Compound 2, a bulky benzyl group at R1 yielded more potent receptor binding than a less bulky methyl or free base (2 vs 2h and 2i). More hydrophobic substitutions at R3 improved receptor binding (2f vs 2h). The R4 position tolerated different substitutions (e.g., hydrogen and halogen).
TABLE 1
Percent inhibition at
R 1
R 2
R 3
10 μM a (mean ± SD)
Benzyl
H
3-Cl
83.0 ± 1.7
Benzyl
H
70.5 ± 3.1
Phenethyl
H
4-OMe
9.5 ± 3.7
2-Methoxyethyl
H
4-Cl
27.3 ± 0.7
Phenethyl
H
2-Cl
23.4 ± 2.4
Isobutyl
Methyl
2,5-F,F
59.2 ± 0.2
Phenethyl
H
4-Cl
18.3 ± 1.3
Cyclopentyl
H
2-Cl
21.6 ± 2.6
2-Methoxyethyl
Methyl
2-Cl
43.0 ± 0.0
Benzyl
Methyl
2-Cl
79.7 ± 1.9
Phenethyl
H
2-Me
25.2 ± 1.8
Isobutyl
Methyl
2-Cl
72.3 ± 1.0
Table 1 of Example 1 details binding affinity of nicotinic acetylcholine receptor antagonists, determined by radiolabeled binding, according to Formula I for the native α7 nAChR in rat brain membranes at 10 μM. Nicotinic acetylcholine receptor antagonists according to Formula I are listed as follows (from top to bottom): Compound 1, Compound 1a, Compound 1b, Compound 1c, Compound 1 d, Compound 1e, Compound 1 f, Compound 1 g, Compound 1h, Compound 1i, Compound 1j, and Compound 1k.
The binding affinity of these compounds for the native α7 nAChR in rat brain membranes was measured at 10 μM using [ 125 I] α-BTX as the radioligand. Non-Specific binding was determined with 1 μM MLA.
TABLE 2 Percent inhibition R 1 R 2 R 3 R 4 at 10 μM a (Mean ± SD) Benzyl H Propyl H 83.8 ± 2.3 Benzyl H Methyl 4-F 50.0 ± 2.0 Benzyl H Methyl 4-Cl 64.1 ± 1.8 Methyl Methyl Methyl 4-F 11.9 ± 2.3 Methyl Methyl Methyl 4-Cl 13.5 ± 5.3 Methyl Methyl Cyclopropyl 2-Furyl 10.5 ± 1.7 Methyl H 4-Tolyl H 23.4 ± 0.8 Methyl Methyl 4-Tolyl H 12.1 ± 1.3 Methyl H Propyl H 3.1 ± 0.1 H H Propyl H 1.0 ± 2.8
Table 2 details binding affinity of nicotinic acetylcholine receptor antagonists, determined by radiolabeled binding, according to Formula II for the native α7 nAChR in rat brain membranes at 10 μM. Nicotinic acetylcholine receptor antagonists according to Formula II are listed as follows (from top to bottom): Compound 2, Compound 2a, Compound 2b, Compound 2c, Compound 2d, Compound 2e, Compound 2f, Compound 2g, Compound 2h, and Compound 2i.
The binding affinity of these compounds for the native α7 nAChR in rat brain membranes was measured at 10 μM using [ 125 I] α-BTX as the radioligand. Non-Specific binding was determined with 1 μM MLA.
Example 3
Binding assay was performed according to the previously reported method noted in Meyer, E. M.; Kuryatov, A.; Gerzanich, V.; Lindstrom, J.; Papke, R. L. J. Pharmacol. Exp. Ther. 1998, 287, 918. using [125I]a-BTX as the radioligand. 28 IC50 of Compound 1=1.6 1M; IC50 of Compound 8=2.9 1V. Dose-response curves of compounds 1 and 2 on the native neuronal α7 nAChR in rat brain membranes. The error bars indicate the standard deviation of the measurements. FIG. 1 details a representative dose response curves of Compound 1 and Compound 2 on the native neuronal alpha-7 nAChR in rat brain membranes. The line containing square-point designations indicates percent inhibition results regarding Compound 1, while the line containing triangle-point designations indicates the results regarding Compound 2.
Example 4
The functional activity of compounds 1, 1i, and 2 is determined by electrophysical experiments on Xenopus oocytes expressing human alpha-7 nAChR. Human alpha-7 nAChR may be expressed in Xenopus oocytes by any means to known in the field. These three compounds are found to inhibit acetylcholine-evoked receptor responses in a dose-dependent manner, suggesting the subject compounds are α7 nAChR antagonists. The IC50 values of 1, 1i, and 2 are 11.9 μM, 3.7 μM, 18.9 μM, respectively. The α7 functional potency was 6-8 fold lower than the affinity estimated from human α7 receptor binding, and this difference may come from interspecies variation (rat vs. human), or variability in receptors (native vs. recombinant), or due to technical aspect of the functional assay in the oocyte expression system. FIG. 2 illustrates the inhibition of human α7 AChR responses expressed in Xenopus oocytes. The line containing solid square-point designations indicates percent inhibition results regarding Compound 1, while the line containing triangle-point designations indicates the results regarding Compound 2. The line containing hollow square-point designations indicates results regarding Compound 1i.
Example 5
The binding selectivity of Compound 1 and Compound 2 can be seen in FIG. 3 . Compound 1 is represented by the solid bar while Compound 2 is represented by the empty bar. The selectivity of compounds 1 and 2 were measured using previously reported methods on three other receptors: neuronal α4β2 nAChRs, muscle-type nAChRs, and 5HT 3 receptors. The binding affinity for the α4β2 receptor was performed on rat cortical membranes using [ 3 H]epibatidine as the radioligand. The muscle-type nAChR binding was determined using human TE671 cells with [ 125 I] α-BTX as the radioligand. 5HT 3 binding was measured on recombinant CHO cells expressing human 5HT 3 receptor using [ 3 H]BRL 43694 as the radioligand. The orthosteric binding sites of the α7 nAChR and the 5HT3 receptor share a high degree of homology, therefore ligands for α7 nAChR and 5HT3 ligands frequently exhibit cross-activity. At 10 1M, compound 1 exhibited 82.5% binding to the α7 receptor and 18.8% and 8.4% binding to the neuronal α4β2 and the 5HT 3 receptor, respectively. Similarly, compound 2 showed binding affinities of 82.5% to α7, 1.3% to α4β2, and 14.3% to 5HT 3 . Meanwhile, both compounds exhibited no detectable binding to the muscle-type nAChR at 10 μM. Taken together, these results demonstrated the selectivity of compounds 1 and 2 for the 5HT 3 receptor over α4β2, muscle-type nicotinic, and 5HT3 receptors The selectivity of compounds 1 and 2 was performed using methods previously discussed in Hope, A. G.; Peters, J. A.; Brown, A. M.; Lambert, J. J.; Blackburn, T. P. Br. J. Pharmacol. 1996, 118, 1237; Lukas, R. J. J. Neurochem. 1986, 46, 1936; Perry, D. C.; Kellar, K. J. J. Pharmacol. Exp. Ther. 1995, 275, 1030.
Example 6
Compounds 1i and Compound 2 were tested in male C57Bl/6 mice (n≧3 per time point) for blood brain barrier after cassette dosing at 10 mg/kg via intraperitoneal (ip) administration. Brain and blood samples were collected at specific time points after drug administration. The area under the curve (AUC) ratios of brain to plasma were 2.8 and 3.1 for Compound 1i ( FIG. 4 a ) and Compound 2 ( FIG. 4 b ), respectively, suggesting good brain penetration for both compounds. Compound 2 achieved high concentration in brain (9 μM). Cassette dosing of compounds can lead to incorrect estimates of plasma drug levels by drug-drug interactions such as at the level of Cytochrome P450 enzymes or by interfering with transporter systems. Without being bound by theory, the biphasic nature of the drug plasma and brain levels would suggest some type of secondary uptake mechanism as is seen for drugs that are eliminated from the blood in part by the bile system and therefore available in the intestine to be taken up into the circulation a second time.
Example 7
Seizure score
Normalized
Normalized
(mean ± SD)
% seizure
% neuroprotection
0 ± 0
0
100
9.1 ± 6.4
100
0
0.6 ± 1.3
6.6
93.4
0.8 ± 1.3
8.8
91.2
The table of Example 7 illustrates the neuroprotective activities of Compound 1i and Compound 2 against seizure induced by the nerve agent diisopropylfluorophosphate (DFP). The acetylcholine receptors (AChRs) are activated by acetylcholine (ACh), which is hydrolyzed to choline by acetylcholineesterase (AChE). When AChE is irreversibly inhibited by organophosphorus nerve agents like DFP and sarin, the uncontrolled accumulation of ACh at peripheral and central muscarinic AChRs (mAChRs) and nAChRs causes the cholinergic syndrome. This syndrome is characterized by sweating, pupillary constriction, convulsions, tachycardia, and eventually death. The mainstay treatment for nerve agent intoxication is the mAChR antagonist atropine together with an oxime reactivator of AChE (e.g., pralidoxime). This treatment regimen does not directly target nicotinic receptors although both mAChRs and nAChRs are involved in nerve agent toxicity. In this study, the new nAChR antagonists, Compounds 1i and 2 were tested in a DFP toxicity animal model to investigate their anti-seizure activity. Compared with the DFP controls, pretreatment with Compounds 1i and 2 antagonized DFP-induced seizure-like behaviors over a 2 h period post-injection by 93.4% and 91.2%, respectively. The results suggest that these compounds could provide neuroprotection against seizure-like behaviors induced by DFP and, therefore, may be useful for treatment of organophosphus nerve agent intoxication.
In summary, pharmacophore-based virtual screening led to the discovery of novel α7 nAChR ligands. A battery of property and functional group filters were applied to eliminate non-drug-like molecules and to reduce false positives. Two distinct families of small molecules (e.g., Compounds 1i and 2) were identified as novel α7 nAChR antagonists with selectivity for the neuronal α7 subtype over other nAChRs and good brain penetration. Neuroprotection against the seizure-like behaviors induced by DFP were observed for these compounds in a mouse model. The compounds should be very useful in discerning the physiological roles of neuronal α7 nAChR under normal and diseased states, and in discovering potential therapies for organophosphorus nerve agent intoxication.
Example 8
FIG. 5 demonstrates the alpha-7 selective ligands that may be used for pharmacophore development.
Three dimensional (3D) pharmacophore models may be developed and, subsequently conducted ligand-based virtual screening may also be conducted to search for novel α7 nAChR selective ligands. Here, six potent and selective α7 ligands are representative of a selected training set for the pharmacophore model. The structures of all compounds could be protonated at physiological conditions (pH 7.4). Flexible structural alignments may be performed to identify the common chemical features responsible for the α7 receptor binding using the Flexible Alignment module within MOE. This alignment method uses a stochastic search algorithm to simultaneously explore the conformation space of all compounds in the training set.
This operation generates several scores to quantify the quality of each alignment with lower scores indicating better alignments. The alignments with the lowest S score may be selected for the 3D pharmacophore development. A six-point pharmacophore model may be obtained based on the unified scheme within MOE ( FIG. 6 ). Feature F1 is a hydrogen bond acceptor with radius 1.5 Å. Feature F2 is a cation atom (radius: 1 Å)—the basic nitrogen, which exists in most known nAChR ligands. Features F3 and F4 are characterized as aromatic rings with radius 1.5 Å. Features F5 and F6 cover hydrophobic regions (radius: 1.0 Å). The pharmacophore model may be used to screen compounds assembled from different sources. In order to remove unwanted structures and accelerate the process of virtual screening, extended Lipinski's rules 22 and three functional group filters were applied before the pharmacophore-based database searching. Extended Lipinski's rules include seven filters: 100<molecular weight≦500 — 2≦Clog P≦5, number of hydrogen bond donors≦5, number of hydrogen bond acceptors≦10, topological polar surface area≦120 A2, number of rings≦5, and number of rotable bonds≦10. These property filters may be chosen to eliminate compounds that lacked sufficient drug-like properties to become drugs. Compounds that passed the above criteria are subjected to three functional group filters: absence of reactive groups, number of non-fluorine halogen atoms≦4, and number of basic nitrogen atoms P1. Reactive groups are defined according to the Oprea set, including heteroatom-heteroatom single bonds, acyl halides, sulfonyl halides, perhalo ketone, and Michael acceptors. These groups can interfere with high-throughput biochemical screening assays and therefore often appear as false positives. A halogen filter may be used to avoid pesticides that often contain a nitrogen atom protonated at physiological conditions (pH 7.4) and this nitrogen atom has been shown to be involved in extensive cation-p interactions between ligand and receptor.
A basic nitrogen filter may be selected to remove compounds that lack this chemical feature. This filter greatly reduced the size of the compound database and therefore improved the speed of conformer generation and pharmacophore matching. Altogether, compounds violating P2 Lipinski's rules or any functional group filters were eliminated from our selection. The resulting compounds are subjected to conformation sampling using the Conformational Import Module, a high throughput method to generate 3D low-energy conformers in MOE. Recent studies revealed that this method performed as well as the established Catalyst FAST module. The ensemble of conformers were then screened by the six-point pharmacophore model by enabling exact match of features F1-F4 and partial match of features F5 and F6. The consequent hits were subjected to database diversity and clustering analyses with the aim to remove close analogs and maximize the chemotypes of the selected compounds for biological tests. The MDL MACCS fingerprints implemented in MOE are calculated for all compounds and fingerprints-based clustering may be carried out by using the Tanimoto coefficient (0.85) as a measure of fingerprint similarity. No more than three representative compounds in the same cluster are selected for the final collection.
About 300 compounds are acquired from different commercial sources for in vitro biological screening, including compounds from Maybridge, Chembridge, Enamine. The binding affinity of these compounds for the native α7 nAChR in rat brain membranes are measured using methods known in the art, particularly with [125I] α-BTX as the radioligand. From the preliminary screening, various chemotypes are found to exhibit P50% inhibition on the α7 nAChR in this assay. Two of them (compound 1 and 2, Tables 1 and 2 in Examples 1 and 2 disclosed herein) exhibit low micromolar inhibition on brain α7 nAChR with an IC50 of 1.6 μM and 2.9 μM, respectively ( FIG. 3 ). The structures of 1 and 2 are confirmed by UPLC-HRMS and found to have purities of 98% and 97%. Several analogs of 1 and 2 with different substitutions at positions of R1, R2, R3, and R4 are identified by substructure searches or chemical synthesis (Tables 1 and 2 in examples 1 and 2 disclosed herein). Structure-activity relationships (SARs) are developed for both compounds using the binding assay. For example, substitution (e.g. methyl and chlorine) at R3 is tolerated for analogs of compound 1. Both benzyl (1i) and isobutyl (1K) at R1 were more favorable than the more flexible phenethyl (1d). For analogs of compound 2, a bulky benzyl group at R1 yielded more potent receptor binding than a less bulky methyl or free base (2 vs 2h and 2i). More hydrophobic substitutions at R3 improved receptor binding (2f vs 2h). The R4 position tolerated different substitutions (e.g. hydrogen and halogen).
Details of Examples 1-8 are disclosed in Peng et al., “Discovery of novel α7 nicotinic receptor antagonists” Bioorganic & Medicinal Chemistry Letters 20 (2010) 4825-4830, the contents of which are incorporated herein by reference in its entirety.
Example 9
Animals were housed in individual standard cages on sawdust bedding in an air-conditioned room (about 20° C.). They were kept under a 12/12 h light/dark cycle (lights on from 19.00 to 07.00) and had free access to food and water. Rats were housed and tested in the same room. A radio, which was playing softly, provided background noise in the room. All testing was done between 09.00 and 17.00 hours.
Compound 1i was tested at 0, 0.3, 1, and 3 mg/kg in a time-dependent memory deficit model, i.e. a 24 h inter-trial interval (See, FIG. 7 a ). Compound 1i was administered by intraperitoneal injection (i.p. injection), 15 minutes before the first trial. The order of the treatments was balanced to prevent the data from being distorted by potential object- and side-preferences of the animals.
The object recognition test was performed as described elsewhere (e.g., Ennaceur and Delacour, 1988). The apparatus consisted of a circular arena, 83 cm in diameter. The back-half of the 40 cm high arena wall was made of gray polyvinyl chloride, the front-half consisted of transparent polyvinyl chloride. The light intensity was equal in the different parts of the apparatus, as fluorescent red tubes provided a constant illumination of about 20 lux on the floor of the apparatus. Two objects were placed in a symmetrical position at about 10 cm from the wall, on a diameter from the left- to the right-side of the arena. Each object was available in triplicate. Four different sets of objects were used. The different objects were: 1) a cone consisting of a gray polyvinyl chloride base (maximal diameter 18 cm) with a collar on top made of aluminum (total height 16 cm), 2) a standard 1 L transparent glass bottle (diameter 10 cm, height 22 cm) filled with water, 3) a massive metal cube (10.0×5.0×7.5 cm) with two holes (diameter 1.9 cm), and 4) a solid aluminum cube with a tapering top (13.0×8.0×8.0 cm). Rats were unable to displace the objects.
A testing session consisted of two trials. The duration of each trial was 3 min. During the first trial (T1) the apparatus contained two identical objects (samples). Rats were placed in the apparatus facing the wall at the middle of the front (transparent) segment. After the first exploration period the rat was put back in its home cage. Subsequently, after a 24 h delay interval, the rat was put in the apparatus for the second trial (T2). The total time an animal spent exploring each object during T1 and T2 was recorded manually with a personal computer.
Exploration was defined as follows: directing the nose to the object at a distance of no more than 2 cm and/or touching the object with the nose. Sitting on the object was not considered as exploratory behavior. A minimal amount of object interaction is required in order to achieve reliable object discrimination, therefore rats that explored less than 7 s in T1 and/or 9 s in T2 were excluded from the analyses. In order to avoid the presence of olfactory cues the objects were always thoroughly cleaned after each trial. All object combinations as well as the location (left or right) of the novel object were used in a balanced manner to avoid potential biases due to preferences for particular locations or objects.
In several studies it was shown that Wistar rats show a good object memory performance when a 1 h delay is interposed between the first trial and the second trial. However, when a 24 h delay is used rats do not discriminate between the novel and the familiar object in the second trial, indicating that the rats do not remember the object that was presented in the first trial. Using a 6 h delay, the discrimination performance is in-between than of the 1 h and 24 h delays, suggesting a delay-dependent forgetting in this task. In the first two weeks, the animals were handled daily and were allowed to get accustomed to the test setup in two days, i.e. they were allowed to explore the apparatus (without any objects) twice for 3 min each day. Then the rats were adapted to the testing routine until they showed a stable discrimination performance, i.e. good discrimination at 1 h interval and no discrimination at twice for 3 min each day. Then the rats were adapted to the testing routine until they showed a stable discrimination performance, i.e. a good discrimination at 1 h interval and no discrimination at. In FIG. 5 a , Compound 1i was injected i.p. 15 before T1 and a 24 h inter-trial interval was used.
The basic measures were the times spent by rats in exploring an object during T1 and T2. The time spent in exploring the two identical samples will be represented by ‘a1’ and ‘a2’. The time spent in T2 in exploring the sample and new object will be represented by ‘a’ and ‘b’, respectively. The following variables were calculated: e1=a1+a2, e2=a+b, and d2=(b−a)/e2. E1 and e2 are measures of the total exploration time of both objects during T1 and T2 respectively. d2 is a relative measure of discrimination corrected for exploration activity in the test-trial (e2). Thus, even if a treatment would affect exploratory behavior the d2 index will be comparable between conditions.
As seen in FIG. 5 a , the relative cognitive score (d2) showed a progressive increase up to 1.0 mg/kg of Compound 1i. There was no increase in cognition at administration of Compound 1i at doses of 3.0 mg/kg.
Example 10
Animals were housed, treated, and a Novel Object Recognition/Object Recognition Test was performed substantially similar to the methods and procedures described in Example 9.
One important difference, however, was that compound 1i was administered one hour after T1 in this example. The results of this test are depicted in FIG. 7 b.
As illustrated by FIG. 7 b , administration of Compound 1i, at a dose of 1.0 mg/kg, post-T1 significantly enhances cognition in treated animals. However, dosages at about 3.0 mg/kg actually reduced cognition in animals that were treated with larger doses 1 hour post-T1. Without being bound by theory, this data, along with the data in FIG. 5 a , suggests a theory wherein in certain circumstances administration of lower doses of alpha-7 nicotinic receptor antagonists disclosed herein (i.e. Compound 1i) may function to prevent desensitization of the nAChR and thereby possibly increase the efficacy of endogenous acetylcholine. Without being bound by theory, the duration of the compound administration may also possibly play an important role.
Example 11
Compounds listed in Tables 1 and 2, of Example 1, can be purchased Maybridge, Chembridge, Enamine. Details for procurement of these compounds is generally disclosed in Peng et al., “Discovery of novel α7 nicotinic receptor antagonists” Bioorganic & Medicinal Chemistry Letters 20 (2010) 4825-4830, the contents of which are disclosed herein by reference. General methods of synthesis are also disclosed in U.S. provisional application 61/501,207, the contents of which are disclosed herein by reference.
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It is an object of the present invention that the novel nicotinic receptor antagonists disclosed herein may be used in a broad array of clinical or medicinal facets. For example, it is a contemplated use of the present invention that the novel nicotinic receptor antagonists be used to inhibit the growth cycle of non-small cell lung cancer cells. Without being bound by theory, it is an object of the present invention that the nicotinic receptor antagonists disclosed herein are believed to possess reversible binding properties. Moreover, the compounds of the present invention are selective for 0.7 nAChR. For example, the compounds of the present invention are not believed to bind to 0.4 (32 nAChR neuromuscular receptors. It is also contemplated that the nicotinic receptor antagonists of the present invention will be used as a counter measure to treat exposure, or potential exposure, to a wide array of potential neurotoxins.
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This application is a national stage filing under 35 U.S.C. 371 of International Application PCT/IT2004/000581, filed on Oct. 22, 2004. The entire teachings of the referenced Application is incorporated herein by reference. International Application PCT/IT2004/000581 was published under PCT Article 21(2) in English.
BACKGROUND
1. Field
The present disclosure concerns a kinematic movement system for operating units of avant-garde bending machines. These are automatic machines for bending and shaping sheet metal.
This kinematic system features the electrical actuation and a particular kinematic drive of the main movements responsible for bending. The disclosure differs from machines currently produced which have hydraulic actuation.
The system according to the disclosure can be applied to a compact bending machine. In terms of weight and size such a machine can fit in a container, without the noisy and cumbersome hydraulic control unit. An ecological advantage is that it does not require topping up with great quantities of mineral oil. The machine is faster and more reliable than current machines and has more limited production costs.
This disclosure can be applied in the production of bending machines, and also to industrial bending machines for sheet metal.
2. General Background
It is known that the industry relative to the production of sheet metal items uses bending machines that allow a series of bends to be made in a single piece of sheet metal, in a completely automatic and controlled way, in order to obtain a finished product such as, for example, a cooker hood or a shelf.
It is also known that bending machines for sheet metal normally consist of:
a fixed bed to support the material, for example sheet metal, to be bent; a support frame for a clamping press; a punch, being part of the press, and a corresponding counter-punch acting as means for clamping the material during the bending phase; one or more bending blades that can be moved towards the material being processed; appropriate kinematic motions designed to move the bending blade or blades along the bed for shaping the piece clamped between the punch and the counter-punch; means for moving the sheet metal or the profile towards the blades in working conditions; transducers or sensors of various types, to control the process, connected to an electronic unit which controls the production process.
A bending machine of the known type described above, marketed by the applicant hereto, comprises a blade-holder structure with a “C” shaped cross-section, movable in two reciprocally orthogonal directions with respect to the fixed bed, on which the bending blade(s) is (are) fixed.
The profile of the bend that can be obtained with a known automatic bending machine is not just the classic fixed angle profile that can be obtained with a manual bending machine. The simultaneous control of the positioning of the sheet metal and of the pressure exerted on it makes it possible to obtain radial profiles.
The use of traditional blades, particular tools and dies, included in the bending cycle, also makes it possible to form special profiles, without the need for the intervention of an operator when the length or the special tool changes.
SUMMARY
The blades are supported by a load-bearing C-shaped structure mounted on the main frame. The unit comprises two blades: the upper one for negative bends (downwards) and the lower one for positive bends (upwards).
The system controls the dimensions of the angles and the thickness of the sheet metal, adjusting the position of the blades by means of proportional valves. All the movements are carried out by proportional control hydraulic cylinders. A special mechanism guarantees the parallelism of the movements of the bending unit.
The presser tool is mounted on an electrowelded structure with four arms, hinged at the rear of the main frame.
The movements of the C-shaped structure and of the tools are controlled by hydraulic cylinders. The cylinders can be programmed by means of the control unit in order to achieve the highest degree of precision during all the bending phases.
Traditional hydraulic bending machines, like other bending machines present on the market, are fitted with a kinematic structure which determines and controls the movement of the blade-holder unit.
This structure can in some cases be the pentalateral type, that is consisting of a closed kinematic chain with five members connected by five kinematic pairs.
The traditional pentalateral type kinematic chain is used in order to provide the machine with torsional rigidity and not therefore with specific mechanical functions. In addition, the pentalateral type is not actuated by frame cranks.
DRAWINGS
The above-mentioned features and objects of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:
FIG. 1 represents a schematic side view of a traditional type bending machine;
FIG. 2 represents the three-dimensional schematic view of a general model of the kinematic system according to the disclosure which drives the blade-holder unit of a bending machine;
FIG. 3 is a schematic view of the same kinematic model represented on the flat, showing the trajectory lines of the links;
FIGS. 4 to 6 show views of kinematic models of the blade-holder drive unit;
FIG. 7 is a block diagram of the bending trajectory generation system in the machine according to the disclosure;
FIGS. 8 and 9 show schematic views of the trajectory of the blade on the sheet metal to be bent, in a first and second operating phase.
FIGS. 10 and 11 respectively show, in the form of a schematic illustration and a block diagram, the calculation procedure of the inverse kinematic system in analytical form for the bending machine according to the disclosure.
DETAILED DESCRIPTION
FIG. 1 shows the kinematic diagram of a traditional system for the movement of the blade-holder unit P.
With reference to FIG. 1 , the letters A, D, L and G indicate the frame fixed torque points around which the members rotate, while the letters B, C, E, F and H indicate the turning couplings that allow a degree of rotation freedom in the relative movement of the members.
In such machines, the pentalateral is not actuated by means of frame cranks but by hydraulic cylinders. This does not present any singularity combination.
This is a mechanism which presents certain structural and functional limitations, such as:
the machine is very noisy since the entire kinematic system is driven by hydraulic type circuits and components; it uses considerable amounts of oil to activate a very complex hydraulic circuit; it uses considerable amounts of electricity for the functioning of the entire complex hydraulic system; the environmental impact of the machine is therefore extremely negative as regards noise and the consumption of oil and electricity.
Specific analyses carried out on traditional bending machines have also shown that the usual mechanism for bending the sheet metal cannot be controlled electrically since the sensitivity coefficients of the tool with respect to the frame cranks are too high.
These high sensitivity coefficients of traditional bending machines are unable to provide the necessary amplification to the torque provided by the reduction motors (brushless motor+epicyclical reduction gear) available on the market. The only type of drive for known kinematic systems is therefore hydraulic.
Other types of motors cannot be used due to the movement laws to be carried out. Other reduction units (ordinary gear trains) are not compatible with the weights and dimensions of the machines.
Another problem is the non-absolute precision of the machine. This is due to the two synchronized movements that make it possible to define the trajectory of the tool are achieved by two groups of hydraulic cylinders which by virtue of their position are not completely independently for the horizontal and vertical movement of the tool.
The hydraulic cylinders responsible for the horizontal movement of the blade-holder unit also produce an unwanted vertical movement. In the same way the vertical cylinders also produce a horizontal movement.
This is due to the positioning of the cylinders which are not at right angles to each other, and also do not form fixed angles with respect to the frame.
This disclosure provides a kinematic system to drive operating units of bending machines. The system is able to eliminate or at least reduce the disadvantages described above.
The disclosure provides a kinematic system to drive operating units of a new concept of bending machines. Servomotors and epicyclical reduction gears are used for the movement of the blade-holder unit instead of the traditional hydraulic actuators.
The servomotors and reduction units make it possible to achieve higher performance levels than those of a hydraulic system. This also ensures a constant delivered torque that cannot be obtained with a hydraulic system that uses accumulators and thus necessarily has a pressure that slowly decreases during bending.
Electric servomotors, by virtue of the intrinsic linearity of their model of behavior, allow the use of advanced control patterns to carry out freely defined trajectories and interpolations, with practically no errors in position and speed. Such levels of performance cannot be achieved with a hydraulic system controlled by means of proportional valves because of the non-linearity caused by the fluid and of the more reduced pass-band of this drive.
These advantages are achieved by a kinematic system for driving the operating units of a bending machine. These features are described in the main claim.
The dependent claims describe advantageous embodiments of the disclosure.
A main advantage of this solution is that the blade-holder unit of the bending machine uses an articulated mechanism. By definition, this is a variable speed mechanism.
This means that, with the same drive speed, very low speeds can be used in the few seconds immediately prior to closing/opening. Decidedly higher speeds can be used during the rest of the presser stroke.
This also allows a further reduction in cycle time and a consequent increase in machine performance.
The machine is actuated electrically, by an appropriate electronic control unit. This employs an original mechanism for the movement of the bending blades. This can produce an amplification of the torque sufficient to generate the force on the tools necessary to bend the thicknesses and lengths as per the machine specifications.
The articulated system that constitutes the mechanism is a kinematic plane mechanism. This is a mechanism in which the members move with plane motion, with the axes of the turning pairs parallel to each other and at right angles to the plane of motion.
From the topological point of view (number of members and type of couplings) this is a closed kinematic chain with five members connected by five kinematic turning pairs.
One of these members is the frame of the machine. This kinematic chain has two actual degrees of freedom. This allows two independent motors. The two frame cranks were chosen as motor elements.
From the geometric point of view, the mechanism:
has the necessary working space for the correct movement of the bending blades in the fields foreseen by the application; presents particular geometric configurations (corresponding to conditions of kinematic singularity in the case of kinematic inversion of motion) in a neighbourhood of the configurations in which the mechanism bends the sheet metal, sufficient to generate the necessary amplification of the torques. There are two of these configurations, corresponding to the so-called positive bend and negative bend.
The mechanism according to this disclosure is such as to be in a condition of dual kinematic singularity (referring to inverse motion) in a neighbourhood of both the above-mentioned configurations.
This dual singularity is achieved by simultaneously aligning the first motor crank with the first connecting rod and the second motor crank with the second connecting rod.
This concept is independent of the geometric dimensions of the members or of the position of the frame kinematic pairs. The amplification effect depends to some extent on these dimensions, and on the working space of the machine.
The blades of the machine according to the disclosure are moved by an articulated system with two degrees of freedom that presents evident kinematic non-linearity, the movement of the bending blades. This is characterized by well-defined bending trajectories, and is made possible and programmable by a special original inverse kinematic algorithm of the non-iterative type. This is inserted in the numerical control or used as a pre-processor. This makes it possible to carry out well-defined trajectories with interpolated axes such as, for example, the classic circular interpolation.
In particular, a method and an algorithm typical of the field of robotics were applied to a machine tool, in an appropriately adapted way. This allows movement control by variables other than the tool coordinates, not orthogonal but independent of each other.
This algorithm defines the law of motion, exactly and without approximation. This corresponds to a desired tool trajectory, unlike what occurs in hydraulic bending machines in which the trajectory is traditionally set in the actuator space, which differs from the Cartesian space, and is therefore approximated regardless of the controller quality.
This algorithm resolves the position kinematics in a non-iterative way and thus with zero error.
According to the disclosure, the inverse kinematic algorithm comprises the subsequent solution of two closed links, each of which corresponds to two non-linear closing equations in two unknown quantities.
The non-iterative solution takes place by geometric type considerations.
This inverse kinematic algorithm, combined with the high precision of the controller that works on electric axes, makes it possible to carry out particular trajectories, other than the circular one, with particular features and uses.
In particular the machine according to the disclosure foresees the use of a new and original bending trajectory. This is unlike the known solutions, which allows the bending blade to turn on the sheet metal without sliding.
This trajectory is particularly useful in processing materials with a protective film as it prevents the film from being torn and the consequent damage to the sheet metal.
In this case, the blade and the sheet metal behave like two conjugate profiles and the resulting trajectory is a sort of circle involute. It can be observed that by mathematically imposing the non-slipping constraint between the blade and the sheet metal, a bond is achieved between the two free (or generalised) coordinates which define the trajectory.
The quality of the semifinished part processed by the machine according to the disclosure is excellent. This is achieved by a considerably quieter machine compared to previous machines and uses reduced quantities of oil for a much simpler hydraulic circuit.
The environmental impact of the new machine is completely different with respect to the solutions known, since it is less noisy and uses considerably less oil.
FIG. 1 shows the described drive method of the blade-holder unit P moved by a hydraulic drive system using actuators. Points A, D, L and G refer to the fixed frame torque points, around which the members turn. B, C, E, F, and H indicate the turning couplings that allow a rotational degree of freedom to the relative motion of the members. This system presents all the problems mentioned above, which the disclosure resolves.
In FIG. 2 , the bending machine according to the disclosure is equipped with a blade-holder unit 10 , which uses servomotors and epicyclical reduction gears instead of traditional hydraulic actuators to control its movements.
From the structural point of view, the rear part of the blade-holder unit is integral with a plurality of supports 11 , while plinths 12 are fixed on its lower part. The supports 11 and the plinths 12 are involved in the action of a particular kinematic system. The chain has two degrees of freedom, depending on two mechanical units indicated, respectively, by 13 and 14 .
The articulated system which makes up the mechanism is kinematically considered a plane mechanism. This is a mechanism in which the members move with plane motion. The axes of the turning pairs are parallel to each other and at right angles to the plane of motion.
From the topological point of view, the number of members and the type of couplings, is a closed kinematic chain with five members connected by five kinematic turning pairs.
One of these members is the frame of the machine. This kinematic chain has two degrees of freedom. This allows two independent motors, each installed on the respective mechanical unit.
The first independent servomotor 15 is part of the first mechanical unit 13 , to which a crank 16 is fitted, attached in turn to a connecting rod 17 , with its other end hinged to a lever 18 .
This lever 18 is equipped with a pivot on the shaft 19 , while its other end, the one opposite to the coupling point with the connecting rod 17 . These branch into a series of elements 18 a and 18 b , which are coupled to the same number of pins 20 a and 20 b positioned on the ends of the supports 11 integral with the blade-holder unit 10 .
The second mechanical unit 14 consists of two servomotors 21 and 22 which drive respective cranks 23 and 24 hinged in turn to respective connecting rods 25 and 26 . The other ends are attached to the plinth 12 of the blade-holder unit 10 .
All the cranks can be constructively represented by eccentric elements having the same function and that the two frame cranks were chosen as motor elements.
From the geometric point of view, the mechanism:
has the necessary working space for the correct movement of the bending blades in the fields foreseen by the application; presents particular geometric configurations (corresponding to conditions of kinematic singularity in the case of kinematic inversion of motion) in a neighborhood of the configurations in which the mechanism bends the sheet metal, sufficient to generate the necessary amplification of the torques. There are two of these configurations, corresponding to the so-called “positive bend” and “negative bend”.
This mechanism is in a condition of dual kinematic singularity (referring to inverse motion) in a neighborhood of both the above-mentioned configurations.
This dual singularity is achieved by simultaneously aligning the first motor crank 23 , 24 with the first connecting rod 25 , 26 and the second motor crank 16 with the second connecting rod 17 .
FIG. 3 shows the trajectories of the links and in particular, the Z references indicate the following kinematic connections:
Z 1 —crank 23 , 24 of the first link between the motor 21 , 22 and the connecting rod 25 , 26 ;
Z 2 —trajectory of the connecting rod 25 , 26 of the first link;
Z 3 —trajectory of the first link between the hinge of the connecting rod 25 , 26 and the blade-holder unit 10 , and the hinge 20 of the lever 18 ;
Z 4 —trajectory of the first link between the hinge 20 of the lever 18 and the pivot 19 of this lever;
ZB 1 —trajectory of the second link between the pivot 19 of the lever 18 and the hinge between the crank 18 and the connecting rod 17 ;
ZB 2 —trajectory of the second link between the hinge of the crank 18 and connecting rod 17 and the hinge of the connecting rod 17 and the crank 16 ;
ZB 3 —trajectory of the second link between the hinge of the connecting rod 17 and the crank 16 , and the shaft axis of the motor 15 .
FIGS. 4 and 5 show the positions of the members, which are represented by vectors. These give rise to the dual singularity of the mechanism in the neighborhood of the bending configurations.
FIG. 4 shows a first singular configuration with the start of a positive bend.
FIG. 5 shows a first singular configuration with the start of a negative bend.
FIG. 6 shows the second singular configuration of the crank 16 and the connecting rod 17 : fine dashed line start of the positive or negative bend and long dashed line end of the bend.
It should also be pointed out that the disclosed concept is independent of the geometric dimensions of the members or of the position of the frame kinematic pairs. It is evident that the amplification effect depends to some extent on these dimensions, and on the working space of the machine.
The blades of the machine according to the disclosure are moved by an articulated system with two degrees of freedom that presents evident kinematic non-linearity. The movement of the bending blades is characterized by well-defined bending trajectories. This is made possible and programmable by a special original inverse kinematic algorithm of the non-iterative type which, inserted in the numerical control or used as a pre-processor. This makes it possible to carry out well-defined trajectories with interpolated axes such as, for example, the classic circular interpolation.
In FIGS. 8 and 9 , the particular new bending trajectory is shown which allows the bending blade to turn on the sheet metal without sliding. This trajectory is particularly useful in processing materials with a protective film as it prevents the film from being torn and the consequent damage to the sheet metal.
The reference X 1 in FIG. 8 indicates the initial gap between the ends of the sheet metal to be bent and the support, while X 2 indicates the radius of the blade.
In FIG. 9 , X 3 indicates the gap and X 4 the bending angle.
The blade and the sheet metal behave like two conjugate profiles and the resulting trajectory is a sort of circle involute. By mathematically imposing the non-slipping constraint between the blade and the sheet metal, a bond is achieved between the two free coordinates which in fact define the trajectory.
The kinematic motion described leads to numerous advantages. The servomotors and the reduction units make it possible to achieve definitely higher levels of performance than those of a hydraulic system and also ensure constant delivered torque. This cannot be achieved with a hydraulic system that uses accumulators and thus necessarily has a pressure that slowly decreases during bending.
In addition, the quality of the semifinished part processed by the machine according to the disclosure is excellent and is achieved by means of a considerably quieter machine compared to previous machines and uses reduced quantities of oil for a much simpler hydraulic circuit.
The environmental impact of the new machine is completely different with respect to the known solutions, since it is less noisy and uses considerably less oil.
FIG. 7 is a block diagram relative to the control program of the bending machine. This block diagram makes it possible to define the mathematical calculus approach used to set a condition of turning and not of sliding of the blade on the sheet metal to be bent.
The disclosure is described above with reference to a preferred embodiment. It is nevertheless clear that the disclosure is susceptible to numerous variations within the framework of technical equivalents.
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A bending machine designed to bend and shape sheet metal comprises a blade-holder unit ( 10 ) with a “C” shaped cross-section, mobile along two mutually orthogonal directions with respect to a fixed bed, and on which one or more bending blades are fixed. This machine comprises a kinematic system for driving the operating units, in which servomotors ( 15, 21, 22 ) and epicyclical reduction gears are used for the movement of the blade-holder unit ( 10 ). Moreover, the blade-holder unit ( 10 ) of the bending machine uses an articulated mechanism consisting of two mechanical units ( 13, 14 ) which form a closed kinematic chain with five members connected by five kinematic turning pairs.
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RELATED APPLICATION
This application is a continuation-in-part of co-pending U.S. application Ser. No. 09/289,237, filed Apr. 9, 1999, entitled “Lamp With Removable Lens.”
BACKGROUND
This invention relates to lamps, and more particularly, to lamps having threaded bases.
In the past, lamps used in display lighting, such as flood lighting and spot lighting, commonly include a bulb contained within a generally frustoconical glass envelope coupled to a threaded base for connection to an electrical socket. The interior of the envelope is metallized to define a reflector. To provide a whiter light throughout its life, the bulb may be filled with a gas, such as a halogen gas. When such a bulb burns out, the entire lamp is usually discarded and replaced with a new one. When used in retail stores and other commercial installations, these lamps are on for many hours of each day. Thus, they must be replaced frequently. The combination of the cost of the bulb-within an-outer-envelope construction and the frequency of replacing the lamp used in display lighting makes such lamps expensive to use.
Lamps have also been provided which have a threaded base detachable from the glass envelope. This allows a user access to the interior of the lamp to replace burnt out bulbs, but requires the user to first unscrew the lamp from the socket. Often, the lamps, when connected to the socket, are in tight quarters making removal from the socket difficult and often time consuming.
SUMMARY
It is a general object of the invention to provide a lamp which avoids the disadvantages of prior lamps while affording additional structural and operational advantages.
An important feature of the invention is the provision of a lamp which is of a relatively simple and economical construction.
In connection with the above feature, another feature of the invention is the provision of a lamp which provides cost reduction by providing for replacement of the bulb of the lamp, thereby permitting the reuse of the outer envelope, the lens and other elements of the lamp.
A further feature of the invention is the provision of a lamp of the type set forth that does not need to be removed from an attached socket to change the bulb.
Certain ones of these and other features of the invention maybe attained by providing a lamp comprising: a threaded base for threadedly coupling to an electrical energy source and having a pair of female terminals; a light-generating bulb having a pair of male terminals removably receivable in the female terminals; a reflective housing connected to the base and having an inner light-directing surface disposed about the bulb, the reflective housing terminating at an outer rim, and defining an opening; a lens; and a mounting assembly mounting the lens on the rim in a covering position closing the opening and accommodating movement of the lens to a non-covering position wherein at least a portion of the opening is uncovered to permit access to the bulb through the opening.
The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawings a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its construction and operation, and many of its advantages should be readily understood and appreciated.
FIG. 1 is a perspective view of the lamp of the present invention with the lens mounted in place;
FIG. 2 is a bottom plan view, partially broken away, of the lamp of FIG. 1;
FIG. 3 is a side elevational view of the lamp of FIG. 1, partially in section;
FIG. 4 is an enlarged fragmentary view of the circled area of FIG. 3;
FIG. 5 is a fragmentary, front elevational view of the lens of FIG. 1, wherein the latch has been moved to a non-engaged position;
FIG. 6 is an front elevational view of the lamp of FIG. 1, with the glass envelope partially broken away and the lens detached;
FIG. 7 is a fragmentary, front elevational view of the lug and slot of the lens mounting assembly engaged with each other;
FIG. 8 is a fragmentary, right-hand side elevational view of the lamp of FIG. 7;
FIG. 9 is an enlarged, fragmentary, front elevational view of the left-hand side of FIG. 3;
FIG. 10 is a fragmentary, left-hand side elevational view of the lamp of FIG. 9;
FIG. 11 is a bottom plan view of another lamp embodiment;
FIG. 12 is an enlarged, fragmentary view in vertical section taken generally along the line 12 — 12 in FIG. 11;
FIG. 13 is a fragmentary, side elevational view of the lamp of FIG. 12, as viewed from the left-hand side thereof;
FIG. 14 is an enlarged, fragmentary, top plan view of the lamp of FIG. 11;
FIG. 15 is a fragmentary, side elevational view of the lamp of FIG. 12, as viewed from the right-hand side thereof;
FIG. 16 is a fragmentary sectional view taken generally along the line 16 — 16 in FIG. 14; and
FIG. 17 is an enlarged, fragmentary, sectional view, taken generally along the line 17 — 17 in FIG. 11 .
DETAILED DESCRIPTION
Referring to FIGS. 1, 3 and 6 , a lamp 20 is provided. The lamp 20 includes a threaded base assembly 22 including a cup-shaped threaded end portion 24 adapted to be threadedly engaged to an associated lamp receptacle (not shown), for electrical connection thereto in a known manner. The threaded end portion 24 is integral with a flared frustoconical shoulder 26 , which terminates in a cylindrical wall portion 28 .
The lamp 20 also includes an envelope or housing 30 fixedly coupled to the base assembly 22 in a known manner. The envelope 30 is typically formed of glass and, as seen in FIGS. 3 and 6, has an end wall 32 and a generally frustoconical-shaped sidewall 34 having interior and exterior surfaces 36 , 38 .
The interior surface 36 is provided with a reflector material to form a reflector 39 or light directing surface. The sidewall 34 terminates at a rim 40 which defines a circular opening 42 (FIG. 6 ). As seen in FIG. 4, the rim 40 has a groove 43 about its periphery. The rim 40 also defines a shoulder surface 44 which projects radially outwardly from the exterior surface 38 to an annular terminal edge 44 a (FIGS. 3, 4 and 6 ).
As seen in FIGS. 3 and 6, two electrical clamps, or connectors 45 , 46 , defining female terminals, are disposed in the end wall 32 of the envelope 30 and are respectively electrically connected to the threaded end portion 24 of the base assembly 22 by wires 48 , 50 in a known manner.
As seen in FIG. 4, the lamp 20 also includes a light-generating bulb 52 , such as a halogen bulb, having a capsule 54 made of hard glass or quartz and a pair of connecting legs, or male terminals 56 , 58 . Legs 56 , 58 respectively have parallel end portions 60 , 62 respectively connected to inclined portions 64 , 66 which converge toward each other. The parallel portions 60 , 62 are respectively removably disposable in clamps 45 , 46 . The clamps 45 , 46 are preferably spring loaded to maintain the parallel portions 60 , 62 therein to maintain electrical contact. As seen in FIG. 3, the inclined portions 64 , 66 contact the upper portion of the clamps 45 , 46 to prevent the end portions 60 , 62 from being inserted too deeply into the clamps 45 , 46 and to properly align the capsule 54 at the focal point of the reflector 39 which is disposed about the capsule 54 .
The lamp 20 also includes a lens 68 , preferably formed of glass, to focus or direct light in a predetermined beam pattern, such as, among others, spot, flood and wide flood.
The lamp 20 also includes a mounting assembly 76 to mount the lens 68 in a covering position, as seen in FIGS. 1 and 3, on the rim 40 to close the opening 42 and to position the lens 68 properly to direct the light from the light generating bulb 52 . As seen best in FIG. 4, the lens 68 has interior and exterior surfaces 70 , 72 and a raised rim 74 about the periphery of the interior surface 70 . When the lens 68 is in the covering position, the raised rim 74 is disposed in the groove 43 .
The mounting assembly 76 includes a ring-like lens holder 78 made of a metal, or other suitable material, which can withstand the operating temperatures of the lamp 20 . The lens holder 78 has an annular bottom wall 80 integral with, and inclined to, an upstanding cylindrical sidewall 82 . The lens holder 78 also includes a latch keeper 84 projecting up from the top of the sidewall 82 and a flange 86 also projecting up and radially inwardly from the top of the sidewall 82 and inclined with respect to the sidewall 82 . The flange 86 , as seen best in FIGS. 1, 2 and 8 , includes a centrally disposed slot 88 formed of two generally parallel sidewalls 90 and a bottom wall 92 connecting the two. The flange 86 is spaced about 180° from the keeper 84 . The lens holder 78 may be adhesively attached to the lens 68 by means of an adhesive 79 (FIG. 2 ), such as an epoxy, disposed between the bottom wall 80 and the lens 68 , or may be attached by mechanical means. The lens holder 78 can also be free from the lens 68 .
The mounting assembly 76 also includes a box-like lug 94 projecting from the exterior surface 38 of the envelope 30 adjacent to the rim 40 . The mounting assembly 76 also includes a latch hook assembly 96 disposed about 180° away from the lug 94 (FIG. 6) and adhesively attached to the exterior surface 38 of the envelope 30 . The hook assembly 96 includes an operating lever 98 and a latch hook 100 having a hooked end 102 .
When the lens 68 is in the covering position, the slot 88 of the flange 86 , as seen in FIGS. 1 , 7 and 8 , is aligned with the lug 94 , so that lug 94 is disposed between the sidewalls 90 of the slot 88 , which prevents the lens holder 78 from rotating with respect to the envelope 30 . Additionally, portions of the radially inwardly projecting flange 86 rest on shoulder surface 44 , which aid in supporting the lens 68 on the envelope 30 (FIGS. 3, 4 and 7 ).
Also, when the lens 68 is in the covering position, the hooked end 102 of the latch hook 100 is engageable with the keeper 84 of the lens holder 78 , as illustrated in FIGS. 3 and 5.
To remove the lens 68 from the covering, the operating lever 98 , as seen in FIGS. 3 and 5, is rotated from the position shown in FIG. 3, in the direction of arrow A (FIG. 5 ), which disengages the hooked end 102 of the latch hook 100 from the keeper 84 . The operating lever 98 can then be rotated in the direction of arrow B (FIG. 5) to provide clearance between the hooked end 102 of the hook 100 and the keeper 84 so a user can pull the lens holder 78 and lens 68 away from the opening 42 (and the rim 40 ), as seen in FIG. 6, to a non-covering position, and thereby can gain access to the light-generating bulb 52 for replacement or repair. After replacement, the lens 68 (and lens holder 78 ) are returned into the covering position shown in FIGS. 1 and 3.
While, the mounting assembly 76 accommodates complete removal of the lens 68 from the envelope 30 , it is contemplated that the lens 68 could also remain coupled to the envelope 30 but moved to a position which leaves at least a portion of the opening 42 uncovered to provide access to the light-generating bulb 52 . More specifically, referring now to FIGS. 11-17, there is illustrated another lamp embodiment, generally designated by 120 , which is similar to the lamp 20 of FIGS. 1-10, but utilizes a different lens mounting assembly. Accordingly, parts of the lamps 20 and 120 which are the same will bear the same reference numbers.
The lamp 120 has an envelope or housing 130 fixedly coupled to the base 22 in the same manner as described above for the lamp 20 . The envelope 130 has a generally frustoconical-shaped side wall 132 with an exterior surface 133 and terminating at a rim 134 (FIG. 17) which defines the circular opening 42 . The rim 134 has a frustoconical outer surface portion 134 a and a cylindrical surface portion 135 which terminates at an annular outer end surface 136 lying in a plane substantially perpendicular to the axis of the lamp 120 . An annular rib 137 projects axially forwardly from the end surface 136 and joins it to an annular inner end surface 138 substantially parallel to the outer end surface 136 . Projecting generally radially outwardly from the exterior surface 133 of the side wall 132 at diametrically opposed locations thereon are two generally prism-shaped lugs 139 (one shown in FIG. 16 ).
Encompassing the rim 134 and fixedly secured thereto is a housing ring, generally designated by the numeral 140 , which may be formed of a suitable plastic material. Referring, in particular, to FIGS. 12, 16 and 17 , the ring 140 has a frustoconical wall 141 integral at its upper end with a more sharply-sloped frustoconical flange 142 and integral at its lower end with a depending, cylindrical flange 143 , the ring 140 being so dimensioned that the wall 141 and the flanges 142 and 143 , respectively, lie along the outer surface 134 a of the rim 134 , the exterior surface 133 of the envelope side wall 132 and the cylindrical surface 135 of the rim 134 . At a plurality of equiangularly spaced locations therearound, the cylindrical flange 143 is provided with radially inwardly extending retaining flanges 144 (one shown in FIG. 17) which underlie and engage the outer end surface 136 of the rim 134 for fixedly retaining the ring 140 in place on the envelope 130 . The retaining flanges 144 may be formed by ultrasonic deformation of the cylindrical flange 143 or by ultrasonic attachment to that flange of separate retaining pieces, after the ring 140 is positioned in place on the rim 134 . Formed at diametrically opposed locations on the ring 140 and projecting radially outwardly therefrom are two generally prism-shaped bosses (one shown in FIGS. 14 and 16 ), respectively defining recesses 146 for receiving the lugs 139 and cooperating therewith to prevent rotation of the ring 140 relative to the envelope 130 . Projecting radially outwardly from the ring 140 , substantially midway between the bosses 145 , is a pair of generally triangular hinge flanges 147 and 148 (FIGS. 12 and 13 ).
The lamp 120 includes a latch mechanism, generally designated by the numeralI 50 , which includes an extension 151 of the frustoconical flange 142 of the ring 140 , disposed diametrically opposite the hinge flanges 147 and 148 . Projecting radially outwardly from the extension 151 is a short, cylindrical boss 152 which defines a cylindrical recess 153 , receiving one end of a helical compression spring 154 . Also projecting radially outwardly from the extension 151 and the adjacent portions of the ring wall 141 and flange 142 , respectively on opposite sides of the boss 152 , are two pivot flanges 155 and 156 (FIGS. 12 and 13 ). The latch mechanism 150 also includes a latch hook 160 disposed between the pivot flanges 155 and 156 and having a hub 161 . A pivot pin 162 is received through complementary openings in the hub 162 and the pivot flanges 155 and 156 for mounting the latch hook 160 for pivotal movement between latching and unlatching positions. Integral with the hub 162 at one end thereof is a stop flange 163 designed to engage the extension 151 in the latching position of the latch hook 160 , illustrated in FIGS. 12 and 13. Also integral with the hub 160 and depending therefrom is a hook flange 165 provided at its distal end with a radially outwardly projecting hook lip 166 having an inclined cam surface 167 thereon. Projecting radially outwardly from the hook flange 165 and spaced a slight distance from the hook lip 166 is a stop lug 168 . Formed in the inner surface of the hook flange 165 behind the stop lug 168 is a spring recess 169 which receives the other end of the spring 154 . Thus, it will be appreciated that the spring 154 resiliently urges the latch hook 160 to its latching position, illustrated in FIG. 12 .
The lamp 120 also includes an annular lens ring 170 , which may be formed of the same plastic material as the housing ring 140 , and includes a cylindrical wall 171 , integral at its forward end with a radially inwardly and forwardly projecting frustoconical flange 142 . Also projecting radially inwardly from the cylindrical wall 171 a slight distance rearwardly of the flange 172 is an annular seating rim 172 , which has radially inwardly projecting therefrom, at equiangularly spacedapart locations thereon, a plurality of retaining flanges 174 (one shown in FIG. 17 ). Extending axially rearwardly and radially inwardly from the cylindrical wall 171 is a hinge arm 175 , disposed in use between the hinge flanges 147 and 148 of the housing ring 140 . A hinge pin 176 is received through complementary openings in the hinge arm 175 and the hinge flanges 147 and 148 for accommodating pivotal movement of the lens ring 170 between a covering position, illustrated in the drawings, and an uncovering position (not shown). Also extending axially rearwardly from the cylindrical wall 171 diametrically opposite the hinge arm 175 , and forming a part of the latch mechanism 150 , is a generally trapezoidal-shaped keeper arm 177 (FIGS. 12 and 13) having a rectangular slot 178 formed therethrough and defining at its upper edge a cam surface 179 .
The rings 140 and 170 cooperate to form a mounting assembly for a lens 180 , similar to the lens 68 of the lamp 20 . The lens 180 has a sloping front surface 181 and stepped cylindrical rim surfaces 182 and 183 , the latter terminating at an annular rear rim surface 184 . In use, the surfaces 181 - 183 , respectively, lie along the frustoconical flange 172 , the cylindrical wall 171 and the seating rim 173 of the lens ring 170 (see FIG. 12 ), with the retaining flanges 174 disposed for engagement with the rear rim surface 184 of the lens 180 (see FIG. 17) for securely fixing it in place in the lens ring 170 . The retaining flanges 174 may be formed in the same manner as was described above for the retaining flanges 144 of the housing ring 140 , after the lens 180 has been assembled in the lens ring 170 .
It will be appreciated that, in use, the lens 180 pivots with the lens ring 170 between the covering and uncovering positions. In the uncovering position, the lens 180 can be moved out of alignment with the envelope opening 42 to permit access to the bulb, as described above. When the lens ring 170 is pivoted from its uncovering position to its covering position, the cam surface 179 on the keeper arm 177 engages the cam surface 167 of the latch hook 160 for pivoting the latch hook 160 in a counter-clockwise direction, as viewed in FIG. 12, against the urging of the spring 154 , to permit passage of the keeper arm 177 . As the keeper arm 177 moves past the hook lip 166 , the hook lip 166 will snap into engagement in the keeper slot 178 under the urging of the spring 154 to latch the lens ring 170 and the lens 180 in their covering position, further movement of the lens ring 170 being limited by engagement of the cam surface 179 with the stop lug 168 . In order to release the latch mechanism 150 , the user simply depresses the latch hook 160 , as by pushing on the stop lug 168 , to release the hook lip 166 from the keeper slot 178 .
While the rings 140 and 170 are described as formed of plastic material, it will be appreciated that other materials could be used, and other techniques could also be utilized for assembling them to the envelope 130 and the lens 180 , respectively.
While particular embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
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A lamp having a threaded base for threadedly coupling to an electrical energy source is provided. The lamp includes a light-generating bulb replaceably coupled to the threaded base and a housing coupled to the base. The housing has an inner light-directing surface disposed about the bulb. The housing terminates at an outer rim, and defines an opening. A mounting assembly, including a lens-holding ring with a keeper and a latch hook on the sidewall, removably mounts a lens on the rim in a covering position closing the opening, whereby removal of the lens permits access to the bulb. The lens holding ring may be separable from the housing or may be pivotally coupled to a ring on the housing.
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BACKGROUND
[0001] This disclosure is directed to a storage assembly, and more particularly a pocket having a closeable lid as is commonly associated with a center console of an automotive vehicle. Selected aspects of the present disclosure may find application in related environments and applications.
[0002] It is known to provide a storage assembly such as a pocket holding loose items or small objects such as coins, fasteners, etc. It is likewise known to provide a selectively openable/closable lid for the storage assembly so that items received in a recess or pocket of the storage assembly are retained therein. Typically, the lid is pivoted between open and closed positions, and is usually mounted in such a manner that the lid pivots or rotates through a generally arcuate path over a terminal edge of a sidewall of the pocket. The terminal edge of the sidewall defines the true maximum fill line for the pocket. That is, other sidewall portions of the pocket may have a different or increased height relative to the sidewall terminal edge. When the lid of the storage assembly is open, users have a tendency to continue to deposit items in the pocket. For example, with the lid in an upright or open position, an undersurface of the lid allows additional items to be inserted into the pocket without overflowing, i.e., fill to an upper edge of the opening that forms the pocket and that substantially coincides with an underside or undersurface of the lid in a closed position. However, when the items are filled above a terminal edge of one of the sidewalls, and the user pivots the lid from the open position to the closed position, items can undesirably spill over the terminal edge of the pocket and thereby obstruct or jam further movement of the lid.
[0003] Consequently, a need exists for an alternative arrangement for the storage assembly that maximizes a volume of the storage pocket. Likewise, a need exists for an alternative arrangement that addresses the obstruction/lid jamming issues associated with prior arrangements.
SUMMARY
[0004] A storage assembly for an associated vehicle includes a surface having a perimeter edge and a pocket extending below the surface for storing associated articles. A lid is pivotally secured and selectively positionable between an open position that allows access to the pocket and a closed position that covers the pocket. The lid has an inner, first surface that coincides with a maximum fill line of the pocket when the lid is in the closed position, a recess formed in the first surface of the lid adjacent a first edge of the lid, and an object bumper extending adjacent at least a portion of the recess for preventing the associated articles from interfering with pivotal movement of the lid relative to the pocket.
[0005] The pocket has a first edge in close proximity to the lid recess during pivotal movement between the open and closed positions.
[0006] The object bumper includes a series of spaced projections extending along an edge of the recess.
[0007] The object bumper projections preferably each have a generally arcuate conformation that allows the lid to pivot from the open position to the closed position, and vice-versa.
[0008] Each object bumper projection has a generally arcuate conformation that allows the lid to pivot from the open position to the closed position, and vice-versa.
[0009] The pocket includes generally tapered sidewalls that extend from a base wall, and a cupped extension provided along one of the sidewalls that extends outwardly in a generally arcuate contour that corresponds to a generally arcuate conformation of the recess in the lid first surface.
[0010] The pocket includes a terminal edge over which the lid pivots between the open and closed positions, the terminal edge having a height less than a fill depth of the pocket.
[0011] The terminal edge has a height less than a remainder of an upper edge of the pocket.
[0012] The pocket includes a terminal edge over which the lid pivots between the open and closed positions, the terminal edge having a height less than a fill depth of the pocket.
[0013] A primary advantage of the new storage assembly is the ability to provide for a maximum fill line for the pocket.
[0014] Another benefit resides in the ability to limit the potential for objects to obstruct the lid during opening and closing movement relative to the pocket.
[0015] Still another advantage is associated with the improved aesthetics associated with the functional structure.
[0016] Yet another benefit relates to the reduced prospect that the lid can be jammed that prevents the lid from opening and closing correctly.
[0017] Still other benefits and advantages will become more apparent to those skilled in the art upon reading and understanding the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a prior art center console that incorporates a storage assembly.
[0019] FIG. 2 is a cross-sectional view of the storage assembly of FIG. 1 with the lid in an open position.
[0020] FIG. 3 is a cross-sectional view of the storage assembly of FIG. 1 with the lid in the closed position.
[0021] FIG. 4 is a cross-sectional view similar to FIG. 2 of an improved storage assembly.
[0022] FIG. 5 is a cross-sectional view similar to FIG. 3 of the improved storage assembly of FIG. 4 .
[0023] FIG. 6 is a perspective view of the lid of FIGS. 4 and 5 in an open orientation.
[0024] FIG. 7 is a perspective view of the lid in an open position.
DETAILED DESCRIPTION
[0025] FIGS. 1-3 illustrate a prior arrangement of the storage assembly SA of the type that is incorporated into a center console C disposed between front seats (not shown) in an automotive vehicle. The storage assembly SA includes a pocket P that is recessed relative to an upper surface of the console. The pocket P receives small items or objects such as coins, tokens, fasteners, clips, receipts, etc. Generally these objects are deemed unsightly and to improve the aesthetics of the interior of the automotive vehicle, it is common for the storage assembly SA to include a lid L that allows selective access to the pocket P. For example, the lid P is mounted for pivoting movement or rotation through a limited range between open and closed positions (shown open in FIGS. 1 and 2 , and shown in a closed position in FIG. 3 ). Oftentimes the user leaves the lid in an open position to allow ready access to the pocket. In this position as shown in FIG. 2 , the pocket P may be filled with items to a level generally shown by the broken line and referred to as a “max fill line”. However, if items are stored to this height or fill line, when the lid L is closed (as shown in FIG. 3 ) items or objects can spill over an upper edge E of one of the walls W defining the pocket sidewall. As will be appreciated from a comparison of FIGS. 2 and 3 , a “true max fill line” represented by the dotted line in FIG. 3 is defined by the height of the upper edge E of the wall W over which the lid pivots. That is, the wall W has a reduced height relative to other portions of the sidewall of the pocket P in order to accommodate the pivoting movement of the lid L. Unfortunately, if items have been introduced into the pocket to the “max fill line” of FIG. 2 , then pivoting movement of the lid L would allow the small items or objects to spill over the edge E of wall W. When the user then seeks to subsequently rotate the lid L to the open position of FIG. 3 , the items can potentially jam or prevent rotation of the lid L and thereby prevent the lid L from opening, or fully opening relative to the pocket P.
[0026] FIGS. 5-7 provide a solution to this problem. More particularly, console 100 has an upper surface 102 . An opening 104 in the upper surface 102 allows access to a pocket 110 which in this embodiment is formed as a recessed member having sidewalls 112 , 114 , 116 , 118 that extend upwardly from a base or bottom wall 120 . Preferably, the sidewalls have a slight taper as they extend upwardly and slightly outwardly from the bottom wall 120 . In addition, sidewall 116 includes a first or lower portion 116 A and a second or upper portion 1168 that is interconnected by a contoured transition region 116 C.
[0027] It is particularly evident in FIGS. 4 , 5 , and 7 that sidewall 116 has a reduced height relative to the remaining sidewalls 112 , 114 , 118 . This reduced height that terminates at upper edge 116 E of the sidewall 116 accommodates pivoting/limited rotating movement of lid 130 between an open position ( FIGS. 4 , 6 , and 7 ) and a closed position ( FIG. 5 ). The lid 130 has a substantially planar conformation but is modified relative to prior art arrangements by the inclusion of recess 132 . In the preferred arrangement, the recess 132 has an arcuate or curvilinear configuration. Particularly, the arcuate recess 132 in the lid is shaped relative to the pivoting or rotational axis of the lid so that the surface of the recess proceeds in closely spaced relation over the upper edge 116 E of the sidewall.
[0028] In addition, an object bumper, or series of object bumpers, 140 are formed in an underside of the lid and are provided adjacent the recess. As perhaps best illustrated in FIG. 6 , the object bumpers 140 extend outwardly from an underside of the lid in spaced relation relative to one another. The object bumpers 140 are preferably interposed between the recess 132 and a terminal edge 142 of the lid. Each of the object bumpers 140 is configured to advantageously extend the curvilinear shape of the recess 132 toward the terminal edge 142 of the lid ( FIG. 5 ). In this way, an inward edge of each of the object bumpers 140 is disposed adjacent the recess 132 while an outboard edge of each of the object bumpers is disposed adjacent the terminal edge 142 of the lid. The longitudinal spacing between the object bumpers is selected to minimize the potential for small objects to pass over the upper edge 116 E of sidewall 116 and into lid-receiving cavity 150 of the console.
[0029] The cavity 150 is formed in part by wall 152 that also has a partially arcuate conformation that tracks the pivoting movement of the lid 130 , and particularly the leading edge 142 as the lid rotates over the sidewall 116 . The cavity 150 is also defined by the contour of the sidewall 116 , including the contour of transitional portion 116 C. This contour of the sidewall closely matches that of the combined recess 132 and object bumpers 140 formed in the underside 130 A of the lid. Thus, when the lid 130 is in a full open position ( FIG. 4 ), the underside 130 A of the lid mates with the sidewall 116 . In addition, the shape of pocket sidewall 116 advantageously hides the object bumpers 140 and the recess 132 when the lid 130 is in a full open position.
[0030] FIGS. 4 and 5 illustrate that the “max fill line” of the pocket, i.e. the depth dimension measured from base wall 120 to the top of sidewalls 114 , 118 , extends upwardly to the lip of the respective sidewalls 112 , 114 , and 118 . As evident in FIG. 5 , the “max fill line” coincides with an undersurface 130 A of the lid in the closed position. When the lid is open, the “max fill line” is maintained because the recess 132 and object bumpers 140 preclude passage of objects or items over the upper edge 116 E of the sidewall 116 into cavity 150 . Thus, even though the sidewall 116 has a height less than a fill depth of the pocket (or less than the “max fill line”), the object bumpers and the recess advantageously limit the potential for items to leave the pocket over the edge 116 E of the reduced height sidewall 116 .
[0031] This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
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A storage assembly for an associated vehicle includes a pocket for storing associated articles. A lid is pivotally secured and selectively positionable between an open position that allows access to the pocket and a closed position that covers the pocket. The lid has an inner, first surface that coincides with a maximum fill line of the pocket when the lid is in the closed position, a recess formed in the first surface of the lid adjacent a first edge of the lid, and an object bumper extending adjacent at least a portion of the recess for preventing the associated articles from interfering with pivotal movement of the lid relative to the pocket.
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BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,399,085 discloses a process whereby the surface of nitriding steels can be readily nitrided to produce a well-hardened case without the formation of the undesirable brittle outer skin known as "white layer".
In the practice of the patented process, the nitriding time should not depend on the surface area being nitrided. Experience has shown that no problem is encountered in choosing the nitriding time to produce a satisfactory case with a predictable hardness profile as long as a relatively large amount of the specified dry NH 3 --H 2 gas mixture is allowed to flow over a comparatively small work load, e.g. 165 cu. ft. of gas per minute per 100 sq. ft. of steel surface area being nitrided in a non-porous-alundum reactor. There is, however, a serious size limitation on the area of steel that can be nitrided if this flow rate is not maintained particularly in an uncoated Inconel reactor. That is to say, at much lower flow rates the nitriding time needed to produce a given hardness profile can no longer be estimated.
This failure to effect suitable and reproducible nitriding in large areas of steel has been attributed to a drop in concentration of NH 3 in the gas mixture which is caused primarily by its decomposition to nitrogen and hydrogen. The problem was, therefore, in part overcome by working at temperatures near the higher end of the permissive range, employing higher concentrations of NH 3 and larger flow rates of the nitriding gas mixture. Such practices, however, add considerably to the cost of the operation and do not eliminate the time selection difficulty.
U.S. Pat. No. 3,684,590 discloses a practice wherein the above problems are overcome. The patented practice is based in part upon the discovery that the above-mentioned difficulties are usually not the result of a reduction of NH 3 concentration as had been believed, but rather are caused by the generation of impurity gases such as hydrogen cyanide, HCN, in side reactions during nitriding, which inhibit the nitriding reaction. These nitriding inhibitors, or poisons, contaminate the nitriding gas somewhat in proportion to the surface area of the steel being nitrided. Amounts of HCN as little as ten parts per million, can cause excessive and erratic retardation of the nitriding reaction. Pursuant to the patented process therefore, the NH 3 --H 2 nitriding atmosphere is recirculated so that nitriding inhibitors can be removed and so that the moisture content can be regulated as desired to minimize formation of nitriding inhibitors. Specifically, the nitriding atmosphere is circulated from the nitriding furnace to a gas-to-gas heat exchanger where the temperature thereof is lower to a preselected level. Thereafter, the atmosphere is conveyed through a thermostated scrubber containing an aqueous alkaline solution which removes HCN and other nitriding inhibitors. The atmosphere is precooled so that the scrubber temperature can be maintained at a predetermined level, i.e. thermostated, to thereby control the water partial pressure in the atmosphere within the desired range of 7 to 20 torrs depending on the concentration of the aqueous caustic solution. The scrubbed atmosphere is then returned to the nitriding furnace via the heat exchanger.
SUMMARY OF THE INVENTION
This invention is predicated upon our further improvements in the above-described process whereby other techniques can be utilized to suppress the formation of the harmful HCN and/or minimize the harmful affects thereof. Pursuant to one embodiment of this invention, the adverse affects of HCN can in part be avoided without the need for a scrubber, i.e. without the need to recirculate the nitriding atmosphere through a heat exchanger and thermostated scrubber. Nevertheless, a recirculation system substantially as described in U.S. Pat. No. 3,684,590 can be utilized to advantage if so desired. Accordingly, we have found that if the interior surfaces of the nitriding system are made of nickel or high nickel base alloy which are coated with a non-porous and non-friable high temperature material such as enamel or a selected catalyst which will decompose HCN but will not crack ammonia to hydrogen and nitrogen, then the formation for nitriding inhibitors, such as HCN are greatly minimized. Therefore, by combining the desired interior surface material with a system to provide adequate moisture control, the formation of nitriding inhibitors can be reduced to such a low level that a scrubber is not necessary. In addition to the above, the use of a non-porous and non-friable interior surface will provide other advantages as will be discussed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the process disclosed in U.S. Pat. No. 3,399,085 does specifically teach a comparable nitriding process without recirculating the nitriding gas through a scrubber, it was pointed out above, and in U.S. Pat. No. 3,684,590, that successful nitriding pursuant thereto required that large amounts of gas be circulated over comparatively small work loads. Thus, a serious size limitation on work load was inherent unless a scrubber were used. Pursuant to this invention, however, no such size limitation problem is encountered with or without a scrubber.
According to one practice of this invention, the nitriding process is a modified version of the process taught in U.S. Pat. No. 3,399,085. As noted above, one modification is the lining in the nitriding furnace itself. In the practice of this invention, a conventional porous and friable refractory lining is not used, but instead the furnace lining exposed to the nitriding gas is made of a nickel base alloy, and further having a high temperature non-porous and non-friable coating thereon. The coating may be either an inert material such as enamel, or a catalytic material, such as platinum, platinum alloys, or other metals of the second and third transition series (i.e. Ru, Rh, Pd, Os, Ir and Pt) which will decompose HCN but not NH 3 .
In the practice of the process, the ferrous metal parts to be nitrided are placed in a nitriding furnace having a lining as above described. The parts are then nitrided under conditions which altogether avoid iron nitride nucleation on the surface thereof. This is effected by heating the parts to a preselected temperature within the range 475 to 550° C. while a ternary mixture of ammonia, hydrogen and water, at substantially atmospheric pressure, is passed thereover. The nitrogen activity of the gas mixture is adjusted to a preselected value within the range 0.2 to 1.8 atmos. -1/2 which represents a gas composition of from about 15 to 55% ammonia by volume at one atmosphere of pressure. Nitrogen activity can be defined by the equation: ##EQU1##
The water content of the nitriding gas mixture should be maintained at a value of from 1 to 3 volume percent, otherwise cyanide generation will proceed at such a rapid rate that a substantially greater gas flow rate will be needed to effect a high nitriding rate.
Upon commencement of the nitriding operation, there will be a higher rate of cyanide formation which continues for about 3 to 7 hours. Thereafter, the cyanide formation rate drops off significantly. It is believed that this initial heavy cyanide formation is due in part to the reaction of ammonia with carbon available at the surface of the steel being case hardened. It follows therefore, that as the surface carbon is depleted, the cyanide formation is reduced. Accordingly, to overcome this effect, the initial nitriding gas flow rate is moderately high, i.e. about an order of magnitude greater than that required when a scrubber is used, or more specifically about 50 to 200 cu. ft. per hour per 100 sq. ft. of steel surface area being nitrided. After this initial period of from 3 to 7 hours, the nitriding gas flow rate is reduced significantly to about 5 to 20 cu. ft. per hour per 100 sq. ft. of steel surface area being nitrided. At both flow rates, it is necessary to maintain the required 1 to 3% water content in the gas. Nitriding should continue at the reduced gas flow rate for a length of time necessary to achieve the degree of hardness desired at specified depths. Nitriding times may vary from several hours to one week.
We have learned that when the nitriding inhibitor contamination is kept low, as in this process, the nitriding rate approaches a diffusion controlled process, which is the maximum rate theoretically possible. At such a nitriding rate, there exists, for any given alloy being nitrided, a nitrogen activity for any given temperature, below which no white layer (iron nitride) can be formed regardless of nitriding time. Thus, maximum case depths without white layer can be obtained in a given time by nitriding slightly below the critical nitrogen activity. The actual preferred nitrogen activity, which is just below the critical, will vary depending upon temperature and the alloy being nitrided. Unfortunately, there is no formula for establishing such critical nitrogen activity, but rather it must be determined experimentally for any given alloy. This can be done by saturating a very thin wafer (0.005") of the alloy under consideration with nitrogen at increasing nitrogen activities until iron nitride (γ'Fe 4 N) is detected. The minimum nitrogen activity at which iron nitride is detected is defined as the critical activity. The table below provides the critical nitrogen activities for two common nitriding alloys at various temperatures.
TABLE______________________________________ Critical NitrogenAlloy* Temperature (°C.) Activity (atmos..sup.-1/2)______________________________________Nitralloy 135M 500 0.78Nitralloy 135M 515 0.56AISI 4140 515 0.33______________________________________ *Quenched and tempered.
Accordingly, the condition for the second step described in U.S. Pat. No. 3,399,085 is improved upon by following the procedure just described. Furthermore, when the nitriding inhibitors are sufficiently reduced by scrubbing, etc., we recommend the new improved second step treatment as a single treatment when using a single nitriding temperature.
As noted, the primary novel feature of this invention is the provision of coated nickel alloy interior surface of the reactor vessel and system. This would include all interior surfaces which contact the hot nitriding gas mixture. Provision of such a coated surface does not only greatly reduce the formation of nitriding inhibitors, such as HCN, as compared to the usual uncoated nickel alloy surfaces, but also permits much closer control of the nitriding atmosphere composition and more uniform nitriding. That is to say, when using conventional refractory liner surfaces, we have found that because of its porous nature, water and/or ammonia will tend to be absorbed thereinto, and thereafter unpredictably and uncontrollably desorb into the furnace atmosphere during nitriding. Such desorption will lessen the operator's ability to control the critical composition of the furnace atmosphere needed to affect maximum nitriding rates, without danger of producing white layer damage. In addition, because of the friable nature of the refractory lining, dust and particulate matter will settle onto the work load and cause soft spots thereon due to incomplete nitriding thereunder. Pursuant to this inventive process, the provision of a non-porous and non-friable coating within the furnace will eliminate these problems.
As noted above, the non-porous and non-friable coating may be either an enamel or a suitable catalyst. While an enamel serves to provide an inert surface which does not promote the production of HCN, a suitable catalyst, such as a platinum alloy, will go one step further and tend to dissociate any HCN which may be formed at the work load surface. Obviously, a catalytic surface which destroys the harmful HCN is more ideal, but also, it is quite costly, and not absolutely necessary. Since such a catalyst no matter where located could decompose the HCN, it is obvious that if one so chooses, he could provide an enamel coating on the furnace walls and also incorporate the catalyst elsewhere within the system to decompose the HCN.
In another embodiment of this invention the coated furnace interior walls as described above could be incorporated into a system having a recirculation circuit and a scrubber, substantially as described in U.S. Pat. No. 3,684,590. The processing parameters would be identical to those noted above except that it would not be necessary to start with an increased nitriding gas flow rate. Since the scrubber is present to remove the nitriding inhibitors, then it is not necessary to start with the higher flow rate which serves only to dilute the adverse effect of the HCN initially formed on the work load. Accordingly, flow rates of about 5 cu. ft. of gas per hour per 100 sq. ft. of steel surface area being nitrided can be used throughout the entire nitriding operation. In a like manner if a catalytic surface is employed, or a catalyst for decomposing HCN is otherwise incorporated into the system, then the larger initial nitriding gas-flow rate can be reduced in proportion to the effectiveness of the catalyst.
Since this process contemplates addition of water along with the hydrogen and ammonia at the primary gas inlet, it would not be necessary to have a thermostated scrubber if a scrubber were desired. Accordingly, one could use a scrubber and yet eliminate the need for a heat exchanger. In such event, molten alkalis could be used as the scrubber medium. Obviously however, one could if he so chose, utilize a thermostated scrubber containing an aqueous scrubbing solution and thus maintain his water level in that way and not add it to the incoming nitriding gas.
It should also be apparent that since the furnace lining is coated to provide the desired interior surface material, such as enamel, it should not matter what material the lining is made of, so long as it is a non-friable high temperature metal. While indeed a mild steel or other such structural metal or alloy could be used in place of the nickel or nickel base alloy, the nickel or nickel alloy is highly preferred. If one were to use a mild steel lining, for example, he would have to be assured that the coating thereon were without defects. Any subsequent scratches in the coating which would expose even a very small amount of the steel therebeneath could cause the steel lining to be nitrided and thus embrittled. Therefore, nickel or a nickel base alloy, such as Inconel, is highly preferred.
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Method of nitriding steel surfaces by circulating thereover a ternary mixture of ammonia, hydrogen and water at an elevated temperature and atmospheric pressure. Most of the harmful effects of HCN formation are avoided by utilizing a furnace lining consisting of a coated nickel base alloy, and by adding from 1 to 3% water to the nitriding gas and flowing the nitriding gas at a rate as low as 5 to 20 cu. ft. per hour per 100 sq. ft. of steel surface area.
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This is a continuation-in-part application of original application Ser. No. 405,945 filed on Aug. 6, 1982 and now abandoned.
FIELD OF THE INVENTION
This invention relates to a hydraulic clutch and pump assembly, in particular of the type used for heavy duty operation.
DESCRIPTION OF THE PRIOR ART
In the hydraulic clutch and pump assembly of the type that has been used so far, the clutch and pump are separate units and this calls for some fluid coupling including a rotary seal to supply the hydraulic fluid under pressure to the clutch. Such seals often leak unless the operating pressure is low. In some prior art patents, the pump rotates with the clutch doing away with the need of a rotary seal but clutch seals are still required, again necessitating a rotatively low operating pressure.
SUMMARY OF THE INVENTION
It is a general object of the present invention to dispense with the need of rotary and clutch seals in a clutch and pump assembly of the above type.
It is an object of the present invention to provide a hydraulic clutch and pump assembly of the above type, which can operate at very high hydraulic pressure whereby the clutching surface areas can be decreased for a given clutching torque.
It is another object of the present invention to provide a hydraulic clutch and pump assembly which is of simple construction, using a relatively small number of parts.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will be better understood with reference to the following detailed description of preferred embodiments thereof which are illustrated, by way of examples, in the accompanying drawings, in which:
FIG. 1 is a cross-sectional view in an axial plane of a hydraulic clutch and pump assembly according to a first embodiment of the present invention embodying a reciprocating pump.
FIG. 1a and FIG. 1b are cross-sections on an enlarged scale, of parts of FIG. 1;
FIG. 2 is a transverse cross-section of the hydraulic clutch and pump assembly of FIG. 1 and taken along line 2--2 of FIG. 1;
FIG. 3 is a view as in FIG. 1 but of a second embodiment featuring a rotary pump driven by a chain and sprocket drive; and
FIG. 4 is a view as in FIGS. 1 and 3 but of a third embodiment featuring a rotary pump driven by gears.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following detailed description, the same elements are identified by the same reference numerals throughout all the embodiments.
The hydraulic clutch and pump assembly, illustrated in FIG. 1, comprises an input or driving shaft 10 formed with an annular flange 11 at its outer end. An output shaft 13 is rotatively carried in any suitable body by ball bearings 14 and is axially aligned endwise with the input shaft 10. The end of the output shaft 13 adjoining the end of the input shaft 10 is formed with a splined portion 15.
Ball bearings 16 rotatively carry the input shaft 10 in a fixed body of which a portion only is shown. That fixed body portion includes the annular end portion 17 of a casing, not otherwise shown. A sleeve member 18 is engaged around the input shaft 10 with the latter freely rotating in it. The sleeve member 18 includes an annular flange 19 to fixedly attach the sleeve member 18 endwise against the annular end portion 17 by screws 20. The sleeve member 18 includes a cylindrical sleeve portion 21 intermediate the flange 19 and the opposite end forming a pump actuation portion or cam 22.
A ring is secured to the flange 11 of the input shaft 10 and includes a main ring member 23 having its inner edge bolted to the flange 11. The ring member 23 is formed, on one side with cylindrical projections 24 and 25 cooperatively forming an annular recess constructed and arranged for axial sliding of an annular pad 26 in it and to cooperatively define with it an annular chamber 27. A ring member 28 is secured to the cylindrical projections 24 and 25, and similarly defines an annular chamber 29 in cooperation with an annular axially slidable pad 30. The pads 26 and 30 are each fixed to one side of an annular clutch plate 31, while an annular clutch lining 32 of any appropriate material, including asbestos and metal, is secured to the other side of clutch plate 31. The linings 32 are arranged to be pressed against the opposite faces of a clutch disk 33. The latter is engaged on the splined portion 15 of the output shaft 13 to bodily rotate with it.
As shown at the bottom of FIG. 1, the two clutch plates 31 have circumferentially spaced ears 31a which extend radially through circumferentially spaced apertures 31b of cylindrical projection 25. Radial ears 25a are fixed to cylindrical projections 25 in register with ears 31a. A pin or bolt 31c extends through openings of ears 31a, 25a and permits axial movement of clutch plates 31 while preventing their rotation. A compression coil spring 65 surrounds bolt 31c between ears 31a and urges the two cluch plates 31 apart into declutched position. Hydraulic liquid under pressure is fed in chambers 27, 29 to apply uniform pressure to annular plates 26, 30 to effect clutching.
According to an essential feature of the present invention, the liquid is not fed directly in chambers 27, 29 but in elastic, flexible annular tubes or bags 27a, 29a as more clearly seen in FIG. 1a. These bags 27a, 29a are made of rubber or suitable elastic and flexible synthetic material. They permit application of very high pressure (100 atmospheres or more) while positively preventing any liquid leak onto the clutching surfaces of disk 33 and clutch shoes 32. Due to the high pressure attainable, clutch shoes 32 can be eliminated and a direct metal to metal clutching contact obtained between disk 33 and both clutch plates 31.
The main ring member 23 is formed on its opposite side relative to the cylindrical projections 24 and 25 with another pair of cylindrical projections 34 and 35. An annular cover 36 is secured by screws 37 against the outer edge of the cylindrical projections 34 and 35. An annular reservoir 37A is provided for the hydraulic liquid inward of the cylindrical projection 35 of the ring 23. The liquid L in reservoir 37A is normally held uniformly distributed by centrifugal force, the letter h indicating the preferred range of minimum and maximum depth of liquid. Hydraulic fluid lines are formed in the ring 23 and fixedly connected to it to selectively supply hydraulic liquid under pressure in the annular bags 27a and 29a or to relieve the pressure. Those hydraulic fluid lines include a pressure fluid line 38 extending circularly in the ring 23 and parallel connected to the outlet of two hydraulic pumps 66, 67 (to be described hereinafter) through check valves 68. The circular fluid line 38 is connected by a transverse line 40 to a branch 41 connected at its other end to a hydraulic fluid line 39 which is connected to bags 27a, 29a by lines 43, 44. Another line 42 connects the line 39 to the annular reservoir 37A.
A control is provided to selectively allow hydraulic fluid under pressure to apply the clutch shoes against the clutch disk. That control comprises a slide valve 45, an adjustable pressure relief valve 46, a valve actuator arm 47, an axially-slidable control sleeve 48, and a manual actuator lever 49. The slide vale 45 includes a slidable piston 50 which is fixedly connected to the valve actuator arm 47 to be displaced by the same. The sliding piston 50 is provided with a pair of transverse fluid passages arranged to selectively register wih one or the other of branches 41 and 42. The safety pressure relief valve 46 is connected to the outer end of the transverse fluid line 40 and drains at 51 into the reservoir 37a. The safety pressure relief valve 46 includes a piston 52, a ball 46a and a compression spring located within piston 52 and compressed between the head of piston 52 and ball 46a and biasing the ball 46a toward closing of the fluid inlet at one end of the valve and outwardly biasing the piston 52 toward the open opposite end of the valve and into engagement with one side of a freely-pivotable arm 53. A partially toothed wheel 54 is bodily rotatable with a cam 55 adjacent the arm 53 for operative engagement of the cam with the opposite side of the arm to pivotally adjust the latter and, thus, adjustably hold the piston 52 more or less inside the valve 46. Thus, when the cam 55 has its radially outermost end in engagement with the arm 53, the piston 52 is in its innermost position and the compression spring inside the valve is compressed to increase the pressure required to open the valve to reservoir 37A. The safety valve 46 remains closed up to a predetermined safe pressure beyond which the valve will open when a higher pressure is produced which occurs when the bags 27a, 29a are full and in clutching position. Therefore, the pumps 66, 67 continue to pump and the liquid is simply recirculated. A rack member 56 is fixed at the end of the valve actuator arm 47 and has its teeth meshing with the teeth of the partially-toothed wheel 54. The axially-slidable sleeve 48 is axially slidable on the sleeve portion 21 of the fixed body portion and is provided with axially-spaced-apart external flanges 57. A push pull member 58 is fixed at one end to the valve actuator arm 47 and is slidably carried by the cylindrical flange 34. The other end of the member 58 is bent radially inward and rotatively carries a roller 59 for rolling engagement of the latter against one or the other of the two axially-spaced-apart flanges 57. That arrangement allows rotation of the arm 47 and member 58, with the ring 23 bodily with the input shaft 10 relative to the control sleeve 48 and it also allows concurrent displacement of the sleeve 48, the member 58 and the arm 47 to actuate both valves 45 and 46. A ring 60 is attached to the sleeve member 48 and is fixedly secured to a member 61, which is slidable endwise in the annular end portion 17 in the axial direction of the input shaft 10. The manual actuator lever 49 is pivotally connected at 62 and 63 to the sliding member 61 and to a pivotable arm 64 attached to the fixed annular end portion 17. Thus, the lever 49 pivots about the axis at point 63 to slide the member 61, the ring 60, the sleeve 48, the arm 58, the arm 47, the piston 50 and the rack member 56, either forward or rearward. When the actuator lever 49 is pivoted to the C position, as shown in FIG. 1, the aforementioned elements are moved to the rearward position defining the clutch-engaging position. The lever 49 in the D position defines the forward position of those elements and the clutch-disengaging position.
In the clutch-engaging position, shown in FIG. 1, the hydraulic liquid pumped in the line 38 flows to the annular bags 27a and 29a through the transverse line 40, the branch 41, the line 39 and the lines 43 and 44. Excess liquid returns to the reservoir 37A only through valve 46 since the branch 42 is cut by the valve 45. In the clutch-disengaging position, not shown, the hydraulic fluid pumped in the line 38 flows into the transverse line 40 but cannot any more flow in the branch 41, since the latter is cut by the piston 50 of the valve 45 which is moved to instead open the branch 42. Since the valve actuator arm 47 has also moved the rack member 56 to the left, the wheel 54 has rotated the cam 55 that now has its least outwardly-projecting end in engagement with the arm 53. The piston 52 is thus outwardly relaxed and the reduced compression of the spring in the valve 46 allows the latter to open to drain the pumped hydraulic fluid through that valve in the reservoir. The fluid in the bags 27a and 29 a is expelled under the bias of the return springs 65, through the branch 42 and the valve 45 into the reservoir.
In the embodiment of FIG. 1, the hydraulic fluid is pumped by a reciprocating pump including a cylinder body 66 and a piston 67 reciprocable endwise in the cylinder 66 in a radial direction relative to the input shaft 10. Fluid line 38 is connected to the closed outer end of the cylinder 66. Inlets 69 are provided in the outer end of the cylinder 66 to allow the entry of hydraulic fluid of the reservoir 37A into the cylinder. A spring 70 surrounds the reciprocating piston 67 and biases the same radially inwardly toward the cam 22. The latter is provided with a circumferential cam surface on and along which a roller 71 rides. The latter is mounted on the external end of the piston such that, upon rotation of the pump bodily with the ring 23 and the shaft 10, the piston 67 is reciprocated in reaction against the cam 22 upon displacement of the roller 71 along the cam surface.
The hydraulic clutch and pump assembly of FIG. 3 is the same as in the first preceding embodiment for most of the elements 10 to 65 inclusive, which have been described in detail with reference to FIG. 1. More specifically and as can be seen in FIG. 3, the second embodiment has a particular output shaft and clutch shoe arrangement and feaures a rotary pump 73 driven by a chain and sprocket drive.
The pump 73 is of any appropriate construction. A sprocket wheel 74 is provided on the outer end of the sleeve member 28 instead of the roller 71 riding on the cam 22, as in the first embodiment. An axle 75 is rotatably mounted and carried by the ring 23 parallel to the input shaft 10. A pair of axially spaced spocket wheels 76, 77 are mounted on the axle 75 to rotate with it. A sprocket wheel 78 is coupled to the rotary pump 73 to rotate it. Chains, not shown, connect the sprocket wheel 74 to the sprocket wheel 76 and the sprocket wheel 77 to the sprocket wheel 78. Thus, when the ring 23 rotates around the sprocket 74, it rotates the sprocket wheels 76, 77, and 78 with it. This causes the chains to rotate the sprocket wheels 76, 77, and 78 and, thus, also the rotary pump 73.
In the second embodiment, only one clutch shoe 26 is used. The clutch disk 33 is axially pressed on its opposite side against the ring 79. Springs 80 are provided to move the clutch disk 33 axially away from the ring 79 when the pressure in the annular bag 27a is dropped to disengage the cluch.
The hydraulic clutch and pump assembly of FIG. 4 is the same as in the embodiment of FIG. 3, with the sole exception being that the rotary pump 73 is driven by gears rather than by a chain and sprocket assembly. For that purpose, a gear 82 is fixedly secured to the outer end of the sleeve member 21. A gear 82 meshes with the gear 81 and drives the rotary pump 73 upon rotation of the ring 23 around and relative to the gear 82.
Referring to FIG. 1a, it is noted that pad 26 is made of heat-insulating material and provided with a felt seal 26'. Seal 26' prevents ingress of dust or dirt into chamber 27, which might damage bag 27a. Pad 26 decreases heat transmission from the clutch to bag 27a.
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This hydraulic clutch is particularly adapted for heavy duty use and is characterized by its doing away with the need for a seal at the clutch shoes and for a rotary seal, at its connection with a supply pump, by provision of an elastic bag for containing the pressurized liquid acting against the clutch shoes and by rotation of the hydraulic liquid supply reservoir and pump with the input shaft of the clutch. The clutch can therefore operate at high hydraulic pressure. This hydraulic clutch and pump assembly comprises a fixed body portion, an input shaft rotatably carried by the fixed body portion, a hydraulic liquid reservoir bodily rotatable with the input shaft, an output shaft bodily rotatable with a clutch disk mounted on it, clutch shoes rotatable with the input shaft and axially displaceable into clutching engagement with the clutch disk in response to fluid pressure applied in the elastic bag against them, a pump bodily rotatable with the input shaft, and a valve and control to selectively provide pressurized fluid operatively within the bag.
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FIELD OF THE INVENTION
This invention relates to microencapsulated materials, articles containing microencapsulated materials and the method of preparing such articles. In particular, the present invention relates to microencapsulated materials adhesively secured between two temporarily adhered surfaces such that upon separation of said two surfaces, the capsules rupture, releasing material contained therein.
BACKGROUND OF THE INVENTION
Encapsulated materials have been used for many years in a wide variety of commercial applications. Early uses of encapsulated materials included paper coated with capsules bearing coloring material therein which could be used as a recording medium. U.S. Pat. No. 3,016,308 discloses one of the early efforts using encapsulated material as the image source on recording paper. U.S. Pat. Nos. 4,058,434 and 4,201,404 show other methods of application of encapsulated coloring materials on paper substrates to be used as imaging media and the like. U.S. Pat. No. 3,503,783 shows microcapsules having coloring material therein which are ruptureable by the application of heat, pressure and/or radiation because of a metal coating on the surface of the capsule. These ruptureable microcapsules, in one embodiment, may be secured between a substrate and a photoconductive top coat to enable photosensitive imaging of the system.
A wide variety of processes exist by which microcapsules can be manufactured. These varied processes provide different techniques for producing capsules of varying sizes, alternative materials for the composition of the capsule shell and various different functional materials within the shell. Some of these various processes are shown in U.S. Pat. Nos. 3,516,846; 3,516,941; 3,778,383; 4,087,376; 4,089,802; 4,100,103 and 4,251,386 and British patent specification Nos. 1,156,725; 2,041,319 and 2,048,206. A wide variety of different materials may also be used in making the capsule shells. A popular material for shell formation is the polymerization reaction product between urea and formaldehyde or melamine formaldehyde, or the polycondensation products of monomeric or low molecular weight polymers of dimethylolurea or methylolated urea with aldehydes. A variety of capsule forming materials are disclosed, for example, in U.S. Pat. Nos. 3,516,846 and 4,087,376 and U.K. patent specification Nos. 2,006,709 and 2,062,570.
As shown in these references, the principal utility of microencapsulated materials is in the formation of a surface coated with the microcapsules in a binder. The microcapsules are ruptured by various means to release the material contained therein. In addition to release of physically observable materials such as ink in order to form a visible image, other types of active ingredients such as odor releasing materials, bacteriostatic materials, chemically active materials and the like have been provided in this manner.
SUMMARY OF THE INVENTION
The present invention relates to a new article containing ruptureable microcapsules. The novel article comprises two sheets of material which are temporarily bonded by means of an adhesive with ruptureable microcapsules dispersed therein. The microcapsules are ruptured by pulling apart the sheets which causes the capsules to rupture and release the ingredients contained therein. By selecting the relative physical properties of the sheet, adhesive, capsules and the binding forces amongst them, a high rate of capsule rupturing can be obtained consistently.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an article comprising at least two sheets temporarily secured by means of a adhesive layer having microcapsules dispersed therein. The sheet materials may effectively be of any composition such as paper, polymeric film, fabric, foil and the like. These sheets may be flexible or rigid, but generally flexible sheets such as paper or coated paper are preferred. The binder material must form a bond to the sheets which is stronger than the cohesive strength of the adhesive with the capsules dispersed therein. Although it is generally desirable to have an adhesive, the cohesive strength of which is less than its adhesive strength to the cover sheets, this is not essential. When capsules are included within the adhesive composition, the effective cohesive strength of the adhesive tends to be reduced. Adhesives, which by themselves would cause the sheets to be damaged during separation, can be used in combination with capsules in the practice of the present invention because of lowered effective cohesive strength. The capsules in the present invention may comprise any ruptureable capsule containing an active ingredient therein. The tensile rupture strength of the capsules must be less than the cohesive tensile strength of the binder used. It has also been found that the size of the capsules plays an important role in the usefulness of capsules within ruptureable sheets according to the practice of the present invention. Generally the capsules must have an average diameter between 12 and 30 microns when the capsule payload is between 80 and 90% by weight of the total capsule weight. It is highly preferred that the capsules have an average diameter between 14 and 26 microns and it is most preferred that the capsules have a diameter between 15 and 25 microns. These dimensions play a surprisingly important role in the ability to control the percentage of rupture of capsules in the practice of the present invention. With lower payloads (e.g., 70-80%), the capsules should be larger to provide the necessary rupture strength. The broadest range of capsule size under any conditions would be about 8 to 30 microns, with 8 micron capsules used with a 90-95% by weight payload.
It has been found that a relationship exists amongst the factors of peel force, adhesive coating weight and the median capsule diameter. This relationship can be expressed as P=k (C w /d 2 ), wherein P equals the peel force, C w equals the adhesive line coating weight, d equals the median diameter of the capsules and k equals a co-efficient relating to binder and substrate properties. The peel force should be in the range of 1.5 to 28 ounces per inch, preferably 1.5 to 8.0 ounces per inch. The coating weight of adhesive and microcapsules should be at a coating weight of approximately one pound for 300 to 800 square feet. Preferably the coating weight should be between approximately one pound for each 400 to 650 square feet. At higher coating weights, the surface of the cover sheets tend to tear, while at lower coating weights, the sheets tend to pull apart and the adhesive tends to rupture in advance of the capsules included therein. The capsules should form between 20 and 90 percent by volume of the total adhesive composition, and preferably between 50 and 85 percent of the total composition volume.
The nature and composition of the adhesive binder is not critical to the practice of the invention as long as the required adhesive and cohesive properties are met. The adhesive may be pressure sensitive, solvent sensitive or thermally activatable. It is generally prefered that the adhesive be activatable by a solvent or heat because the desired physical properties are more readily obtained in those classes of adhesives. There is also no need for rejoining the sheets after rupturing of the capsules and so the pressure sensitive function is not necessary.
The adhesive (with microcapsules) may be applied between two separate sheets in either a continuous or discontinuous patterns. It is usually desirable to leave at least some portion of at least one outer edge of the sheets unbonded so as to provide an area where separation can be easily started. A single sheet may be folded so as to form two facing sheets joined along one edge. The adhesive may be applied on the interior area adjacent the fold. This provides a folded article that can be readily opened, rupturing the capsules, yet leaves a single artifact rather than two sheets after use.
It is preferred that the coated inside portion of the single sheets (e.g., from the fold to the end of the adhesive) constitute from 5 to 40% of the surface area of the sheets. In two sheet constructions, 10 to 95 percent binder coverage is used. Some uses may allow for only a single corner to be uncoated so as to provide a starting point for the separation of the sheets, but the 5 to 40% range is preferred with 10 to 30% more preferred.
Any class of adhesives including but not limited to polyurethanes, polyacrylates, polyvinyl resins, polyamides, polyesters, polyolefins, starches, gum arabic, gelatin and the like may be readily used in the practice of the present invention.
In effect, to best practice the present invention it is desirable that certain properties within the article have relative values for each of the materials used. The cohesive strength of the sheet material should exceed the adhesive strength between the binder and the sheet. The adhesive strength of the binder to the sheet should exceed the cohesive strength of the binder and capsules therein. The cohesive strength of the binder should exceed the tensile rupture limits of the capsules.
As previously noted, the size of the capsules has an important effect upon the practice of the present invention. With capsules less than 12 microns, there is so little rupturing of the capsules as to prevent the useful release of materials. Above 30 microns, the particles are so large that they are readily burst by handling of the sheets and manufacturing procedures. Furthermore, with the large size particles it is extremely difficult to control bursting upon separation of the sheets because of increased effects upon adhesive and cohesive properties of materials in contact with the capsules. The preferred range of 15 to 25 microns is important to the practice of the present invention. Within these limits, rupture in excess of 50 percent of the particles can be easily obtained. Rupture in excess of 80 percent of the capsules can usually be accomplished in the practice of the present invention within those limits.
The capsules may contain a wide variety of active materials therein. The least useful of materials to be included therein would be coloring agents since separation of the sheets would generally produce uniform coloration rather than a distinct image. The most preferred types of ingredients would be fragrant materials or materials which provide chemically active vapors or liquids. These may or may not also be colored. For example, a testing kit for the presence of chemical vapors could be produced by providing material within the capsules which would react in the vapor phase with the material for which a leak is being investigated. By separating the sheet, rupturing the capsules and exposing the vapor test material, a color forming reaction in the air or on the sheet could be really observable. Another particularly useful format would be to include the microcapsules within a water-remoistenable adhesive and to use the mixture as the binding adhesive for novelty envelopes. For example, the microcapsules could contain the aromatic essence of baby oil, cake or pizza for invitation envelopes for a baby shower, wedding (or birthday party), or general party, respectively.
This invention may be practiced with a number of various modifications that provide new and useful articles and processes. For example, the adhesive composition with capsules may be associated with various printed formats to form novelty items. The exterior sheets or exposed inner face of the sheets may have questions or stories or rhymes, and under the adhesive may be a printed picture answering the question, depicting the story or completing the rhyme, with the released fragrance emphasizing the picture further.
The capsule bearing adhesive layer in the construction of the present invention may also be used for a security device. In an article such as a coupon, lottery ticket or gaming card, the important display could be located under the adhesive. Once the article had been opened and the fragrance released, any subsequent recipient would be aware of its prior use and could be apprised of the possibility of tampering. The adhesive being nonpressure sensitive, it is not repositionable, the sheets are not easily rebonded, and there would be no release of fragrance if the sheets were rebonded with additional non-fragranced adhesive and reopened. The absence of fragrance would indicate that the article had been tampered with.
These and other aspects of the present invention will be shown in the following examples.
EXAMPLE
An oil having the aroma of Concord grapes was encapsulated in a urea-formaldehyde resin made according to the process of Example 20 of U.S. Pat. No. 3,516,941. The capsules had an average diameter of about 17 micrometers and an estimated payload of 85% by weight (ratio of oil to total capsule weight).
A coating formulation was prepared comprising 64 parts capsules, 35 parts polyvinyl alcohol and 1 part glycerine (plasticizer) in a water slurry. This formulation was coated at 4.5 lbs. per 1300 sq. ft. (dry weight) onto coated paper base stock. The coating was made in a stripe down the middle of the paper and the paper folded sharply around the stripe after coating. The coated and folded paper was air dried at ambient conditions for two days.
Sections of the coated paper were cut to provide a folded sheet with a 20% portion of the paper extending from the fold coated with adhesive and capsules. The edges of the sheets were grasped by hand and pulled open sharply. There was a burst of grape aroma after the interior adhesive strip was ruptured.
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Microcapsules containing material therein can be burst to release the encapsulated material when the capsules are contained in an adhesive securing two surfaces together and the surfaces are pulled apart.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the fabrication of semiconductor integrated circuits and, in particular, to a self-aligned masking technique for use in ultra-high energy implants, i.e. implants of 1 MeV and greater. The technique has application to the formation of both localized buried implants and localized buried isolation structures.
2. Discussion of the Prior Art
The technology of integrated circuits is based upon controlling electric charge in the surface region of a semiconductor material. Typically, the semiconductor material is crystalline silicon. Control of electric charge in the crystalline silicon lattice is achieved by introducing impurity or "dopant" atoms into selected regions of the lattice.
The regions of the silicon lattice substrate to which dopant atoms are to be introduced are defined by transferring a corresponding pattern from a photographic "mask" to the substrate surface by a photolithographic, or "photomasking", process. In a typical sequence of steps in the photomasking process, a layer of silicon dioxide is first grown on the surface of the silicon substrate. A thin coating of photosensitive material, known as photoresist, is then formed on the oxide layer. The "negative" photoresist is then exposed to light through the mask. The portion of the photoresist not covered by opaque portions of the mask polymerize and harden as a result of this exposure (for a "positive" photoresist, the results would be the reverse). The unexposed portions are then washed away, leaving a photoresist pattern on the oxide surface that corresponds to the mask pattern. The portions of the silicon oxide that are not covered by the photoresist mask are then etched utilizing appropriate chemical procedures. The photoresist is then stripped, leaving an oxide layer that includes a desired pattern of "windows" through the oxide to the silicon surface. Dopant atoms are then introduced through the windows to the exposed silicon either by diffusion or by ion implantation.
Dopant diffusion is performed by placing the silicon substrate in a furnace through which flows an inert gas that contains the desired dopant atoms, causing the dopant atoms to diffuse into the exposed regions of the silicon surface.
In an ion implantation process, dopant atoms are introduced into the silicon by bombarding the exposed silicon regions with high-energy dopant ions. During the implantation process, the depth of penetration of the dopant ions into the silicon lattice is controlled by the ion implant energy, which is set by an accelerating field. The density of the implanted ions is controlled by the implant beam current. Typical commercial implant energy levels range from 30-200 kilo-electron-volts (KeV). Generally, a 1 micron layer of polysilicon, oxide or nitride is sufficient as a stopping material for these KeV implants.
When implanted dopant ions penetrate the silicon surface, they damage the lattice by producing defects and dislocations, in effect amorphizing the crystalline silicon structure. These localized amorphized regions are recrystallized by annealing the silicon at temperatures on the order of 500°-600° C. subsequent to the ion implantation step.
Recently, ultra-high energy implant machines that operate in the million-electron-volt (MeV) range have become commercially available. The ability to impart MeV range implant energies translates to the ability to create integrated circuit technologies that take advantage of the fact that dopant species can now be placed deeply into the silicon substrate at very high concentrations. However, full utilization of these ultra-high energy (i.e 1 MeV and greater) implants requires new techniques to create masks that can be used both as implant stoppers and to effectively pattern the silicon substrate target as desired.
The approach to masking MeV implants into silicon, for example, differs in kind from KeV implants. Differences arise due to the fact that relatively massive quantities of structurally firm material must be used to adequately stop the ultrahigh energy dopant ions from reaching the substrate other than in the desired regions defined by the mask. Moreover, materials used for ultra-high energy masking should possess qualities that permit differential etching for creation of special purpose implant structures.
SUMMARY OF THE INVENTION
The present invention provides a self-aligned masking technique for ultra-high energy implants with application to localized buried implants and localized buried isolation structures.
In a general masking procedure in accordance with the present invention, a sequence of alternating polysilicon and thin silicide layers is used to mask dopants over a wide range of MeV implant energies. The polysilicon and silicide layered structure terminates with a final polysilicon layer that is separated from the underlying silicon substrate by a layer of silicon oxide. The oxide layer is present, in part, to block secondary implantation from the masking materials due to interaction with the ultra-high energy dopant species.
The ability to place dopant deep within a suitable semiconductor substrate can be exploited to form localized buried regions. Thus, the generalized masking process of the present invention, coupled with the ultra-high energy implants, can be used to create new types of integrated circuit structures based on localized buried implants and localized buried isolation structures.
A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description and accompanying drawings which set forth an illustrative embodiment in which the principles of the invention are utilized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1E illustrate a general self-aligned masking procedure for use in ultra-high energy implants in accordance with the present invention.
FIGS. 2A-2D illustrate application of the ultra-high energy self-aligned masking procedure to create localized deeply buried dopant regions.
FIGS. 3A-3D illustrate application of ultra-high energy implants to create buried, localized isolation structures in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Simulation of ultra-high energy ion implantation (i.e. ion implantation in the million-electron-volt (MeV) and greater range) through various stopping materials was used to explore appropriate implant stopping thicknesses. One set of simulations employed the Boltzmann transport model in SUPREM-3, while a second set used a three-dimensional Monte Carlo implant program, MARLOWE. Both SUPREM-3 and MARLOWE are well-known simulation programs. The results of these simulations showed that approximately 2 microns of tungsten is needed to effectively shield a 10 16 /cm 2 dose of silicon or phosphorous implanted at 2 MeV; a 25% increase in layer thickness to 2.5 microns permits polysilicon to be used.
We have also found that a polysilicon layer having a thickness of about 1.0-1.25 microns per 1 Mev increment in implant energy is sufficient as a blocking layer for a silicon implant. Thus for a dopant species D having atomic weight W D , a polysilicon layer have the following thickness per 1 MeV increment in implant energy shold be sufficient as a block layer for the D dopant implant: ##EQU1## where W S is the atomic weight of silicon.
As shown in FIG. 1A, a combination of alternating 2.0-2.5 micron polysilicon layers (10a,10b,10c) and thin titanium or tungsten silicide layers (12a,12b) can be used to mask dopants over a wide range of MeV implant energies. This layered approach is utilized to reduce strain problems that can occur if the thickness of a single polysilicon layer exceeds 2.5 microns and to provide a conductive silicide layer at convenient depths in the device structure.
The polysilicon/silicide layering terminates with the bottom polysilicon layer 10c being separated from the substrate 14 by a silicon dioxide layer 16 greater than about 0.1 microns thick, preferably about 0.5 microns thick. The oxide layer 16 is present, in part, to block secondary implantation from the overlying masking materials due to interaction with the ultra-high energy dopant species and to provide a plasma etch stopper during patterning of the adjacent polysilicon layer, as described below.
A detailed process suitable for masking 6 MEV silicon or phosphorous implants is illustrated schematically in FIGS. 1A-1E. The illustrated masking process begins with formation of the FIG. 1A structure described above. Consistent with our finding that a polysilicon thickness of about 1.0-1.25 microns is required for each 1 MeV increment in implant energy, the FIG. 1A structure utilizes three layers of polysilicon (10a,10b,10c), each about 2.0-2.5 microns thick, separated by silicide (tungsten or titanium) layers (12a,12b) about 0.05-0.3 microns, preferably about 0.2 microns, thick.
Referring to FIG. 1B, the initial stage of a trench 11 for providing the window to the silicon substrate 14 is formed by first forming an oxide layer 18 on the upper polysilicon layer 10c. A photoresist layer 20 is then deposited on the upper oxide layer 18. The photoresist 20 is then patterned and etched to expose the oxide 18, which is then etched using hydrofluoric acid to expose the underlying polysilicon layer 10a. The exposed polysilicon 10a is then plasma etched to the underlying silicide layer 12a.
Next, as shown in FIG. 1C, the overlying photoresist 20 is stripped and an oxidation step is performed to grow oxide 22 along the exposed polysilicon walls of the trench 11. A selectively etched oxide is then formed on the exposed silicide layer 12a and the oxidized silicide is selectively etched to expose the intermediate polysilicon layer 10b. The intermediate layer 10b of polysilicon is then plasma etched to expose the lower silicide layer 12b.
Referring to FIG. 1D, an oxidation step is then performed to extend the oxide 22a along the walls of the trench 11 on the sidewalls of the intermediate polysilicon layer 10b. A selectively etched oxide is then formed from the silicide 10b and the lower layer 12b of silicide is selectively etched. The lower polysilicon layer 10c is then plasma etched to the oxide layer 16.
Finally, as shown in FIG. 1E, the oxide, including both oxide layer 16 and the sidewall oxide in the trench 11, is stripped using hydrofluoric acid to expose a desired region 24 of the underlying
FIGS. 2A-2D illustrate an application of the above-described general ultra-high energy self-aligned masking procedure to create localized deeply buried dopant regions.
FIG. 2A shows a 2.0-2.5 micron polysilicon stopping layer 100 sandwiched between an overlying layer of thin oxide approximately 0.05 to 0.2 microns thick and a 0.2 to 0.5 micron oxide layer 104 formed on silicon substrate 106; the FIG. 2A structure is consistent with the polysilicon/oxide/substrate structure described above with respect to FIGS. 1A-1E.
In the example to be described, the objective is to form a relatively deep, localized, buried (approximately 2 micron) high density n-type region utilizing a 2 MeV phosphorous implant. As described above, a Monte Carlo simulation has indicated that the 2.0-2.5 micron polysilicon layer 100 is sufficient to act as a stopper for a phosphorous implant at this energy.
Referring to FIG. 2B, the first step in the process is to create an implant trench 108 in accordance with the generalized procedure described above. That is, a layer of photoresist 110 is first deposited on the upper oxide layer 102. The photoresist 110 is patterned to expose the underlying oxide 102 which is, in turn, etched with hydrofluoric acid to expose the underlying polysilicon 100. The polysilicon 100 is then plasma etched to the lower oxide layer 104. The oxide 104 is then etched to complete the trench 108 and expose a region 112 of the underlying silicon substrate 106.
Next, referring to FIG. 2C, the photoresist 110 is stripped and the upper oxide 102 is removed in an HF dip. Phosphorous is then implanted into the exposed region 100 of the substrate 106 at a dose greater than 10 13 /cm 2 and at an implant energy of about 2 MeV. This results in the formation of a buried region 112 with its peak implant concentration approximately 2 microns deep. The peak implant concentration region 112 is also the region of the greatest lattice damage.
Referring to FIG. 2D, the final step in the process is to recrystallize the damaged lattice region 112 to provide the desired n-type buried region in the silicon substrate 106. This is accomplished by first depositing resist over the entire exposed surface region 112 to protect the underlying silicon substrate 106. The resist is then patterned to expose the polysilicon 100, which is removed in a plasma etching step. Next, the resist is stripped from the region 112 and the oxide 104 is removed in an HF dip. Finally, the structure is exposed to a high temperature RTA or furnace anneal at 900° C. to effect the recrystallization of the damaged lattice region 112 to form the n-type buried region 114.
In accordance with another aspect of the present invention, the generalized process described above with respect to FIGS. 1A-1E can be used to form buried isolation structures.
It has been shown experimentally that extensive damage or complete amorphization takes place in the silicon lattice region where an ion implant peaks. However, this lattice damage is not distributed throughout the pathway of the energetic dopant. Thus, high energy MeV implants can be used to amorphize buried regions in silicon. If silicon is used as the amorphizing agent, then the substrate will not ultimately be altered. However, when silicon is used as the amorphizing agent, oxidation is enhanced only by a factor of 2, approximately, with respect to crystalline silicon. Using an n-type dopant species enhances the relative oxidation rate considerably.
One embodiment of the envisioned procedure is schematically illustrated in FIGS. 3A-3D.
FIG. 3A shows a crystalline silicon substrate 200.
As shown in FIG. 3B, the first step in the construction of localized buried isolation structures is to deposit or grow a pad oxide layer 202 on the entire surface of the silicon substrate 200. Next, a 2 MeV implant of silicon or phosphorous is performed at a dose greater than 5×101 15 /cm 2 . This creates a region 204 of peak implant concentration and greatest lattice damage about 2 microns below the silicon surface. Next, a layer of resist 206 is deposited and patterned to exposed desired regions of the pad oxide 202.
Next, referring to FIG. 3C, the structure is plasma etched to form trenches 208 to a depth below the region 204 of peak implant concentration. Next, the resist 206 is removed and a high pressure oxidation step is performed to form an oxide coating 210 on all exposed silicon areas and to convert the amorphized silicon regions 204 to isolation oxide 212. This results in isolated silicon regions 214 being formed in selected regions of the substrate 200. A high pressure oxidation is utilized to provide rapid distribution of oxygen to the amorphized regions of the lattice to increase the oxidation rate, since the natural tendency of the amorphized regions is toward recrystallization.
As shown in FIG. 3D, a selective oxide etch produces the finalized localized buried isolation structures.
In forming the isolation structures, the trenches 208 are suitably distributed to permit introduction of high pressure oxidation processes. The trenches 208 also offer an avenue for the relaxation of strain resulting from the oxidation of the buried amorphous layer.
The FIG. 3A-3D example is directed to the formation of an amorphized region 204 (FIG. 3B) underlying the entire surface of the silicon substrate 200, i.e. wafer-wide. Those skilled in the art will appreciate that the masking procedure described above with respect to FIGS. 1A-1E can be utilized to create more localized isolation structures, as desired.
It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and apparatus within the scope of these claims and their equivalents be covered thereby.
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A self-aligned masking process for use with ultra-high energy implants (implant energies equal to or greater than 1 MeV) is provided. The process can be applied to an arbitrary range of implant energies. Consequently, high doses of dopant may be implanted to give high concentrations that are deeply buried. This can be coupled with the fact that amorphization of the substrate lattice is relatively localized to the region where the ultra-high energy implant has peaked to yield a procedure to form buried, localized isolation structures.
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BACKGROUND OF THE INVENTION
[0001] Inorganic particles hydrophobized with fluorosilanes have been used to impart hydrophobic as well as oleophobic properties as exemplified by U.S. Patent Application, US2006/0222815, filed by Oles et al. which teaches making such hydrophobized particles by the covalent bonding (i.e. grafting) of fluorosilanes upon the surface of inorganic particles (e.g. silica). The fluorosilanes employed by Oles et al. consist of a silicon atom having four bonds, three of which are direct bonds to hydrolysable groups which can react with the surface of an inorganic particle thereby covalently bonding the fluorosilane to particle. The remaining bond is a direct bond from the silicon atom to a perfluoroalkyl group.
[0002] Despite the advances of Oles et al., it would be desirable to discover hydrophobized inorganic particles having improved ability to impart hydrophobic as well as oleophobic properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a simplified depiction of a hydrophobized particle made from silica particles (AEROSIL 200) obtained in accordance with the invention.
[0004] FIG. 2 are spectra obtained by solid-state 29 Si NMR cross-polarization magic angle spinning analysis (CPMAS) of: 1) hydrophobized particle made from silica particles (AEROSIL 200) obtained in accordance with the invention; and 2) untreated silica particles (AEROSIL 200).
BRIEF SUMMARY OF THE INVENTION
[0005] Whereas previously known hydrophobized inorganic particles comprise residues from fluorosilanes wherein the silicon atom is directly bonded to a perfluoroalkyl group, the hydrophobized inorganic particles of the present invention comprise residues from fluorosilanes wherein the silicon atom is first bonded to a divalent organic linking group which in turn is bonded to a perfluoroalkyl group. It has been discovered that incorporation of the aforementioned divalent organic linking group can improve the ability of resulting hydrophobized inorganic particles to impart hydrophobic as well as oleophobic properties.
[0006] The present invention relates to surface modified inorganic particles (also known as hydrophobized inorganic particles) made by the method of covalently grafting fluorosilanes to their surface thereby imparting to the particles hydrophobic and/or oleophobic properties. The fluorosilanes used in the present invention have a divalent organic linking group which bonds the silicon atom thereof to a fluorine rich group such as a perfluoroalkyl group. The fluorosilanes useful in the aforementioned method of covalent grafting are described in U.S. patent application Ser. 12/323,593 filed Nov. 26, 2008 hereby incorporated by reference.
[0007] Specifically, the surface modified inorganic oxide particles comprise an oxide of M wherein M is independently selected from the group consisting of Si, Ti, Zn, Zr, Mn, Al, and combinations thereof; at least one of said particles having a surface covalently bonded to at least one fluorosilane group represented by Formula (1):
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —(Z 1 ) a —[C(X 1 )] x —(Z 2 ) l —Q 1 —R f
[0000] wherein:
[0008] L 1 represents an oxygen covalently bonded to an M; and each L 2 independently selected from the group consisting of H, a C 1 -C 2 alkyl, and OH; d and c are integers such that: d≧1, c≧0, d+c=3;
[0009] each n is independently an integer from 1 to 12;
[0010] a, x, and l are integers chosen such that the moiety of Formula 1 represented by —(Z 1 ) a —[C(X 1 )] x —(Z 2 ) l — further represents at least one of the following moieties:
i) a first moiety wherein a=1, x=1, and l=1; and ii) a second moiety wherein a=1, x=0, and l=0;
[0013] R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl can be optionally replaced by hydrogen, and/or ii) the perfluoroalkyl can be optionally interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group;
[0014] Q 1 is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group;
[0015] X 1 is chosen from O or S;
[0000] the first moiety further defined wherein Z 1 and Z 2 are chosen such that:
[0016] a) Z 1 is —NH— and Z 2 is from the group consisting of —NH—, —O—, —S—, —NH—S(O) 2 —, —N[C(O)H]—, —[HC(COOH)(R 1 )]CH—S—, and —(R 1 )CH—[HC(COOH)]—S—;
[0017] b) alternatively, Z 2 is —NH— and Z 1 is from the group consisting of —O—, and —S—;
[0018] c) each R 1 is independently chosen from hydrogen, phenyl, or a monovalent C 1 -C 8 alkyl optionally terminated by —C 6 H 5 , preferably H or CH 3 ;
[0000] the second moiety further defined wherein:
[0019] a) Z 1 is —N[—Q 3 —(R f )]—; and
[0020] b) Q 1 and Q 3 are independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one of —C(O)—O— or —O—C(O)—, and optionally further interrupted by at least one divalent organic group.
[0021] Unless otherwise stated herein the definitions used herein for L 1 , L 2 , d, c, n, Z 1 , X 1 , Z 2 , Q 1 , Q 3 , R 1 , and R f are identical to the definitions set forth above for Formula 1.
[0022] In one preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a urea or thiourea fluorosilane group such that in Formula (1):
[0023] a=1,x=1,and l=1;
[0024] Z 1 is —NH— and Z 2 is —NH—;
[0000] said urea or thiourea fluorosilane group represented by the formula:
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —NH—C(X 1 )—NH—Q 1 —R f
[0000] wherein:
[0025] X 1 is O to form a urea fluorosilane group, or X 1 is S to form a thiourea fluorosilane group; and
[0026] Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0027] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a urea or thiourea fluorosilane group such that R f is chosen from a C 2 -C 12 perfluoroalkyl and Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0028] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a urea or thiourea fluorosilane group such that R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl is replaced by hydrogen, and/or ii) the perfluoroalkyl is interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0029] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a carbamate fluorosilane such that in Formula (1):
[0030] Z 1 is —NH— and Z 2 is —O—, or Z 1 is —O— and Z 2 is —NH—; and
[0031] X is O;
[0000] said particle having a surface covalently bonded to an isocyanate derived a carbamate fluorosilane group represented by the formulae:
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —NH—C(O)—O—Q 1 —R f , or
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —O—C(O)—NH—Q 1 —R f
[0000] wherein:
[0032] Q 1 is a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —NH—C(O)—NH—, —NH—C(S)—NH—, —S—, —S(O)—, —S(O) 2 —, —(R 1 )N—S(O) 2 —,
[0000]
[0033] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a carbamate fluorosilane group such that R f is chosen from a C 2 -C 12 perfluoroalkyl and Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0034] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a carbamate fluorosilane group such that R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl is replaced by hydrogen, and/or ii) the perfluoroalkyl is interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0035] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a thiolcarbamate fluorosilane group such that in Formula (1):
[0036] Z 1 is —NH— and Z 2 is —S—, or Z 1 is —S— and Z 2 is—NH—; and
[0037] X 1 is O;
[0000] said thiolcarbamate fluorosilane group represented by the formulae:
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —NH—C(O)—S—Q 1 —R f or
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —S—C(O)—NH—Q 1 —R f
[0000] wherein:
[0038] Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, —N(R 1 )—C(O)—, —C(O)—N(R 1 )—, —(R 1 )N—S(O) 2 —, and
[0000]
[0039] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a thiolcarbamate fluorosilane group such that R f is chosen from a C 2 -C 12 perfluoroalkyl and Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0040] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a thiolcarbamate fluorosilane group such that R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl is replaced by hydrogen, and/or ii) the perfluoroalkyl is interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0041] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a N-sulfone urea fluorosilane group such that in Formula (1):
[0042] Z 1 is —NH—, and Z 2 is —NH—S(O) 2 —; and
[0043] X is O;
[0000] said N-sulfone urea fluorosilane group represented by the formula:
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —NH—C(O)—NH—S(O) 2 —Q 1 —R f
[0000] wherein:
[0044] Q 1 is independently chosen from the group consisting of an uninterrupted C 2 -C 12 hydrocarbylene.
[0045] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a N-formyl urea fluorosilane group such that in Formula (1):
[0046] a=1, x=1, and l=1; and
[0047] Z 1 is —NH—, and Z 2 is —N[C(O)H]—;
[0000] said N-formyl urea group represented by the formula:
[0000] (L 1 ) d (L 2 ) c Si—(CH 2 ) n —NH—C(X 1 )—N[C(O)H]—Q 1 —R f
[0000] wherein:
[0048] Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S— and —NH—.
[0049] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a thioether succinamic acid fluorosilane group such that in Formula (1):
[0050] a=1, x=1, and l=1;
[0051] Z 1 is —NH— and Z 2 is —[HC(COOH)(R 1 )]CH—S— or —(R 1 )CH—[HC(COOH)]—S—;
[0052] X 1 is O; and Q 1 is —(CH 2 ) 2 —
[0000] said thioether succinamic acid group represented by the formulae:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—[HC(COOH)(R 1 )]CR 1 —(CH 2 ) m —S—(CH 2 ) 2 —R f , or
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—(R 1 )CH—[CR 1 (COOH)]—(CH 2 ) m —S—(CH 2 ) 2 —R f
[0000] wherein m is 1 or 0; wherein each R 1 is independently chosen from methyl or hydrogen preferably H.
[0053] In another preferable embodiment, the surface modified inorganic oxide particles comprise at least one particle having a surface covalently bonded to a tertiary amine fluorosilane group such that in Formula (1):
[0054] a=1, x=0, and l=0; and
[0055] Z 1 is —N[—Q 3 —(R f )]—;
[0000] said tertiary amine fluorosilane group represented by the formula:
[0000]
[0000] wherein
[0056] Q 1 and Q 3 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one —C(O)—O— and optionally further interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, —N(R 1 )—C(O)—, —C(O)—N(R 1 )—, —(R 1 )N—S(O) 2 —, and
[0000]
DETAILED DESCRIPTION OF THE INVENTION
[0057] The hydrophobized inorganic particles of the present invention can be made by covalently grafting fluorosilanes to their surface in order to impart to them both hydrophobic and oleophobic properties. The fluorosilanes used in the present invention have a divalent organic linking group which connects the silicon atom to a fluorine rich group such as a perfluoroalkyl group. Fluorosilanes useful for the invention have at least one hydrolysable group which reacts with the surface of an inorganic particle thereby creating a covalent bond between the fluorosilane and the inorganic particle. Fluorosilanes that are useful in the present invention are also known as fluoroalkyl silanes which are further described in U.S. patent application Ser. No. 12/323,593 filed Nov. 26, 2008 hereby incorporated by reference.
[0058] The hydrophobized inorganic particles of the present invention can be made by dispersing inorganic particles in a non-polar solvent (e.g. toluene) and adding to this dispersion the desired fluorosilane. The dispersion is then heated to an elevated temperature (e.g. 80-100° C.) for about 8-10 hours. The dispersion is then allowed to cool to ambient temperature (about 20° C.). The dispersion is then placed in a centrifuge, the solvent is decanted, and the resulting inorganic particles are washed with fresh solvent. Washing is preferably done at least twice. The washed inorganic particles are then dried in an oven at elevated temperature (about 100-110° C.). The resulting dried inorganic particles are the final product of the invention. However, the resulting dried inorganic particles can be re-dispersed in a non-polar solvent (e.g. toluene) and additional fluorosilane can be added to this dispersion by repeating the entire procedure described in this paragraph.
[0059] The procedure for making hydrophobized inorganic particles in the preceding paragraph is preferable and is known as the “convergent” approach. Alternatively, some of the hydrophobized inorganic particles of the present invention can also be made via a “divergent” approach wherein “functionalized inorganic particles” are made by reacting untreated inorganic particles with a first precursor wherein the first precursor comprises a silicon atom bonded to at least one terminal hydrolysable group which reacts with the surface of the inorganic particle thereby creating a covalent bond between the first precursor and the inorganic particle. The first precursor further comprises a terminal reactive group (e.g. an amine or an isocyante derived from an amine or an isothiocyanate derived an amine) thereby creating functionalized inorganic particles having “anchors” which comprise the terminal reactive group. These functionalized inorganic particles are then reacted with a second precursor wherein the second precursor comprises a corresponding reactive group (e.g. a terminal amine, an isocyante, an isothiocyanate, vinyl, sulfonyl chloride, or sulfonamide) capable of reacting with the terminal reactive group of the “anchors.” The second precursor is also known herein by the term “capping agent.” An example of a useful first precursor and second precursor combination is wherein the first precursor comprises a terminal amine group and the second precursor comprises a terminal isocyante, isothiocyanate, vinyl, sulfonyl chloride, or sulfonamide.
[0060] Inorganic particles useful to the invention include any inorganic particles that have reactive groups on the surface thereof wherein such groups are capable of reacting with the hydrolysable groups of the fluorosilanes (or precursors thereof) of the invention thereby creating a covalent bond between the inorganic particle and the fluorosilane (or precursor thereof). Particularly useful inorganic particles are oxides, such as oxides of silicon, titanium, zinc, zirconium, manganese, and aluminum.
[0061] As stated earlier, the “convergent” approach is preferable for making the hydrophobized inorganic particles of the invention. Fluorosilanes useful in the convergent approach are represented by
[0000] (L) 3 —Si—(CH 2 ) n —(Z 1 ) a —[C(X 1 )] x —(Z 2 ) l —Q 1 —R f Formula 2
[0000] wherein:
[0062] each n is independently an integer from 1 to 12;
[0063] a, x, and l are integers chosen such that the moiety of Formula 2 represented by —(Z 1 ) a —[C(X 1 )] x —(Z 2 ) l — further represents at least one of the following moieties:
i) a first moiety wherein a=1, x=1, and l=1; and ii) a second moiety wherein a=1, x=0, and l=0;
[0066] L is independently chosen from a hydrolysable or non-hydrolysable monovalent group
[0067] R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl can be optionally replaced by hydrogen, and/or ii) the perfluoroalkyl can be optionally interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group;
[0068] Q 1 is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group;
[0069] X 1 is chosen from O or S;
[0000] the first moiety further defined wherein Z 1 and Z 2 are chosen such that:
[0070] a) Z 1 is —NH— and Z 2 is from the group consisting of —NH—, —O—, —S—, —NH—S(O) 2 —, —N[C(O)H]—, —[HC(COOH)(R 1 )]CH—S—, and —(R 1 )CH—[HC(COOH)]—S—;
[0071] b) alternatively, Z 2 is —NH— and Z 1 is from the group consisting of —O—, and —S—;
[0072] c) when Z 1 or Z 2 is O, Q 1 is interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, —NR 1 —S(O) 2 —, —N(CH) 3 S(O) 2 —, and
[0000]
[0073] d) each R 1 is independently chosen from hydrogen, phenyl, or a monovalent C 1 -C 8 alkyl optionally terminated by —C 6 H 5 , preferably H or CH 3 ;
[0000] the second moiety further defined wherein:
[0074] a) Z 1 is —N(—Q 3 —R f ; and
[0075] b) Q 1 and Q 3 are independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one of —C(O)—O— or —O—C(O)—, and optionally further interrupted by at least one divalent organic group.
[0076] A preferred fluorosilane of Formula 2 is an isocyanate derived fluorosilane being a urea or thiourea fluorosilane wherein:
[0077] Z 1 and Z 2 are both —NH—;
[0000] said urea or thiourea represented by the formula:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(X 1 )—NH—Q 1 —R f
[0000] wherein:
[0078] X 1 is O to form a urea fluorosilane, or X 1 is S to form a thiourea fluorosilane; and
[0079] Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0080] A preferred urea or thiourea fluorosilane is one wherein R f is chosen from a C 2 -C 12 perfluoroalkyl and Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0081] A preferred urea or thiourea fluorosilane is one wherein R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl is replaced by hydrogen, and/or ii) the perfluoroalkyl is interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0082] Another preferred isocyanate derived fluorosilane of Formula 2 is a carbamate fluorosilane wherein:
[0083] Z 1 is —NH— and Z 2 is —O—, or Z 1 is —O— and Z 2 is —NH—; and
[0084] X 1 is O;
[0000] said carbamate represented by the formulae:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—O—Q 1 —R f , or
[0000] (L) 3 Si—(CH 2 ) n —O—C(O)—NH—Q 1 —R f
[0000] wherein:
[0085] Q 1 is a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —NH—C(O)—NH—, —NH—C(S)—NH—, —S—, —S(O)—, —S(O) 2 —, —(R 1 )N—S(O) 2 —,
[0000]
[0086] A preferred carbamate fluorosilane is one wherein R f is chosen from a C 2 -C 12 perfluoroalkyl and Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0087] A preferred carbamate fluorosilane is one wherein R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl is replaced by hydrogen, and/or ii) the perfluoroalkyl is interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0088] Another preferred isocyanate derived fluorosilane of Formula 2 is a thiolcarbamate fluorosilane wherein:
[0089] Z 1 is —NH— and Z 2 is —S—, or Z 1 is —S— and Z 2 is —NH—; and
[0090] X 1 is O;
[0000] said carbamate represented by the formulae:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—S—Q 1 —R f or
[0000] (L) 3 Si—(CH 2 ) n —S—C(O)—NH—Q 1 —R f
[0000] wherein:
[0091] Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, —N(R 1 )—C(O)—, —C(O)—N(R 1 )—, —(R 1 )N—S(O) 2 —, and
[0000]
[0092] A preferred thiolcarbamate fluorosilane is one wherein R f is chosen from a C 2 -C 12 perfluoroalkyl and Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, and —O—C(O)—NH—.
[0093] A preferred thiolcarbamate fluorosilane is one wherein R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl is replaced by hydrogen, and/or ii) the perfluoroalkyl is interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0094] Another preferred isocyanate derived fluorosilane of Formula 2 is a N-sulfone urea fluorosilane wherein:
[0095] Z 1 is —NH—, and Z 2 is —NH—S(O) 2 —; and
[0096] X 1 is O;
[0000] said N-sulfone urea represented by the formula:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—NH—S(O) 2 —Q 1 —R f
[0000] wherein:
[0097] Q 1 is independently chosen from the group consisting of an uninterrupted C 2 -C 12 hydrocarbylene.
[0098] Another preferred isocyanate derived fluorosilane of Formula 2 is a N-formyl urea fluorosilane wherein:
[0099] a=1, x=1, and l=1; and
[0100] Z 1 is —NH—, and Z 2 is —N[C(O)H]—;
[0000] said N-formyl urea represented by the formula:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(X 1 )—N[C(O)H]—Q 1 —R f
[0000] wherein:
[0101] Q 1 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one divalent moiety chosen from the group consisting of —S— and —NH—.
[0102] Another preferred fluorosilane of Formula 2 is a thioether succinamic acid fluorosilane wherein:
[0103] a=1, x=1, and l=1;
[0104] Z 1 is —NH— and Z 2 is —[HC(COOH)(R 1 )]CH—S— or —(R 1 )CH—[HC(COOH)]—S—;
[0105] X 1 is O; and Q 1 is —(CH 2 ) 2 —
[0000] said thioether succinamic acid represented by the formulae:
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—[HC(COOH)(R 1 )]CR 1 —(CH 2 ) m —S—(CH 2 ) 2 —R f , or
[0000] (L) 3 Si—(CH 2 ) n —NH—C(O)—(R 1 )CH—[CR 1 (COOH)]—(CH 2 ) m —S—(CH 2 ) 2 —R f
[0106] wherein m is 1 or 0, preferably 0, wherein each R 1 is independently chosen from methyl or hydrogen preferably H.
[0107] Another preferred fluorosilane of Formula 2 is a tertiary amine fluorosilane wherein:
[0108] a=1, x=0, and l=0; and
[0109] Z 1 is —N[—Q 3 —(R f )]—;
[0000] said tertiary amine represented by the formula:
[0000]
[0110] Q 1 and Q 3 is independently chosen from the group consisting of a C 2 -C 12 hydrocarbylene interrupted by at least one —C(O)—O— and optionally further interrupted by at least one divalent moiety chosen from the group consisting of —S—, —S(O)—, —S(O) 2 —, —N(R 1 )—C(O)—, —C(O)—N(R 1 )—, —(R 1 )N—S(O) 2 —, and
[0000]
EXAMPLES
[0111] The following inorganic particles were used as indicated in the examples below.
[0000]
TABLE 1
Name of
Inorganic
Oxide
Description of Inorganic Oxide
SiO 2 #1
Silica having a primary particle size of about 12 nm
obtained as AEROSIL 200 from Degussa AG now Evonik
Degussa Industries AG.
ZnO #1
Zinc oxide nanopowder having a primary particle size of
about 50-70 nm obtained from Sigma-Aldrich Corporation
TiSiO 4 #1
Silica coated titanium oxide nanopowder having a primary
particle size of about 100 nm from Sigma-Aldrich
Corporation.
SiO 2 #2
Silica having a primary particle size of about 7 nm
obtained as AEROSIL 300 from Degussa AG now Evonik
Degussa Industries AG.
SiO 2 #3
Silica having a primary particle size of about 20 nm
obtained as AEROSIL 90 from Degussa AG now Evonik
Degussa Industries AG.
SiO 2 #4
Silica having a primary particle size of about 40 nm
obtained as OX50 from Degussa AG now Evonik Degussa
Industries AG.
SiO 2 #5
Silica having an average particle size of about 11000 nm
obtained as SPHERICEL 110P8 from Potters Industries
Inc.
SiO 2 #6
Silica having an average particle size of about 7000 nm
obtained as SPHERIGLASS 5000 from Potters Industries
Inc.
[0112] The following fluorosilanes were used as indicated in the examples below.
[0000]
TABLE 2
Name of
Fluoro-
silane
Description of Fluorosilane
FS #A
(CH 3 O) 3 Si—(CH 2 ) 2 —(CF 2 ) 5 —CF 3
FS #B
(CH 3 O) 3 Si—(CH 2 ) 2 —(CF 2 ) 7 —CF 3
FS #C
(CH 3 O) 3 Si—(CH 2 ) 3 —C 6 F 5
FS #1
(CH 3 O) 3 Si—(CH 2 ) 3 —NH—C(O)—NH—(CH 2 ) 2 —S—
(CH 2 ) 2 —(CF 2 ) 5 —CF 3
Convergent Fluorosilane Single Grafting
[0113] The term “convergent fluorosilane single grafting” as used throughout the examples refers to the following procedure. About 125 g of a chosen inorganic oxide was placed in a 3 liter round bottom flask equipped with a mechanical stirrer and under nitrogen atmosphere. The stirred mixture was heated to about 50° C. for about 2 hours in order to achieve a homogeneous dispersion. 25 g of a chosen fluorinated silane was then quickly added to the stirred mixture followed by nitrogen sparging for 30 minutes. The reaction mixture temperature was then raised to 75° C. and stirred for about 15 hours under a nitrogen atmosphere. After this allotted reaction time period, the reaction mixture was cooled and centrifuged in portions at 3000 rpm for about 2 minutes. Excess hydrocarbon solvent was decanted and the remaining fluorine grafted fumed inorganic oxide product were washed 3 times with ethanol and centrifuged followed by drying in a vacuum oven at 110° C. for about 12 hours.
Convergent Fluorosilane Double Grafting
[0114] The term “convergent fluorosilane double grafting” as used throughout the examples refers to a procedure identical to “convergent fluorosilane single grafting” with the following additional steps. About 125 g the inorganic oxide product obtained after a convergent fluorosilane double grafting was placed in a 3 liter round bottom flask equipped with a mechanical stirrer and under nitrogen atmosphere. The stirred mixture was heated to about 50° C. for about 2 hours in order to achieve a homogeneous dispersion. 25 g of the same fluorinated silane used in the convergent fluorosilane single grafting was then quickly added to the stirred mixture followed by nitrogen sparging for 30 minutes. The reaction mixture temperature was then raised to 75° C. and stirred for about 15 hours under a nitrogen atmosphere. After the allotted reaction time period, the reaction mixture was cooled and centrifuged in portions at 3000 rpm for about 2 minutes. Excess hydrocarbon solvent was decanted and the remaining fluorine double grafted fumed inorganic oxide product were washed 3 times with ethanol and centrifuged followed by drying in a vacuum oven at 110° C. for about 12 hours.
Thin Film Casting
[0115] The term “thin film casting” as used throughout the examples refers to the following procedure. About 5 wt. % of chosen hydrophobized inorganic particles or untreated inorganic particles were dispersed in isopropanol. A thin film was made by casting three layers of this solution onto a clean glass slides wherein the slide were allowed to dry for about 10 minutes at 60° C. after each casting thereby creating a homogenous coating of particles on the glass slides.
Advancing Water Contact Angle Measurement (“H 2 O Adv.”)
[0116] The terms “advancing water contact angle” or “H 2 O Adv.” refer to the results of a measurement conducted using a Ramé-Hart Standard Automated Goniometer Model 200 employing DROP image standard software and equipped with an automated dispensing system with 250 μl syringe, having an illuminated specimen stage assembly. A sample was glued to a glass slide using double-sided tape. The goniometer, which is connected through an interface to a computer with computer screen, had an integral eye piece connected to a camera having both horizontal axis line indicator and an adjustable rotating cross line and angle scale, both independently adjustable by separate verniers. The syringe used were carefully cleaned with alcohol and allowed to dry completely before use.
[0117] Prior to contact angle measurement, the sample on the glass slide was clamped into place and the vertical vernier adjusted to align the horizontal line (axis) of the eye piece coincident to the horizontal plane of the sample, and the horizontal position of the stage relative to the eye piece positioned so as to view one side of the test fluid droplet interface region at the sample interface.
[0118] To determine the contact angle of the test fluid on the sample, approximately one drop of test fluid was dispensed onto the sample using a small syringe fitted with a stainless steel needle and a micrometer drive screw to displace a calibrated amount of the test fluid, which was deionized water.
[0119] Horizontal and cross lines were adjusted via the software in the Model 200 after leveling the sample via stage adjustment, and the computer calculated the contact angle based upon modeling the drop appearance. Alternatively, immediately upon dispensing the test fluid, the rotatable vernier was adjusted to align the cross line and cross position, that is the intersection of the rotatable cross line and the fixed horizontal line, coincident with the edge of the test fluid droplet and the sample, and the cross line angle (rotation) then positioned coincident with the tangent to the edge of the test droplet surface, as imaged by the eye piece. The contact angle was then read from the angle scale, which was equivalent to the tangent angle.
[0120] Contact angle was measured after the droplet has been added to a surface.
Receding Water Contact Angle Measurement (“H 2 O Rec.”)
[0121] The terms “receding water contact angle” or “H 2 O Rec.” refer to the results of a measurement identical to the advancing water contact angle measurement described above except contact angle was measured after the droplet was partially withdrawn from a surface.
Advancing Oil Contact Angle Measurement (“C 16 H 12 Adv.”)
[0122] The terms “advancing oil contact angle” or “C 16 H 12 Adv.” refer to the results of a measurement identical to the advancing water contact angle measurement described above except hexadecane was used as the test liquid instead of water.
Receding Oil Contact Angle Measurement (“C 16 H 12 Rec.”)
[0123] The terms “receding oil contact angle” or “C 16 H 12 Rec.” refer to the results of a measurement identical to the advancing oil contact angle measurement described above except contact angle was measured after the droplet was partially withdrawn from a surface.
Evaluation of Contact Angle
[0124] Higher advancing and/or receding water contact angle measurements indicated higher water repellency while lower water contact angles measurements indicated lower water repellency. Cases where no water contact angle could be measured indicate wetting and very poor water repellency. Higher advancing and/or receding oil contact angle measurements indicated higher oil repellency while lower oil contact angles measurements indicated lower oil repellency. Cases where no oil contact angle could be measured indicate wetting and very poor oil repellency. A surface is said to be “super hydrophobic” in cases where the advancing water contact angle and receding water contact angle was greater than about 150 degrees and the hysteresis (difference between advancing and receding water contact angle) is less than about 10 degrees. A surface is said to be “super oleophobic” in cases where the advancing oil contact angle and receding oil contact angle was greater than about 150 degrees and the hysteresis (difference between advancing and receding oil contact angle) is less than about 10 degrees. A surface that is both super hydrophobic and super oleophobic is said to be “super amphiophobic.”
Weight Percent Fluorine Measurement
[0125] The percent fluorine in any given hydrophobized particle was determined by the Wickbold Torch method and are shown in the tables below under a column labeled “% F.”
Untreated Control Example
[0126] Using thin film casting, eight films were made respectively from SiO 2 #1, ZnO #1, TiSiO 4 #1, SiO 2 #2, SiO 2 #3, SiO 2 #4, SiO 2 #5, SiO 2 #6. The water and oil contact angles (advancing and receding) were measured for each of these eight films. In all eight cases, no water or oil contact angles could be measured which indicated wetting and very poor water and oil repellency.
Comparative Example A
[0127] Convergent fluorosilane single grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #A resulting in hydrophobized particles. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Comparative Example B
[0128] Convergent fluorosilane single grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #B. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Comparative Example C
[0129] Convergent fluorosilane single grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #C. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Example 1
[0130] Convergent fluorosilane single grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #1. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Example 2
[0131] Convergent fluorosilane single grafting was conducted wherein the chosen inorganic oxide was ZnO #1 and the chosen fluorosilane was FS #1. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Example 3
[0132] Convergent fluorosilane single grafting was conducted wherein the chosen inorganic oxide was TiSiO 4 #1 and the chosen fluorosilane was FS #1. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Comparative Example D
[0133] Convergent fluorosilane double grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #A resulting in hydrophobized particles. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Comparative Example E
[0134] Convergent fluorosilane double grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #B. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Comparative Example F
[0135] Convergent fluorosilane double grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #C. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Example 4
[0136] Convergent fluorosilane double grafting was conducted wherein the chosen inorganic oxide was SiO 2 #1 and the chosen fluorosilane was FS #1. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Example 5
[0137] Convergent fluorosilane double grafting was conducted wherein the chosen inorganic oxide was ZnO #1 and the chosen fluorosilane was FS #1. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
Example 6
[0138] Convergent fluorosilane double grafting was conducted wherein the chosen inorganic oxide was TiSiO 4 #1 and the chosen fluorosilane was FS #1. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 3.
[0000]
TABLE 3
Inorganic
Contact Angle Measurements (°)
Oxide
H 2 O
H 2 O
C 16 H 12
C 16 H 12
Example
Particle
% F
Fluorosilane
Adv.
Rec.
Adv.
Rec.
single
A
SiO 2 #1
4.49
FS #A
145
126
*
*
grafting
B
SiO 2 #1
6.71
FS #B
159
156
*
*
C
SiO 2 #1
2.87
FS #C
149
129
*
*
1
SiO 2 #1
13.6
FS #1
81
80
105
92
2
ZnO #1
3.09
FS #1
124
107
80
62
3
TiSiO 4 #1
18.0
FS #1
160
157
*
*
double
D
SiO 2 #1
5.51
FS #A
153
149
*
*
grafting
E
SiO 2 #1
12.8
FS #B
158
155
*
*
4
SiO 2 #1
22.1
FS #1
160
158
155
150
5
ZnO #1
5.75
FS #1
161
161
98
72
6
TiSiO 4 #1
11.2
FS #1
161
161
154
149
* indicates contact angle could not be measure because of wetting
[0139] In reference to Table 3 above, the fluorosilane used in Comparative Examples A-E is a fluorosilane wherein the silicon atom is directly bonded to a perfluoroalkyl group. In contrast, that the fluorosilane used in Examples 1-6 is a fluorosilane wherein the silicon atom is first bonded to a divalent organic linking group, represented by —NH—C(O)—NH—(CH 2 ) 2 —S—(CH 2 ) 2 —, which in turn is bonded to a perfluoroalkyl group. As shown by comparing the contact angle measurements of Example 1 to Comparative Examples A-C, without the incorporation of a divalent organic linking group it was only possible to achieve adequate water repellency but impossible to also achieve adequate oil repellency. The incorporation of a divalent organic linking group in Example 1 results in adequate water repellency as well as adequate oil repellency. Even when double grafting is performed such as in Comparative Examples D-E, without the incorporation of a divalent organic linking group it was only possible to achieve adequate water repellency but impossible to also achieve adequate oil repellency. Table 3 also shows that double grafting improves oil repellency over single grafting as evidenced by comparing: Example 1 to Example 4; Example 2 to Example 5; and Example 3 to Example 6.
Divergent Synthesis—Single Functionalization
[0140] The term “single functionalization” as used throughout the examples refers to the following procedure. About 125 g of a chosen inorganic oxide was placed in a 3 liter round bottom flask equipped with a mechanical stirrer and under nitrogen atmosphere. The stirred mixture was heated to about 50° C. for about 2 hours in order to achieve a homogeneous dispersion. 25 g of a first precursor, (CH 3 O) 3 Si—(CH 2 ) 3 —NH 2 (commercially available as AMMO from Degussa AG), was then quickly added to the stirred mixture followed by nitrogen sparging for 30 minutes. The reaction mixture temperature was then raised to 75° C. and stirred for about 15 hours. After the allotted reaction time period, the reaction mixture was cooled and centrifuged in portions at 3000 rpm for about 2 minutes. Excess hydrocarbon solvent was decanted and the remaining fluorine grafted fumed inorganic oxide product were washed 3 times with ethanol and centrifuged followed by drying in a vacuum oven at 110° C. for about 12 hours. All of the above steps were preformed in a nitrogen atmosphere.
Divergent Synthesis—Double Functionalization
[0141] The term “double functionalization” as used throughout the examples refers to a procedure identical to “single functionalization” with the following additional steps. About 125 g of the inorganic oxide product obtained after single functionalization was placed in a 3 liter round bottom flask equipped with a mechanical stirrer and under nitrogen atmosphere. The stirred mixture was heated to about 50° C. for about 2 hours in order to achieve a homogeneous dispersion. 25 g of the first precursor, (CH 3 O) 3 Si—(CH 2 ) 3 —NH 2 (commercially available as AMMO from Degussa AG), was then quickly added to the stirred mixture followed by nitrogen sparging for 30 minutes. The reaction mixture temperature was then raised to 75° C. and stirred for about 15 hours. After the allotted reaction time period, the reaction mixture was cooled and centrifuged in portions at 3000 rpm for about 2 minutes. Excess hydrocarbon solvent was decanted and the remaining fluorine double grafted fumed inorganic oxide product were washed 3 times with ethanol and centrifuged followed by drying in a vacuum oven at 110° C. for about 12 hours. All of the above steps were preformed in a nitrogen atmosphere.
Comparative Example F
[0142] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #2 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
Comparative Example G
[0143] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #1 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
Comparative Example H
[0144] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #3 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
Comparative Example I
[0145] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #4 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
Comparative Example J
[0146] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #5 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
Comparative Example K
[0147] Double functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #6 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
Comparative Example L
[0148] Double functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #1 resulting in treated particles. A film sample was made by thin film casting using these treated particles. Contact angle measurements were conducted on this film sample and are shown in Table 4.
[0000]
TABLE 4
Inorganic
Contact Angle Measurements (°)
Oxide
H 2 O
H 2 O
C 16 H 12
C 16 H 12
Example
Particle
% F
Adv.
Rec.
Adv.
Rec.
F
SiO 2 #2
0
26
25
*
*
G
SiO 2 #1
0
27
23
17
11
H
SiO 2 #3
0
*
*
*
*
I
SiO 2 #4
0
*
*
*
*
J
SiO 2 #5
0
40
14
36
21
K
SiO 2 #6
0
*
*
*
*
L
SiO 2 #1
0
4
*
*
*
* indicates contact angle could not be measure because of wetting
[0149] In reference to Table 4 above, it was shown that single functionalization or double functionalization does not result in adequate water or oil repellency.
Capping Step
[0150] The term “capping step” as used throughout the examples refers to the following procedure. Inorganic particles obtained after single functionalization or after double functionalization are reacted with a chosen “capping agent” in an inert environment in toluene solvent. When the capping agent was a succinic anhydride,
[0000]
[0000] the capping agent was synthesized in toluene and immediately reacted with the inorganic particles obtained after single functionalization or after double functionalization. Synthesis of the succinic anhydride was conducted as taught in U.S. Pat. No. 4,171,282 hereby incorporated by reference.
Example 7
[0151] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #2 resulting in treated particles. These treated particles wherein subjected to the capping step wherein the chosen capping agent was
[0000]
[0000] thereby making hydrophobized particles. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 5. The resulting fluorosilane residue on these hydrophobized particles was
[0000]
[0152] The symbol
[0000]
[0000] represents three covalent bonds from silicon, at least one of which is bonded to the particle surface.
Example 8
[0153] Example 7 was repeated except the chosen inorganic oxide was SiO 2 #1.
Example 9
[0154] Example 7 was repeated except the chosen inorganic oxide was SiO 2 #3.
Example 10
[0155] Example 7 was repeated except the chosen inorganic oxide was SiO 2 #4.
Example 11
[0156] Example 7 was repeated except the chosen inorganic oxide was SiO 2 #5.
Example 12
[0157] Example 7 was repeated except the chosen inorganic oxide was SiO 2 #6.
Example 13
[0158] Double functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #2 resulting in treated particles. These treated particles wherein subjected to the capping step wherein the chosen capping agent was
[0000]
[0000] thereby making hydrophobized particles. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 5. The resulting fluorosilane residue on these hydrophobized particles was
[0000]
[0159] The symbol
[0000]
[0000] represents three covalent bonds from silicon, at least one of which is bonded to the particle surface.
Example 14
[0160] Example 13 was repeated except the chosen inorganic oxide was SiO 2 #1.
[0000]
TABLE 5
Inorganic
Contact Angle Measurements (°)
Oxide
H 2 O
H 2 O
C 16 H 12
C 16 H 12
Example
Particle
% F
Adv.
Rec.
Adv.
Rec.
7
SiO 2 #2
10.7
158
155
*
*
8
SiO 2 #1
13.5
159
159
140
126
9
SiO 2 #3
6.23
159
157
34
16
10
SiO 2 #4
1.66
148
122
*
*
11
SiO 2 #5
0.72
*
*
47
35
12
SiO 2 #6
0.15
58
52
74
55
13
SiO 2 #2
13.2
160
160
*
*
14
SiO 2 #1
16.6
156
148
139
121
* indicates contact angle could not be measure because of wetting
Example 15
[0161] Single functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #2 resulting in treated particles. These treated particles wherein subjected to the capping step wherein the chosen capping agent was Cl—S(O) 2 —(CH 2 ) 2 —(CF 2 ) 5 —CF 3 thereby making hydrophobized particles having a fluorosilane residue of Si—(CH 2 ) 3 —NH—S(O) 2 —(CH 2 ) 2 —(CF 2 ) 5 —CF 3 . The symbol “ ” represents three covalent bonds from silicon, at least one of which is bonded to the particle surface. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 6.
Example 16
[0162] Example 15 was repeated except the chosen inorganic oxide was SiO 2 #1.
Example 17
[0163] Double functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #2 resulting in treated particles. These treated particles wherein subjected to the capping step wherein the chosen capping agent was Cl—S(O) 2 —(CH 2 ) 2 —(CF 2 ) 5 —CF 3 thereby making hydrophobized particles having a fluorosilane residue of Si—(CH 2 ) 3 —NH—S(O) 2 —(CH 2 ) 2 —(CF 2 ) 5 —CF 3 . The symbol “ ” represents three covalent bonds from silicon, at least one of which is bonded to the particle surface. A film sample was made by thin film casting using these hydrophobized particles. Contact angle measurements were conducted on this film sample and are shown in Table 6.
Example 18
[0164] Example 17 was repeated except the chosen inorganic oxide was SiO 2 #1.
[0000]
TABLE 6
Inorganic
Contact Angle Measurements (°)
Oxide
H 2 O
H 2 O
C 16 H 12
C 16 H 12
Example
Particle
% F
Adv.
Rec.
Adv.
Rec.
15
SiO 2 #2
11.3
149
140
*
*
16
SiO 2 #1
12.9
150
148
132
126
17
SiO 2 #2
12.4
145
139
*
*
18
SiO 2 #1
10.6
147
146
147
144
* indicates contact angle could not be measure because of wetting
Example 19
[0165] Double functionalization was conducted wherein the chosen inorganic oxide was SiO 2 #1 resulting in treated particles. These treated particles wherein subjected to the capping step wherein the chosen capping agent was CH 2 ═CH 2 —C(O)—O—(CH 2 ) 2 —(CF 2 ) 5 —CF 3 thereby making hydrophobized particles having a fluorosilane residue of Si—(CH 2 ) 3 —N[(CH 2 ) 2 —C(O)—O—(CH 2 ) 2 —(CF 2 ) 5 —CF 3 ] 2 . The symbol “ ” represents three covalent bonds from silicon, at least one of which is bonded to the particle surface. A film sample was made by thin film casting using the hydrophobized particles obtained after second precursor double grafting. Contact angle measurements were conducted on this film sample and are shown in Table 7.
[0000]
TABLE 7
Inorganic
Contact Angle Measurements (°)
Oxide
H 2 O
H 2 O
C 16 H 12
C 16 H 12
Example
Particle
% F
Adv.
Rec.
Adv.
Rec.
15
SiO 2 #1
18.9
154
151
129
116
* indicates contact angle could not be measure because of wetting
NMR Analysis of Example 14
[0166] The hydrophobized particles made from SiO 2 #1 (AEROSIL 200) silica particles obtained in Example 14 were subjected to solid-state 29 Si NMR cross-polarization magic angle spinning analysis (CPMAS) resulting in the spectra shown in FIG. 2 . Also shown in FIG. 2 is the spectra using the same 29 Si NMR CPMAS analysis of untreated SiO 2 #1 (AEROSIL 200) silica particles.
[0167] FIG. 1 is a simplified depiction of a hydrophobized particle made from SiO 2 #1 (AEROSIL 200) silica particles obtained in Example 14. Referring to FIG. 1 , the silicon atom of fluorosilane residues is depicted by A 1 , A 2 , B 1 , B 2 , C 1 , and C 2 . In the formula of the fluorosilane residue depicted in FIG. 1 , L 2 represents —OCH 3 or —OH. A 1 and A 2 show the silicon atom of fluorosilane residues bonded to the surface of the silica particle through one oxygen atom. B 1 and B 2 show the silicon atom of fluorosilane residues bonded to the surface of the silica particle through two oxygen atoms. C 1 and C 2 show the silicon atom of fluorosilane residues bonded to the surface of the silica particle through three oxygen atoms. D 1 , D 2 , D 3 , and D 4 depict silicon atoms at the surface of the silica particle which are not bonded to a fluorosilane residue.
[0168] Referring to FIG. 2 and the spectra of hydrophobized particles, 1 depicts a signal consistent with the silicon atom of fluorosilane residues depicted as C 1 and C 2 in FIG. 1 . Referring to FIG. 2 and the spectra of hydrophobized particles, 2 depicts a signal consistent with the silicon atom of fluorosilane residues depicted as B 1 and B 2 in FIG. 1 . Referring to FIG. 2 and the spectra of hydrophobized particles, 3 depicts a signal consistent with the silicon atom of fluorosilane residues depicted as A 1 and A 2 in FIG. 1 . Referring to FIG. 2 and the spectra of hydrophobized particles, 6 depicts a signal consistent silicon atoms at the surface of the silica particle which are not bonded to a fluorosilane residue depicted as D 1 , D 2 , D 3 , and D 4 in FIG. 1 .
[0169] Referring to FIG. 2 and the spectra of untreated particles, 5 depicts a signal consistent with silicon atoms at the surface of the silica particle which are not bonded to a fluorosilane residue depicted as D 1 , D 2 , D 3 , and D 4 in FIG. 1 . Referring to FIG. 2 and the spectra of untreated particles, notably absent are any signals corresponding to those depicted by 1 , 2 , and 3 in the spectra of hydrophobized particles.
|
Inorganic particles hydrophobized with fluorosilanes have been used to impart hydrophobic as well as oleophobic properties as exemplified by U.S. Patent Application, US2006/0222815, filed by Oles et al. which teaches making such hydrophobized particles by the covalent bonding (i.e. grafting) of fluorosilanes upon the surface of inorganic particles (e.g. silica). The fluorosilanes employed by Oles et al. consist of a silicon atom having four bonds, three of which are direct bonds to hydrolysable groups which can react with the surface of an inorganic particle thereby covalently bonding the fluorosilane to particle. The remaining bond is a direct bond from the silicon atom to a perfluoroalkyl group. In contrast, the hydrophobized inorganic particles of the present invention comprise residues from fluorosilanes wherein the silicon atom is first bonded to a divalent organic linking group which in turn is bonded to a perfluoroalkyl group. It has been discovered that incorporation of the aforementioned divalent organic linking group can improve the ability of resulting hydrophobized inorganic particles to impart hydrophobic as well as oleophobic properties.
| 2
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CROSS REFERENCED TO RELATED PATENT APPLICATIONS
This application is a continuation-in-part of Ser. No. 088,288 filed Oct. 26, 1979 titled Bleed Fast Cationic Dyestuffs which application is a division of Ser. No. 902,661, filed May 4, 1978, now U.S. Pat. No. 4,221,562 issued Sept. 9, 1980.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention concerns water-insensitive, cationic dyestuffs, cellulosic fibers dyed with the dyestuffs and water based printing fluids made with specific, water-soluble cationic dyestuffs and a watersoluble dialdehyde which fluid is particularly suitable for printing and coloring cellulosic webs.
2. Description of the Prior Art
Aqueous printing fluids employing water-soluble dyes and having good bleed fastness (water insensitivity) after drying of the fluid, especially on cellulosic fibers, have been made by combining water-soluble, cationic, thermosetting resins with water-soluble dyes compatible with the resin in a water solution. Drying of the printing fluid upon cellulosic fibers, cures or sets the thermosetting resin. The cured resin entraps and/or reacts with the dye and gives it some permanence because of the water insensitivity of the cured resin.
Examples of such printing fluids employing a resin and a dye are disclosed in U.S. Pat. No. 3,860,547 entitled PRINTING FLUID, inventor R. W. Faessinger et al; U.S. Pat. No. 3,864,296 entitled AQUEOUS PRINTING FLUIDS FOR PAPER, inventor R. W. Faessinger; U.S. Pat. No. 3,880,792 entitled ROTOGRAVURE PRINTING PROCESS, inventor R. W. Faessinger and U.S. Pat. No. 3,839,291 entitled WET-STRENGTH RESINS AND PROCESSES FOR MAKING AND USING SAME, inventor R. P. Avis.
Many different classes of water-soluble, cationic dyestuffs are known. However, one particular class of water-soluble, cationic dyestuff is required for use in the present invention. The required type of dye is disclosed in U.S. Pat. No. 3,709,903 entitled WATER-SOLUBLE QUATERNARY AMMONIUM PHTHALOCYANINE DYE-STUFFS, inventor P. J. Jefferies et al and other patents by the same inventor, based in part upon the '903 patent and differing mainly in the chromophore component of the dyestuff. Other patents disclosing suitable dyestuffs by P. J. Jefferies et al, include U.S. Pat. Nos. 3,784,599; 3,935,182; 3,996,282; 4,065,500; 4,081,239 and 4,103,092. Other suitable cationic water-soluble dyes are disclosed in U.S. Pat. No. 2,761,868.
SUMMARY OF THE INVENTION
An aqueous printing fluid for cellulosic fibers is provided that produces a water-insensitive dyestuff on cellulosic fibers. The printing fluid comprises a water solution of a dialdehyde, preferably glyoxal or glutaraldehyde and a water-soluble, cationic dyestuff of a type disclosed in said P. J. Jefferies et al patents or dyestuffs equivalent thereto by having a lower alkylene amine group capable of reacting with a dialdehyde. Drying of the water solution on cellulosic fibers produces a dyestuff which is the reaction product of the water-soluble, cationic dyestuff and the dialdehyde. The solution of the water-soluble, cationic dyestuff and the dialdehyde is substantive to cellulosic fibers and can be used in the papermaking pulp slurry to produce a colored web. Cellulosic fibers and cellulosic webs dyed with the reaction product of the water-soluble, cationic dyestuff and the water-soluble dialdehyde have excellent bleed fastness in the presence of water, milk, or soap.
DETAILED DESCRIPTION OF THE INVENTION
It has been discovered that a certain class of water-soluble, cationic dyestuffs will react with a water-soluble aldehyde to significantly enhance the bleed fastness of the dyestuff when applied to cellulosic fibers and dried.
DYESTUFFS
A water-soluble, cationic dyestuff suitable for use in the present invention can be selected from among the following formulae: ##STR1## wherein R 0 is hydrogen, lower-alkyl or hydroxy-lower-alkyl;
R 1 is lower-alkyl, lower-alkenyl or hydroxy-lower-alkyl;
R 2 is lower-alkyl, lower-alkenyl, hydroxy-lower-alkyl or (lower-alkylene)-NR 0 Y or R 1 and R 2 together with the nitrogen atom, are pyrrolidino, piperidino or 4-lower-alkanoyl piperazino;
Y is hydrogen or ##STR2## wherein R is hydrogen, lower-alkyl, lower-alkenyl, phenyl or phenyl-lower-alkyl;
A is a dyestuff residue attached to the quaternary ammonium nitrogen atom through a lower-alkylene bridge.
k is a small integer whose value is dependent on the nature of A such that it has a range from one to two;
R 8 is lower-alkyl, lower-alkenyl or hydroxy-lower-alkyl;
R 9 is lower-alkyl, hydroxy-lower-alkyl or NH 2 ;
R 10 is lower-alkyl or lower-alkenyl;
A 1 is a dyestuff residue attached to the quaternary ammonium nitrogen atom through a lower-alkylene bridge;
g is a small integer whose value is dependent on the nature of A 1 such that it has a range from one to two;
R 8' is lower alkyl;
R 9' is lower-alkyl, lower-alkenyl or hydroxy-lower-alkyl;
R 10' is lower-alkyl, lower-alkenyl or hydroxy-lower-alkyl or R 9' and R 10' together with the nitrogen atom are morpholino;
A 2 is a dyestuff residue attached to the quaternary ammonium nitrogen atom through a lower-alkylene bridge;
h is a small integer whose value is dependent on the nature of A 2 such that it has a range from one to two; and
An is anion.
Water-soluble cationic dyestuffs of the above formulae are disclosed in trade literature of the Hilton-Davis Chemical Company, a division of Sterling Drug, Inc. of Cincinnati Ohio entitled ZIP DYES--A NEW SERIES OF CATIONIC COLORANTS FOR PAPER DYEING, co-authors Nathan N. Crounce, Patrick J. Jefferies, E. Kenneth Moore and Bruce G. Webster, a copy of which is enclosed herewith. The water-soluble cationic dyes of the above formulae, their method of synthesis and their properties are disclosed in five U.S. patents issued to Patrick J. Jefferies et al, Pat. Nos. 3,709,903; 3,784,599; 3,935,182, 3,996,282 and 4,065,500, copies of which are enclosed herewith and which patents are incorporated herein by reference with respect to the disclosure of dyes of the above formulae. Functionally equivalent, water-soluble cationic dyestuff with respect to obtaining the bleedfastness improvement provided by the present invention are those which react with said aldehydes disclosed herein.
Of special interest in the above formulae is the lower-alkylene amine group which may contain 1 to 5 carbon atoms i.e. --(CH 2 ) n NH 2 . The site on the water-soluble dyestuff where reaction takes place with the dialdehyde is believed to be the lower alkylene amine group and accordingly the broadest embodiment of this invention calls for the use of water-soluble, cationic dye having a functional lower alkylene amine group capable of reacting with formaldehyde, glyoxal or glutaraldehyde to enhance the bleedfastness of the dyestuff on cellulosic fibers. Dyes with different dye residues or otherwise different than the dyes disclosed in the Jefferies et al patents but having a functional group capable of reacting with formaldehyde, glyoxal or glutaraldehyde are functionally equivalent, for the purposes of this invention, to the dyes disclosed in the Jefferies et al patents.
Additional water-soluble cationic dyes that are functionally equivalent to the dyes disclosed in the Jefferies, et al patents are disclosed in Netherlands Pat. No. 7,802,478 which is based upon U.S. patent application Ser. No. 775,935 now U.S. Patent No. 4,143,034. The test for functional equivalency is whether the water-soluble cationic dye has a functional group capable of reacting with formaldehyde, glyoxal or glutaraldehyde to produce a dyestuff having improved bleedfastness on cellulosic fibers. Said U.S. Patent No. 4,143,034 discloses dyestuffs that are a mixture comprising a disazo compound which is polyaminomethylated with an average of x aminomethyl groups per molecule wherein said disazo compound is selected from the group consisting of ##STR3## in which x represents a number in the range of one to eight
Y represents a divalent moiety selected from the class having the formulas ##STR4## R represents hydrogen, C 1 to C 3 alkyl, C 1 to C 3 alkoxy or N-phenylsulfamoyl,
R 1 represents hydrogen, C 1 to C 3 alkyl, C 1 to C 3 alkoxy, halo, N-phenylsulfamoyl or 6-methylbenzothiazol-2-yl,
R 2 , R 3 , R 6 , R 7 , R 8 , R 10 , R 11 and R 12 represent hydrogen, C 1 to C 3 alkyl, C 1 to C 3 alkoxy or halo,
R 4 represents hydrogen, C 1 to C 3 alkyl or C 1 to C 3 alkoxy,
R 5 represents hydrogen or a monovalent moiety selected from the class having the formulas ##STR5## R 9 represents hydrogen or C 1 to C 3 alkyl; and the acid-addition salt forms of said mixtures.
The water-soluble, cationic dyestuffs of the type defined above are critical to the practice of the present invention because they are capable of reacting with formuladehyde or a water-soluble dialdehyde to improve their bleed fastness on cellulosic fibers and will be referred to hereinafter as the "Required Cationic Dyestuff."
Commercially, Required Cationic Dyestuff are usually available as a water solution containing from 25% to 50% active dyestuff solids by weight. References herein to parts of Required Cationic Dyestuff mean parts by weight based upon the weight of active dyestuff solids.
ALDEHYDES
The Required Cationic Dyestuff, when dissolved in water with an aldehyde such as formaldehyde or a dialdehyde, will, upon drying while in contact with cellulosic fibers, react with the dialdehyde, formaldehyde and/or the cellulosic fibers to produce a reaction product that is a dyestuff having significantly enhanced bleedfastness (water-insensitivity) on cellulosic fibers. The aldehyde is believed to function as a cross-linking agent. It must be formaldehyde, a water-soluble dialdehyde, preferably glyoxal or glutaraldehyde or water-soluble or dispersible equivalents thereof. The weight ratio of Required Cationic Dyestuff to the aldehyde should be sufficient to improve the bleed fastness of the dyestuff. Preferably a ratio of 1 part dyestuff to 0.125 parts formaldehyde or dialdehyde by weight is preferred although ratios of dyestuff to formaldehyde or dialdehyde of from about 1:1 to about 1:0.001 can be used. The cross-linking agents such as formaldehyde, glyoxal and glutaraldehyde, can be used singularly or in combination. Hereinafter, the term "dialdehyde" refers to formaldehyde in addition to glyoxal or glutaraldehyde.
Aqueous Printing Fluid
An aqueous printing fluid of the present invention is obtained by combining the Required Cationic Dyestuff with the dialdehyde in water. The preferred aqueous printing fluid contains from 0.1 to 10 percent Required Cationic Dyestuff and from 0.005 percent to 10 percent dialdehyde. Most preferred is one percent Required Cationic Dyestuff and 0.125 percent dialdehyde with the balance water. All parts and percents used herein are by weight and based upon the active solids.
The aqueous printing fluid of the present invention is very stable (1 to 3 month) and does not tend to cross-link or gel upon aging. The pH of the printing fluid is preferably acidic with a pH of from about 2 to about 7 being preferred.
The viscosity and tackiness of the printing solution can be adjusted for the optimum printing properties depending upon the mode of printing chosen. Known agents for this purpose can be used.
Substantivity
The combination of the Required Cationic Dyestuff and the dialdehyde in water is substantive to cellulosic fibers. Accordingly, the aqueous solution of them is suitable for use in the wet-end of a papermaking process. For example, the Required Cationic Dyestuff and the dialdehyde can be combined with cellulosic fibers in the pulp furnish prior to making a wet-laid paper web. This will produce an overall colored web as opposed to a printed web. Because of the substantivity, most of the Required Cationic Dyestuff and dialdehyde will be deposited upon the cellulosic fibers rather than draining through the web with the water. Upon drying, the colored web has improved bleed fastness.
Printing
An aqueous solution of the Required Cationic Dyestuff and the dialdehyde can be printed directly onto an already formed cellulosic web and subsequently dried to form the reaction product dyestuff, which has excellent bleed fastness on the cellulosic fibers. A mordant or other means of affixing the dye to the cellulosic fiber is not required.
The printing fluid is suitable for application techniques such as spraying, foam application, bath saturation, and coating in addition to conventional printing techniques such as rotogravure, intaglio or flexographic printing.
The advantage of the present invention in comparison with the use of the Required Cationic Dyestuff without the dialdehyde is that the dialdehyde reacts with the dyestuff so that the resulting dyestuff reaction product is significantly more water insensitive especially on cellulosic fibers.
Another technical advantage of the present invention is that the reaction product of the dialdehyde and the Required Cationic Dyestuff does not require a separate polymeric or wet-strength resin for bleed fastness on cellulosic fibers.
An analagous reaction product is not produced by the combination of any of the many known water-soluble direct or cationic dyestuffs other than the Required Cationic Dyestuff with the water-soluble dialdehyde.
In the following examples, representative samples of different classes of direct or cationic dyestuffs were combined with a dialdehyde in water to produce a printing fluid. The types of dyestuffs are listed in Table I. The resulting printing fluids were compared with the printing fluids of the present invention. In all of the examples, the printing fluid contained by weight, 1% water-soluble dyestuff, a percentage dialdehyde as indicated in Table I and the balance water. The printing fluid was printed onto a sample of an ordinary absorbent cellulosic web not containing wet strength resins (wet-laid cellulosic web). The printed web was dried and then subjected to three tests for bleed fastness, one with water, one with milk and one with an alkaline soap solution. The invention is very suitable for use on cellulosic webs containing wet-strength resins however, a non-wet-strengthen web was used in the examples in order to prove that the improvement in bleed fastness was due to the invention and not due to a presence of a wet-strength resin. Bleed fastness was tested as follows:
Bleed Fastness Test
The purpose of the test is to measure bleed fastness or resistance to bleed (color transfer) which is a measurement of the intensity of the color transferred from one square inch of paper onto a specified filter paper under a specified weight after exposure to a liquid.
The materials and apparatus used for the determination of bleed fastness are: Whatman No. 1 filter paper (5.5 CM diameter), stainless steel plates of dimension 1/16×1.5×1.5 inches and stainless steel weight weighing two pounds with approximate dimensions of 11/2 inch diameter and 4 inch height.
Bleed fastness is tested after exposure to different liquids selected as representing the foodstuffs, liquids and cleansing agents usually encountered by a paper towel in household use. The liquids are:
(1) Soap and Water solution:
0.5% Ivory Liquid Soap solution pH-10.2±0.2
Temperature-60° C.-140° F.
(2) Milk-Homogenized milk-butterfat content, minimum 3.25%
(3) Water--General tap water.
The samples to be tested are cut into one inch squares which are layered to 4 plies with the decoration or printing facing outward (outer plies).
The sample should be aged seven days before tested for bleed fastness or cured at a temperature and time for artificial aging selected to approximate a 7-day natural aging.
The specimen to be tested is wet for 3-5 seconds in the liquid, placed on white absorbent paper and excess liquid is eliminated by rolling the specimen and the absorbent paper, without pressing, 4 times with the two-pound weight.
Three sheets of filter paper are placed on one of the 1.5 inch steel plates, the wet specimen is centered on the top sheet of filter paper and three additional sheets of filter paper are placed over the specimen. An additional 1.5 inch steel plate is placed above the top filter paper. On top of the steel plate is placed the two-pound weight.
After 15 minutes the test is stopped and the filter paper in contact with the specimen is evaluated for bleed fastness by visual comparison against four standards. The standards represent a range of bleed levels identified on a 0, 1, 2 and 3 system whereby "0" is no color transfer and "3" is severe color transfer with 1 and 2 being equally spaced between 0 and 3. Individual ratings are recorded to the nearest 0.5 pt. increment (an individual sample judged to be mid-way between the 1 and 2 visual standards should be recorded as 1.5). The rating of bleed is the Bleed Transference Value of the dyestuff on cellulosic fibers. The lower the rating the greater the bleed fastness.
EXAMPLE 1
The Required Cationic Dyestuff used as the water-soluble yellow dyestuff in this example was obtained from Hilton-Davis under the tradename Aquonium, Yellow, 20-4453. It has the chemical formula: ##STR6## The Required Cationic Dyestuff was combined with water and with various quantities of glyoxal or glutaraldehyde as indicated in Table II, to form printing solutions containing 1% Required Cationic Dyestuff, dyaldehyde and the balance water. The pH of the printing fluid was on the acidic side. The printing fluid was used to print a yellow colored pattern on the absorbent cellulosic web. The printed web was dried to form the reaction product of the Required Cationic Dyestuff and dialdehyde on the cellulosic fibers and the bleed fastness of the web printed with the reaction product was tested. The results of the test are given in Table II along with the bleed fastness of a control printing fluid not containing any dialdehyde.
EXAMPLE 2 AND COMPARATIVE EXAMPLES A THROUGH P
For Example 2, the procedure of Example 1 was repeated and the bleed fastness of the printed cellulosic web was tested. Formaldehyde, glyoxal and gluteraldehyde were each tested in amounts shown in Table II. The Required Cationic Dyestuff used in Example 2 is known as Aquonium Turquoise 20-2358 which is defined chemically in said U.S. Pat. No. 3,709,903. In the comparative examples, 16 different water-soluble dyestuffs containing primary or secondary nitrogen atoms but not containing a lower-alkylene amine group were employed and, accordingly, fall outside the present invention. The dyestuff used in each of the examples is identified chemically in Table 1 according to their Colour Index Number and name as published in the Colour Index, Third Edition, 1971, published by The Society of Dyers and Colourists, Great Britian. Table II contains the results of the tests for bleed fastness. The values are defined as the Bleed Transference Value of the printed cellulosic fibrous or web.
SIGNIFICANCE
As can be seen from the results of the examples performed according to the present invention and the comparative examples, a particular class of water-soluble, cationic dyestuffs are capable of reacting with formaldehyde, glyoxal or glutaraldehyde (both dialdehydes) to produce a reaction product dyestuff that is water insensitive on cellulosic fibers.
The reaction product dyestuff upon cellulosic fibers exhibits greater water insensitivity and bleed fastness than the combination of water-soluble, cationic thermosetting resins and dyestuffs as disclosed in the Faessinger patents and also exhibits greater bleed fastness and water insensitivity than the other water-soluble dyestuffs with a dialdehyde.
TABLE I______________________________________Example DyestuffNo. Type C.I. Name C.I. Number______________________________________1 Cationic Aquonium Yellow* 20-4453*2 Cationic Aquonium Turquoise* 20-2358*A Diazo I or II Direct Blue 15 24400B Diazo I or II Direct Blue 1 24410C Diazo I or II Direct Violet 22 22480D Diazo I or II Direct Blue 218 24401E Diazo III Direct Red 16 27680F Diazo III Direct Red 81 28160G Diazo IV Direct Yellow 44 29000H Diazo IV Direct Yellow 50 29025I Diazo IV Direct Orange 10 29156J Diazo IV Direct Red 72 29200K Triazo 1 Direct Brown 95 30145L Anthraquinone Acid Blue 40 62125M Azine Acid Black 50420N Phthalocyanine Direct Blue 86 741801O Stibine Direct Orange 15 40002-03P Xanthene Basic Red 1 45160______________________________________ *Manufacture's tradename and number for the dyestuff.
TABLE II______________________________________Example Dialdehyde Bleed FastnessNo. Type Percent Soap Milk Water______________________________________1 Glutaraldehyde 0 3.0 2.5 3.01 Glutaraldehyde 0.25 0 0 01 Glutaraldehyde 1.0 0 0 01 Glutaraldehyde 2.0 0 0 01 Glyoxal 0.25 0 0 01 Glyoxal 1.0 0 0 01 Glyoxal 2.0 0 0 02 Glutaraldehyde 0 0 0 3.02 Glutaraldehyde 0.25 0 0 0.52 Glutaraldehyde 1.0 0 0 02 Glyoxal 0.25 0 0 0.52 Glyoxal 1.0 0 0 0A Glyoxal 1.0 3 3 3B Glyoxal 1.0 3 3 3C Glyoxal 1.0 3 3 3D Glyoxal 1.0 3 3 3E Glyoxal 1.0 3 3 3F Glyoxal 1.0 3 3 3G Glyoxal 1.0 3 3 3H Glyoxal 1.0 3 3 3I Glyoxal 1.0 3 3 3J Glyoxal 1.0 3 3 3K Glyoxal 1.0 3 3 3L Glyoxal 1.0 3 3 3M Glyoxal 1.0 3 3 3N Glyoxal 1.0 3 3 3O Glyoxal 1.0 3 3 3P Glyoxal 1.0 3 3 32 Formaldehyde 0.5 0.5 0.5 32 Formaldehyde 0.094 0 1.0 1.52 Formaldehyde 0.375 0 1.0 1.52 Formaldehyde 1.875 0 0.5 1.02 Formaldehyde 2.625 0 0 1.0______________________________________
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Bleed-fast, dyed cellulosics particularly absorbent papers have been obtained with a particular class of water-soluble, cationic dyes reacted with a water-soluble aldehyde, preferably formaldehyde, glyoxal or glutaraldehyde. An aqueous printing fluid containing the water-soluble cationic dye and the aldehyde, upon drying, produces a water-resistant dyestuff having improved bleed fastness upon cellulosic fibers.
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FIELD OF THE INVENTION
This invention relates to a method of making a foundation and is specifically concerned with the making of a foundation for a wind turbine.
A currently accepted method of making a foundation for a wind turbine is described in U.S. Pat. No. 5,586,417, to which reference should be made. The foundation is constructed of cementitious material poured in situ between inner and outer cylindrical corrugated metal pipe shells. The foundation is formed within a ground pit which is externally and internally back-filled.
An anchor ring is embedded in the lower end of the foundation and sets of inner and outer circumferentially spaced bolts have their lower ends attached to the anchor ring and their upper ends projecting outwardly of the top of the foundation. The upper ends of the bolts pass through holes in a base flange of a tubular tower resting on the foundation and nuts are threaded downwardly upon the upper ends of the bolts and against the base flange.
An essential feature of this foundation is that the bolts are all pre-stressed. This type of foundation is accordingly often referred to as a “tensionless” tube.
It is an object of the present invention to provide a method of making a foundation, particularly a foundation for a wind turbine, which is more economical than the method of U.S. Pat. No. 5,586,417.
SUMMARY OF THE INVENTION
According to the present invention there is provided a method of making a foundation, particularly a foundation for a wind turbine, said method comprising:
a) forming a pit,
b) providing a cylindrical open-bottomed steel can,
c) lowering the can into the pit,
d) accurately aligning the steel can,
e) concreting the steel can in position in the pit, and
f) back-filling the interior of the can.
Concreting of the can in position in the pit is preferably effected in a first stage and a second stage, the first stage involving the introduction of concrete into the bottom of the pit to a depth sufficient to form a concrete layer in the open lower end of the can and around the lower end of the can, and the second stage involving the subsequent introduction of concrete around the can to substantially ground level. The second stage will preferably be carried out at least twenty four hours after the first stage to allow time for setting of the concrete introduced in the first stage.
The open-ended steel can preferably includes a plurality of sections of different wall thickness, with the lowermost section being of the lowest wall thickness and with the upper section of greatest wall thickness. The steel can may, for example, comprise three sections of different wall thickness. For a steel can having a depth of eight metres, there may be an upper section having a depth of 2 metres and a wall thickness of 23 mm., an intermediate section having a depth of 3 metres and a wall thickness of 18 mm., and a lowermost section having a depth of 3 metres and a wall thickness of 16 mm. It will be appreciated that the depths of the sections and the wall thickness can be varied depending on the required parameters for the finished foundation.
The pit is preferably formed by excavation and is preferably of substantially square cross-section. However, as opposed to excavating a pit of substantially square cross-section using a conventional excavating machine, it is possible to drill a circular hole, of greater diameter than the external diameter of the steel can.
Back-filling of the interior of the can may be effected using the as-dug excavated material. Compaction of the as-dug excavated material will not normally be required. Once the interior of the can has been filled to the required level, a layer of concrete is preferably laid on top of the in-fill material.
The can is preferably supported, during lowering thereof, from a three-point levelling support frame.
The upper end of the steel can is provided with fixing means designed to facilitate connection of the structure being supported by the foundation to the steel can. Such fixing means may comprise, for example, an inwardly extending flange at the upper end of the steel can, which flange is formed with a plurality of angularly spaced apertures to receive fixing bolts for connection of the flange at the upper end of the steel can to a corresponding flange at the lower end of the structure.
Other connection means may, of course, be provided, particularly if the structure is a wind turbine. For example, the upper end of the steel can may, when installed, extend above ground level to an extent such as to facilitate welding of the upper end of the steel can to the base of the wind turbine.
The foundation will thus function as a monopile and, in a typical example, the steel can will have a depth of 8 metres and an outside diameter of 3 metres. The pit which is formed to receive the steel can will then be of square configuration with minimum dimensions of 3.3×3.3 metres square and 7.85 metres deep and maximum dimensions of 4×4 metres square and 8 metres deep.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a completed monopile foundation, and
FIG. 2 is a plan view showing a support and levelling frame used in producing the foundation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a cylindrical steel can 10 installed in a pit 11 ready for attachment of the base of the tower of a wind turbine (not shown) to an internally directed flange 12 at the upper end of the can 10 . As can be seen from FIG. 1, the upper end portion of the can 10 is above ground level so that access can readily be obtained to the flange 12 which is formed with a plurality of angularly spaced apertures to enable the flange 12 to be bolted to a corresponding inwardly directed flange or flanges at the base of the tower of the wind turbine. For example, there may be a double flange at the base of the tower with a double row of bolts. Alternatively, the upper end portion of the can 10 may be welded to the base of the tower, the upper end portion of the can 10 then extending above ground level to an extent such as to facilitate welding of the uppermost portion of the can 10 to the base of the tower. The steel can 10 is open at both top and bottom.
The pit 11 is formed by means of an excavator and, to receive a can 10 which has a height of 8 metres and an external diameter of 3 metres, the pit 11 will have a depth which is between 7.85 and 8 metres and will be from 3.3×3.3 metres square to 4×4 metres square. As an alternative to forming the pit 11 by excavation, it may be formed by drilling and will then have a depth within the range indicated above and a diameter within the range of from 3.5 to 4 metres.
The steel can 10 is in the form of a shell of varying thickness, with the thickness of the shell being greatest at the top of the can 10 . Thus, for a can 10 having a height of 8 metres, the can 10 may be formed as three interconnected sections, with the uppermost section having a height of 2 metres and a wall thickness of 23 mm., a middle section having a height of 3 metres and a wall thickness of 18 mm., and a lowermost section having a height of 3 metres and a wall thickness of 16 mm.
After the pit 11 has been formed, a three-point levelling support frame 13 is positioned above the open mouth of the pit 11 . The frame 13 has three feet 14 which are each positioned at least 1 metre from the adjacent edge of the pit 11 and each foot 14 includes a screw jack and a bearing pad so that the feet 14 can be adjusted independently of one another. At the top of the frame 13 , suspension means (not shown) is provided for supporting the steel can 10 during lowering thereof into the pit 11 . Such suspension means is of known construction and standard control means is provided for controlling lowering of the steel can 10 into the pit 11 .
The steel can 10 is lowered into a position in which the lower edge of the can is spaced a nominal 0.1 metres above the base of the pit 11 . Adjustment of the position of the can 10 is then effected to ensure that the central longitudinal axis of the can 10 is accurately aligned with the vertical. Once the alignment of the can 10 has been verified, a layer 15 of C7.5/H7.5 concrete is introduced into the base of the pit 11 , such concrete being so introduced that it is situated both within the lower end portion of the can 10 and outside the lower end portion of the can 10 . The layer 15 has a minimum depth of 1 metre and is such that the lowermost portion of the steel can 10 is embedded in the concrete layer 15 with the concrete layer 15 extending upwardly from the lower edge of the can 10 by a distance of at least about 0.75 metres.
The initial layer 15 of C7.5/H7.5 concrete is allowed to set for a minimum of twenty four hours before the annular space around the steel can 10 is filled with C7.5/H7.5 concrete to form a concrete sleeve surrounding the can 10 and extending upwardly from the concrete layer 15 to substantially ground level. The interior of the can 10 is back-filled using the as-dug excavated material. Compaction is not normally required.
It is to be noted that there is a 200 mm. diameter hole in the wall of the can 10 about 1 metre from the upper edge of the can 10 and that, before all the concrete has been introduced around the can 10 and before back-filling of the interior of the can 10 has been completed, a cable duct 16 is passed through this hole. The cable duct 16 is for the provision of services to the interior of the turbine.
After the interior of the can 10 has been filled to the required depth with the as-dug excavated material, a nominally 150 mm. thick slab 17 of C25/H25 concrete incorporating a steel mesh is laid on top of the in-fill material. The cable duct 16 passes through the slab 17 , which has its upper surface a nominal 160 mm. below the upper edge of the can 10 .
The arrangement shown in the drawings is given purely by way of example and many modifications thereof are possible. The foundation loads for the specific construction having the dimensions set out above are as follows:
Moment=14400 kN.
Shear force=305 kN. And
Vertical=866 kN.
Important advantages of the present invention as compared to that disclosed in U.S. Pat. No. 5,586,417 are as follows:
a) reduced overall foundation costs,
b) minimum usage of concrete and therefore reduced costs of handling of concrete to (remote) sites,
c) it is possible to use low-strength concrete rather than high-strength concrete and therefore obtaining a cost saving,
d) off-site pre-fabrication of the monopile steel can provides further cost savings, and
e) installation of the foundation involves few elements and no complex procedures, thereby speeding up installation which again leads to reduced costs.
The following details and/or options may be included in the specific method described above depending on the site conditions and/or performance criteria:
a) The use of shear studs, welded seams or any other form of shear connector on the outside of the steel can 10 to improve the shear resistance between the shear can 10 and the concrete sleeve,
b) Back-filling of the inside of the steel can 10 with concrete and/or cement-bound hardcore or selected back-fill in lieu of soil,
c) The use of a reinforced concrete plug at the base of the steel can 10 and a reinforced concrete slab at the top of the steel can 10 to limit distortion of the steel can 10 , lateral deflection of the steel can 10 and stress concentration in the steel can 10 ,
d) The use of flange stiffeners and/or gussets to limit distortion of the steel can 10 , lateral deflection of the steel can 10 and stress concentration in the steel can 10 ,
e) The use of compacted hardcore, granular material, selected back-fill, cement-bound hardcore or cement-bound selected backfill around the outside of the steel can 10 to fill the excavation,
f) The internal slab 17 may be set lower in the steel can 10 to provide additional space for location of a transformer and/or a control panel and/or other equipment. The floor over the internal slab 17 may be a steel grating or the like,
g) The use of a reinforcement in the concrete sleeve around the steel can 10 to control cracking, distribute stresses and the like, and
h) The use of a nominal flange at the bottom of the steel can 10 to improve the end bearing resistance.
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An improved method of making a foundation for a wind turbine comprises:
a) forming a pit,
b) providing a cylindrical open-bottomed steel can,
c) lowering the can into the pit,
d) accurately aligning the steel can,
e) concreting the steel can in position in the pit, and
f) back-filling the interior of the can.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dental replicas and, more particularly, to a method for mounting dental replicas and to a base plate assembly for mounting replicas.
2. Description of the Prior Art
When a dentist determines that a patient requires a crown, bridge, inlay or other common dental prostheses, it is necessary that the dentist first obtain a negative impression of the patient's teeth and gums, including the negative impression of the dental quadrant or quadrants containing the affected teeth. Dental impressions may be unilateral, bilateral, upper or lower, etc. depending on the work to be done. This is customarily accomplished by having the patient bite into a mass of yieldable, rubber-like impression material carried on a holder so that a mold cavity of teeth and associated gums is created. The material will cure in a short time and retain an exact impression of the patient's teeth and gums. This negative impression will then be sent to a dental technician who will use it in any of a variety of conventional techniques to arrive at a stone cast dental replica. The cast replica is mounted in such a way to allow individual replicas of affected teeth, such as the tooth needing a crown or cap, to be segregated from the greater replica. This individual segment is ordinarily removed and repositioned into the greater model several times as work progresses to ensure that the end product being fashioned has proper alignment and visual conformity with the greater model.
Preparation of the negative dental impression is a well known preliminary step, however there are a variety of techniques and devices employed by the dental technician in processing the negative dental impression into a stone cast replica that is mounted in a fashion suitable for work on the individual removable dental segments. Unfortunately, none of the conventional and prior art methods and devices are without limitations and drawbacks. For example, several well established prior art techniques require two pourings of mold material, one for the die stone replica of the teeth and gums, and another for the formation of the base upon which the replica is attached. Oftentimes the base of the replica must undergo grinding to from a flat surface in which drill hole locations must be located and marked. Special drilling equipment is then used to drill holes, and dowel pins are then selected and mounted in the holes by use of adhesive. In many cases sleeves are applied to the mounted pins and the sleeved pins inserted into the uncured base which dries to retain the embedded sleeves. Such techniques are inevitably tedious and time consumptive, as well as consumptive of materials and supplies. It is also noted that the special electrically powered equipment represents an appreciable cost outlay. Additionally, special training and skill of the technician must be relied on in order to properly implement such techniques.
U.S. Pat. No. 4,122,606 is an example of a two-pour system that involves the drilling of holes and the use of dowel pins, etc. U.S. Pat. Nos. 4,767,330, 4,398,884 and 3,937,773 purport to bring certain improvements to the industry. Nevertheless, each of these disclosures requires the steps of making two molds and bring associated costs in labor, material, supplies and time. It is also noted in these prior art techniques that a die stone surface of a removable tooth segment must be brought into engagement with another stone cast surface or with a rigid plastic surface every time the segment is replaced in the greater replica. This can lead to an abrasion of the die stone and a loss in the integrity of the fit.
The prior art also includes some one-pour techniques that avoid some of the aforestated drawbacks. For example, U.S. Pat. Nos. 4,371,339, 4,368,042 and 4,721,464. It is noted, however, that U.S. Pat. No. 4,721,464 involves the positioning and aligning of individual dowel pins and guides, and die stone surfaces must be brought against hard plastic surfaces. U.S. Pat. No. 4,371,339, even though it employs a special base element for releasably supporting its dental replica, nevertheless involves the tedious and skill-required task of locating pin hole locations and drilling holes in which pins must be mounted using adhesives, heat or pressure. While U.S. Pat. No. 4,368,042 does not require two pours, it does require the use of two jaw-shaped plates, pre-molded of rigid plastic or the like. One of the plastic plates must be sawed through when an individual tooth is to be segregated.
It is also noted that the prior art is replete with various devices useful in the formation and mounting of a dental replica, but they invariably appear to be complex and costly.
SUMMARY OF THE INVENTION
In view of the foregoing shortcomings and limitations of prior techniques and apparatus, it is a general object of the invention to provide an apparatus and a technique by which the dental technician can mount a working model of a dental replica in a manner that is expeditious, accurate and reliable, yet economical in time and materials.
Another, more particular object is to provide a technique and apparatus by which a minimum of steps is required to produce and mount a dental replica with removable segments.
A further object is to provide a method for mounting a dental replica which can be successfully carried out without an undue amount of special training and skill of the technician.
Yet another object of the invention is to provide for the production and mounting of a dental replica that does not require dowel pins, hole drilling, grinding of surfaces and special adhesives.
Yet a further object is to provide means that allow individual tooth segments to be repeatedly removed and replaced to the greater replica with deterioration of mating and interlocking surfaces.
A still further object of the present invention is to employ a modular mounting plate for a dental replica, which modular plate can be used singly to support any selected dental quadrant, or connected to another identical modular piece to provide a base for a full upper or lower bilateral replica.
Yet a further object is to provide such a modular base plate in a method that does not require it to be sawed through in order to construct an individual dental segment replica.
These and additional objects and advantages are provided by the present invention of a one-pour method for making and mounting a stone cast replica of a patient's teeth and gums. The improved method features providing a base plate assembly that includes a base plate having a configuration commensurate with a least one quadrant of a person's dental structure and including a flange that has a planar upper surface characterized by an arrangement of a plurality of elongate transverse sockets spaced therealong.
The base plate assembly further includes a plurality of mounting blocks that are releasably securable to the flange planar surface. Each block has opposed side walls, a top and a bottom, the bottom designed to engage the upper planar surface for vertical support, and from the bottom there is a downward projection designed to be frictionally and releasably received in a corresponding one of the sockets, to stabilize the blocks in side-by-side relationship along the flange upper planar surface. Each block has an anchoring tab extending upwardly from its top.
The improved one-pour method of the invention includes filling a negative dental impression with uncured pourable dental casting stone, inverting the base plate assembly and immersing the anchoring tabs of the blocks within the wet stone material, and then allowing the material to harden so as to fixedly secure the tabs within the hardened material. The dental impression mold is then removed from the cured stone to provide a dental replica attached to the novel base assembly. Individual, removable dental segments may then be provided by making vertical saw cuts through the die stone replica, each cut extending to upper edges of at least one block to provide a removable model segment that comprises a selected tooth and gum replica affixed to at least one of the blocks.
In a preferred embodiment of the base plate assembly, the base plate has a modular structure with advantages of versatility and economy that will become evident, and the base plate includes a support core having a main generally straight interconnecting side and an arcuate side from which extends a flange which provides the aforementioned upper planar surface for supporting the mounting blocks of the invention. Additionally in this preferred modular embodiment the support core provides an arcuate wall that adjoins the planar surface and which arcuate wall is adapted for attachment to an articulator, a hinged device used throughout the industry for simulating jaw movement. The symmetry of the modular plate is such that the flange has a lower side that is the mirror image of the upper side of the plate with respect to a planar surface for supporting mounting blocks and an arcuate wall. A further feature of the preferred embodiment is the provision of androgynous connecting means on the main side of the support core by which one modular unit can be connected to another identical modular unit to provide a plate having a curvature commensurate with that of two adjoining bilateral dental quadrants. Additionally, it is noted that the sockets preferably have a generally rectangular transverse cross-sectional configuration and that each downward projection has an upper portion shaped to snugly fit the upper part of a socket to hold the block against lateral movement and has a lower portion with lateral protuberances that frictionally engage the socket walls to hold the block against unwanted outward movement, particularly when the base plate is inverted. The protuberances are spaced on opposite sides of the downward projection such that their engagement with the socket causes the downward projection to resiliently bow about a vertical axis through the downward projection.
The accompanying drawings illustrate the invention with more clarity and particularity, and together with the detailed description serves to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a preferred embodiment of a base plate assembly according to the present invention, and employed in the process of the invention for forming a working dental model;
FIG. 2 is an exploded perspective view illustrating the use of a modular base plate according to the present invention;
FIG. 3 is a top plan view of a base plate assembly with blocks mounted, according to the present invention;
FIG. 4 is a side elevational view of a mounting block according to the present invention;
FIG. 5 is an enlarged sectional view taken along the line 5--5 of FIG. 3;
FIG. 6 is an exploded perspective view illustrating the use of the inventive mounting plate assembly in a method according to the present invention;
FIG. 7 is exploded perspective view of a dental replica mounted according to the present invention;
FIG. 8 is a side elevational view of a removable and replaceable dental replica segment under the present invention; and
FIG. 9 is a sectional view taken along the line 9--9 of FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 shows a preferred embodiment of a base plate assembly according to the present invention, which assembly will be seen to be advantageously employed in an improved method for mounting a dental replica. The base plate assembly 11 is seen to comprise at least a first base plate 13a and a number of mounting blocks including exemplary blocks 15a and 15b which are adapted to be releasably mounted upon the base plate in a manner to be described. These components of the invention are constructed of a suitable dense polymeric material, such as ABS or styrene plastic for example, according to techniques well known in the plastics molding industry. These components can also be fashioned of various other suitable materials including certain composite materials, and metals such as aluminum.
It is noted that plate 13a is preferably provided with a unique structure that allows it to function as a modular unit with, among other things, advantages of economy and versatility, and is structured such that as best shown in FIG. 2, a second unit 13b, identical to unit 13a, can be easily attached to unit 13a to form a generally U-shaped combined base plate 19, shown in FIG. 1. A closer look at FIG. 2 shows that base plate module 13b includes a core portion 21, an arcuate wall member 23, a flange 25 that extends from wall member 23, a set of male locking tabs 27 that project from the upper part of wall 29, and a pair of female locking slots 41, within the lower part of wall 29. Note that what is known in the plastics industry as"crush ribs," are provided on wall 29 as indicated by reference numeral 46. As suggested by FIG. 2, a first modular plate 13b can be attached to a second modular plate 13a by aligning the two plates such that the cylindrical ends 35 of the male locking tabs 27 are moved vertically into frictional attachment with the cylindrical cavities 37 of the modular plate 13a. It will be appreciated that at the same time, the male locking tabs 39 of modular plate 13a will be frictionally received in corresponding slots 41 in the modular piece 13b. The "crush ribs" 46 of one plate will frictionally engage the wall 29 of the other plate during the connection process. This operation will quickly and firmly secure the two modular pieces together to form the combined base plate 19 shown in FIG. 1.
As shown in FIG. 1, in the combined base plate 19 wall members 23 and 24 combine to form a generally U-shaped configuration and the upper planar surfaces 43 and 44 of flanges 25 and 26 respectively also combine in a generally U-shaped configuration. It is to be noted that the bottom side of a base plate 13a is a mirror image of its upper side with respect to its planar surface and arcuate wall member. It will be later appreciated that the combined wall members 23 and 24 advantageously provide a generally U-shaped top platform to which any suitable adhesive such as hot melt adhesive can be applied to attach a combined base plate assembly to an articulator device. In some cases, as dictated by the articulator design, the wall members 23 and 24 can be adapted for being attached to the articulator using threaded fasteners. An array of rectangular through-slots 45 are provided in the flange 25 of each modular base plate.
The base plate assembly 11 as aforementioned also features a number of mounting blocks 15a that have a rectangular configuration in plan view and that are attachable to the straighter portions of the surfaces 43 and 44. The blocks 15b have a generally wedge-shaped configuration and are designed to be attached along the curved portions of the plate planar surfaces.
FIG. 4 shows that a representative mounting block 47 includes a rear wall 49, a bottom 51, and a top wall 53. A generally rectangular anchor tab 55 extends from the top wall 53 and is provided with an aperture 57. The downward projection 59 has a rectangular seat 61 in its upper portion, and a single protuberance 63 on one side and two protuberances 65 projecting from the other side. The downward projections 59 of mounting blocks 15a and 15b are designed to be received in the slots 45 such that a full array of blocks 15a and 15b are releasably secured to the flange 25 in side-by-side relationship as best illustrated in FIG. 3, with the rear walls 49 of the blocks abutting the outer face of wall members 23.
FIG. 5 best shows how mounting blocks 15 will engage the upper flange surface 43 and the inner walls of slots 45 in a manner that firmly supports the blocks in an upright orientation in which they are stabilized against lateral movement or tilting, and holds them against vertical outward movement. More particularly, FIG. 5 shows how the flat bottom surface of a block 15 is supported against the flat flange surface 43, and how the vertical side walls 69 of seat portion 61 snugly engage the upper walls of slot 45. The front and rear walls 71 and 73 respective, of the seat portion, shown in FIG. 4, will snugly engage front and rear walls (not shown) of slot 45. FIG. 5 also shows how the protuberances 63 and 65 engage the sides of slot 45 to frictionally yet releasably bind a block in place. The two protuberances 65 and the single protuberance 63 will engage the walls of slot 45 in the fashion of an interference fit and will resiliently bow the downward projection 59 as shown in exaggerated fashion in FIG. 9 to provide the spring force which urges the protuberances into frictional engagement with the slot walls. It will be seen that the resulting holding force will hold the blocks in place for normal use of the base plate assembly, yet will allow a given block to be removed by hand when required. The protuberances have inclined upper and lower surfaces to ensure easy insertion and removal from a slot 45. Since the invention requires mutual engagement of plastic surfaces rather than surfaces that can be abraded, proper seating and alignment of blocks upon the base plate will be maintained in spite of repeated removals and replacements. Since the slots 45 pass completely through the flange, any required cleaning of them is facilitated. This also provides access to the bottoms of the downward projections of the blocks to allow pushing on the bottoms to assist removal of a block should it be necessary.
The aforedescribed mounting plate assembly can be employed in an improved one-pour method for making a dental replica and for mounting it in a fashion useful to the dental technician. The method is performed in the following matter. First, a denture impression (negative mold) is made of the patient's teeth and gums in a well-known manner and is supported on an impression holder 75 as illustrated in FIG. 6.
If it is desired to mount a replica of the entire upper quadrants or lower quadrants of the patient's teeth and gums, two of the invention's modular base plates are readily connected to form a combined base plate 19, supporting a full array of mounting blocks 15 in inverted fashion.
The denture impression carried on holder 75 is filled with a pourable form of a suitable die cast material which is shaped into a generally level surface 77 shown in FIG. 6. The process proceeds by aligning the base plate assembly 11 by hand with the U-shaped surface 77 of the wet die stone. The anchor tabs 55 may be pretreated by having small quantities of wet die stone applied thereto, using a spreader or the like. Next the assembly 11 is pressed downwardly into the surface 77 of the die stone, the anchor tabs 55 being completely immersed and the upper surfaces 53 of the mounting blocks being pressed into engagement with surface 77. Following the usual die stone curing period the somewhat rubber-like impression mold can be easily peeled away from the hardened stone to provide a stone-cast dental replica mounted upon base plate assembly 11. A neater, more aesthetically pleasing model can result if excess die stone gum mold is trimmed away using customary techniques so that the bottom edges of the molded gum will align with the curvature of the base plate. An example of the resulting structure is illustrated in FIG. 7 which shows the stone-cast denture replica 83 mounted according to the invention.
Finally, in order to segregate a particular stone denture segment, such as for example a segment 91 shown in FIG. 7 containing the replica of a tooth stub 87, two generally vertical saw cuts are made through the die stone to terminate at the upper edges of a selected block. In order to mount a relatively wide dental segment, two adjacent blocks may be used. Thus a selected stone replica segment is firmly affixed atop at least one block, and the segregated unit, such as individual replica 91 in FIG. 7, may be readily disengaged from its base plate and repeatedly removed and replaced as required during subsequent processing by the dental lab technician using known techniques. If it is necessary to mount the above working replica to an articulator, then this can be conveniently accomplished as described above. It should be evident that a single modular unit rather than the combined unit shown in FIG. 7 will be advantageously employed when only one denture quadrant is to be replicated. It will also be evident, because of the bilateral symmetry of a modular unit, that a modular unit will serve for either upper or lower quadrant replicas.
While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto. Various modifications and variations may readily occur to those of ordinary skill in the art without departing from the true scope and breadth of the invention as defined in the claims which follow.
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Disclosed is a base plate assembly for use in mounting a die-stone dental replica, the assembly including a base plate that has a configuration commensurate with at least one dental quadrant, and having a planar upper surface characterized by an array of transverse elongate rectangular sockets. A plurality of mounting blocks are assembled in side-by-side relationship along the plate planar surface, each block having a downward projection adapted to frictionally and releasably hold the block on the base plate, and extending from the tops of the blocks are anchoring tabs designed to be embedded in the wet positive mold of a dental impression and affixed therein when the mold material cures. In a preferred embodiment, the base plate has a modular configuration and is interconnectable with an identical modular unit to form a combined base plate having a configuration commensurate with full bilateral upper or lower dental quadrants.
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CLAIM OF PRIORITY
[0001] The present application claims priority from Japanese patent application JP 2007-243219 filed on Sep. 20, 2007, the content of which is hereby incorporated by reference into this application.
FIELD OF THE INVENTION
[0002] This invention relates to a heat storage material for effectively maintaining the specified temperature of cells, etc.
BACKGROUND OF THE INVENTION
[0003] Temperature conditions cause fluctuations to occur in the stress on cells such as cells serving as biological samples. Therefore some type of temperature regulation is required in most cases when transporting samples such as cells. Demands are made for example to transport cells at 36° C. which is higher than normal outdoor temperatures and close to body temperature. There are multiple types of culture vessels for holding cells and certain shipping methods must be used according to the shape of the culture vessel. Cells typically tend to adhere to the bottom of the culture vessel, and culture vessel shapes are in dish or plate shapes. In the case of suspended cells, the cells float while suspended in the culture solution and a tube-shaped container is used to ship these suspended cells. This tube container is a vertically long structure. If this tube container is placed horizontally during shipping, then the culture medium adheres to the lid of the culture contained and becomes a likely cause of biological contamination. The culture vessel must therefore be maintained in a suitable position during shipping according to the vessel shape. Tube type culture vessels must be maintained in a vertical (standing) position.
[0004] Heat storage materials have been reported containing hydrocarbons (paraffin, etc.) that induce a phase transition from a liquid to a solid state at approximately 36° C. (See JP-A-2006-232331, for example.).
[0005] Methods in the related art for controlling the temperature of the liquid phase substance include a technique for installing a magnetically rotated agitator in the container holding the fluid (See for example JP-A-1999-113560.). In this technique, an agitator is affixed in the container holding the fluid substance, the agitator magnetically rotated to induce an agitating current, for supplying a uniform culture medium.
SUMMARY OF THE INVENTION
[0006] Besides functioning heat source during covering and shipping of culture vessels containing cells, the heat storage material also possesses a buffering function due to its liquid state. The environmental temperature of the sample can be maintained at approximately 36° C. for a long time by enclosing this heat storage material with insulating material and storing it within an outer container (This structure is hereafter called a portable homothermal container.).
[0007] When shipping the culture vessels containing cells etc., covered with a heat storage material whose sealed interior contains hydrocarbons (paraffin, etc.) for inducing a phase transition from the liquid state to solid state at approximately 36° C., the heat storage material radiates heat from the external circumferential section in contact with outer air at a temperature lower than the internal section. The heat storage material therefore gradually hardens from the liquid state starting from the outer circumferential section. The heat storage material at this time starts hardening from the outer circumferential section as the heat is radiated away. The heat discharge (or radiating) efficiency is proportional to the temperature differential between the outer air and the outer circumferential section of the heat storage material so that as the outer circumferential section of the heat storage material cools and the temperature differential becomes smaller, the heat discharge efficiency drops, and heat remains within the interior of the heat storage material. The time that the internal temperature is maintained within the portable homothermal container consequently becomes shorter. Moreover, the outer circumferential section of the heat storage material quickly hardens so that the buffering function is lost.
[0008] In many cases when shipping tube culture vessels containing suspended cells, the tube culture vessels must be maintained in an upright state during shipping in order to avoid biological contamination. Tube culture vessels are long in the vertical direction so the heat storage material needed for covering the outer circumference of the culture vessel must also be a structure that is long in the vertical direction.
[0009] When creating an agitating current inside the heat storage material, the heat storage material whose heat was lost to the outer circumference is immediately taken into to the interior of the heat storage material. The heat distribution within the heat storage material consequently becomes uniform and there is no hardening of molecules just at positions on the outer circumferential section. Therefore, the cooling and hardening of just the outer circumferential section can be avoided as long as there is an agitating current. The buffering function can also be maintained.
[0010] In the method disclosed in JP-A-1999-113560, the agitator tool formed beforehand is magnetically rotated and causes an agitating current within the heat storage material. However, the heat storage material covering the culture vessel is a structure long in the upright (vertical) direction when shipping tube culture vessels. The agitator tool is in this case located on the bottom of the heat storage member so the agitating current occurs from the bottom surface, and a sufficiently strong agitating current does not occur upwards in the heat storage material. In other words, the upper part of the heat storage material is not agitated, and is cooled and hardened by the outer air. The lower part on the other hand is kept sufficiently agitated. The temperature differential between the upper section and lower section of the heat storage material consequently widens, and an uneven internal temperature distribution occurs within the tube culture vessel.
[0011] In order to provide a motive force to rotate the agitator tool, a magnetic agitator and its drive device are required for generating a rotating magnetic field. Even if the interior of the portable homothermal container for shipping the cells, contained this drive device, the portable homothermal container would need a large amount of space so that temperature regulation would be impossible. Moreover, an electrical drive device would no longer operate if the storage battery failed or the electrical circuits broke down so that ensuring reliable operation during shipping was impossible. Therefore for the above reasons, the temperature must be regulated during shipping, even for tube culture vessels long in the upright (vertical) direction; moreover the maintenance of buffering functions and heat discharge efficiency in the heat storage material must be improved by utilizing a small, light-weight and low-cost member.
[0012] The following aspects are proposed to resolve the problems of the background art.
[0013] An agitator tool that basically does no react with the heat storage material is installed in the interior of the heat storage material. More specifically, one or multiple agitator tools having a certain mass and size are installed beforehand in interior of the heat storage material. This agitator tool may also have a shape that allows easily changing its position relative to the heat storage material during shipping. The agitator tool may be made from a material that essentially does not react with the hydrocarbons sealed within the heat storage material, and capable of moving smoothly without any mutual reaction. This agitator tool may be able to easily change its relative position in the heat storage material by way of motion such as the tilt, vibration, or swaying naturally applied to the portable homothermal container. The change in position by the agitator tool induces an agitating current in the sealed liquid hydrocarbons that achieves a uniform distribution of heat. Paraffin which is a saturated chain hydrocarbon general in the form of C n H 2n+2 may for example be utilized. In particular, n-Eicosane which is expressed chemically as C 20 H 42 and has a melting point of 36.4° C. is used here.
[0014] This invention yields the effect that the agitating current occurring in the upper section in the heat storage material the same as in the lower section so that a uniform heat distribution is achieved regardless of whatever position is vertical. The internal temperature of the heat storage material is uniform so the problem of early cooling and hardening of upper section can be avoided. Moreover the buffering function can be maintained for a long time since the outer circumferential section can be maintained in a liquid state for a long period of time. Still further, an agitating current is efficiently induced within the heat storage material during shipping even when transporting tube culture vessels that are long in the vertical direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is an overall view of the heat storage material and one agitator tool;
[0016] FIG. 2 is an overall view of the heat storage material and three agitator tools;
[0017] FIG. 3 is an overall structural view showing the heat storage material for improving the heat propagation characteristics and the agitator tool;
[0018] FIG. 4 is a graph for assessing temperature fluctuations over elapsed time when the agitator tool and heat storage material height ratios were changed;
[0019] FIG. 5 is a graph showing the time that the heat storage material is maintained in the vicinity of the melting point versus the ratio of agitator tool to heat storage material height;
[0020] FIG. 5 is a graph showing the time that the heat storage material temperature is maintained in the vicinity of the melting point versus the ratio of agitator tool to heat storage material heights;
[0021] FIG. 6 is a graph showing the sustained period that the heat storage material temperature is maintained in the vicinity of the melting point per unit of heat storage material relative to the agitator tool to heat storage material height ratio;
[0022] FIG. 7 is a graph for evaluating the change in the (temperature) sustained period when the number of agitator tools is changed;
[0023] FIG. 8 is an overall structural view showing the temperature regulating members containing agitator tools stacked on each other vertically;
[0024] FIG. 9 is a drawing showing agitator tool shapes; and
[0025] FIG. 10 is a drawing showing the structure of the portable homothermal container.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The embodiments of this invention are described next while referring to the drawings. FIG. 1 shows the structure of the heat storage material and the agitator tool. FIG. 1 is an overall view of the temperature regulating member made up of the heat storage material, the agitator tool installed in the interior of the heat storage material, and the container for holding the heat storage material and agitator tool. A container 11 is provided for holding (sealing in) the solidified hydrocarbon (n-Eicosane) 10 utilized as the heat source, and the sphere-shaped agitator 12 is installed inside the interior of that container. The shape of the container is for example is shown as a rectangular parallelepiped. The agitator tool is installed so as to make contact with the hydrocarbons. The agitator tool surface possesses properties that essentially do not react with the heat storage material. Materials such as glass and steel can be used.
[0027] FIG. 2 is an overall view of the temperature regulating member made up of the heat storage material, multiple agitator tools (in this embodiment, 3 agitator tools) installed in the interior of the heat storage material, and the container for holding the heat storage material and agitator tools. Three agitator tools 22 , 23 , 24 are installed in the container in the structure of the heat storage material shown in FIG. 1 . Multiple agitator tools can be installed but in this example three agitator tools are used.
[0028] FIG. 3 is a drawing showing, among the containers holding the heat storage material, a heat propagation member 30 made from material possessing high heat propagation characteristics serving as the section making contact with the culture vessel storing the cells; and the insulating member 31 as the remaining section for enhancing the heat discharge efficiency. In the structure of the heat storage material shown in FIG. 1 , the container 11 has been changed to combine a high heat propagation film 30 serving as a heat propagation member possessing high heat transfer, with a high heat insulating member 31 . The container structure is made up of the high heat propagation film 30 and the heat insulator wall 31 . During shipping (transport), the upper part of the high heat propagation film 30 is in contact with the culture vessel holding the cells, and heat propagates via the high heat propagation film 30 to maintain the temperature of the culture vessel at approximately 36° C. At all other locations, the insulating effect of the heat insulator wall 31 suppresses the discharge of heat. A wasteful discharge of heat is prevented in this way. An agitator tool 32 is installed in the interior of the container. In this figure one agitator tool is used but multiple agitator tools (for example, 3) may be installed the same as shown in FIG. 2 .
[0029] FIG. 4 is drawings showing an example of fluctuations as the temperature drops along with dissipation of heat from the heat storage material over elapsed time when the agitator tool and heat storage material heights are changed. In this example, one agitator tool as a sphere with a diameter of approximately 1.6 cm was installed. The material of this agitator tool was glass. Here, n-Eicosane which is expressed chemically as C 20 H 42 and has a melting point of 36.4° C. is utilized as the hydrocarbons sealed within the container and serving as the heat storage material. The agitator tool and the heat storage material do not react with each other, and the agitator tool is capable of smooth movement. The bottom surface of the container holding the heat storage material was circular and approximately 4.5 cm in diameter, and the heat storage material in the container was set at heights of 1, 2, 3, 4, 5, 6, and 7 cm. A container holding heat storage material with a height of 7 cm and with no agitator tool inserted was utilized as the control. In the above described structure, heat storage material was heated beforehand to 45° C. by a thermostat to liquefy the hydrocarbons to form a liquid, and then was placed in a state where a rotational motion and gentle gradient were applied under an outside temperature of 32° C. This rotational motion and gentle gradient served as a model for the motions sustained during shipping. During this period, the temperature sensor measured the temperature fluctuations in the upper part of the heat storage material, and changes over time in the upper section temperature as well as the state of the hardened heat storage material were assessed.
[0030] Under all conditions, the heat storage material was heated in advance by the thermostat to 45° C., the temperature quickly lowered after exposure to an outside temperature of 32° C., and reached a fixed state at the melting point of the sealed hydrocarbons which is approximately 36° C. In the case where there was no agitator tool, the heat storage material gradually hardened starting from the outer circumferential section. However in the case where an agitator tool was used, the agitator tool continually moved over a longer period of time compared to the case of no agitator tool, and hardening just on the outer circumferential section did not occur. The time that the heat storage material was held in the vicinity of the melting point or in other words the sustained period, is defined as the difference between the time that the heat storage material temperature drops to 36.4° C., and the time afterward that the temperature is fixed at approximately 36° C., and then drops to 35.5° C. An evaluation using this numerical value was made under each condition.
[0031] FIG. 5 is a graph showing the time that the heat storage material is maintained in the vicinity of the melting point versus the ratio of agitator tool and heat storage material height. The ratio A/B (Max diameter of agitator in vertical direction/max diameter of heat storage material) where A is the maximum diameter of the agitator tool vertically and B is the maximum diameter of the container was evaluated. The sustained period when no agitator tool was used is set as the value 1, and the ratio (sustained period ratio) then calculated for each condition. As the ratio A/B between the maximum diameter A of the agitator tool in the vertical direction and the maximum diameter B of the container becomes larger, the quantity of heat storage material sealed within the container becomes smaller and the sustained period becomes shorter. If the ratio A/B between the maximum diameter A of the agitator tool in the vertical direction and the maximum diameter B of the container drops to 0.75 or less, then the sustained period drastically increases due to the agitator tool and the sustained period can be maintained longer than when no agitator tool is used. When using the ratio C/D consisting of the agitator tool volume C and the container internal volume D to make an evaluation, the sustained period can be maintained longer than when no agitator tool is used, if the ratio C/D is 6.7×10 −2 or lower.
[0032] FIG. 6 is a graph showing the time that each unit of heat storage material temperature is maintained in the vicinity of the melting point relative to the agitator tool and heat storage material height ratio. The ratio A/B (maximum diameter of agitator tool in vertical direction/max diameter of heat storage material) where A is the maximum diameter of the agitator tool vertically and B is the maximum diameter of the container was evaluated. To find the sustained period per unit of heat storage material, the sustained period when no agitator tool was used was set as the value 1, and the ratio (sustained period ratio per unit of storage material) then calculated for each condition. As the ratio A/B for the maximum diameter A of the agitator tool in the vertical direction and the maximum diameter B of the container becomes larger, the agitation of the heat storage material becomes more efficient and the temperature uniformity improves. The time that each unit of heat storage material can be maintained can consequently be extended. The sustained period increases to 50 percent or higher if the ratio A/B reaches 0.3 or more. When using the ratio C/D consisting of the agitator tool volume C and the container internal volume D to make an evaluation, the sustained period can be increased to 50 percent or higher if the ratio C/D is 4×10 −2 or more.
[0033] Results from FIG. 5 and FIG. 6 show in particular that when adjusting the height ratio of the heat storage material and the agitator tool, the sustained period for maintaining the temperature of the heat storage material in the vicinity of the melting point can definitely be increased. If the ratio A/B for the maximum diameter A of the agitator tool and the maximum diameter B of the container oriented vertically is higher than 0.3 or lower than 0.75, then the sustained period of the heat storage material can be increased to 50 percent or higher. When the A/B ratio equals 0.53 then the sustained period reaches a maximum of 170.6 percent. If the ratio C/D consisting of the agitator tool volume C and the container internal volume D is larger than the 3.4×10 −2 and smaller than 6.7×10 −2 , then the sustained period of the heat storage material will increase by the same 50 percent or more. When the ratio C/D equals 4.5×10 −2 , then the sustained period reaches a maximum of 170.6 percent.
[0034] FIG. 7 is a drawing showing the changes in the sustained period when maintaining the temperature of the heat storage material in the vicinity of the melting point when the number of agitator tools is changed. The agitator tool is a sphere of glass material and approximately 1.6 cm in diameter the same as in the FIG. 4 . The number of agitator tools was set to 0, 1, 2, 3, 4 and 5. Here, n-Eicosane which is expressed chemically as C 20 H 42 and has a melting point of 36.4° C. is utilized as the hydrocarbons sealed within the container and serving as the heat storage material. The bottom surface of the container holding the heat storage material was circular and approximately 4.5 cm in diameter, and the height of the heat storage material in the container was set at 6 cm. The heat storage material was heated beforehand to 45° C. by a thermostat to liquefy the hydrocarbons to form a liquid, and then was placed in a state where a rotational motion and gentle gradient were applied under an outside temperature of 32° C. During this period, the temperature sensor measured the temperature fluctuations in the upper part of the heat storage material, and changes over time in the upper section temperature as well as the state of the hardened heat storage material were assessed. The sustained period was defined and calculated the same as in FIG. 4 . The value for the sustained period when no agitator tool was inserted was set as 1, and the ratio (resolved time ratio) calculated for each condition.
[0035] As can be seen in the figure, the larger the number of agitator tools, the larger the agitating current inside the container became. The sustained period also increased along with the larger number of agitator tools. The surface area at the bottom of the container on the other hand became smaller with a larger number of agitator tools, so that the agitator tools possessed less freedom of movement. In this case, the amount agitator tool motion sharply decreased when the number of agitator tools was increased to four, and the sustained period decreased inversely (to the number of agitator tools) When two or three agitator tools were used, then the sustained period rate increased respectively 3.8 percent and 3.0 percent compared to when only one agitator tool was used.
[0036] FIG. 8 shows an example of a structure where the temperature regulating members containing the agitator tools are stacked vertically on each other. In the example, four temperature regulating members are stacked together. If the ratio A/B for the maximum diameter A of the agitator tool and the maximum diameter B of the container oriented vertically is 0.3 or higher and 0.75 or lower, or if the ratio C/D consisting of the agitator tool volume C and the container internal volume D is 3.4×10 −2 or larger and 6.7×10 −2 or smaller, then the same effect as described above is achieved.
[0037] Each container structure includes a high heat propagation film 80 , and a heat insulator wall 81 . A heat storage material 82 and an agitator 83 are installed inside the container structure. During shipping, the high heat propagation film 80 reaches a state in contact with the culture vessel holding the cells, and heat is conveyed via the high heat propagation film 80 , the temperature inside the culture vessel is maintained at approximately 36° C. The heat insulating effect of the heat insulator wall 81 suppresses the discharge of heat from all other locations so wasteful heat discharge is prevented. An agitator tool 83 is installed inside the container. The container in this figure utilizes one agitator tool but multiple agitator tools may be utilized the same as the case shown in FIG. 2 .
[0038] FIG. 9 shows typical agitator tool shapes. The agitator tool is made in a shape that allows easily changing position within the heat storage material. An agitator tool 93 combines a cone and sphere in a cubic shape that is a combination of a spherical agitator tool 90 , a cylindrical agitator tool 91 , and a conic agitator tool 92 . The spherical agitator tool 90 is able to change its relative position most easily within the interior of the heat storage material.
[0039] FIG. 10 shows the tube-shaped culture vessel inside the portable homothermal container made from the temperature regulating member and heat insulator section. Here, the temperature regulating members (containers) whose structure is made from heat storage material and agitator tools are stacked vertically in multiple units. The total height of the multiple stacked heat storage material, or in other words the multiple temperature regulating members is set to the approximate height of the tube culture vessel. One or multiple agitator tools are installed within the respective heat storage material. Agitator tool movement within the heat storage material causes an agitating current in the interiors of all the stacked temperature regulating members (containers), and eliminates thermal non-uniformities within the interior. Consequently, the integrated, stacked heat storage material is capable of eliminating thermal non-uniformities within the interior whether in the upper portion or the lower portion.
[0040] The transport container is made from an outer container 100 and a lid 101 . A heat insulator section 102 is installed inside the outer container 101 , and serves to prevent heat from leaking outwards. The reference numeral 103 is the heat storage material enclosed by a heat insulator wall 104 and a high heat propagation film 105 for conveying heat and possessing expansion/contraction properties. The reference numeral 106 denotes the agitator tool. The high heat propagation film 105 functions as a container for storing the heat storage material and the agitator tool. Containers holding the heat storage material and the agitator tool are stored stacked in four levels. If the ratio A/B for the maximum diameter A of the agitator tool and the maximum diameter B of the container oriented vertically is 0.3 or higher and 0.75 or lower; or if the ratio C/D consisting of the agitator tool volume C and the container internal volume D is 3.4×10 −2 or larger and 6.7×10 −2 or smaller, then the same effect as described above can be achieved. A tube culture vessel 107 whose interior contains for example cells, is stored inside the heat container holding the heat storage material. The culture vessel makes contact by way of the high heat propagation film 105 so that the heat storage material in a liquid state functions as a cushioning member besides maintaining the temperature via the heat storage material. When the culture vessel makes contact with the heat storage material by way of the high heat propagation film 105 of the container on the side surface in the longitudinal direction and preferably in applicable side surface that is essentially the entire surface, then the temperature maintenance and cushioning effects can be further enhanced.
[0041] The section of the temperature regulating member (container) holding the heat storage material and making contact with the tube culture vessel is capable of expanding and contracting and may even be a film that can clamp the culture vessel in position. The sections making contact with tube culture vessel and the section where the heat storage material makes mutual contact are a material with high heat propagation, and a heat insulating material may be used in all other sections. The efficiency that the heat propagates to the cells may in this case be adjustable. Material such as glass or iron may be used for the agitator tool.
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A temperature regulating member for avoiding a deterioration in heat radiating output efficiency and deterioration in buffering occurring due to a non-uniform heat distribution within the heat storage material. Heat non-uniformities within the heat storage material are eliminated by inserting one or multiple agitating tools inside the heat storage material by generating an agitating current occurring due to use of agitator tools whose relative positions change within the heat storage material during shipping.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to a system and method for channel mapping and, more specifically, to avoiding inefficiencies associated with channel map features for digital-ready televisions.
BACKGROUND OF THE INVENTION
[0002] This section is intended to introduce the reader to various aspects of art, which may be related to various aspects of embodiments of the present invention that are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of embodiments of the present invention. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
[0003] Digital television, a service offered by many cable distributors, utilizes digital technology to facilitate provision of a larger number of channels to users than would be available with analog channels alone. Using video compression and digital channels, cable distributors may increase the number and diversity of programs available on their existing cable networks without requiring network additions. In view of the number of channels available from both digital and analog sources, it may be desirable or necessary to store a channel map to facilitate navigation through available broadcasts. A channel map may be defined as a list of channels present in a given cable or antenna lineup.
[0004] It is often more cost effective to produce a digital-ready television that receives both digital and analog signals by using a non-integrated tuning solution. In other words, it is often desirable to use a digital component for accessing digital channels and a separate analog component for accessing analog channels. This can be the case for a number of reasons. For example, analog components are generally cheaper than digital components and the cost of integrating the two is generally considered a prohibitive development cost. However, while utilizing an analog component to access analog channels and a digital component to access digital channels can be more cost effective, performance can be negatively impacted. For example, when a channel map is being created by performing a channel search to identify available channels, there may be some inefficiency based on underutilized overlap between digital and analog channel maps.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Advantages of the invention may become apparent upon reading the following detailed description and upon reference to the drawings in which:
[0006] FIG. 1 is a block diagram of an electronic device in accordance with an exemplary embodiment of the present invention; and
[0007] FIG. 2 is a process flow diagram representing channel map processing in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0008] One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
[0009] FIG. 1 is a block diagram of an electronic device in accordance with an exemplary embodiment of the present invention. The electronic device (e.g., a television) is generally referred to by the reference number 100 . The electronic device 100 comprises a receptor 102 (e.g., a cable inlet or an antenna), a tuner 104 , a processor 106 , a memory 108 , a display 110 , and a controller 111 (e.g., remote control). The memory 108 may be adapted to hold machine-readable computer code that causes the processor 106 to perform an exemplary method in accordance with the present invention. The tuner 104 includes an analog component 112 and a digital component 114 . The analog component 112 and the digital component 114 are separate (i.e., a non-integrated solution). The tuner 104 is utilized in performance of separate analog and digital channel searches that are combined in accordance with present embodiments to establish a channel map. The processor 106 may receive the channel map data via the tuner and/or other information from a service provider (e.g., a cable provider).
[0010] Embodiments of the present invention are directed to reducing the time required to establish a channel map including both analog and digital channels. More specifically, embodiments of the present invention are directed to providing an efficient system that utilizes a non-integrated solution. This is achieved by establishing the type of channel to be mapped first and by sharing data between the separate analog and digital components of the non-integrated solution.
[0011] FIG. 2 is a process flow diagram 200 representing channel map processing in accordance with an exemplary embodiment of the present invention. For example, mapping channels (e.g., video signals) and storing them in memory may include searching available channels with the tuner 104 and mapping those channels having a sufficiently clear signal. Specifically, in accordance with present embodiments, a channel search for analog channels is performed by the analog component 112 , as illustrated by block 202 . A list of channels found during the analog channel search of block 202 are then stored in the memory 108 , as illustrated by block 204 . This list of found analog channels is transmitted via a command protocol to the digital component 114 , as illustrated by block 206 . In one embodiment, the list of found analog channels may be transmitted from the analog component 112 to the digital component 114 . Once the list of found analog channels is received by the digital module 114 , the digital module 114 performs a digital channel search on the channels that were not found in the analog channel search, as illustrated by block 208 .
[0012] By performing the analog channel search (block 202 ) prior to the digital channel search (block 208 ), the overall time required for a channel search in the non-integrated solution is reduced compared to traditional techniques and systems involving non-integrated solutions. Indeed, traditional techniques require a digital channel search on all channels. This can require a significant amount of time. Since the search for a signal on a digital channel requires more time than on an analog channel, embodiments of the present invention, which prevent the digital channel search from spending time on analog channels that have already been found, are more efficient than traditional techniques and systems. For example, present embodiments may be especially efficient in an environment which contains a large number of analog channels, such as a cable provider input.
[0013] The channels searched in accordance with present embodiments may be designated based on a mode of operation. For example, channels 2-69 may be searched in a terrestrial mode, and channels 1-135 may be searched in a cable mode.
[0014] The analog channel search represented by block 202 may be performed using the analog component 112 of the tuner 104 . For analog channels, the tuner 104 is tuned to a nominal frequency to check for the automatic fine tuning (AFT) component and sync to determine if an analog channel is available. For terrestrial mode, tuning to the nominal frequency is sufficient. For cable mode, additional steps are performed such as a determination of whether an incoming signal employs harmonically related carriers (HRC) or incrementally related carriers (IRC).
[0015] The digital channel search represented in block 206 , which is performed after the analog channel search in block 202 , may be performed using the digital component 114 of the tuner 104 . The tuner is tuned to a nominal frequency for the channel. For the digital channel search, a modulation scheme is used to determine valid transport packets. In terrestrial mode, an 8 vestigial side band (8 VSB) modulation scheme may be utilized. For cable mode, an 8 VSB, 64 quadrature amplitude modulation (QAM) or 256 QAM modulation scheme may be utilized. Once a modulation scheme is selected, a link checks for valid transport packets. If no valid transport packets are found, it is determined that there is no digital channel available on the designated frequency. This may be performed on all channels that are not already designated as found analog channels.
[0016] FIG. 2 further illustrates production of a channel map in block 210 based on a combination of the found analog and found digital channels. Further block 212 represents selection of channels for display by a user. For example, this may include selecting certain channel numbers on a television panel or remote control for display of the associated content on a television screen.
[0017] Typically, there are more analog channels than digital channels available from a given provider. Accordingly, present embodiments significantly reduce the number of channels over which a digital channel search is performed. In other words, because many channels will already be designated as found analog channels, fewer channels will be searched in the digital channel search. Thus, channel searching will be more efficient. However, as more and more digital channels are made available, this logic can be reversed in accordance with present embodiments such that digital channels are searched first and then analog channels are searched only on the channels that are not found during the digital channel search. For example, a user may select which type of channel search to perform first by designating the analog module 112 or the digital module 114 as a primary module. For example, this may be achieved via a switch or button-activated command disposed on a controller of the device 100 (e.g., the controller 111 ).
[0018] While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.
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There is provided a system and method for coordinating analog and digital channel mapping features. More specifically, in one embodiment, there is provided a method, comprising performing an analog channel search to identify available analog channels, storing a list of the available analog channels found during the analog channel search, and performing a digital channel search after performing the analog channel search, wherein the digital channel search excludes the available analog channels in the list from being searched.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a torque converter with a lock-up mechanism in an automatic transmission for a vehicle. More particularly, it relates to a torque converter with a lock-up mechanism which can achieve an improvement in transmission torque capacity by a simple construction and can prevent vibration (judder) created by stick-slip.
2. Related Background Art
Generally, a torque converter can realize smooth running because it transmits power through a fluid, while it suffers from the disadvantage that fuel consumption is aggravated because of the energy loss due to the slip of the fluid. In order to overcome this, the latest torque converters are provided with a lock-up mechanism.
The lock-up mechanism is a mechanism which comprises a direct-coupled clutch (lock-up clutch) and in which when the speed of vehicle reaches a predetermined or higher speed, the flow of the fluid in the torque converter automatically changes to urge the friction surface of a frictional material attached to the piston of the direct-coupled clutch against the front cover of the torque converter to thereby directly couple an engine and a drive wheel together. Thereby, the influence of the slip of the fluid is eliminated and therefore, an improvement in fuel consumption can be achieved.
When the piston (lock-up piston) of the direct-coupled clutch is fastened to the front cover of the torque converter, a pressure force by hydraulic pressure is acting on the sliding portion, between the friction surface of the frictional material attached to the piston and the front cover. To keep the fastened state of the piston and the front cover in the sliding portion good, it is necessary to increase the pressure force by the hydraulic pressure. Accordingly, in the fastened state, high pressure is being applied to the frictional material.
When the pressure force becomes higher, excess reaction due to the distribution of the hydraulic pressure becomes greater thereby and the possibility of imparting an adverse effect to the fastened state of the friction surface of the piston and the front cover becomes high and therefore, as a countermeasure for preventing this, it has been practiced to form a groove in the surface of the frictional material as described in Japanese Laid-Open Utility Model Application No. 1-128057 or to form a groove in the surface of the piston as described in Japanese Laid-Open Patent Application No. 6-346951.
In recent years, it has often been the case that slip control is adopted for the lock-up clutch with a view to improve fuel consumption, but judder vibration occurs during slip. Therefore, it is necessary to prevent judder vibration and as a measure for preventing it, it is practiced to subject the friction surface of the lock-up clutch to a predetermined amount of cutting work and in addition, use low ps oil to make μ-V characteristic into a positive gradient (note: a negative gradient would cause judder vibration).
Such an example is described, for instance, in Japanese Laid-Open Patent Application No. 5-99297. FIGS. 23 and 24 of the accompanying drawings are views for illustrating this example of the prior art, and an annular frictional material 140 is attached to the front cover side of the piston 100 of a lock-up clutch, and as shown in FIG. 24, the surface of the frictional material 140 from the radially outer peripheral edge portion A thereof to the intermediate point B thereof is subjected to cutting work between the outer peripheral edge portion A and the inner peripheral edge portion C. In FIG. 23, it is an annular area 130. By doing so, any stick-slip occurring during the liberation and fastening of the lock-up clutch can be prevented.
In the above-described construction, however, when the engagement hydraulic pressure changes from low pressure to high pressure, the area of contact and Rm (average effective radius) become smaller as the manner of bearing of the friction surface shifts from the bearing against the outer diameter to the bearing against the inner diameter (see FIG. 25 of the accompanying drawings). That is, by the hydraulic pressure coming round from the outer peripheral portion of the frictional material into between the friction surfaces as indicated by arrow in FIGS. 25 and 26 of the accompanying drawings, a distribution of hydraulic pressure is created radially and circumferentially of the frictional material 140 to thereby reduce the piston thrust which brings the piston 100 into pressure contact with the front cover 200. Accordingly, due to these factors, there has arisen the problem that during high hydraulic pressure, transmission torque capacity is reduced (see FIG. 26). FIG. 25 shows-the manner in which during low hydraulic pressure, the frictional material 140 bears against the front cover 200 on the outer diameter side, and FIG. 26 shows the manner in which during high hydraulic pressure, the frictional material 140 bears against the front cover 200 on the inner diameter side.
The countermeasure by the above-described construction is effective for the prevention of judder, but may result in a reduction in the transmission torque capacity during high hydraulic pressure. As measures for improving the transmission torque capacity, it would occur the diameter of the clutch larger, to construct the clutch of multiple plates and to increase the hydraulic pressure, but this would conversely make the structure of the lock-up clutch complicated and bulky and still, would result in an increase in fuel consumption.
For such a reason, it has heretofore been very difficult to prevent any reduction in the transmission torque capacity during high hydraulic pressure by a combination of a lock-up clutch having its friction surface subjected to a set amount of cutting work and low μs oil.
When a pressure force becomes high, the excess reaction due to the distribution of hydraulic pressure also becomes great, and this may adversely affect the joined state of the friction surface of the piston and the front cover and also may impart damage such as deformation to the torque converter itself.
Particularly, it is important to decrease the distribution of hydraulic pressure and increase the piston thrust in order to prevent any reduction in transmission torque capacity during the operation of the lock-up clutch at high hydraulic pressure.
SUMMARY OF THE INVENTION
Consequently, it is the object of the present invention to provide a torque converter with a lock-up mechanism which can efficiently decrease a distribution of hydraulic pressure in the radial direction and circumferential direction of a frictional material created by hydraulic pressure coming around from the outer peripheral portion of the frictional material into and between the friction surfaces and can prevent the creation of any excess reaction due to the distribution of hydraulic pressure and can efficiently give a fastening force to the frictional material even during high hydraulic pressure to thereby improve the necessary transmission torque capacity even during high pressure.
To achieve the above object, the torque converter of the present invention can be a torque converter with a lock-up mechanism provided with a direct-coupled clutch displaceable between a fastened state and a liberated state and slip-controllable, and a torque converter body for transmitting power by a fluid, characterized in that a frictional material is fixed to an axial pressure contact surface of the piston of a direct-coupled clutch, a friction surface of a radially outer portion of the frictional material has been subjected to cutting work, and hydraulic pressure distribution reducing means for reducing a distribution of hydraulic pressure created around the frictional material is provided on a radially inner portion of the frictional material which has not been subjected to cutting work.
Since the friction surface of the frictional material in the radially outer portion thereof is subjected to cutting work and the hydraulic pressure distribution reducing means for reducing the distribution of hydraulic pressure created around the frictional surface is provided on the radially inner portion of the frictional material which is not subjected to cutting work, the distribution of hydraulic pressure in the radial direction and circumferential direction of the frictional material created by hydraulic pressure coming a round from the outer peripheral portion of the frictional material into and between the friction surfaces is decreased during the operation of the lock-up clutch at high hydraulic pressure to thereby increase the piston thrust. As a result, it becomes possible to prevent any reduction in transmission torque capacity during high hydraulic pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross-sectional view of a torque converter with a lock-up mechanism to which each embodiment of the present invention can be applied.
FIG. 2 is a front view of a piston 1 having a frictional material 40 attached thereto showing a first embodiment of the present invention.
FIG. 3 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the first embodiment of the present invention.
FIG. 4 is a front view of a piston 1 having a frictional material 40 attached thereto showing a second embodiment of the present invention.
FIG. 5 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the second embodiment of the present invention.
FIG. 6 is a front view of a piston 1 having a frictional material 40 attached thereto showing a third embodiment of the present invention.
FIG. 7 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the third embodiment of the present invention.
FIG. 8 is an axial cross-sectional view showing the state of a lock-up clutch in the first embodiment shown in FIGS. 2 and 3 during high hydraulic pressure.
FIG. 9 is a front view of a piston 1 having a frictional material 40 attached thereto showing a fourth embodiment of the present invention.
FIG. 10 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the fourth embodiment of the present invention.
FIG. 11 is a front view of a piston 1 having a frictional material 40 attached thereto showing a fifth embodiment of the present invention.
FIG. 12 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the fifth embodiment of the present invention.
FIG. 13 is a front view of a piston 1 having a frictional material 40 attached thereto showing a sixth embodiment of the present invention.
FIG. 14 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the sixth embodiment of the present invention.
FIG. 15 is an axial cross-sectional view showing the state of a lock-up clutch in the fourth embodiment shown in FIGS. 9 and 10 during high hydraulic pressure.
FIG. 16 is a front view of a piston 1 having a frictional material 40 attached thereto showing a seventh embodiment of the present invention.
FIG. 17 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the seventh embodiment of the present invention.
FIG. 18 is a front view of a piston 1 having a frictional material 40 attached thereto showing an eighth embodiment of the present invention.
FIG. 19 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the eighth embodiment of the present invention.
FIG. 20 is a front view of a piston 1 having a frictional material 40 attached thereto showing a ninth embodiment of the present invention.
FIG. 21 is an axial cross-sectional view of the piston 1 having the frictional material 40 attached thereto showing the ninth embodiment of the present invention.
FIG. 22 is an axial cross-sectional view showing the state of a lock-up clutch in the seventh embodiment shown in FIGS. 16 and 17 during high hydraulic pressure.
FIG. 23 is a front view of a piston having a frictional material attached thereto showing the construction of the friction surfaces of a frictional material and a piston according to the prior art.
FIG. 24 is an axial cross-sectional view of the piston having the frictional material attached thereto showing the construction of the friction surfaces of the frictional material and the piston according to the prior art.
FIG. 25 is an axial cross-sectional view of the piston illustrating the manner in which the frictional material according to the prior art bears against a front cover during low pressure.
FIG. 26 is an axial cross-sectional view of the piston illustrating the manner in which the frictional material according to the prior art bears against the front cover during high pressure.
FIG. 27 is a graph showing the relation between the hydraulic pressure of the slip surface of a direct-coupled clutch and transmission torque capacity.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Each embodiments of the present invention will hereinafter be described in detail with reference to the accompanying drawings throughout which like portions are designated by like reference numerals.
FIG. 1 is an axial cross-sectional view of a torque converter 30 to which each embodiment of the present invention can be applied, which is shown in the liberated state of a direct-coupled clutch. The torque converter 30 comprises a front cover 2 forming a part of the housing of the torque converter 30, an impeller 23 which is a doughnut-shaped vane wheel fixed to the front cover 2, a turbine 24 which is a doughnut-shaped vane wheel having vanes opposed to the vanes of the impeller 23, and a stator 25 rotatably provided between the impeller 23 and the turbine 24. The impeller 23, the turbine 24 and the stator 25 together constitute a torque converter body.
The impeller 23 is connected to the crank shaft of the engine of a vehicle, not shown, and is rotated with the rotation of the engine together with the front cover 2. The turbine 24 is directly coupled to an output shaft 28 and is connected to a wheel, not shown, through a transmission mechanism, not shown. The stator 25 is in a form sandwiched between the impeller 23 and the center of the inner periphery of the turbine 24 and has the function of changing the flow of a fluid filling the interior of the torque converter 30. The piston (lock-up piston) of a direct-coupled clutch which is a circular ring-shaped plate effecting piston movement having a frictional material 40 adhesively attached and fixed to the surface thereof opposed to the inner surface of the front cover 2 is provided between the inner surface of the front cover 2 and the outer surface of the turbine 24, and is rotated with the output shaft 28. The friction surface of the frictional material 40 is opposed to the inner surface of the front cover 2. An annular member 41 is joined to the radially outer portion of the frictional material 40.
Between the outer surface of the turbine 24 and the piston 1, there is provided a damper mechanism comprising coil springs 26 and 27 in order to alleviate the shock when the piston 1 has been fastened. Also, a central space 8 is defined at the center of the torque converter 30.
The operation of the piston 1 will now be described. When the speed of the vehicle reaches a predetermined or higher speed, it is feedback-controlled by a control mechanism, not shown, and the flow of the fluid in the torque converter 30 defined by the impeller 23 and the turbine 24 automatically changes. By the change, the piston 1 is urged against the inner surface of the front cover 2 and the frictional material 40 of the piston 1 is joined to the inner surface of the front cover 2, and the piston 1 becomes directly coupled, whereby the drive force of the engine is directly transmitted to the output shaft 28. Accordingly, the drive side and the output side are mechanically connected (directly coupled) together without the intermediary of the fluid and therefore, fluid loss can be prevented and fuel consumption can be improved.
The torque converter 30 is connected to a hydraulic control mechanism, not shown, which changes, namely, increases or decreases the flow rate of oil while keeping the pressure difference between the front and rear of the piston 1 substantially constant in order to maintain the slip state of the direct-coupled clutch, namely, by keeping a substantially constant pressure difference between the two oil paths on the opposite sides of the piston 1, i.e., the outer peripheral side and the inner peripheral side of the piston.
FIGS. 2 and 3 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a first embodiment of the present invention. An annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
That surface of the frictional material 40 which is adjacent to the front cover 2 is divided into an annular cut surface 42 (flat surface) having its outer diameter portion subjected to cutting work, and an annular non-cut surface 43 (inclined surface) having its inner diameter portion not subjected to cutting work. The construction in which the frictional material 40 has the cut surface 42 and the non-cut surface 43 is common to each embodiment which will hereinafter be described. Accordingly, it need not be described in a second and subsequent embodiments.
The non-cut surface 43 is formed with a circumferentially continuously extending oil groove 45 and a plurality of oil grooves 46 connected to and communicating with the oil groove 45 and radially inwardly extending to the inner diameter edge portion of the frictional material 40. The oil grooves 46 comprise eight grooves formed radially and circumferentially equidistantly, but of course, the number thereof can be set arbitrarily. Also, the radial width of the oil groove 45 and the circumferential width and radial length of the oil grooves 46 can of course be set arbitrarily as required.
FIG. 8 is an axial cross-sectional view showing the state of the lock-up clutch in the first embodiment shown in FIGS. 2 and 3 during high hydraulic pressure. As shown, during high hydraulic pressure, the frictional material 40 bears against the front cover 2 with the inner diameter side thereof as the center. At this time, by the oil grooves 45 and 46 being provided, the distribution of hydraulic pressure in the radial direction and circumferential direction of the frictional material 40 created by hydraulic pressure coming around from the outer peripheral edge portion of the frictional material 40 to the friction surface between the front cover 2 and the frictional material 40 can be decreased during the operation (fastening) of the lock-up clutch at high hydraulic pressure. Accordingly, the piston thrust is increased. As a result, it becomes possible to prevent any reduction in transmission torque capacity during high hydraulic pressure. In other words, these oil grooves 45 and 46 are provided for depressurization at locations which do not hinder the fastening function of the lock-up clutch during the operation thereof. This holds true in each embodiment which will hereinafter be described.
The oil grooves 45 and 46 do not extend in the cut surface 42 of the friction surface which is subjected to cutting work. Accordingly, the deficiency of the quantity of oil on the friction surface and the fluctuation of hydraulic pressure do not result during slip control and therefore, it is possible to maintain conventional heat resistance and judder resistance.
FIGS. 4 and 5 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a second embodiment of the present invention. FIGS. 4 and 5 both show only one side of the piston 1 (cut in half at the center). As in the first embodiment, an annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
A non-cut surface 43 is formed with a plurality of oil grooves 47 radially inwardly extending to the inner diameter edge portion of the frictional material 40. The oil grooves 47 comprise eight grooves formed independently radially and circumferentially equidistantly, but the number thereof can of course be set arbitrarily. Also, the circumferential width and radial length of the oil grooves 47 can of course be arbitrarily set as required.
FIGS. 6 and 7 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a third embodiment of the present invention. FIGS. 6 and 7 both show only one side of the piston 1 (cut in half at the center). As in the first embodiment, an annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
A non-cut surface 43 is formed with a plurality of oil grooves 48 radially inwardly extending to the inner diameter edge portion of the frictional material 40. The oil grooves 48 comprise eight grooves formed independently and circumferentially equidistantly substantially in the tangential direction of the center circle of the piston 1, but the number thereof can of course be set arbitrarily. Also, the circumferential width and radial length of the oil grooves 48 can of course be arbitrarily set as required.
FIGS. 9 and 10 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a fourth embodiment of the present invention. An annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
That side of a non-cut surface 43 which is opposite to the front cover 2, i.e., that surface of the frictional material 40 which is adjacent to the surface 11 of the piston 1, is formed with a circumferentially continuously extending oil groove 49 and a plurality of oil grooves 50 connected to and communicating with the oil groove 49 and radially inwardly extending to the inner diameter edge portion of the frictional material 40. The oil grooves 50 comprise eight grooves formed radially and circumferentially equidistantly, but the number thereof can of course set arbitrarily. Also, the radial width of the oil groove 49 and the circumferential width and radial length of the oil grooves 50 can of course be arbitrarily set as required.
FIG. 15 is an axial cross-sectional view showing the state of a lock-up clutch in the fourth embodiment shown in FIGS. 9 and 10 during high hydraulic pressure. As shown, during high hydraulic pressure, the frictional material 40 bears against the front cover 2 with the inner diameter side thereof as the center. As this time, by the oil grooves 49 and 50 being provided in that side of the non-cut surface 43 of the frictional material 40 which is opposite to the front cover 2, as in each of the above-described embodiments, the distribution of hydraulic pressure in the radial direction and circumferential direction of the frictional material 40 created by hydraulic pressure coming around from the outer peripheral edge portion of the frictional material 40 to the friction surface between the front cover 2 and the frictional material 40 can be decreased during the operation (fastening) of the lock-up clutch at high hydraulic pressure. Accordingly, the piston thrust is increased. As a result, it becomes possible to prevent any reduction in transmission torque capacity during high hydraulic pressure.
The oil grooves 49 and 50 do not extend onto the cut surface 42 of the friction surface which is not subjected to cutting work. Accordingly, during slip control, the deficiency of the quantity of oil on the friction surface and the fluctuation of hydraulic pressure do not result and therefore, it is possible to maintain conventional heat resistance and judder resistance.
FIGS. 11 and 12 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a fifth embodiment of the present invention. FIGS. 11 and 12 both show only one side of the piston 1 (cut in half at the center). As in the first embodiment, an annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
That side of a non-cut surface 43 which is opposite to the front cover 2, i.e., the surface 11 side of the piston 1, is formed with a plurality of oil grooves 51 radially inwardly extending to the inner diameter edge portion of the frictional material 40. The oil grooves 51 comprise eight grooves formed independently radially and circumferentially equidistantly, but the number thereof can of course set arbitrarily. Also, the circumferential width and radial length of the oil grooves 51 can of course be arbitrarily set as required.
FIGS. 13 and 14 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a sixth embodiment of the present invention. FIGS. 13 and 14 both show only one side of the piston 1 (cut in half at the center). As in the first embodiment, an annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
That side of a non-cut surface 43 which is opposite to the front cover 2, i.e., the surface 11 side of the piston 1, is formed with a plurality of oil grooves 52 radially inwardly extending to the inner diameter edge portion of the frictional material 40. The oil grooves 52 comprise eight grooves formed independently and substantially in the tangential direction of the center circle of the piston 1 and circumferentially equidistantly, but the number thereof can of course be set arbitrarily. The circumferential width and radial length of the oil grooves 52 can also be arbitrarily set as required.
FIGS. 16 and 17 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing a seventh embodiment of the present invention. An annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
In the seventh embodiment, the frictional material is formed without an oil groove, but the surface 11 of the piston 1 to which the frictional material 40 is attached and fixed is formed with oil grooves. The surface 11 of the piston 1 to which the frictional material 40 is attached and fixed is formed with a circumferentially continuously extending oil groove 53 and a plurality of oil grooves 54 connected to and communicating with the oil groove 53 and radially inwardly extending. The oil grooves 54 comprise eight grooves formed radially and circumferentially equidistantly, but the number thereof can of course be set arbitrarily. Also, the radial width of the oil groove 53 and the circumferential width and radial length of the oil grooves 54 can of course be arbitrarily set as required. Each of the oil grooves 54 is formed in the surface 11 from the oil groove 53 beyond the inner peripheral edge portion of the frictional material 40. Accordingly, a portion of the oil grooves 54 on the inner diameter side is not covered with the frictional material 40, but is exposed.
Also, as in other embodiments, the oil grooves 53 and 54 are formed in the surface 11 of the portion corresponding to the back side of the non-cut surface 43 of the frictional material 40.
FIG. 22 is an axial cross-sectional view showing the state of a lock-up clutch in the seventh embodiment shown in FIGS. 16 and 17 during high hydraulic pressure. As shown, during high hydraulic pressure, the frictional material 40 bears against the front cover 2 with the inner diameter side thereof as the center. At this time, by the oil grooves 53 and 54 being provided in the surface 11 of the piston 1 which is the back side of the non-cut surface 43 of the frictional material 40, as in the case of each of the above-described embodiments, the distribution of hydraulic pressure in the radial direction and circumferential direction of the frictional material 40 created by hydraulic pressure coming around from the outer peripheral edge portion of the frictional material 40 to the friction surface between the front cover 2 and the frictional material 40 can be decreased during the operation (fastening) of the lock-up clutch at high hydraulic pressure. Accordingly, the piston thrust is increased. As a result, it becomes possible to prevent any reduction in transmission torque capacity during high hydraulic pressure.
The oil grooves 53 and 54 do not extend on the cut surface 42 side of the friction surface which is subjected to cutting work. Accordingly, the deficiency of the quantity of oil on the friction surface and the fluctuation of hydraulic pressure do not result during slip control and therefore, it is possible to maintain conventional heat resistance and judder resistance.
FIGS. 18 and 19 are a front view and an axial cross-sectional view, respectively, of a piston 1 having a frictional material 40 attached thereto showing an eighth embodiment of the present invention. FIGS. 18 and 19 both show only one side of the piston 1 (cut in half at the center). As in the first embodiment, an annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
In the present embodiment., the frictional material 40 is formed without an oil groove, but the surface 11 of the piston 1 to which the frictional material 40 is attached is formed with oil grooves. The surface 11 of the piston 1 which is the back side of a non-cut surface 43 is formed with a plurality of oil grooves 55 radially inwardly extending beyond the inner diameter edge portion of the frictional material 40. The oil grooves 55 comprise eight grooves formed independently radially and circumferentially equidistantly, but the number thereof can of course be set arbitrarily. Also, the circumferential width and radial length of the oil grooves 55 can of course be arbitrarily set as required.
FIGS. 20 and 21 are a front view and an axial cross-sectional view of a piston 1 having a frictional material 40 attached thereto showing a ninth embodiment of the present invention. FIGS. 20 and 21 both show only one side of the piston 1 (cut in half at the center). As in the first embodiment, an annular frictional material 40 formed of a porous material or the like is attached and fixed, by a predetermined adhesive agent, to the annular surface 11 of the piston 1 which is opposed to the front cover 2 (see FIG. 1).
In the present embodiment, the frictional material 40 is formed without an oil groove, but the surface 11 of the piston 1 to which the frictional material 40 is attached is formed with oil grooves. The back side of a non-cut surface 43, i.e., the surface 11 of the piston 1 which is opposite to the front cover 2, is formed with a plurality of oil grooves 56 radially inwardly extending beyond the inner diameter edge portion of the frictional material 40. The oil grooves 56 comprise eight grooves formed independently substantially in the tangential direction of the center circle of the piston 1 and circumferentially equidistantly, but the number thereof can of course be set arbitrarily. Also, the circumferential width and radial length of the oil grooves 56 can of course be arbitrarily set as required.
When, as in the seventh to ninth embodiments, the surface 11 of the piston 1 of the lock-up clutch to which the frictional material 40 is attached is formed with oil grooves, any reduction in the strength of the frictional material 40 does not result and therefore, it is possible to maintain conventional heat resistance and judder resistance.
FIG. 27 is a graph showing the transmission torque capacities of a lock-up mechanism according to the prior art and a lock-up mechanism in each of the embodiments of the present invention. It can be seen from the graph that in the lock-up mechanism according to the prior art, as indicated by a broken line (1), the transmission torque capacity falls when the slip surface of the direct-coupled clutch reaches high hydraulic pressure, while according to each embodiment of the present invention, as indicated by a solid line (2), the transmission torque capacity does not fall even when the slip surface of the direct-coupled clutch reaches high hydraulic pressure..
While in each of the above-described embodiments, the frictional material 40 is provided only on one side of the piston 1, the present invention can also of course be applied to a direct-coupled clutch of the type in which the frictional material 40 is provided on the front cover 2 side and the frictional material 40 is provided on each side of the piston 1.
According to the above-described torque converter with a lock-up mechanism in accordance with the present invention, there is obtained such an effect as will hereinafter be described.
The friction surface of the radially outer portion of the frictional material is subjected to cutting work and the radially inner portion of the frictional material which is not subjected to cutting work is provided with hydraulic pressure distribution reducing means for reducing the distribution of hydraulic pressure created around the frictional material and therefore, during the operation of the lock-up clutch at high hydraulic pressure, the distribution of hydraulic pressure in the radial direction and circumferential direction of the frictional material created by hydraulic pressure coming around from the outer peripheral portion of the frictional material into and between the friction surfaces is decreased and the piston thrust is increased. As a result, it becomes possible to prevent any reduction in transmission torque capacity during high hydraulic pressure. Accordingly, an improvement in fuel consumption can be expected.
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In a torque converter with a lock-up mechanism which can decrease a distribution of hydraulic pressure in the radial and circumferential directions of a frictional material, which can prevent the creation of any excess reaction by the distribution of hydraulic pressure, and which can efficiently give a fastening force to the frictional material to thereby improve transmission torque capacity, an oil groove for reducing the distribution of hydraulic pressure is provided on the frictional material or a piston. This oil groove is provided for depressurization at a location which does not hinder the fastening function.
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The present application claims the benefits under 35 U.S.C.§119(e) of U.S. Provisional Application Ser. No. 60/124,149, filed Mar. 12, 1999 and entitled “STEEP PITCH HELIX PACKER”.
FIELD OF THE INVENTION
The present invention relates to an expandable composite seal assembly which finds application in a packer for use in wells.
BACKGROUND OF THE INVENTION
The present invention was conceived as a means to specifically provide an adequate level of hydraulic isolation between zones in a non-cased horizontal oil well bore. As such, a cost effective method was being sought to install two or more packers in a tubing ‘string’ as a means to shut off zones of high water inflow. However, the device configurations developed to meet the requirements of this particular application may be applied more generally to include many other applications serviced by packers or bridge plugs and indeed by other annular sealing devices such as blowout preventers.
However the invention will be described in the context of downhole packers and bridge plugs.
Within the context of petroleum drilling and completion systems, existing methods to provide hydraulic isolation (sealing) between portions of a well bore or well bore annulus, whether cased or open, may be broadly divided into two types of seal element: 1) bulk expansion (compression set) and, 2) inflatable. Devices employing either of these seal element methods are commonly referred to as either bridge plugs or packers, depending respectively on whether full cross sectional or annular closure is ultimately required. Since closure of an annular space with respect to the device is always required, the term Packer is employed herein to refer generally to all such devices.
In either case the packer must provide sufficient annular clearance to first permit insertion into the well bore to the desired depth or location and a means to subsequently close this annular clearance to effect an adequate degree of sealing against a pressure differential. It is often also desirable to retract or remove these devices without milling or machining.
Packers relying on bulk expansion of the seal element typically employ largely incompressible but highly deformable materials, such as elastomers, as the sealing element or element ‘stack’ where the element is cylindrically or toroidally shaped and is carried on an inner mandrel. U.S. Pat. Nos. 5,819,846 and 4,573,537 are two examples of such devices using an elastomer and ductile metal (non-elastomeric) respectively for the deformable seal element material. The seal is formed by imposing axial compressive displacement of the element, causing the material to incompressibly expand radially to close off the annular region, and after contact with the confining borehole or casing is achieved, to apply sufficient pre-stress to promote sealing. The amount of annular expansion and sealing achievable with elastomers is dependent on several variables but is generally limited by the extrusion gap allowed by the running clearance. The size of annular gap sealable with ductile metals is similarly limited, although for slightly different reasons, and since the deformation is largely irreversible presents a further impediment to retrieval. For either elastomer or ductile metals practically achievable axial seal lengths are short, in the order of a few inches, and therefore sealing on rough surfaces is not readily achievable. This limitation to sealing small clearances with relatively short seal lengths and limited conformability, even for elastomers, tends to preclude using this method for sealing against most open bore hole surfaces. Furthermore, this style of device must usually also provide a means to react axial load, e.g., slips, separate from the sealing element. Such axial loads arise from pressure differentials acting on the sealed area plus loads transmitted by attached or contacting members. The axial loads typically exceed either the frictional or strength capacity of the seal material. This is especially true as the sealed area (hole diameter) is increased. Managing the setting and possible release of the associated anchoring systems adds considerable complexity to these devices with associated cost and reliability implications. Similarly, the degree of complexity, cost and uncertainty is further increased where the application requires axial load reversal as arises when the pressure differential may be in either direction. Both the sealing and mechanical retaining hardware tends to require significant annular space, therefore the maximum internal bore diameter is significantly smaller than the setting diameter.
Devices relying on inflation of the ‘membrane’ seal element employ a generally cylindrical sealing element (visualize hose), capable of expanding radially outward when pressured from the inside with a fluid. The sealing element is carried on a mandrel with end closure means, to contain pressure, and accommodate whatever axial displacement is required during inflation. The sealing element in these devices is typically of composite construction where an elastomer is reinforced by stiffer materials such as fibre strands, wire, cable or metal strips (also commonly referred to as slats). U.S. Pat. No. 4,923,007 is one example of such a device employing axially aligned overlapping metal strips. Pressure containment by these elements relies largely on membrane action. The sealing element may be considerably longer and more conformable than in bulk expansion devices. Inflation packers are therefore most commonly employed for sealing against the open bore hole wall. The inflation material may be either a gas, liquid or ‘setting’ liquid such as cement slurry. Where the inflation material stays fluid, pressure must be continuously maintained to effect a seal. If the device develops a leak after inflating, the sealing function will be lost. To circumvent this weakness a setting liquid may be used, e.g., cement; therefore pressure need only be maintained until sufficient strength is reached. However the device then becomes much more difficult to remove since it cannot be retracted through reverse flow of the inflation fluid. Typically it can only be removed by machining or milling. Similar to the bulk expansion method, the membrane strength of these devices significantly limits the ability to react axial load and the annular space requirements of membrane end seals and mandrel can be quite large. Therefore inflatable packer elements tend to suffer from the same limited axial load and through bore capacities as bulk expansion packer elements.
SUMMARY OF THE INVENTION
The present invention is founded on the geometric and structural properties of one or more closely spaced helical coils, preferably joined at their ends, to form a helical cage. The helical cage may be visualized as several identical loosely wound coil springs, formed from rectangular section strips coaxially ‘screwed’ together, where the individual coil ends are preferably joined at both ends to sleeves, preferably of diameter equal to the spring diameter. The coils preferably have a steep pitch (say with helix angles of about 45°), leaving little gap between adjacently strip bodies. To provide sealing, the gaps or slits between adjacent coils are bridged by a suitable material, typically an elastomer, thereby forming a composite wall system usable as a packer element. In addition to enabling fluid tight bridging, an elastomer layer or sleeve may be employed on either or both sides of the cage to further promote contact sealing. This composite wall is not unlike that formed in reinforced hose construction, where a metal spring made of rigid material is imbedded in the hose wall of an otherwise flexible material to provide structural support resisting collapse and burst pressure loads.
In the present case the helical cage makes the ‘hose’ capable of being expanded as the axial length is reduced, i.e., the helical cage enables a ‘setting’ response characteristic of bulk expansion packer elements. It should be clear this implies that the inverse retraction response occurs with axial extension, i.e., an inverse relation exists between axial and radial deformation. The axial length change and associated inverse diameter change may be accomplished by release of stored elastic energy (coils acting as springs), application of differential pressure or application of axial load where any of these activation mechanisms may be used either separately or in combination. In addition, the helical cage is capable of bearing significant compressive load when confined inside a cylindrical bore. Combined with the usual pressure containment ability of a hose, these properties together make this system very suitable for use in a variety of packer applications.
It should also be mentioned that expansion of the helical cage can also be accomplished by rotation, opposite to the direction of coil winding. This may in fact be combined with axial movement, however for simplicity of presentation, and consistent with the preferred embodiment, only non-rotational axial setting movement is used hereinbelow to explain the principles of the method. It should then be clear to one skilled in the art, how setting rotation may be used to further advance the utility of the method in certain applications.
In a preferred embodiment, the individual coils exist as strips separated by gaps or slits in a rigid cylinder (tube) where the slits occur over an interval of the total cylinder length such that the coil ends are left attached to an uncut portion of the tube, effectively leaving cylindrical sleeves at both ends. The helix angle and number of circumferentially distributed strips may be varied, along with other properties such as strip thickness, to obtain helical cage configurations having geometry and structural characteristics desirable for construction of packer sealing elements. Some of the more significant of these desirable properties are large expansion capacity, small extrusion gaps between or around reinforcing strips, high mechanically retained seal contact force and high tension and compression load capacity. Expansion without significant rotation is also a desirable design characteristic as this tends to simplify several design factors.
For purposes of this description, the phrase “structural helical coil” indicates a coil formed of material having some elasticity, so that the coil may be deformed under the application of compressive load into contact with a confining, adjacent, substantially cylindrical wall (such as a borehole wall), said coil being operative to transmit compressive load along the helix without local buckling.
For purposes of this description, the phrase “elastomeric” indicates a solid coil formed of material having some elasticity, so that the coil may be deformed under the application of compressive load into contact with a confining, adjacent, substantially cylindrical wall (such as a borehole wall), said coil being operative to transmit compressive load along the helix without local buckling.
For purposes of this description, the phrase “elastomeric” indicates a solid resilient material (such as nitrile) whose stiffness is substantially less than the structural material of the coil (typically steel).
Broadly stated then, in one embodiment the invention is directed to a radially expandable seal element for bridging an annular clearance, comprising: a cylindrical cage having a side wall formed by a plurality of structural, coaxial, helically parallel coils having side edges; and elastomeric means for sealing the side edges of the coils to provide pressure containment across the cage side wall. Preferably the ends of the coils are connected to end sleeves.
In another embodiment, the invention is directed to the radially expandable seal element as just described but comprising inner and outer cylindrical cages, the coils of one cage preferably having a helix screw direction opposed to the helix screw direction of the other cage, with elastomeric means for sealing the side edges of the coils as aforesaid.
The present invention therefore introduces a novel type of radially expandable seal element useful in a packer downhole. This architecture may be described as a membrane seal element packer, where the element is capable of being expanded by and reacting axial load thus enabling a variety of differentiating performance characteristics and design alternatives. These include the ability to expand the device through application of internal pressure and mechanically maintain the expanded state after fluid pressure is removed. Alternately the device may be compression set and mechanically retained. It tends to be self anchoring since the element is capable of reacting significant axial loads. It also accommodates retrieval, is amenable to either open or cased hole applications and has a symmetric response to direction of axial loading. In the preferred embodiment, the simplicity of architecture lends itself to reduced manufacturing coast and small annular space requirements, both significant advantages over the existing alternatives.
Helical Cage Geometric Design Properties
Placing the helical cage in this design context, first consider how the helix angle, defined here as the angle formed between the cylinder axis and a line tangent to a coil, affects two significant geometry relationships of a helical cage: 1) diameter change (diametrial strain) as a function of axial length change (axial strain) and, 2) coil spacing (strain normal to coil direction) also as a function of axial length change. In the limits the helix angle approaches either 90°, as occurs in typical coil springs, or zero degrees as occurs in inflatable packers employing overlapping strips as previously referenced in U.S. Pat. No. 4,923,007.
In the first case, helix angle approaching 90°, diameter is insensitive to change in axial length (axial strain) however change in coil spacing is almost directly proportional to change in axial length per unit pitch. High helix angles are thus only suitable for applications requiring little expansion capacity. In addition, this configuration requires that the design accommodate a large range of gap variation. In the second case, helix angel near zero, expansion initially occurs with negligible axial compression and the change in coil spacing is directly proportional to circumferential expansion per coil. Thus while low helix angles provide the greatest expansion capability, they suffer from the same limitation of large gap variation as high helix angle cages. Mitigating this effect is in large part the motive behind methods such as the interlocking strips, described in U.S. Pat. No. 4,923,007, which correspond to helix angles near zero.
However, if the helix angle falls between these two ‘conventional’ limits, say near 45°, the geometric behavior has characteristics which are peculiarly well suited to packer applications. In this third case the diametral strain is about equal to axial compressive strain but coil spacing is comparatively insensitive to axial strain. This implies that the helical cage may be considerably expanded with only slight changes in coil spacing, greatly facilitating elastomer membrane containment.
Helical Cage Structural Design Properties
Next consider the structural characteristics of a helical cage when expanded inside a cylindrical confining surface. To promote sealing, the packer must be kept in its expanded state. In general, this implies adequate contact stress must be maintained between the packer element and the confining wall. In some applications low enough seepage rates may be achievable without significant contact stress as such, provided a sufficiently small gap is maintained between the packer element and confining wall for a given packer length. Nonetheless, it is almost always desirable to maintain some level of contact stress even to support such seepage control applications.
In many applications a further structural need arises where the packer must react an axial load into the confining wall. It is therefore desirable to have elements that can react significant axial loads, in addition to sealing, as this can greatly simplify design complexity. In such cases, maintaining contact stress is imperative since the reaction mechanism depends on developing sufficient friction resistance over the interfacial region.
Depending on the helix angle, contact stress can be maintained either mechanically, hydraulically or both. Referring to the three helix angle cases already introduced, a high angle helix is only amenable to compressive activation, a low angle to pressure activation but at intermediate angles both may be used although pressure activation is further limited to cases where the helix angle is such that the pressure end load induced axial load does not cause diameter reduction.
Maintaining contact stress by pressure activation of a seal element constructed using a helical cage is similar to the action in strip or cable reinforced or retained inflatable packers. In these devices, the element is mounted on a mandrel where at least one end sleeve forms a sliding seal. Application of differential pressure into the confined space between the interior surface of the expansion element and the mandrel causes the element to expand and foreshorten. As expansion causes the element to contact the confining surface, increased inflation tends to increase the contact stress over the contacting length interval so that the packer only seals if this pressure is maintained. As will be apparent to one skilled in the art, for angles near zero, the helical cage behavior approaches that of a conventional strip reinforced inflatable packer where the contact pressure is essentially equal to the applied pressure over the contact interval length.
However as the helix angle is increased above zero, the relationship between contact stress and pressure is somewhat more complex. Neglecting the ‘spring’ forces arising in the cage strips as the element is expanded, this relationship may be understood in terms of membrane action which requires that the axial pressure end load be reacted by the helix strips at the helix angle, both at the expanded diameter, resulting in development of an equivalent hoop stress. Therefore as the helix angle is increased above zero a portion of pressure will be reacted by this equivalent hoop stress so that contact stress will decrease. This hoop stress component is also manifest as a torsion at each end which must be reacted. If the angle is increased sufficiently, a point is reached where the pressure induced axial and hoop stresses are balanced so that none of the pressure is reacted through contact stress and the packer will not tend to expand. For helical cage angles equal to or greater than this angle (dependent on end area and helix angle at the expanded diameter) contact stress and indeed expansion cannot be achieved by the application of differential internal pressure alone but requires axial load either with or without internal pressure.
The helical cage enables development of contact stress through axial compressive load because, unlike existing strip reinforced inflatable packers where the ‘helix’ angle is essentially zero, curvature of the helix tends to induce an ‘arching action’ when in contact with a confining surface. This arching action not only enables the development of compression induced contact stress, but also enables reaction of significant axial compressive loads.
Where means are provided to ‘lock’ in the set force, this arching action of the helical cage enables the packer element to be mechanically retained in its set position whether set by pressure or axial displacement. This ability to be mechanically retained does not preclude pressure retention methods where flow control devices are provided to trap and perhaps also release the setting pressure.
The magnitude of compressive load which the helical cage can react depends on the full spectrum of solid mechanics design parameters but in general increases with helix angle and may be limited by buckling. The utility of the method is not restricted to the elastic limit of the cage material but may exploit its plastic capacity.
Combined Geometric and Structural Design Properties of Helical Cage
From the foregoing, it should be apparent to one skilled in the art, that the design variables of helix angle and number of strips, enables a helical cage to be configured as the primary reinforcing component of a composite expandable packer element to meet a large spectrum of design requirements for packer devices. It should also be apparent that the helix angle need not be constant nor does the diameter. However helix angles near 45° are particularly well suited to petroleum drilling and completion applications as anticipated for the preferred embodiment.
The cages may also be configured with means to provide linking between strips in combination with or without overlapping of the strips as a means to prevent excess gap openings, provided the linking does not unduly inhibit the relative sliding movement between strips occurring during expansion or retraction.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cut away view of a device utilizing the helical cage method to create a packer suitable for oil field down hole service;
FIG. 2 is an assembly drawing showing a cross sectional view of this tool in its unexpanded or unset configuration;
FIG. 3 shows a cross sectional view of the tool assembly as it would appear set in a well bore; and
FIG. 4 shows a cross sectional view of the friction ratchet employed to control relative axial movement between the end fitting at the second end and the mandrel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
While the properties of single steep pitch helical cages have been summarized to teach how their design variables may be adjusted to meet differing economic and functional requirements of packers, it should be apparent to one skilled in the art that this method can be combined with itself and other methods to create a packer tool. One such took, suitable for inclusion in a well bore casing completion string, is shown in FIG. 1 . In this tool, two helical cages, enclosing an elastomeric membrane, are combined to form a composite packer element system. As shown in FIG. 2, this packer element is further combined with a ratcheting inner mandrel to provide additional functionality.
Dual Steep Pitch Helix Packer Element Assembly
The composite element system is comprised of a flexible cylindrical sealing membrane (elastomeric hose), inner and outer helical cages and end fittings. The cages are both formed of suitable rigid materials with similar helix angles but of opposite direction. When coaxially assembled, the flexible cylindrical sealing membrane is confined between the inner and outer helix cages where the ends of the cages and membrane are joined together with end fittings to form rigid and sealing connections at the first and second ends of the assembly as shown in FIG. 2 .
Each cage is formed from a pipe, slit along say six (6) evenly spaced helical lines starting and ending within the tube length and interrupted periodically to form six individual coils fastened to the uncut portion of the tube at each end and ‘stitched’ to each other at intervals along the slit. The tube lengths and uncut intervals at each end of the inner and outer cages are such that all or a portion of the uncut intervals overlap at both ends when coaxially assembled. The ‘stitches’ are provided to facilitate assemlby and resist installation loads but are sufficiently weak to be sheared when the setting load or pressure is applied. For each tube, helix angles of 35° are specified. The diameter to thickness ratio of the cylindrical cages is approximately 40 and the cage lengths are typically 10 or more times the diameter. But as previously disclosed, the helix angle and other geometry variables may be adjusted to suit various application requirements.
When subjected to axial compressive load or pressure sufficient to shear the stitches, the cages tend to expand cooperatively carrying the membrane with them. Torsion required to prevent rotation of one cage is supplied by the other cage because the helixes are of opposite wind or screw direction and similar pitch. The combined element system is thus largely torque or rotation neutral.
The flexible cylindrical membrane is specified as a hose, constructed using a suitable elastomeric material (e.g., nitrile) and reinforced with outer and inner uni-direction rubber calendering fibre layers. To ensure deformation compatibility with the cage, the elastomeric reinforcement should not tend to prevent expansion, therefore the fibre lay angles are approximately equal to magnitude to the adjacent helix cage angle but of opposite sign. In the preferred embodiment, this hose is constructed in a manner typical of high pressure applications, such as concrete placement hoses, where an inner layer of calendered cable wire is placed on a forming mandrel at the specified lay angle, followed by a middle layer of elastomer (rubber) and an outer layer of calendered cable wire at the same lay angle but opposite wind direction. The membrane (hose) wall thickness is sufficient to largely fill the annular space between the cages promoting concentric placement of the helical coils. The membrane length is sufficient for its ends to overlap at least a portion of the overlapping uncut intervals of both the assembled inner and outer cages, in which mutually overlapping interval, a seal is formed.
For the immediately anticipated application, where sealing modest pressure differentials against smooth open hole of relatively soft rock is required, the packer element is expected to provide adequate performance without an external elastomeric layer as shown in FIG. 1 . However in other applications, contact sealing may be further promoted by providing an outer elastomeric layer, suitably bonded or attached to the outer helix. In this case bonding between the outer layer and the membrane may be promoted by providing holes at locations where the midsection lines of the inner and outer helix cage strips intersect.
Mandrel and Friction Ratchet
The addition of an inner mandrel and ratchet to the packer element, as shown in FIG. 2, provides a means to hold or lock the packer in its set position after the setting load or pressure is removed. The mandrel is configured to have its first end fastened to, or retained at, the first end of the element assembly and its second end passed through the friction ratchet placed on the inside of the second end of the element assembly. As would a conventional toothed ratchet, the friction ratchet is arranged to permit relatively free sliding of the mandrel during setting but grips the mandrel preventing relative movement between the mandrel and element second end in the unset direction. FIG. 3 shows the packer in its set configuration where the mandrel has been stroked through the ratchet which now prevents axial rebound.
As shown in FIG. 4, the friction ratchet is comprised of a coiled wire—in essence a coil spring—placed between the outside surface of the mandrel and the helically formed or buttress threaded inner surface of the end fitting. As shown, the flanks of the thread form, commonly referred to as the load and stab flanks, are configured to have differing angles. The load flank is nearly 90° to the cylinder axis and the stab flank is much less. The unloaded coil inside diameter is somewhat less than the mandrel outside diameter so that when mounted on the mandrel the coil exerts a radial force and ‘grips’ the mandrel. It thus tends to move with the mandrel if the mandrel is displaced axially relative to the end fitting. However such movement will cause the wire to contact one of the two flanks depending on direction. Under the application of loads tending to expand the packer the wire contacts the load flank and will slide on the mandrel. However for displacement in the reverse direction, friction forces will tend to cause the wire to roll under the stab flank and become entrapped between the mandrel and end fitting, thus preventing further relative movement between them. As should be apparent to one skilled in the art, the design must consider the possible range of friction coefficients to ensure the stab flank angle is sufficiently shallow to trigger entrapment rather than sliding. And for this angle, the other mechanical design parameters such as thread length, diameter, wall thickness, material properties, etc. must provide sufficient strength to accommodate the expected axial loads.
While the friction ratchet thus provided has the advantage that it can grip on the relatively smooth outside surface of the mandrel allowing a shorter tool length, a conventional toothed ratchet may be employed as an alternative. However if such a ratchet is employed, ‘teeth’ must be placed on the second end of the mandrel over an interval long enough to accommodate the anticipated stroke. Since this surface is not compatible with the sliding seal the length of the second end fitting must be increased to accommodate the toothed portion of the mandrel between the sliding seal and ratchet.
For applications where retrieval is required, the fastening system at the first end of the mandrel is configured to shear or release at a predetermined magnitude of applied axial tensile load. Once released, the mandrel no longer prevents stroking in the unset direction and the packer will tend to retract.
To facilitate pressure inflation, the mandrel is provided with a pressure access port and seals are provided between the mandrel and end fittings as shown in FIG. 2 . This arrangement allows fluid entering the port to inflate the packer. Although not shown, the pressure port may be further equipped with a check valve and other flow control devices, well known in the art, to both retain inflation pressure and provide for subsequent release.
Operation of the Packer Tool
To illustrate the operation of the packer tool, consider its use in applications requiring water shut off or zonal isolation in horizontal wells as discussed in the “Background to the Invention”. In this case it is required that two packers joined by a tubing string be run in the wellbore on a carrier string, the packers set at a location so as to straddle the water inflow zone, and the carrier string then released from the top packer and pulled out of the hole leaving the inflated packers and connecting tubing to act as a water ‘inflow patch’. The reverse operation is also required where a carrier string is run in to latch the top packer, unset the packers and remove the entire ‘inflow patch’ comprising top and bottom packers and connecting tubing.
In this application, the present invention may be used for the top and bottom packers where the first end of the bottom packer is made up to the bottom end of the casing string, the second end of the top packer is made up to the top of the tubing string and the first end of the top packer made up to a fixture containing the carrier string latching mechanisms such as a J-latch commonly employed for such purposes. The second end of the mandrel is further fitted with an inner ring capable of catching a retrievable wiper plug. During running, the packers must react axial load arising from the weight of any components carried below the packers plus drag induced by string movement plus end load from bridges or obstacles. Where the net axial installation load is tensile, the packer element and mandrel together react the load because the ratchet tends to prevent extension; but where the installation load is compressive, only the packer element is loaded since the ratchet slides relatively freely in compression. As mentioned earlier, the ‘stitches’ between helix strips, formed at locations where the helical cuts are interrupted, provide the necessary axial strength preventing the packer from premature setting. This axial load capacity also provides flexural stiffness to resist buckling tendencies under installation loads.
Once the packers have been run in to the required wellbore location, the bottom packer is set by pumping down a wireline retrievable plug and pressuring against it. Fluid entering the pressure access port provided in the mandrel causes the packer to inflate. Setting may be further augmented by the application of compressive load which will tend to further set the packer and improve the degree of conformable contact between the packer outer cage and the wellbore. Application of further axial compressive load and or pressure will then cause the upper packer to set where the difference in set force between the upper and lower packer is controlled by the number and size of ‘stitches’ and the pressure end load. Once both packers are thus set, pressure is removed and the carrier string manipulated to unlatch it from the ‘inflow patch’ and remove the carrier string from the hole.
Retrieval is accomplished by reentering the hole with the carrier string and latching the top packer. Because the set packers act as anchors, application of tensile load will first cause the mandrel shear connection of the upper packer to release allowing the packer to retract followed by the lower packer. Once retracted, both packers with the conjoining tubing (the inflow patch) may be pulled from the well bore.
Alternate Embodiments
As an alternative embodiment, we believe a packer similar to that shown in FIGS. 1 to 3 , but where either the inner or outer helical cage is omitted, may be used to provide sealing in applications where only a unidirectional through wall pressure differential is anticipated, i.e., if the outer cage is omitted the membrane will only be supported by the remaining inner cage against an external pressure differential. Similarly if the inner cage is omitted the membrane will only be supported by the remaining outer cage against an external pressure differential. In this form, the torsional load of the single cage under axial load will no longer be compensated by the second cage therefore other means must be provided to react this force. This may be provided through the connecting tubulars external to the packer system or may be reacted through the mandrel by providing a sliding key-way or splined connection between the end fitting of the second end and the mandrel as will be evident to one skilled in the art.
In another aspect of the preferred embodiment, the mandrel may be adjusted to carry the axial load by providing it with connections suitable for joining to the rest of the tubular string. This architecture is that typically used for inflatable packers, where one or both end fittings slide and seal on the mandrel, but does not provide for the ability to directly activate packer expansion through the application of axial compressive load. In this alternate configuration packer expansion may be initiated by internal pressure or may be ‘rotation set’ as is commonly employed for solid element packers. Mechanical latching may still be provided but means to retract the element then become less direct and more complex.
In another aspect of the preferred embodiment, we believe the packer can be configured to provide annular sealing by inward displacement in application where sealing or loading against an inside rod or tube is required. For this application the packer as shown in FIGS. 1 and 2 would be essentially inverted so that the element would appear on the inside and radial movement inwards caused by tensile load.
In another aspect of the preferred embodiment the seals between the mandrel and end fittings may be omitted where pressure setting is not required.
In another aspect of the preferred embodiment, where it is not required to mechanically retain the packer, the ratchet may be omitted.
In another aspect of the preferred embodiment, where it is not required to mechanically retain the packer and the element provides sufficient flexural rigidity, the ratchet and mandrel may be omitted.
In another aspect of the preferred embodiment, the use of stitches as described in the preferred embodiment should be understood as only one means to control the relationship between setting forces and radial displacement. Other methods such as hoop straps or links between strips may be provided such that they fail at a predetermined setting load or pressure before allowing significant radial displacement. In fact, the elastic properties of the membrane layers and the cages alone may provide sufficient control of radial expansion under the range of design loads.
In another aspect of the preferred embodiment, we believe the slits between strips may be arranged to have a continuous or intermittent saw tooth pattern so as to provide a ratcheting action as shear displacement occurs during setting or unsetting actions. This ratcheting action will be seen to arise as the ‘ratchet teeth’ snap past each other where the load required to cause such displacement depends on the saw tooth angles and inter-strip contact forces. This ratcheting action may be employed with or without stitches or their equivalent to control the relationship between setting forces and radial displacement. Similarly this ratcheting action may be used to retain the packers in its set configuration to either augment or replace the function of the mandrel mounted friction ratchet described in the preferred embodiment.
We further believe the ability to expand the packer and develop radial contact forces on the surface of the borehole the packer can be exploited to advantage in applications requiring such forces with or without the ability to seal. In these applications the helical cage design parameters such as helix angle and wall thickness can be adjusted to provide radial forces capable of expanding say deformed or collapsed well casing. For these applications the number of helical cages may also be increased so that several cage layers are nested to provide greater load capacity. The function of the membrane between the layers may either be unnecessary in which case it may be omitted or it may become more one of lubrication or friction reduction, rather than sealing, in which case the membrane may be retained but its material selection adjusted to provide less sliding resistance.
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A seal element is provided which comprises inner and outer, concentric, radially spaced apart, tubular helical cages. Each cage is formed by a plurality of helically parallel steel coils joined at their upper and lower ends by integral sleeves. A nitrite bladder is positioned between the cages. The seal element can be expanded by supporting its base and applying compressive load.
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This is a continuation of application Ser. No. 594,737 filed Mar. 29, 1984 now abandoned.
BACKGROUND ART
Many prior workers have sought to increase the sorbency of fibrous web products by addition of "super absorbent" particles, e.g., modified starch or other polymeric particles which sorb and retain under pressure large volumes of liquids, especially aqueous liquids. The previous products prepared by such additions all have had significant limitations. For example, one commercial product, which comprises sorbent particles adhered between two sheets of tissue paper, decomposes in use, whereupon the sorbent particles are washed out of the product and into liquid being treated. Another commercial product, comprising a rather stiff open-mesh fabric or cheese cloth to which essentially a single layer of sorbent particles is adhered, sorbs only limited amounts of liquid.
A different product taught in U.S. Pat. No. 4,103,062 is made by dispersing particles in an air-laid cellulosic fiber web and densifying the web with heat and pressure to increase its strength. However, this product sorbs only a limited amount of liquid, because of the nonexpansible nature of the densified web, and because sorbent particles at the edge of the web swell upon initial liquid intake and prevent permeation of additional liquid into internal parts of the web. U.S. Pat. No. 4,105,033 seeks to avoid such edge blockage by distributing the sorbent particles in spaced layers separated by layers of fibers, but such a construction requires added processing steps and is subject to delamination. In other products sorbent particles are simply cascaded into a loose fibrous web (see U.S. Pat. No. 3,670,731), but both U.S. Pat. No. 4,103,062 and U.S. Pat. No. 4,105,033 note that it is difficult to deposit the particles uniformly, and the particles tend to move within the web during subsequent processing, storage, shipment or use of the web and thereby develop nonuniform properties.
U.S. Pat. No. 4,235,237 teaches a different approach in which a fibrous web is sprayed, immersed or otherwise contacted with sorbent material dispersed in a volatile liquid. Vaporization of the volatile liquid leaves a web in which sorbent particles envelop the fibers, principally at fiber intersections. Disadvantages of this approach include the need for multiple steps to prepare the product, limitations on amount of sorbent that can be added to the web, brittleness of the dried webs, and the tendency for sorbent material to be concentrated at the web surface.
Many of these problems have been overcome by the sorbent sheet product described in U.S. Pat. No. 4,429,001. In this product, an array of solid high-absorbency liquid-sorbent polymeric particles are uniformly dispersed within a coherent web of melt blown fibers. However, even greater improvement in the rate of liquid sorption would be desirable, since swelling of a mass of the high sorbency particles upon initial liquid sorption can still limit rapid permeation of additional liquid into internal parts of the web. Further, the coherency of the web of melt blown fibers tends to somewhat limit the swelling of the high-sorbency particles during liquid sorption. Surprisingly, the present invention provides a product having increased rate of sorption and greater liquid sorbency than the product disclosed in U.S. Pat. No. 4,429,001.
SUMMARY OF THE INVENTION
The present invention provides further advantages over the prior art products and provides a new sorbent sheet product with unique capabilities beyond those of any known prior-art product. Briefly, this new sheet product comprises a coherent fibrous web that includes entangled blown fibers, and liquid transport fibers intermingled with the blown fibers and an array of solid high-sorbency liquid-sorbent polymeric particles uniformly dispersed and physically held within the web, the particles swelling upon sorption of liquid and the transport fibers causing increased and more rapid sorption of liquid by conducting the liquid from external portions of the web to internal portions of the web. Additionally, the web may contain other constituents such as binders and wetting agents. The blown fibers may be prepared by extruding liquid fiber-forming material into a high-velocity gaseous stream, where the extruded material is attenuated and drawn into fibers. A stream of fibers is formed, which is collected, e.g., on a screen disposed in the stream, as an entangled coherent mass. According to the invention, sorbent particles and transport fibers may be introduced into the stream of melt blown fibers, e.g., in the manner taught in U.S. Pat. No. 4,118,531, and the mixture of melt blown fibers, transport fibers and particles is collected as an entangled coherent mass in which the sorbent particles and transport fibers are entrapped or otherwise physically held. A particle-filled fibrous web containing transport fibers is formed in essentially one step, and the only further processing required may be simply cutting to size and packaging for use.
A sheet product of the invention is integral and handleable both before and after immersion in liquid, because the collected blown fibers are extensively tangled or snarled and form a strong coherent web, and the sorbent particles and transport fibers are lastingly held and retained within this web.
Large quantities of liquid can be sorbed at a rapid rate, with the amount dependent principally on the sorption capacity of the individual sorbent particles and the rate of sorption greatly enhanced by the transport fibers. Liquid is rapidly sorbed by sorbent particles located in even the inner parts of the sheet product, due to the sorbent particles being held apart by the web structure and the transport fibers conducting the liquid to particles located in the interior portion of the web. The melt blown fibers of the web are preferably wet by the liquid being sorbed, e.g., as a result of use of a fiber-forming material that is wet by the liquid or by addition of a surfactant during the web-forming process, which further assists sorption.
The sorbent particles swell and expand in size during sorption, and although the blown fibers are extensively entangled, the web of fibers expands as the particles expand and the sorbed liquid tends to be retained in the product even when the product is subjected to pressure. The transport fibers also serve to separate the melt blown fibers, especially when in crimped form, producing a less dense web with greater potential for expansion on sorption of liquid. On sorption of liquid, the transport fibers allow the blown fibers to slip and move to a degree that the fibrous web is pushed apart by the swelling sorbent particles while the web integrity is maintained.
The sorbent sheet product of the invention has a variety of uses, particularly where rapid sorption, high liquid retention and soft hand are desired, such as in disposable incontinent devices, diapers, surgical swabs, bed pads, sanitary napkins and filters for separating water from organic liquids.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of apparatus used in practicing the present invention; and
FIG. 2 is a greatly enlarged sectional view of a portion of a sheet product of the invention.
DETAILED DESCRIPTION
A representative apparatus useful for preparing sheet product of the invention is shown schematically in FIG. 1. The apparatus is generally similar to that taught in U.S. Pat. No. 4,118,531 for preparing a web of melt-blown fibers and crimped bulking fibers.
This apparatus prepares webs with melt-blown fibers (prepared by extruding molten fiber-forming material and which are preferred in many webs of the invention), but solution-blown and other types of fibers may also be used. The fiber-blowing portion of the illustrated apparatus can be a conventional structure as taught, for example, in Wente, Van A. "Superfine Thermoplastic Fibers", in Industrial Engineering Chemistry, Vol. 48, pages 1342 et seq (1956), or in Report No. 4364 of the Naval Research Laboratories, published May 25, 1954, entitled "Manufacture of Superfine Organic Fibers" by Wente, Van A.; Boone, C. D.; and Fluharty, E. L. Such a structure includes a die 10 which has an extrusion chamber 11 through which liquified fiber-forming material is advanced; die orifices 12 arranged in line across the forward end of the die and through which the fiber-forming material is extruded; and cooperating gas orifices 13 through which a gas, typically heated air, is forced at very high velocity. The high-velocity gaseous stream draws out and attenuates the extruded fiber-forming material, whereupon the fiber-forming material solidifies as fibers during travel to a collector 14. The collector 14 is typically a finely perforated screen, which in this case is in the form of a closed-loop belt, but which can take alternative forms, such as a flat screen or a drum or cylinder. Gas-withdrawal apparatus may be positioned behind the screen to assist in deposition of fibers and removal of gas. Alternatively, two dies may be used and arranged so that the streams of melt blown fibers issuing from them intersect to form one stream that continues to a collector 14.
The apparatus shown in FIG. 1 also includes means for introducing sorbent particles and staple transport fibers into the sheet product of the invention. The transport fibers are introduced into the stream of melt blown fibers through the use of a lickerin roll 16. A web 17 of transport fibers, typically a loose, nonwoven web such as prepared on a garnet machine or "Rando-Webber", is supplied from a supply roll 18 under a drive roll 19 where the leading edge engages against the lickerin roll 16. The lickerin roll 16 turns in the direction of the arrow and picks the transport fibers from the leading edge of the web 17, dissociating the transport fibers from one another. The sorbent particles are supplied from a particulate hopper 20 through an inductor 21 which meters the amount of particles flowing into a venturi 22 which is in duct 23. An air stream flows through duct 23 for conveying the sorbent particles. The sorbent particles are conveyed to inclined duct 24 where the fluidized stream of sorbent particles becomes the carrier stream for the transport fibers delivered by the lickerin roll 16. The sorbent particles and transport fibers are conveyed in the air stream through inclined duct 24 and into the stream of melt blown fibers where the sorbent particles and transport fibers become mixed with the melt blown fibers. The mixed stream of melt blown fibers, transport fibers and sorbent particles then continues to the collector 14 where a web of randomly intermixed and intertangled microfibers 31, transport fibers 32, and sorbent particles 33, as shown in FIG. 2, is formed. A spray jet 25 may be used to apply materials, such as binders and wetting agents, to the mixed stream of blown fibers, sorbent particles and transport fibers prior to collection at collector 14.
Melt-blown fibers are greatly preferred for sheet products of the invention, but solution-blown fibers in which the fiber-forming material is made liquid by inclusion of a volatile solvent can also be used. U.S. Pat. No. 4,011,067 describes useful apparatus and procedures for preparing a web of such fibers; however, in preparing sheet products of this invention fiber-forming material is generally extruded through a plurality of adjacent orifices rather than the single orifice shown in the patent.
The sorbent particles and transport fibers are preferably introduced into the fiber stream at a point where the blown fibers have solidified sufficiently that the blown fibers will form only a point contact with the sorbent particles (as taught in U.S. Pat. No. 3,971,373) and transport fibers. However, the sorbent particles and transport fibers can be mixed with the melt blown fibers under conditions that will produce an area contact with the sorbent particles and transport fibers.
Once the sorbent particles and transport fibers have been intercepted in the blown fiber stream, the process for making the sheet product of the invention is generally the same as the process for making other blown fiber webs; and the collectors, methods of collecting, and methods of handling collected webs are generally the same as those for making non-particle-loaded blown fiber webs.
The layer of melt blown fibers, sorbent particles and transport fibers formed in any one revolution of the collection screen, and a completed sheet product of the invention may vary widely in thickness. For most uses of sheet products of the invention, a thickness between about 0.05 and 2 centimeters is used. For some applications, two or more separately formed sheet products of the invention may be assembled as one thicker sheet product. Also, sheet products of the invention may be prepared by depositing the stream of fibers and sorbent particles onto another sheet material such as a porous nonwoven web which is to form part of the eventual sheet product. Other structures, such as impermeable films, can be laminated to a sheet product of the invention through mechanical engagement, heat bonding, or adhesives.
The blown fibers are preferably microfibers, averaging less than about 10 micrometers in diameter, since such fibers offer more points of contact with the particles per unit volume of fiber. Very small fibers, averaging less than 5 or even 1 micrometer in diameter, may be used, especially with sorbent particles of very small size. Solution-blown fibers have the advantage that they may be made in very fine diameters, including less than one micrometer. Larger fibers, e.g., averaging 25 micrometers or more in diameter, may also be prepared, especially by the melt-blowing process.
Blown fibrous webs are characterized by an extreme entanglement of the fibers, which provides coherency and strength to a web and also adapts the web to contain and retain particulate matter and staple fibers. The aspect ratio (ratio of length to diameter) of blown fibers approaches infinity, though the fibers have been reported to be discontinuous. The fibers are long and entangled sufficiently that it is generally impossible to remove one complete fiber from the mass of fibers or to trace one fiber from beginning to end. Despite such entanglement, a sheet product will expand greatly in size during sorption.
The fibers may be formed from a wide variety of fiber-forming materials. Representative polymers for forming melt-blown fibers include polypropylene, polyethylene, polyethylene terephthalate, and polyamides. Representative polymers for forming solution-blown fibers include polymers or copolymers of vinyl acetate, vinyl chloride, and vinylidene chloride. Inorganic materials also form useful fibers. Fibers of different fiber-forming materials may be used in the same sheet product in some embodiments of the invention, either in mixture in one layer or in different layers.
Many of the fiber-forming materials form hydrophobic fibers, which can be undesirable in water sorbing sheet products. To improve the sheet product for such a use, a surfactant in powder or liquid form may be introduced into the sheet product, as by mixing powders with the sorbent particles before they are introduced into the web or spraying liquids onto the web after it is formed. Useful surfactants, which typically comprise molecules having oleophilic and hydrophilic moieties, include dioctyl ester of sodium sulfosuccinate and alkylaryl polyether alcohol. A small amount of the surfactant, such as 0.05 to 1 weight-percent of the sheet product, will generally provide adequate hydrophilicity, but larger amounts can be used. Use of oleophilic fibers together with water-sorbing particles can have the advantage of dual absorption, in that the fibrous web sorbs organic liquids such as oils while the particles sorb water.
As indicated above, the sorbent particles used in the invention are generally super absorbent particles, which rapidly absorb and retain under pressure large quantities of liquids. The preferred particles for sorbing water comprise modified starches, examples of which are described in U.S. Pat. No. 3,981,100, and high-molecular-weight acrylic polymers containing hydrophilic groups. A wide variety of such water-insoluble water-sorbing particles are available commercially, and they typically sorb 20 or more times their weight of water and preferably 100 or more times their weight of water. The amount of water sorbed declines as impurities are included in the water. Alkylstyrene sorbent particles (such as marketed by Dow Chemical Company under the trademark "Imbiber Beads") are useful for sorbing liquids other than water. They tend to sorb 5 to 10 times or more their weight of such liquids. In general, the sorbent particles should sorb at least their own weight of liquid.
The sorbent particles may vary in size, at least from 50 to 3000 micrometers in average diameter. Preferably, the particles are between 75 and 1500 micrometers in average diameter.
The amount of sorbent particles included in a sheet product of the invention will depend on the particular use to be made of the product and will involve balancing the amount of sorbency desired with other properties, such as integrity or strength of the web, or desired web thickness. Generally, sorbent particles account for at least about 20 g/m 2 for 100 g/m 2 of the blown fiber, more typically 150 to 300 g/m 2 for 100 g/m 2 of the blown fiber, and can account for as much as 500 g/m 2 or more for 100 g/m 2 of the blown fiber.
To achieve high loading of sorbent particles, a binding material is preferably added to the product. The binding material should be sufficiently sticky to tack the fibers and particles together, but not bond the web structure itself. The binding material is preferably hydrophilic. The end use of the product may also be considered in selecting the binding material. Materials which may be used as binding material include glycerol, polyethylene glycol, polyols, and polyethers. A small amount of the binding material, such as about 0.5 to 5% by weight of the sheet product, preferably about 0.5 to 2% by weight, is generally sufficient to provide the additional cohesion necessary to retain the sorbent particle within the web when using sorbent particle loadings of 500 weight percent or more based on the weight of the blown fiber.
The transport fibers used in the invention are generally absorbent staple fibers which rapidly absorb and wick the fluid being absorbed. Fibers useful as transport fibers are those having a water retention value of at least about 10%, preferably about 20% and more preferably about 25% when tested according to ASTM Test Method D2402. Fibers having such a water retention value have been found to provide a desired transport of liquid into the interior of the web. Such fibers include rayon, cotton, wool and silk. A particular preferred fiber is "Absorbit" rayon fiber supplied by American Enka Company.
The size of the transport fibers is preferably in the range of about 1 to 50 denier, more preferable about 1 to 30 denier. The size of the transport fibers depends on the end use of the product. Transport fibers of lower denier provide a softer hand and better mechanical hold of the sorbent particles. When using equipment such as a lickerin roll to dissociate the transport fibers during production of the product, the fibers should average between about 2 to 15 centimeters in length. Preferably, the transport fibers are less than about 7 to 10 centimeters in length.
The transport fibers may be crimped to further enhance the anti-blocking effect provided by the fibers. Crimped staple transport fibers provide additional freedom of expansion to the product as the sorbent particles swell during liquid sorption. This additional freedom of expansion reduces any tendency for the entangled blown fiber web to limit expansion of the web and thereby limit the quantity of water sorbed by the sorbent particles. Crimped transport fibers provide a mechanical release of the web which reduces the constrictive forces on the swelling sorbent particles during liquid sorption. However, the amount of crimp in the fiber cannot be so great as to excessively separate the blown fibers and sorbent particles to the extent that the interstitial movement of fluid though the web is reduced.
The amount of transport fibers included in the sheet product of the invention will depend on the particular use to be made of the product and the amount and type of sorbent particles included in the sheet product. Generally, at least 10 g/m 2 of transport fibers per 100 g/m 2 of blown fibers will be used to provide sufficient transport and wicking of the sorbed liquid to overcome the blocking effect of swollen sorbent particles and to achieve the desired rapid sorbency. Generally, the amount of transport fiber will not exceed about 100 g/m 2 per 100 g/m 2 of the blown fibers to maintain the strength and integrity of the blown fiber matrix. Generally, greater amounts of transport fiber may be used when the denier of the fiber is higher. Preferably, the sheet product contains about 20 to 60 g/m 2 of transport fibers per 100 g/m 2 of the blown fiber. Where high quality, faster sorbency sorbent particles are used, less transport fiber is required to overcome the blocking effect than where low quality sorbent particles are used. In some cases, where the sorbent particles have very rapid sorbency and are present at high loadings in the web, addition of transport fibers of lower water retention values may be unnecessary and even undesirable. Economic considerations, as well as end use requirements, may be used to determine the choice and optimum balance of transport fiber and sorbent particles.
The advantages of the sorbent sheet product of the invention are illustrated in the following examples which are not to be construed as limiting its scope.
In the following Examples, sorbency tests were run using a Demand Sorbency Test which is carried out as follows:
A 4.45 cm (1.75 inch) in diameter test sample of web is placed on a 25-50μ porous plate in a filter funnel. A pressure of 1.0 kPa is applied to the sample by a plunger which is freely movable in the barrel of the funnel. Test fluid at zero dynamic head is conducted from reservoir through a siphon mechanism to the upper surface of the porous plate where the test sample sorbs the test fluid. The amount of test fluid withdrawn from the reservoir by the test sample is then measured to determine the amount of test fluid sorbed by the test sample.
In the Demand Sorbency Tests where synthetic urine is used as the sorbed liquid, the synthetic urine has the following formulation:
______________________________________0.6% calcium chloride0.10% magnesium sulfate0.83% sodium chloride1.94% urea97.07% deionized water______________________________________
The synthetic urine solution has a conductance of 15.7 mΩ.
EXAMPLES 1-7
Sorbent sheet products were prepared from polypropylene microfibers with sorbent particles (Water-Lock J-500 supplied by Grain Processing Corp.) and staple transport fibers of the invention (Examples 1 to 4), comparative staple fibers (Examples 5 and 6), or no staple fiber as indicated in Table 1. The fibers used in these examples are as follows:
rayon--3.3 denier Absorbit rayon staple supplied by American Enka Co.
cotton--2.6-2.7 mike cotton fiber (0.92 denier)
polypropylene--3.0 denier polypropylene staple
In each Example, the sorbent sheet contained 110 g/m 2 polypropylene microfibers, 150 g/m 2 sorbent particles, 0.4 g/m 2 anionic surfactant, 1.6 g/m 2 glycerol, and staple fiber in the amounts indicated in Table 1. Demand Sorbency Tests were then conducted with synthetic urine on each prepared sheet. The results are shown in Table 1.
TABLE 1__________________________________________________________________________ Amount ofStaple Staple Weight of Synthetic urine Sorbed andFiber Fiber Retained for Time Shown (1/m.sup.2)ExampleType (g/m.sup.2) 1 min 2 min 3 min 4 min 5 min__________________________________________________________________________1 rayon 20 3.0 5.0 6.3 6.8 7.02 rayon 60 3.4 5.7 7.1 7.7 7.93 cotton 20 2.9 4.8 6.0 6.6 6.84 cotton 60 3.2 5.3 6.8 7.7 8.25 polypropylene 20 2.6 4.4 5.5 6.1 6.96 polypropylene 60 2.5 4.4 5.7 6.6 7.27 -- -- 2.5 4.2 5.2 5.7 5.9__________________________________________________________________________
The data of Table 1 shows that the rayon and cotton transport fibers, when used with the J-500 particles at a loading of 150 g/m 2 , provides the sheet product with more rapid sorbency and increased total sorbency than does the comparative polypropylene fibers. This can be seen when the percent increase in liquid sorbed of the sheet product containing cotton or rayon over the sheet product containing polypropylene is calculated as in Table 2.
TABLE 2______________________________________ Percent Increase in Weight ofStaple Amount of Synthetic urine Sorbed Over WebFiber Staple Fiber Containing Polypropylene FiberType (g/m.sup.2) 1 min 2 min 3 min 4 min 5 min______________________________________rayon 20 15.4 13.6 14.5 11.5 1.4cotton 20 11.5 9.1 9.1 8.2 -1.4rayon 60 36.0 29.5 24.6 16.7 9.7cotton 60 28.0 20.5 19.3 16.7 13.9______________________________________
EXAMPLES 8-14
Sorbent sheet products were prepared as in Examples 1-7, except that the sorbent particles were loaded in the sheet product at 300 g/m 2 . Demand Sorbency Tests were then conducted with synthetic urine on each prepared sheet. The results are shown in Table 3.
TABLE 3__________________________________________________________________________ Amount ofStaple Staple Weight of Synthetic urine Sorbed andFiber Fiber Retained for Time Shown (1/m.sup.2)ExampleType (g/m.sup.2) 2 min 4 min 6 min 8 min 10 min 12 min 14 min__________________________________________________________________________ 8 rayon 20 3.6 6.0 7.5 8.4 8.9 9.3 9.9 9 rayon 60 4.0 6.6 8.4 9.3 9.9 10.4 11.110 cotton 20 3.0 5.1 6.4 7.2 7.8 8.2 8.911 cotton 60 3.3 5.5 7.0 7.8 8.2 8.8 9.512 polypropylene 20 3.2 5.3 6.8 7.5 8.1 8.5 9.113 polypropylene 60 3.1 5.2 6.5 7.3 7.9 8.4 9.014 -- -- 3.5 5.9 7.2 7.9 8.2 8.6 9.0__________________________________________________________________________
The data of Table 3 shows that the rayon transport fiber, at both 20 g/m 2 and 60 g/m 2 , when used with the J-500 particles at a loading of 300 g/m 2 , provides the sheet product with more rapid sorbency and increased total sorbency. The cotton transport fiber provides improved liquid sorbency at the 60 g/m 2 level. With the high loading of very rapid sorbency sorbent particles, 20 g/m 2 of the fine cotton transport fiber was found to be insufficient to provide the desired increase in sorbency. This is seen in Table 4 where the percent increase in weight of water sorbed by the webs containing cotton or rayon over the web containing polypropylene is calculated.
TABLE 4__________________________________________________________________________Stable Amount of Percent Increase in Weight of Synthetic urine Sorbed OverFiber Staple Fiber Web Containing Polypropylene FiberType (g/m.sup.2) 2 min 4 min 6 min 8 min 10 min 12 min 14 min__________________________________________________________________________rayon 20 12.5 13.2 10.3 12.0 9.9 9.4 8.8cotton 20 -6.3 -3.8 -5.9 -4.0 -3.7 -3.5 -2.2rayon 60 29.0 26.9 29.2 27.4 25.3 23.8 23.3cotton 60 6.5 5.8 7.7 6.8 3.8 4.8 5.6__________________________________________________________________________
EXAMPLES 15-21
Sorbent sheet products were prepared as in Examples 1-7, except that Water-Lock A-200 sorbent particles, supplied by Grain Processing Corp. were used instead of the J-500 particles. The loading rate of particles was 150 g/m 2 . Demand Sorbency Tests were then conducted with synthetic urine on each prepared sheet. The results are shown in Table 5.
TABLE 5__________________________________________________________________________ Amount ofStaple Staple Weight of Synthetic urine Sorbed andFiber Fiber Retained for Time Shown (1/m.sup.2)ExampleType (g/m.sup.2) 1 min 2 min 3 min 4 min 5 min__________________________________________________________________________15 rayon 20 2.0 3.4 4.3 4.8 4.916 rayon 60 2.1 3.4 4.1 4.4 4.517 cotton 20 1.8 3.0 3.9 4.3 4.318 cotton 60 1.9 3.2 4.1 4.5 4.519 polypropylene 20 1.0 1.9 2.7 3.4 3.820 polypropylene 60 1.2 2.3 3.4 4.1 4.521 -- -- 1.0 2.0 2.8 3.5 4.1__________________________________________________________________________
The data of Table 5 shows that the rayon and cotton transport fibers, when used with the A-200 sorbent particles at a loading of 150 g/m 2 , provide more rapid sorption of the synthetic urine than does polypropylene staple fiber. This can be seen when the percent increase in liquid sorbed of the sheet product containing cotton or rayon over the sheet product containing polypropylene is calculated as in Table 2. The use of rayon or cotton transport fibers also provides a greater increase in sorbency of the sheet product when used with the less sorbent A-200 sorbent particles than when used with the more sorbent J-500 particles.
TABLE 6______________________________________ Percent Increase in WeightStaple Amount of Synthetic urine Sorbed Over WebFiber Staple Fiber Containing Polypropylene FiberType (g/m.sup.2) 1 min 2 min 3 min 4 min 5 min______________________________________rayon 20 100.0 78.9 59.3 41.1 28.9cotton 20 80.0 57.9 44.4 6.5 13.2rayon 60 75.0 47.8 20.6 7.3 0cotton 60 58.3 39.1 20.6 9.8 0______________________________________
EXAMPLES 22-28
Sorbent sheet products were prepared as in Examples 15-21, except that the A-200 sorbent particles were loaded at a rate of 300 g/m 2 . Demand Sorbency Tests were conducted with synthetic urine on each prepared sheet. The results are shown in Table 7.
TABLE 7__________________________________________________________________________ Amount ofStaple Staple Weight of Synthetic urine Sorbed andFiber Fiber Retained for Time Shown (1/m.sup.2)ExampleType (g/m.sup.2) 1 min 2 min 3 min 4 min 5 min__________________________________________________________________________22 rayon 20 1.7 3.3 4.5 5.5 6.323 rayon 60 1.7 3.4 4.7 5.8 6.424 cotton 20 1.7 3.4 4.6 5.5 5.925 cotton 60 1.5 3.1 4.4 5.5 6.126 polypropylene 20 0.9 1.9 2.8 3.6 4.427 polypropylene 60 0.8 1.6 2.3 3.0 3.728 -- -- 1.0 2.1 3.1 4.0 4.6__________________________________________________________________________
The data of Table 7 shows that the rayon and cotton transport fibers, when used with the A-200 sorbent particles at a loading of 300 g/m 2 , provide more rapid and higher liquid sorption than do the comparative polypropylene fibers. This can be seen when the percent increase in liquid sorbed of the sheet product containing cotton or rayon over the sheet product containing polypropylene is calculated as in Table 8.
TABLE 8______________________________________ Percent Increase in Weight ofStaple Amount of Synthetic urine Sorbed Over WebFiber Staple Fiber Containing Polypropylene FiberType (g/m.sup.2) 1 min 2 min 3 min 4 min 5 min______________________________________rayon 20 88.8 73.7 60.7 52.3 43.2cotton 20 88.8 78.9 64.3 52.3 34.1rayon 60 112.5 112.5 104.3 93.3 7.30cotton 60 87.5 93.8 91.3 83.3 64.9______________________________________
EXAMPLES 29-31
A sorbent sheet product of the invention, Example 29, and comparative Examples 30 and 31 were prepared having the constituents shown in Table 6. The initial thickness of each sheet was measured. 5 cm×5 cm samples of each sheet product were prepared and placed in water for 30 seconds. The thickness of each sheet was again measured. Initial and final thicknesses are shown in Table 6.
TABLE 9______________________________________Constituents Example 29 Example 30 Example 31______________________________________Polypropylene microfiber 100 100 100(g/m.sup.2)J-500 (g/m.sup.2) 300 300 13Rayon *(g/m.sup.2) 60 -- --Surfactant (g/m.sup.2) 0.4 0.4 0.4Glycerol (g/m.sup.2) 1.6 1.6 0Initial Thickness (cm) 0.5 0.4 0.2Final Thickness (cm) 3.5 2.0 0.7______________________________________ *"Absorbit" rayon fiber supplied by American Enka Co.
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Sorbent sheet products are prepared comprising a coherent fibrous web that includes entangled blown fibers and liquid transport fibers intermingled with the blown fibers and an array of solid high sorbency liquid-sorbent polymeric particles uniformly dispersed and physically held within the web. The particles swell upon sorption of liquid, and the transport fibers cause increased and more rapid sorption of liquid by conducting the liquid from external portions of the web to internal portions of the web.
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This application is a continuation application of U.S. Patent Application Ser. No. 09/606,062, filed Jun. 29, 2000, now U.S. Pat. No. 6,795,530 which is herein incorporated by reference in its entirety.
BACKGROUND
1. Field of the Invention
The present invention relates generally to telecommunications systems. More particularly, the present invention relates to voicemail and other personal communications telephone services.
2. Background of the Invention
Personal communications services have become a nearly ubiquitous means for facilitating communication between people. Such systems include, e.g., voicemail systems allowing callers to leave and/or retrieve messages at any time of the day or night, and “one number” type services wherein an incoming call is rerouted multiple times until the call is answered by a subscriber or an answering service. Such services generally allow information to flow between parties regardless of the immediate availability or location of each party. These services further simplify the communications process by allowing a service subscriber to give out a single telephone number to all of his or her business or social contacts.
Personal communications services have increased the possibility that a subscriber will receive information from a caller calling the subscriber's telephone number. However, such services have reduced the personal contact between the parties. In conventional personal communication services when a caller dials the subscriber's telephone number, an automated system offers a greeting to the caller and requests a response from the caller. The greeting may be a voice message from the subscriber, or a more general message provided by the system. The problem with such conventional personal communication services is that all callers receive the same greeting, regardless of the caller's relationship with the subscriber. Therefore, the subscriber's spouse, child, supervisor, close friends, and telemarketers all receive the identical greeting. Thus, subscribers tend to provide generic information in the greeting to avoid disclosing too much personal information to third parties. The problem is further illustrated by the following example.
Suppose a subscriber wishes to provide a general greeting to any unknown callers calling the subscriber's telephone number. Suppose further that the subscriber wishes to provide more specific information to important existing clients. Such specific information may include, e.g., the subscriber's home telephone number or address. Suppose further, that the subscriber wishes to greet his or her spouse or child with a more personal greeting. Using conventional services, the subscriber cannot distinguish between callers without maintaining multiple telephone numbers or mailboxes. Because all callers receive the same greeting, the subscriber is forced to choose between providing too many details or not enough details in the greeting.
Some conventional voicemail services can distinguish between internal and external callers, provided the system is operated through a private branch exchange (“PBX”). Such systems, however, can only provide two levels of personalization. That is, the caller either is, or is not calling from the same PBX. If the former is true, the caller receives one greeting, and if the latter is true, the caller receives another greeting. Such systems provide no distinction between different internal callers or different external callers.
A system and method is needed for facilitating more personalized communications between callers and personal communications service subscribers.
SUMMARY OF THE INVENTION
The present invention is a system and method for providing customized greeting announcements to callers according to instructions provided by a personal communications service subscriber. The invention uses a database for storing specific telephone numbers designated by the subscriber to receive a personal greeting. The invention further allows the subscriber to create different greetings for different groups of callers, and a default greeting for any unidentified callers or those callers calling from a telephone number not listed in the database.
When an incoming call is answered by the personal communications service, the system checks the database to see whether or not the subscriber has identified that calling party number (“CgPN”) as a number that receives a personalized greeting. If the CgPN is in the database, the system plays the specific greeting selected by the subscriber for that specific caller (or group of callers if the CgPN is designated to receive a group greeting). If the CgPN is not in the database, the system plays a default greeting to the caller.
The system of the present invention comprises two main components: (1) a server system and (2) a messaging system. The server system comprises the database of designated numbers and a software module (programming logic) for using or manipulating the information contained in the database. The messaging system stores the customized announcements and has the capability to play selected announcements to a caller. The server system and the messaging system could be operated on a single integrated computer system or on multiple computers.
The present invention further provides an automated administration system allowing the subscriber to update his or her personal greetings and the associated list of callers, i.e., designated telephone numbers. To access the administration system, the subscriber calls an access telephone number. When connected, the subscriber may be prompted to provide authentication information such as the subscriber's telephone number and password. If the subscriber is authenticated, a menu-driven system of options is provided to the subscriber. For example, the administration system may prompt the subscriber to enter a telephone number to be added to, deleted from, or modified in the database.
A telephone service provider may deploy the present invention in the context of the Advanced Intelligent Network (“AIN”). In this case, a suitable AIN trigger on the subscriber's line causes the call to be temporarily suspended while the service control point (“SCP”) determines the proper routing for the call. In a preferred embodiment, the SCP routes the call to a service node (“SN”) based on the AIN trigger and the called party number, i.e., the subscriber's number. The SN then retrieves the subscriber's telephone number and the caller's telephone number and acts accordingly. Once the appropriate personal greeting has been played, the caller may be instructed to leave a message. Alternatively, the call may be disconnected or routed back to the SCP for further call processing. In other embodiments, the SN is not part of the call routing process.
It is an object of the present invention to provide a system and method facilitating more personalized communication between two or more parties.
It is a further object of the present invention to provide subscribers more flexibility to manage calls via a plurality of customized greeting announcements.
It is a further object of the present invention to provide a system and method allowing subscribers to offer individual personalized greetings to a plurality of callers.
These and other objects of the present invention are described in greater detail in the detailed description of the invention, the appended drawings and the attached claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the components of one embodiment of the present invention.
FIG. 2 is a flow diagram showing the steps executed in an example illustrating the administration system in one embodiment of the present invention.
FIG. 3 is a flow diagram showing the steps executed in an example illustrating the greeting system in a preferred embodiment of the present invention.
FIG. 3 a is a flow diagram showing the steps executed in an example illustrating the greeting system in an alternative embodiment of the present invention.
FIG. 4 is a schematic diagram showing an embodiment of the present system operating within the Advanced Intelligent Network.
DETAILED DESCRIPTION OF THE INVENTION
As discussed above, the present invention uses a database for storing subscription data for each subscriber of the service. Subscription data includes the calling party numbers designated by a subscriber and allows the subscriber to create a personalized greeting for each calling party number, or groups of calling party numbers, so designated. A computer having suitable processing speed and data storage medium provides the platform for the database of the present invention. The database may be created and managed using any suitable database software.
Table 1, below, identifies subscription data used in a preferred embodiment of the present invention. For example, the database preferably includes the subscriber's telephone number and a password. Note that the subscriber's telephone number, as used herein, means the telephone number that callers use to communicate with the subscriber. Table 2 is an example showing the type of data that may be stored in the database fields.
TABLE 1
Subscriber Telephone Number
PIN
Designated List
CgPN 1 , Announcement ID
CgPN 2 , Announcement ID
CgPN 3 , Announcement ID
. . .
CgPN n , Announcement ID
Undesignated Numbers, Default
Announcement
TABLE 2
202-123-2222
123456
202-123-3333, Message 1
202-123-4444, Message 2
202-123-5555, Message 1
303-456-6666, Message 3
Undesignated Numbers,
Message 4
One of ordinary skill in the art of database programming can implement a database for storing fields such as shown in Tables 1 and 2. The purpose of the database is to allow the subscriber to designate which callers should receive a customized greeting, and to identify which customized greeting to play when an incoming call is received. FIG. 1 illustrates how the information in Table 2 is used in an embodiment of the present invention. Telephones 105 , 110 and 115 have telephone numbers (202) 123-3333, (202) 123-4444 and (202) 123-1111, respectively, as shown in FIG. 1 . All calls, including a call from one a caller using of these telephones, to the subscriber's telephone number (202) 123-2222 are handled by server system 120 , where database 122 resides. Database 122 contains, among other things, the items shown in Table 2. Server system 120 checks database 122 to determine which message messaging system 125 should play to the caller. For example, a call from telephone 105 results in message 1 being played by messaging system 125 because it is from a designated calling number, while a call from telephone 115 results in the default message (message 4) being played because the telephone number (202) 123-111 has not been designated by the subscriber and stored in database 122 .
Database 122 must be populated with subscription data for each subscriber of the customized greeting service. The service provider initially populates some or all of the data when a new subscriber is added to the service. Once the data is in place, subscribers may review or modify the information as required to customize the service using administration system 130 , as shown in FIG. 1 . Administration system 130 is also used to review or modify the customized greetings associated with each telephone number designated by the subscriber which are stored on messaging system 120 . In a preferred embodiment, the subscriber could use subscriber telephone 135 which, in for example, has telephone number (202) 123-2222 to access administration system 130 to review or modify the database information. As explained below, when inbound calls are received by administration system 130 , the system checks database 122 to see if the CgPN belongs to a subscriber. If the CgPN is a subscriber's telephone number, administration system 130 allows the subscriber access to the subscriber's subscription data. If the CgPN is not a subscriber's telephone number, administration system 130 may request additional information from the subscriber before granting access to the data, as described below.
The flow diagram in FIG. 2 is an example of steps that can be executed to carry out a preferred embodiment of the present invention. In this example, the administration system can be accessed by calling a telephone access number for the administration system (step 205 ). A subscriber using a touch-tone telephone can place the call. The administration system in this embodiment further uses the CgPN to determine whether or not the caller is a subscriber of the service (step 210 ). In step 215 the system determines if the CgPN is in the subscriber telephone number field of the database. If the CgPN does not correspond to a subscriber's telephone number in the database, the subscriber is prompted to enter his or her telephone number, unless the system is restricted (steps 220 and 225 ). If the administration system is restricted, then the administration system only accepts calls from subscribers using a designated telephone line to access the system. In that case, when the CgPN is not found in the database, the subscriber is instructed to hang up and call back from the proper telephone line (step 230 ). As noted above, if the administration system is not restricted, the system prompts the subscriber to enter a telephone number (step 225 ). In step 226 , the system determines whether the telephone number entered is a valid subscriber number. If the telephone entered is not valid, i.e., the number is not found in the database, the system moves on to step 230 , where the caller is instructed to hang up. Otherwise, if the telephone number is found in the database, the system moves on to step 235 .
In step 235 , the administration system prompts the subscriber for authentication information (e.g., a password or personal identification number (“PIN”)). In step 240 , the administration system compares the authentication information provided by the subscriber with the information in the database. If the authentication information matches the information in the database, the system leads the subscriber through a menu-driven system to implement the desired database updates in steps 245 – 265 , as described below.
For example, the system prompts the subscriber to enter the telephone directory number to be added, deleted or modified on the system (step 245 ). In step 250 , the system looks for the entered telephone number in the subscriber's personal list of telephone numbers. If the number is not located, the system asks the subscriber in step 255 whether the number is to be added to the subscriber's personal list. This step helps identify problems such as the subscriber entering a wrong number. If the subscriber does not wish to add this number, the system returns to step 245 and prompts the subscriber for a new telephone number. If the subscriber chooses to add the number, the system prompts the subscriber to enter or select a personal greeting to use for calls coming from this number (step 260 ). In step 265 , the system determines whether or not the subscriber has additional updates to the database. If the subscriber has additional updates, the system returns to step 245 and the subscriber is prompted to enter to telephone number to be added, deleted or modified.
If in step 250 the system was able to identify the telephone number entered by the subscriber as an existing number in the database the system moves on to step 270 . In step 270 , the system determines whether the subscriber wishes to edit the greeting or delete the number from the subscriber's designated list. If the subscriber wishes to delete the number, the system moves on to step 275 in which the number is removed from the subscriber's personal list. After deleting the number, the system allows the subscriber to add, edit or delete more numbers in step 265 , as described above. If the subscriber wishes to edit the telephone number or the greeting, the system moves on to step 260 where the system prompts the subscriber to create or select a personal greeting, as described above.
In another embodiment of the present invention, subscribers can create a greeting for one or more groups of callers. In this embodiment, when the subscriber adds a new caller's number to the personal list, the administration system provides the option for selecting a pre-existing greeting to be played for the caller. In another embodiment, the system prompts the subscriber to enter a list of caller numbers designated to receive a group greeting. In this embodiment, caller numbers can be added to or deleted from the group, and the group greeting can be modified using the administration system.
FIG. 3 is an example of the steps to can be executed in a preferred embodiment of the present invention to provide a personal greeting. In step 305 , a caller calls the subscriber's telephone number. If the call is answered by the subscriber's personal communications service, the personal greeting system of the present invention looks up the subscriber's number, i.e., the CdPN and the callers' number, i.e., the CgPN, in the database (step 310 ). If the calling party number is located on the subscriber's personal list, i.e., the list associated with the CdPN (step 315 ), the system moves on to step 320 . In step 320 , the system plays the personal greeting to the caller. If the caller's number is not located on the list, the greeting system plays the subscriber's default greeting (step 325 ).
FIG. 3 includes steps 330 and 335 , which are used in an alternate embodiment of the present invention. In this embodiment, the system determines whether or not the subscriber has multiple listings for a particular telephone number on his or her personal list (step 330 ). As discussed above, this embodiment allows the subscriber to provide personalized greetings even when the calling party number is a shared line. If the personal list has multiple entries for the CgPN, the system prompts the caller to enter his or her name or some other identifying code (step 335 ). The system then matches the name or code with the appropriate greeting and plays the greeting in step 320 .
The location of the personal communication service of the present invention within the telephone network is not important. Thus, the personalized greetings could be offered as an integral part of systems operated by third party service providers. Alternatively, the personalized greetings could be delivered directly by the telephone service provider or it could be a part of the PBX at the called party number. In either case, the personal communications service of the present invention obtains the CgPN using conventional calling line identification service.
FIG. 4 is a schematic diagram showing an example of an embodiment of the present invention using the AIN. FIG. 4 shows greeting service subscriber 410 having telephone 411 connected to telephone subscriber line 412 . Subscriber line 412 is connected to SSP 421 in the telephone service provider's central office facility. When subscriber 410 signs up for the personal greeting service, an AIN trigger is provisioned on subscriber line 412 at SSP 421 . In one embodiment, the trigger is a termination attempt trigger (“TAT”). When caller 413 , using telephone 414 connected to telephone subscriber line 415 , calls the subscriber's telephone number, the call hits the TAT at SSP 421 . As shown in FIG. 4 , caller 413 need not be part of the same telephone network 420 operated by subscriber 410 's telephone service provider. Thus, the call from caller 413 may pass through inter-exchange carrier (“IXC”) 416 , as shown in FIG. 4 , before encountering the TAT at SSP 421 or it may go directly to SSP 421 .
In response to the TAT, SSP 421 suspends call processing, sends a query to SCP 422 for further instructions. Queries and responses, using the well known transactions capabilities user part (“TCAP”), are transmitted between SSP 421 and SCP 422 via Common Channel Signaling System Number 7 (“SS7”) 423 as shown in FIG. 4 . SCP 422 looks up the CDPN, i.e., the subscriber's number, in database 422 a , and sends a response back to SSP 421 . The response instructs SSP 421 to route the call to SN 424 . When the call is connected to SN 424 , the subscriber's number is retrieved from the redirecting party number field in the call setup message. The caller's number is retrieved from the calling party number field in the call setup message. SN 424 looks up the subscriber's number and the caller's number in database 424 a to determine the appropriate personal greeting to play to caller 413 . Once the appropriate personal greeting has been played, the call continues as it would in conventional systems. That is, for example, the call may be routed to voicemail system (“VMS”) 425 , or the call processing could continue with attempts to reroute the call to a different telephone or the call may simply be disconnected.
In another embodiment, SN 424 is not used. In this embodiment, SCP 422 routes the call directly to VMS 425 . VMS 425 would then retrieve the subscriber's number and the caller's number and play the appropriate greeting to the caller.
The foregoing disclosure of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
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A system and method for providing customized announcements to callers based on the called party telephone number and the calling party telephone number. The system comprises a server system and a messaging system. The server system detects that a customized announcement is to be delivered and the messaging system delivers the announcement to the caller. The customized announcements may be provided in conjunction with voicemail systems or other services for processing calls when a called party is not available. In a preferred embodiment the customized announcements are provided via a service node in an advanced intelligent network.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Application No. 61/038,115, filed Mar. 20, 2008 entitled “Apparatus for Firearm Maintenance.”
FIELD OF THE INVENTION
The disclosed apparatus relates to the proper maintenance of firearms. More particularly, the invention discloses a tool useful for removing the floorplate of a firearm's magazine.
BACKGROUND ART
A magazine also called a clip is an ammunition storage and feeding device within or attached to a firearm. Magazines may be integral to the firearm (fixed) or removable (detachable). The cartridges in the magazine are loaded or fed into the firearm's chamber either automatically or manually depending on the firearm, but almost always by a spring. The most common type of magazine is the detachable “box” type.
Firearms must be clean to function reliably and safely. One common area of firearm malfunction, especially in the field (i.e., hunting, a law enforcement operation or military combat), is dirt or debris inside the magazine which interferes with the proper loading of ammunition from the magazine to the chamber. Accordingly, it is desirable to have a tool that allows quick and easy access to the magazine's magazine tube, via removal of the magazine's floorplate, so that the magazine tube and spring can be cleaned to insure proper operation.
Some firearms, such as some Glock® pistols, have magazines that are very difficult to disassemble and clean. One possible method of removing a magazine's floorplate is known in the prior art. The method relies upon a pliers-like device to remove the floorplate. The pliers' beaks must be held in place, while the handles are at a distance from the magazine, making it difficult to apply pressure on the locking tabs, maintain control of the magazine and manipulate the release of the floorplate with the other hand. Consequently, a device that provides easy application of force on the locking tabs while removing the floorplate is desirable. The current invention allows the user to secure the magazine and apply force to the magazine releasing the locking tabs in a manner which is easily accomplished with one hand, allowing the other hand to remove the floorplate and preventing damage to the magazine.
BRIEF DESCRIPTION OF DRAWINGS
It should be noted that identical features in different drawings are shown with the same reference numeral.
FIG. 1 shows a perspective view of a firearm magazine.
FIG. 2 shows a perspective view of a firearm magazine with the floorplate removed exposing the locking tabs on the magazine and the retaining cut outs on the floorplate.
FIGS. 3 a and 3 b show a three quarter (¾) view of one embodiment of the tool disclosed herein.
FIG. 4 shows a side view of one embodiment of the tool disclosed herein.
FIG. 5 shows a top view of one embodiment of the tool disclosed herein with the magazine (shown in dotted lines) inserted into the tool.
FIG. 6 shows a side view of a magazine inserted into one embodiment of the tool.
FIG. 7 shows one possible embodiment inserting the magazine into one embodiment of the tool.
DETAILED DESCRIPTION
The current invention discloses a tool used for removing a floorplate of a firearm's magazine. The tool allows its user to apply sufficient force to the magazine's side walls to disengage locking tabs on the magazine from retaining cut-outs on the floorplate and to remove the floorplate.
FIGS. 1 , 2 , 6 and 7 show a firearm magazine 22 used to store ammunition (not shown). The ammunition is stored in a magazine tube 26 and is fed by a spring-loaded mechanism (not shown) into the firearm's chamber (not shown). To assure safe and dependable operation of the firearm, the magazine 22 must be cleaned from time-to-time. Many magazines 22 have a floorplate 24 , located on the bottom of the magazine 22 , which must be removed to clean the magazine 22 . Some floorplates 24 employ locking tabs 28 located on the magazine 22 (often the locking tabs 28 are located on opposite sides of the sidewalls 32 ) that fit into retaining cut outs 30 a and 30 b on the floorplate 24 locking the floorplate 24 into position thereby enclosing the lower end of the magazine tube 26 . It is desirable to preserve the structural integrity, i.e., the “locking mechanism”, by preserving the shape of the locking tabs 28 and the retaining cutouts 30 a and 30 b assuring a close fit between the floorplate 24 and the magazine 22 . One method of preserving the integrity of the locking mechanism is to completely or nearly completely disengage the locking tabs 28 from the retaining cut-outs 30 a and 30 b before attempting to remove the floor plate 24 .
Generally, to remove the floorplate 24 from the magazine 22 , one must apply sufficient force to the magazine's side walls 32 to depress the locking tabs 28 and disengage them from the retaining cut-outs 30 a and 30 b . Once the locking tabs 28 are disengaged, the floorplate 24 may be slid off the magazine 22 in a horizontal or nearly horizontal motion as depicted in FIG. 2 . This particular embodiment shows the method of removing the floorplate from a “Generation I” magazine for the Glock® pistol. “Generation II” and “Generation III” Glock® magazines have a retaining pin which is part of the reinforcement plate which must be depressed with a punch or other similar instrument before depressing and disengaging the locking tabs. The present invention will work with any generation of the Glock® magazines.
One embodiment of the invention is depicted in FIGS. 2 , 3 a , 3 b , 4 , 5 and 7 . The tool 10 has an upper surface 6 , lower surface 2 , an inner surface 4 , an open-end having a slit 16 , a long horizontal axis 8 and two (2) arms 18 a and 18 b . The slit 16 allows the user to squeeze the tools arms 18 a and 18 b together, but only to the point the arms 18 a and 18 b touch. This particular embodiment has a notch 12 located on the upper surface 6 of the tool 10 located opposite the open-end. The notch 12 allows for easy removal of the floorplate 24 . The tool 10 has a plurality of projections 14 a and 14 b on its inner surface 4 .
In this particular embodiment, the tool 10 is a rectangularly-shaped hollow ring made of a plastic, nylon or other polymer. The tool 10 may be made from a rigid or semi-rigid material (the “construction material”) having the stiffness and strength to displace the locking tabs 28 from the floorplate's retaining cut-outs 30 a and 30 b , yet flexible enough (i) to allow the user to “squeeze” or apply pressure to the tool's arms 18 a and 18 b together creating the force necessary to use the tool 10 and (ii) allow the tool 10 to return to its original shape after each use. In one embodiment, the construction material is glass filled nylon. In one embodiment the glass filled nylon contains between about 0 to 20 percent glass. In another embodiment glass filled nylon contains between about 21 to 40 percent glass. In yet another embodiment, the glass filled nylon contains between about 41 to 60 percent glass. In yet another embodiment, the glass filled nylon contains over 60 percent glass. Other materials may be added to the construction material to yield the desired flexibility and stiffness. Accordingly, as one skilled in the art will realize, the tool 10 may be made from a variety of materials.
Further in this embodiment, the tool 10 has two (2) projections 14 a and 14 b on its inner-surface 4 and a slit 16 perpendicular to its long horizontal axis 8 . In an alternate embodiment (not shown) the tool has four (4) projections on its inner surface. The slit 16 is located opposite the notch 12 . In this embodiment, the tool 10 has measurements of about 2.5″ long, about 1.25″ wide and about 0.75″ tall. Further, the slit 16 in this embodiment may be about 0.125″ wide. However, the slit 16 may range from about 0.0625″ to 0.250″ wide. In an alternate embodiment the slit is not perpendicular to the long horizontal axis 8 . These dimensions of the embodiment of the invention are designed to fit a magazine for a Glock® pistol with a caliber of either 9 mm, 0.40 S&W, or 0.357 Sig. For a Glock® pistol with a caliber of 10 mm, 0.45 ACP, or 0.45 GAP, the dimensions will be larger due to the larger diameter of this ammunition and the correspondingly larger width of the magazine 22 . For magazines with a “single stack” configuration, the dimensions of the invention will be smaller due to the decreased width of the magazine 22 . If the tool 10 is configured to receive magazines for different firearms, the tool 10 may have different dimensions as would be obvious to one skilled in the art.
FIGS. 5 , 6 and 7 show one possible embodiment of using the tool 10 . In this embodiment, the tool 10 is configured to receive or slide over a Glock® firearm's magazine 22 . After sliding the tool 10 lengthwise, from top to bottom, along the magazine 22 until the tool 10 rests against the locking tabs 28 , the user squeezes the tool's arms 18 a and 18 b together creating pressure points on the magazine's side walls 32 . The projections 14 a and 14 b create pressure points immediately adjacent to the magazine's locking tabs 28 , sufficient to disengage the locking tabs 28 from the floorplate's retaining cut-outs 30 a and 30 b . As shown in FIG. 7 , after the locking tabs 28 are disengaged from the floorplate's retaining cut-outs 30 a and 30 b , the floorplate 24 is slid in a horizontal or nearly horizontal motion off of the magazine 22 . Once the floorplate 24 is removed, the user can clean the inside the magazine tube 26 to remove debris and other materials which may interfere with the proper operation of the firearm.
To replace the floorplate 24 after cleaning, the user will again slide the tool 10 lengthwise, from top to bottom, along the magazine 22 and squeeze the arms 18 a and 18 b of the tool 10 , applying pressure to the magazine's side walls 32 , thereby allowing user to slide the floorplate 24 and corresponding retaining cut-outs 30 a and 30 b over the locking tabs 28 into a secure position.
Other embodiments of the present invention are possible. For example, some magazines 22 (such as Glock®'s second and third generation magazines) have additional attachment mechanisms attaching the floorplate 24 to the magazine 22 . One such mechanism is a retaining pin 40 which must be released before the floorplate 24 may be removed. The present invention should be understood to assist the user in removing a floorplate 24 from any magazine 22 including without limitation the second and third generation Glock® magazines.
The current invention has several advantages. First, the tool 10 minimizes the wear on the magazine's locking tabs 28 and the floorplate's 24 retaining cut-outs 30 a and 30 b during disassembly (or assembly) by disengaging the locking tabs 28 from the retaining cut-outs 30 a and 30 b , allowing the floorplate 24 to be easily removed (or replaced) preserving the structural integrity of the retaining cut-outs 30 a and 30 b and the locking tabs 28 . Further, using the tool 10 , the magazine 22 may be disassembled (or assembled) without marring or scuffing the magazine 22 . This is especially important when the tool 10 is used to remove the floorplate of a Glock® firearm's magazine as Glock® magazines are often made of polymers (i.e., composite materials) which may be marred or scuffed during assembly and disassembly. Additionally, the tool 10 limits the amount of force that can be applied to the magazine's side walls 32 . By limiting the amount of force applied to the magazine's side walls 32 during disassembly or assembly, damage to the magazine's metal liner (not shown) may be avoided. Finally, the tool's 10 precise fit over the magazine 22 allows for easy disassembly, assembly and cleaning of the magazine 22 by one person.
While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed here.
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The present disclosure teaches an apparatus for removing a firearm magazine's floorplate comprising a substantially elliptically shaped element comprising an open end, a top surface, a bottom surface and an inner surface, a notch located in the upper surface of the element, a slit on the open end opposite the notch and a plurality of projections located on the inner surface. Methods of using the apparatus are also disclosed.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an apparatus for analyzing a failure for a semiconductor memory device.
[0003] 2. Description of the Related Art
[0004] Conventionally, a memory test method using BIST (Built-in Self Test) has been widely used as a method for analyzing a failure of a memory for a semiconductor memory device or the like. The BIST is a test in which a test pattern is previously made inside a semiconductor chip and a test is conducted on all the memory cells in the chip using the test pattern, and whether or not there is a failure on the memory is output as information indicative of PASS or FAIL to the outside of the semiconductor chip.
[0005] The employment of such a test method by the BIST provides a merit of capability of conducting a memory test at a high speed. However, there is a problem that information obtained only concerns whether or not there is trouble on the memory, and it is impossible to obtain any information concerning where the trouble exists on the memory cell, at how many locations the trouble exists.
[0006] It is possible to specify the failure locations and the number of failures of the memory cells by adding registers for holding trouble information in accordance with the memory cells to a BIST circuit. However, this considerably increases the circuit size of the BIST. Thus, the larger BIST circuit is required to obtain the more pieces of trouble information. If no trouble occurs, the circuit which have been added to hold trouble information become needless.
[0007] [0007]FIG. 1 is a block diagram showing a configuration of a conventional memory BIST circuit including registers for holding trouble information as described above. As shown in FIG. 1, the memory BIST circuit comprises an address counter circuit 101 for outputting address information to specify a memory cell in a memory (RAM) 100 , a data generator circuit 102 for generating an expected value of a test result, a comparator circuit 103 for comparing the output signal of the memory 100 with the expected value and determining whether the memory 100 is good or bad, and a BIST controller circuit 104 for controlling the state of the memory BIST operation.
[0008] The address counter circuit 101 , the data generator circuit 102 , and the comparator circuit 103 are individually controlled by the BIST controller circuit 104 . The comparator circuit 103 has a function capable of holding the comparison result in a register by every bit-line. Therefore, an inspection of the state of the register makes it possible to specify at least failures on each bit-line. However, there is a problem that the failure location can not be specified in more detail because of the absence of a function of holding address information.
[0009] Meanwhile, a test method is conducted in which the output signals of all the memory cells and test addresses are output to an external terminal of the semiconductor chip and input to an exclusive memory tester or the like to be examined, but the problem thereof is impossibility of a test on the memory operating at a high speed. In other words, since the operating speed of the memory tester is low relatively to the operating speed of the memory, there is a limit to a test on a recent high speed memory by the exclusive memory tester.
[0010] A product mounting a plurality of memories on a semiconductor chip requires many selector circuits in order to give output signals of all the memory cells to an external terminal of the semiconductor chip. Therefore, the test circuit for the entire product increases in size, besides, there is a problem that the propagation speed of a signal decreases to affect the system operating speed of the product.
[0011] For the above reason, a failure analysis using the BIST method is performed as follows under the present circumstances. First, a memory test is conducted by the BIST method to determine the presence or absence of trouble on a memory subjected to the test. In this determination method, the memory output signal is compared with a previously prepared expected value, and when both values disagreement with each other, the register is allowed to store information indicative of “presence of trouble,” and the information is output to the external terminal. The information thus obtained indicates only the presence or absence of occurrence of trouble.
[0012] When the occurrence of trouble is recognized, a failure analysis is then performed. In this failure analysis, the BIST operation is performed, and then the BIST operation is suspended when a trouble occurrence pattern is found. The circuit state is set such that information indicative of the failure location (bit-line/word-line information) at that time is output to the external terminal, thereby obtaining failure information.
[0013] However, in such a test method, it is necessary to repeat the BIST operation and the failure information detection operation to obtain the full failure information for a memory having a plurality of failures. Thus, sequentiality of the BIST operation is lost, resulting in the case in which the test result differs from the initial test result at the time of examining the presence or absence of trouble. Further, since it is not recognized in which pattern the trouble occurs, the BIST operation needs to be carried out to the last pattern to obtain the trouble information, which brings about a problem that it takes much time to detect the failure information.
SUMMARY OF THE INVENTION
[0014] The present invention is made to solve the above problems and its object is to specify the presence or absence, locations, the number, and the like, of failures, by one BIST test without addition of a complicated circuit configuration and to reduce considerably the processing time required for a memory test.
[0015] In an apparatus for analyzing a failure for a semiconductor memory device of the present invention, failure determination of the inside of the semiconductor memory device is made in sequence based on address information supplied to the semiconductor memory device using a test circuit of the semiconductor memory device, and resultant output failure determination information and the address information are fetched and held in a scan register circuit. This scan register circuit is made by using an originally provided logic scan circuit used at the time of conducting a test on a logic circuit other than the semiconductor memory device, and adding a function capable of obtaining failure determination result information thereto.
[0016] The present invention comprises the above-described technical means, thereby making it possible to use efficiently the scan register circuit originally existing for a logic test also for a memory test thereby to hold the failure determination result information detected upon the test of the semiconductor memory device in sequence into the scan register circuit with the address information. Accordingly, even if the present invention does not include an addition of a complicated circuit configuration, it becomes unnecessary to repeat processing of suspending the test operation at every detection of failure to specify the failure location, and it becomes possible to obtain information concerning one or more failure locations and the number of failures into the scan register circuit by one test.
[0017] Consequently, it is possible to obtain information concerning one or more failure locations and the number of failures by one test without addition of a complicated circuit configuration and to reduce considerably the processing time required for a memory test.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a block diagram showing the configuration of a conventional memory BIST circuit;
[0019] [0019]FIG. 2 is a block diagram showing an example of configuration of an apparatus for analyzing a failure for a semiconductor memory device according to an embodiment of the present invention;
[0020] [0020]FIG. 3 is a block circuit diagram of a circuit configuration of one scan flip-flop composing a logic scan chain;
[0021] [0021]FIG. 4 is a block diagram showing a configuration of a register chain using the scan flip-flop shown in FIG. 3;
[0022] [0022]FIG. 5 is a block diagram showing an example of configuration of a failure flag generator circuit;
[0023] [0023]FIG. 6 is a block diagram for explaining a switching method between a clock used at the time of a logic scan and a clock used at the time of a memory scan by BIST; and
[0024] [0024]FIG. 7 is a block diagram showing another example of configuration of the apparatus for analyzing for a semiconductor memory device according to the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Hereinafter, an embodiment of the present invention will be explained with reference to drawings.
[0026] [0026]FIG. 2 is a block diagram showing an example of configuration of an apparatus for analyzing a failure for a semiconductor memory device according to an embodiment of the present invention.
[0027] In FIG. 2, a memory BIST circuit 16 according to this embodiment comprises an address counter circuit 11 , a data generator circuit 12 , a comparator circuit 13 , and a BIST controller circuit 14 . The address counter circuit 11 outputs address information for specifying a memory cell in a memory (RAM) 10 . The data generator circuit 12 generates an expected value of a test result.
[0028] The comparator circuit 13 compares a signal output from the memory 10 based on the address information with the expected value output from the data generator circuit 12 at every read pattern to determine whether the memory 10 is good or bad. The BIST controller circuit 14 controls the state of memory BIST operation. The above-described address counter circuit 11 , data generator circuit 12 , and comparator circuit 13 are individually controlled by the BIST controller circuit 14 .
[0029] A logic scan chain 15 comprises scan flip-flops. The logic scan chain 15 is divided into a plurality of shift registers 15 - 1 , 15 - 2 , . . . , and 15 - n . Each of the divided shift registers 15 - 1 , 15 - 2 , . . . , and 15 - n comprises substantially the same number of registers as that of memory cells existing on one bit-line (for example, 72 cells),
[0030] This logic scan chain 15 is configured to be originally provided to improve a failure detectivity at the time of conducting a test on a logic part (not shown) other than the memory 10 , and the originally provided configuration is thus used for a memory test in this embodiment.
[0031] At the time of conducting a normal logic test, the respective shift registers 15 - 1 , 15 - 2 , . . . , and 15 - n perform shift operations in an X-direction (a lateral direction in the drawing). In contrast to this, at the time of conducting a memory test, they perform shift operations in a Y-direction (a vertical direction in the drawing). In this embodiment, a configuration for allowing performance of the shift operations also in the Y-direction is added to the existing configuration that the logic scan chain 15 includes. The detail of this will be described later.
[0032] When conducting a memory test by the BIST by means of the failure analyzing apparatus configured as described above, the logic scan chain 15 activates the shift register in the Y-direction. At this time, the address information output from the address counter circuit 11 and the failure determination result information on the memory 10 (failure determination information on each memory cell connected to one bit-line) output from the comparator circuit 13 are output all the time to the shift register 15 - 1 at the first stage in the logic scan chain 15 .
[0033] In this case, as a result of conducting the BIST test on the bit-line indicated by a piece of address information, when there is no problem in the respective memory cells on the bit-line, the failure determination result information indicative of all values being “0” is output to the shift register 15 - 1 at the first stage. When there is a problem in any one of the memory cells on the bit-line, the failure determination result information indicative of the value of the corresponding part to the memory cell being “1” is output to the shift register 15 - 1 at the first stage.
[0034] When a failure is detected, a clock is generated which causes the logic scan chain 15 to operate, whereby the address information and the failure determination result information are fetched in the register. Even when one failure is detected, the memory test by the BIST is continuously conducted. When a plurality of failures are detected, the failure information stored in the registers is sequentially shifted in the Y-direction, as shifted from the shift register 15 - 1 at the first stage to the shift register 15 - 2 at the second stage, and from the shift register 15 - 2 at the second stage to the shift register 15 - 3 at the third stage, . . . This makes it possible to hold n pieces of failure information at the maximum in the shift registers 15 - 1 , 15 - 2 , . . . , and 15 - n respectively.
[0035] Through the inspection of the result of the above BIST test, the state of information held in the respective shift registers 15 - 1 , 15 - 2 , . . . , and 15 - n , the failure locations on the memory 10 can be identified in detail based on the address information. Moreover, it is also easy to know how many failures there are on the memory 10 .
[0036] [0036]FIG. 3 is a block diagram showing a circuit configuration of one scan flip-flop making up the aforesaid logic scan chain 15 .
[0037] As shown in FIG. 3, a scan flip-flop comprises a D-type flip-flop (DFF) 21 and two selectors 22 and 23 . Scan flip-flops each having the same configuration are arranged in a matrix form as shown in FIG. 4 to form the logic scan chain 15 shown in FIG. 2. In FIG. 4, dotted lines show the flows of scan operations in the X-direction used at the time of the logic test, and solid lines show the flows of scan operations in the Y-direction used at the time of the memory test.
[0038] In FIG. 3, provided are input terminals SIx and SIy of the scan chain, and output terminals SOx and SOy of the scan chain. A logic scan chain (shift operations in the X-direction) at the time of conducting a test on a not-shown logic part is realized by the input terminal SIx and the output terminal SOx. More specifically, information output from the output terminal SOx of a certain scan flip-flop is input to the input terminal SIx of the scan flip-flop at the next stage situated next thereto in the X-direction.
[0039] Further, the BIST state (shift operations in the Y-direction) at the time of conducting a test on the memory 10 is realized by the input terminal SIy and the output terminal Soy. More specifically, information output from the output terminal SOy of a certain scan flip-flop is input to the input terminal SIy of the scan flip-flop at the next stage situated At next thereto in the Y-direction.
[0040] The selector 22 performs switching operation between the X-direction and the Y-direction as described above, on the basis of a memory test mode signal MT. More specifically, the information from the input terminal SIx in the X-direction and the information from the input terminal SIy in the Y-direction are input into the selector 22 . The selector 22 selects either piece of information in accordance with the input memory test mode signal MT and outputs the selected piece of information to the selector 23 .
[0041] The information selected by the selector 22 and information Sys-in which is provided during the normal system operation except for during the test time are input into the selector 23 . The selector 23 selects either piece of information in accordance with an input select enable signal SE and outputs the selected piece of information to the DFF 21 . The selector 23 selects the output information from the selector 22 at the time of the logic test or the memory test before shipment of the product and always selects the system information Sys-in after the shipment of the product.
[0042] As described above, the selector 22 is added to the selector 23 and the DFF 21 which are originally provided as components of the scan flip-flop, thereby making it possible to perform shift operations also in the Y-direction at the time of the memory test by the BIST in this embodiment.
[0043] The information selected at the selector 23 is held in the DFF 21 in accordance with a clock CK supplied to the DFF 21 . The clock CK at the time of conducting the memory test by the BIST is generated in accordance with a failure flag generated based on the determination result of the BIST in the comparator circuit 13 in FIG. 2. A circuit for generating the failure flag is configured as in FIG. 5 by way of example.
[0044] As shown in FIG. 5, a failure flag generator circuit 41 is added to the comparator circuit 13 shown in FIG. 2. The comparator circuit 13 includes comparison processing portions 42 - 1 , 42 - 2 , . . . , 42 - m , the number of which is the same as that of the memory cells existing on one bit-line (for example, 72 cells). Each of the comparison processing portions 42 - 1 , 42 - 2 , . . . , 42 - m is composed of an XOR circuit 43 with the output signal from the memory cell in the memory 10 and the expected value from the data generator circuit 12 as two inputs, an AND circuit 44 with the output signal from the XOR circuit 43 and a read enable signal RE as two inputs, and a register 45 for holding the output signal of the AND circuit 44 in accordance with the clock CK.
[0045] The read enable signal RE becomes “H” in the read state and “L” in the write state. Accordingly, when a disagreement between the signal read out from the memory cell of the memory 10 and the expected value is detected, the output signal of the register 45 becomes “H”. Such failure determination operation is performed in the plurality of comparison processing portions 42 - 1 , 42 - 2 , . . . , 42 - m individually, and all the results are input to the OR circuit 46 in the failure flag generator circuit 41 .
[0046] Consequently, as a result of failure determination being individually made about the plurality of memory cells existing on some bit-line in the plurality of comparison processing portions 42 - 1 , 42 - 2 , . . . , 42 - m , when a failure is found in any one of the memory cells, a signal “H” is output from the OR circuit 46 . The output signal of the OR circuit 46 is input to the NAND circuit 47 with the clock CK, and the output signal of the NAND circuit 47 is output as the failure flag. Thus, a pulse in opposite phase to the clock CK is output as the failure flag.
[0047] The failure flag thus generated by the failure flag generator circuit 41 is used as an operation clock for the logic scan chain 15 shown in FIG. 2. A schematic block diagram in that case is shown in FIG. 6. FIG. 6 is a block diagram for explaining a switching method between a clock used at the time of the logic scan and a clock used at the time of the memory scan by the BIST and shows a configuration including the aforesaid failure flag generator circuit 41 . Components in FIG. 6, to which the same numerals and symbols as those of the components in FIG. 2 are given, have the same functions, therefore the description thereof is omitted.
[0048] As shown in FIG. 6, either the failure flag output from the failure flag generator circuit 41 or the clock CK supplied from the outside is selected at a selector 51 in accordance with the memory test mode signal MT, and the selected signal is used as the operation clock for the logic scan chain 15 . The clock CK supplied from the outside is supplied to the logic scan chain 15 at the time of the logic scan, and the failure flag is supplied as the operation clock CK to the logic scan chain 15 at the time of the memory scan.
[0049] Therefore, at the time of the memory scan, the logic scan chain 15 fetches failure information into the shift registers 15 - 1 , 15 - 2 , . . . , 15 - n in sequence only when the failure is detected on the memory 10 .
[0050] More specifically, when a failure is detected on a certain bit-line in the memory 10 , the failure flag is output from the failure flag generator circuit 41 , the address information output from the address counter circuit 11 and the failure determination result information output from the comparator circuit 13 are input to the shift register 15 - 1 at the first stage of the logic scan chain 15 , and the failure determination result information is fetched by a rising edge of the failure flag.
[0051] When two failures are detected, the failure information held in the shift register 15 - 1 at the first stage is shifted to the shift register 15 - 2 at the second stage in synchronization with the rising edge of the failure flag, and new failure information is overwritten in the shift register 15 - 1 at the first stage. When three or more failures are detected, the failure information held in the register is shifted in the Y-direction in sequence in the same manner. Consequently, n pieces of failure information at the maximum are held in the shift registers 15 - 1 , 15 - 2 , . . . , 15 - n.
[0052] After the completion of all the BIST operations, the memory test mode signal MT is switched to bring about the logic scan state, and holding results of the shift registers 15 - 1 , 15 - 2 , . . . , 15 - n are output from an external SDO terminal and then examined, whereby the locations where failures occur and the number thereof can be precisely detected.
[0053] It should be noted that the case of one memory 10 has been explained in the aforesaid embodiment, but it is possible to conduct tests concurrently on a plurality of memories and collect failure information at once by changing the length of the logic scan chain 15 .
[0054] [0054]FIG. 7 is a block diagram showing an example of configuration in the case in which tests are conducted concurrently on two memories 60 - 1 and 60 - 2 . Components in FIG. 7, to which the same numerals and symbols as those of the components in FIG. 2 are given, have the same functions, and therefore the overlapping description thereof is omitted.
[0055] A memory BIST circuit 61 shown in FIG. 7 comprises an address counter circuit 11 , a data generator circuit 12 , two comparator circuits 13 - 1 and 13 - 2 , and a BIST controller circuit 14 . The address counter circuit 11 outputs the same address information to the two memories 60 - 1 and 60 - 2 . In response to this, the memories 60 - 1 and 60 - 2 output information on the memory cells at designated the same address to the two comparator circuits 13 - 1 and 13 - 2 . The comparator circuits 13 - 1 and 13 - 2 perform failure determination processing in parallel.
[0056] A logic scan chain 62 shown in FIG. 7 is divided into a plurality of shift registers 62 - 1 , 62 - 2 , . . . , 62 - n . Each of the divided shift registers 62 - 1 , 62 - 2 , . . . , 62 - n is composed of substantially the same number of registers as the total number of memory cells existing on one bit-line which are included in each of the two memories 60 - 1 and 60 - 2 . In other words, supposing that each of the memories 60 - 1 and 60 - 2 has the same capacity as the memory 10 in FIG. 2, the number of registers included in the shift registers 62 - 1 , 62 - 2 , . . . , 62 - n in FIG. 7 is twice the number of registers included in the shift registers 15 - 1 , 15 - 2 , . . . , 15 - n in FIG. 2.
[0057] Also in the case of the configuration in FIG. 7, when a memory test by the BIST is conducted, the logic scan chain 62 activates the shift register in the Y-direction. At this time, the address information output from the address counter circuit 11 and the failure determination result information of the memories 60 - 1 and 60 - 2 output from the two comparator circuits 13 - 1 and 13 - 2 are output all the time to the shift register 62 - 1 at the first stage in the logic scan chain 62 .
[0058] In this case, as a result of conducting the BIST test on the bit-line indicated by a certain piece of address information, when there is no problem in the respective memory cells on the bit-line, the failure determination result information indicative of all values being “0” is output to the shift register 62 - 1 at the first stage. When there is a problem in any one of the memory cells on the bit-line, the failure determination result information indicative of the value of the corresponding part to the memory cell being “1” is output to the shift register 62 - 1 at the first stage.
[0059] When a failure is detected, a clock is generated which causes the logic scan chain 62 to operate, whereby the address information and the failure determination result information are fetched in the register. Even when one failure is detected, the memory test by BIST is continuously conducted. When a plurality of failures are detected, the failure information stored in the register is sequentially shifted in the Y-direction, as shifted from the shift register 62 - 1 at the first stage to the shift register 62 - 2 at the second stage, and from the shift register 62 - 2 at the second stage to the shift register 62 - 3 at the third stage. This makes it possible to hold n pieces of failure information at the maximum in the shift registers 62 - 1 , 62 - 2 , . . . , and 62 - n at the same time.
[0060] After the completion of all the BIST operations, the memory test mode signal MT is switched to bring about the logic scan state, and holding results of the shift registers 62 - 1 , 62 - 2 , . . . , 62 - n are output from an external terminal SDO and then examined, whereby the locations where failures occur and the number thereof can be precisely detected in the two memories 60 - 1 and 60 - 2 .
[0061] The aforesaid embodiments only show concrete examples for carrying out the present invention, and the technical range of the present invention is not intended to be interpreted in a narrow sense thereby. Therefore, the present invention may be carried out in various forms without departing from the spirit and the main features thereof.
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Failure determination of a memory is made in sequence based on address information supplied to the memory using a test circuit built inside the memory, and resultant failure determination information output from a comparator circuit and the address information output from an address counter circuit are fetched in sequence and held in a logic scan chain, whereby the logic scan chain which is originally provided for a logic test is efficiently used also for a memory test so as to obtain information concerning one or more failure locations and the number of failures by one BIST test without addition of a complicated circuit configuration.
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TECHNICAL FIELD
[0001] The present invention relates to a method for producing lithium titanate. More particularly, the invention relates to a low-cost, efficient method for producing lithium titanate. The invention also relates to lithium titanate produced by the method, and an electrode active material and an electric storage device which include the same.
BACKGROUND ART
[0002] Lithium titanate, which has been developed as a material for an electric storage device, is used as an electrode active material excellent in safety and life property for an electric storage device, in particular, a negative electrode active material for a lithium secondary battery. The use of a lithium secondary battery as a small battery for power supply to a portable device or the like has rapidly spread. Furthermore, a large lithium secondary battery has been developed for use in power generation industries or on vehicles etc. The electrode active material for a large lithium secondary battery requires long term reliability and high input/output characteristics, and the use of lithium titanate as a negative electrode active material, in particular, is promising, due to excellence in safety and life property.
[0003] Examples of the lithium titanate include several compounds as described in Patent Literature 1. Patent literature 1 describes compounds represented by a general formula Li x Ti y O 4 , where 0.8≦x≦1.4 and 1.6≦y≦2.2, including typical examples LiTi 2 O 4 , Li 1.33 Ti 1.66 O 4 , and Li 0.8 Ti 2.2 O 4 . Examples of the known method for producing the lithium titanate include: a wet method (Patent Literature 2) by mixing predetermined amounts of a lithium compound and a titanium compound in solvent, drying the mixture, and firing the dried mixture; a spray drying method (Patent Literature 3) by spray-drying the mixture for drying in the wet method; a dry method (Patent Literatures 1 and 4) by dry-mixing predetermined amounts of a lithium compound and a titanium compound and firing the mixture.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: JP 06-275263 A
Patent Literature 2: JP 2001-213622 A
Patent Literature 3: JP 2001-192208 A
Patent Literature 4: JP 2000-302547 A
SUMMARY OF INVENTION
Technical Problem
[0008] In both of the dry method and the wet method, a lithium compound and a titanium compound are fired to produce lithium titanate. The low reactivity due to a solid phase diffusion reaction between the respective raw materials easily allows a by-product having a different composition or the unreacted raw materials other than a target lithium titanate to remain. This prevents a battery using lithium titanate from having a sufficient electric power capacity. Meanwhile, although higher firing temperature improves the reactivity, the volatilization loss of lithium occurs easily and the contraction, sintering, and grain growth of lithium titanate particles are accelerated, resulting in reduction of the specific surface area of lithium titanate particles. This easily causes the reduction in rate characteristics of a battery using lithium titanate.
Solution to Problem
[0009] The present inventors performed earnest research on the method for efficiently producing a target lithium titanate, through the improvement of reactivity between a lithium compound and a titanium compound and found that the problem can be solved by heating at least a titanium compound and a lithium compound to be described later having a volume average particle diameter of 5 μm or less, thus having completed the present invention.
Advantageous Effects of Invention
[0010] A method for producing lithium titanate of the present invention uses a lithium compound having a volume average particle diameter of 5 μm or less to improve the reactivity of a titanium compound and the lithium compound. As a result, a target lithium titanate can be efficiently produced. According to the method of the present invention, a sub-phase having a different composition is less formed, less unreacted raw materials remain, sintering proceeds less rapidly, and the specific surface area is less reduced. A target lithium titanate can be reliably and stably produced at a heating temperature lower than that in a conventional production method.
[0011] The use of the lithium titanate produced by the method as an electrode active material allows for production of an electric storage device excellent in battery characteristics, in particular, rate characteristics.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a chart illustrating powder X-ray diffraction patterns of Samples 1, 4, and 6.
[0013] FIG. 2 is a graph illustrating the rate characteristics of the electric storage devices of Sample A and Sample B.
DESCRIPTION OF EMBODIMENTS
[0014] Measurement methods used in the present specification are described below. Specific surface area
[0015] In the present specification, the specific surface area was measured by single-point BET nitrogen adsorption. Monosorb made by Yuasa-Ionics Co., Ltd. or Monosorb MS-22 made by Quantachrome Instruments was used as a measurement device.
Particle Diameter (Lithium Compound)
[0016] In the present specification, the average particle diameter of a lithium compound is the volume average particle diameter measured by a laser diffraction method. The volume average particle diameter was measured with a laser diffraction/scattering particle size distribution measurement device, using ethanol as dispersion medium. In the measurement, the refractive index of ethanol was set as 1.360, and the refractive index of a lithium compound was appropriately set corresponding to the species of the compound. For example, when the lithium compound was lithium carbonate, the refractive index was set to 1.500. As the laser diffraction/scattering particle size distribution measurement device, LA-950 made by Horiba, Ltd. was used.
Particle Diameter (Titanium Compound)
[0017] In the present specification, the average particle diameter of primary particles of a titanium compound is the average value of particle diameters of 100 primary particles in an image picture of a transmission electron microscope (an electron microscope method).
[0018] In the present specification, the average secondary particle diameter of secondary particles of a titanium compound is the volume average particle diameter measured by a laser diffraction method. The volume average particle diameter was measured with a laser diffraction/scattering particle size distribution measurement device, using pure water as dispersion medium. In the measurement, the refractive index of pure water was set as 1.333, and the refractive index of a titanium compound was appropriately set corresponding to the species of the compound. For example, when the titanium compound was anatase-type titanium oxide, the refractive index was set to 2.520. As the laser diffraction/scattering particle size distribution measurement device, LA-950 made by Horiba, Ltd. was used.
Particle Diameter (Precursor Mixture)
[0019] In the present specification, the average particle diameter of a lithium titanate precursor mixture is a volume average particle diameter measured by a laser diffraction method. The volume average particle diameter was measured with a laser diffraction/scattering particle size distribution measurement device, using ethanol as dispersion medium. In the measurement, the refractive index of ethanol was set as 1.360, and the refractive index of the measured particles was set to a value of the species of the lithium compound. For example, when the lithium compound was lithium carbonate, the refractive index was set to 1.567. As the laser diffraction/scattering particle size distribution measurement device, LA-950 made by Horiba, Ltd. was used.
Particle Diameter (Lithium Titanate)
[0020] In the present specification, the average particle diameter of primary particles of lithium titanate is the average value of particle diameters of 100 primary particles in an image picture of a transmission electron microscope (an electron microscope method).
[0021] In the present specification, the average secondary particle diameter of secondary particles of lithium titanate is the volume average particle diameter measured by a laser diffraction method. The volume average particle diameter was measured with a laser diffraction/scattering particle size distribution measurement device, using pure water as dispersion medium. In the measurement, the refractive index of water was set as 1.333, and the refractive index of lithium titanate was appropriately set corresponding to the species of the compound. When the lithium titanate was Li 4 Ti 5 O 12 , the refractive index was set to 2.700. As the laser diffraction/scattering particle size distribution measurement device, LA-950 made by Horiba, Ltd. was used in the present invention.
Bulk Density
[0022] In the present specification, the bulk density was obtained by a cylinder method (calculated from the volume and mass of a sample placed in a graduated cylinder).
Impurities
[0023] In the present specification, sodium and potassium as impurities were measured by an atomic absorption spectroscopy, SO 4 and chlorine were measured by an ion chromatography method or with a fluorescent X-ray analyzer, and other elements such as silicon, calcium, iron, chromium, nickel, manganese, copper, zinc, aluminum, magnesium, niobium, and zirconium were measured by ICP method. SO 4 was measured with a fluorescent X-ray analyzer (RIGAKU RIX-2200).
[0024] The present invention is described in the following.
[0025] The present invention relates to a method for producing lithium titanate, which includes heating at least the following two compounds: (1) a titanium compound; and (2) a lithium compound having a volume average particle diameter of 5 μm or less.
(1) Titanium Compound
[0026] The titanium compound for use may include an inorganic titanium compound and an organic titanium compound such as a titanium alkoxide. Examples of the inorganic titanium compound include a titanic acid compound such as metatitanic acid represented by TiO(OH) 2 or TiO 2 .H 2 O and orthotitanic acid represented by Ti(OH) 4 or TiO 2 .2H 2 O, titanium oxide (crystalline titanium oxide such as rutile-type, anatase-type, brookite-type, and bronze-type titanium oxide, or amorphous titanium oxide), and a mixture thereof. The titanium oxide may be a type of titanium oxide having diffraction peaks from a single crystal structure in the X-ray diffraction pattern or a type of titanium oxide having diffraction peaks from a plurality of crystal structures such as the diffraction peaks from anatase and the diffraction peaks from rutile. In particular, crystalline titanium oxides are preferable.
[0027] The titanium compound is preferably composed of fine particles, resulting in high reactivity with a lithium compound. The average primary particle diameter (an electron microscope method) is preferably in the range of 0.001 μm to 0.3 μm, more preferably 0.005 to 0.3 μm, further preferably 0.01 to 0.3 μm, and furthermore preferably 0.04 to 0.28 μm. The titanium compound preferably has a large specific surface area, resulting in high reactivity with a lithium compound. The specific surface area is preferably 20 to 300 m 2 /g, more preferably 50 to 300 m 2 /g, further preferably 60 to 300 m 2 /g, and furthermore preferably 60 to 100 m 2 /g. In the case of using secondary particles granulated of the titanium compound, the average secondary particle diameter (a laser diffraction method) is preferably 0.05 to 5 μm, more preferably 0.1 to 3.0 μm, and further preferably 0.5 to 2.0 μm.
[0028] The titanium compound preferably has a high purity, usually 90% or more by weight, more preferably 99% or more by weight. The content of Cl or SO 4 as impurity is preferably 0.5% or less by weight. The content of each of other elements is preferably in the following specific range: silicon (1000 ppm or less), calcium (1000 ppm or less), iron (1000 ppm or less), niobium (0.3% or less by weight), and zirconium (0.2% or less by weight).
(2) Lithium Compound
[0029] It is important that the lithium compound for use in the present invention has a volume average particle diameter of 5 μm or less, with an appropriate lower limit, so as to improve the reactivity with a titanium compound. The volume average particle diameter is preferably in the range of 0.5 to 5 μm, more preferably in the range of 1 to 5 μm. Alternatively the volume average particle diameter may be 4 μm or less, preferably in the range of 0.5 to 4 μm, more preferably in the range of 1 to 4 μm. The use of lithium compound having a volume average particle diameter of 5 μm or less in production of lithium titanate allows a target lithium titanate to have a high single-phase rate due to the improved reactivity with a titanium compound. On the other hand, the use of lithium compound having a volume average particle diameter of more than 5 μm allows a target lithium titanate to have a low single-phase rate due to poor reactivity with a titanium compound.
[0030] The single-phase rate of lithium titanate is represented by the following expression 1, which is an index of the content rate of a target lithium titanate, preferably 95% or more, more preferably 96% or more, more preferably 97% or more:
[0000] Single-phase rate (%)=100×(1−Σ( Y i /X ) (Expression 1)
[0031] where X represents the main peak intensity of a target lithium titanate in a powder X-ray diffraction measurement using the Cu-Kα ray, Y i represents the main peak intensity of each sub-phase. In the case of Li 4 Ti 5 O 12 , X is the peak intensity in the vicinity of 2θ=18°, while the peak intensity in the vicinity of 2θ=25° (anatase-type TiO 2 ), the peak intensity in the vicinity of 2θ=27° (rutile-type TiO 2 ), and the peak intensity in the vicinity of 2θ=44° (Li 2 TiO 3 ) are used as Y i , since anatase-type TiO 2 , rutile-type TiO 2 , and Li 2 TiO 3 are likely to be present as sub-phases.
[0032] The lithium compound having a volume average particle diameter of 5 μm or less may be produced under appropriate production conditions. Alternatively a lithium compound having a volume average particle diameter of more than 5 μm may be produced or purchased so as to be grain-refined to 5 μm or less. A known method may be used in grain refining. In particular, the volume average particle diameter of the lithium compound may be reduced by crushing to preferably 5 μm or less, more preferably 4 μm or less.
[0033] A lithium compound particle has a polyhedron shape in general. Crushing allows the particle diameter to be reduced and the angles of the polyhedron shape to be rounded. It is speculated that this enhances flowability of powder, resulting in high miscibility with a titanium compound so as to further improve the reactivity of a lithium titanate precursor.
[0034] A known crusher can be used in crushing a lithium compound. A dry crusher such as a flake crusher, a hammer mill, a pin mill, a bantam mill, a jet mill, a Fret mill, a pan mill, an edge runner, a roller mill, a Mix-Muller, and a vibration mill is preferable. Preferably crushing is performed such that the amount of coarse particles is reduced. Specifically, in the particle size distribution measured by the method, a D 90 (diameter at a cumulative frequency of 90%) of 10 μm or less, preferably 9 μm or less, and further preferably 7 μm or less, is suitable for easily producing the effect of the present invention.
[0035] A hydroxide, a salt, an oxide of lithium, and the like may be used as the lithium compound, without a specific limitation. Examples may include lithium hydroxide, lithium carbonate, lithium nitrate, lithium sulfate, and lithium oxide. These may be singly used or in combination of two or more. Among the lithium compounds, lithium hydroxide, lithium carbonate, or lithium oxide is preferably used, in order to prevent an acid radical from remaining in lithium titanate. In particular, lithium hydroxide or lithium carbonate is more preferably used, and lithium carbonate is further preferably used, due to easiness in crushing.
[0036] In the present invention, the acid radical means a sulfate radical (SO 4 ) and a chlorine radical (Cl).
[0037] The lithium compound preferably has a high purity, usually 98.0% or more by weight. In the case of using lithium carbonate as the lithium compound, the content of Li 2 CO 3 is preferably 98.0% or more by weight, more preferably 99.0% or more by weight, the content of impurity metal elements such as Na, Ca, K, and Mg is 1000 ppm or less, and the content of Cl and SO 4 is 1000 ppm or less, preferably 500 ppm or less. Preferably water is sufficiently removed. The content of water is preferably 0.3% or less by weight. The lithium compound preferably has a higher specific surface area for reactivity. In the case of lithium carbonate, for example, the specific surface area is preferably 0.8 m 2 /g or more, more preferably in the range of 1.0 to 3.0 m 2 /g.
(3) Lithium Titanate Compound Having the Same Crystal Structure as That of a Target Lithium Titanate
[0038] The lithium titanate compound is used if needed. It is believed that the lithium titanate compound suppresses the sintering of the produced lithium titanate, or acts as a seed crystal. The use of the lithium titanium compound allows the heating process to be hereinafter described to be performed at a relatively low temperature and the grain growth of lithium titanate in the heating process to be properly controlled, so that the target lithium titanate can be easily produced. Having the same crystal structure as that of the target lithium titanate is thus required. The particle diameter (an electron microscope method) of the lithium titanate compound is not specifically limited. The lithium titanate may have a particle diameter comparable to the particle diameter (an electron microscope method) of a target lithium titanate, for example, in the range of 0.5 to 2.0 μm. The lithium titanate compound can be manufactured by the method of the present invention. The compounding amount is preferably 1 to 30 weight parts calculated in terms of Ti, more preferably 5 to 20 weight parts, relative to 100 weight parts of a titanium compound being a raw material. A mixing aid or the like may be used in addition to the (1), the (2), and the (3).
[0039] In the present invention, at least the (1) titanium compound and the (2) lithium compound having a volume average particle diameter of 5 μm or less are heated together with the (3) lithium titanate compound having the same crystal structure as that of the target lithium titanate and the like on an as required basis as described above so as to produce lithium titanate.
[0040] The ratio of the volume average particle diameter (B μm) of the lithium compound to the volume average particle diameter (A μm) of secondary particles of the titanium compound (B/A) is preferably 0.1 to 80, more preferably 0.1 to 20, further preferably 0.1 to 8. The B/A in the range allows the particle diameters of the lithium compound and the titanium compound to be relatively uniformed, easily producing a lithium titanate precursor mixture having a narrow particle size distribution. This allows a lithium titanate precursor mixture having higher reactivity between a lithium compound and a titanium compound to be easily produced. The B/A is more preferably in the range of 1.0 to 5.0, further preferably 1.0 to 4.0.
[0041] Preferably, prior to the heating, the aforementioned raw materials are mixed to prepare a mixture (hereinafter may be referred to as “precursor mixture”) in advance. Preferably, the mixing includes dry-mixing at least the (1) titanium compound and the (2) lithium compound having a volume average particle diameter of 5 μm or less. In the case of using the (3) lithium titanate compound having the same crystal structure as that of a target lithium titanate for production, preferably the lithium titanate compound is dry-mixed with the above two.
[0042] A known mixing machine may be used for preparing the precursor mixture. For example, a dry-mixing machine such as a Henschel mixer, a V-shape mixer, a powder mixer, a double cone blender, and a tumbler mixer is preferably used. Mixing atmosphere is not specifically limited.
[0043] In preparation of the precursor mixture, crushing of a lithium compound and crushing of a titanium compound may be concurrently performed to prepare the precursor mixture (the method may be hereinafter referred to as “mixed crushing”). In that case, a known crushing machine may be used. A dry-crushing machine such as a flake crusher, a hammer mill, a pin mill, a bantam mill, a jet mill, a cyclone mill, a Fret mill, a pan mill, an edge runner, a roller mill, a Mix-Muller, and a vibration mill is preferable, and an air flow crusher such as a jet mill and a cyclone mill is further preferable.
[0044] In mixed crushing, both of a titanium compound and a lithium compound may be fed into a crushing machine. After initiation of crushing the one, the other may be then fed; or crushing may be initiated after feeding both. Alternatively, both may be mixed in a known mixer such as a Henschel mixer in advance, and then the mixture may be fed into a crushing machine so as to be crushed. The crushing under coexistence of the titanium compound and the lithium compound allows the lithium titanate precursor mixture of the titanium compound and the lithium compound which are sufficiently mixed to be obtained. Each of the titanium compound and the lithium compound may have an intended size after crushing.
[0045] The crushing under coexistence of at least the lithium compound and the titanium compound more easily increases the degree of mixture of the titanium compound and the lithium compound compared with the mere mixing of fine particles in general, and preferably provides the lithium titanate precursor mixture of the lithium compound and the titanium compound having a narrow particle size distribution with a uniform particle diameter more easily. The preferable lithium titanate precursor mixture having higher reactivity between the lithium compound and the titanium compound is thus more easily obtained.
[0046] In the case of using an air flow crusher for mixed crushing, a titanium compound having a low bulk density, more specifically a bulk density in the range of 0.2 to 0.7 g/cm 3 , produces a preferable lithium titanate precursor mixture having high reactivity. It is believed that the titanium compound having a relatively low bulk density is easily dispersed in the air flow in the crusher so as to be uniformly mixed with a lithium compound. The range of the bulk density is more preferably 0.2 to 0.6 g/cm 3 , further preferably 0.2 to 0.5 g/cm 3 .
[0047] Concurrently with mixed crushing and/or after mixed crushing, the mixture is preferably placed under pressure. Since a crushed mixture has a bulky volume (low bulk density) and a large occupied volume per unit mass in general, productivity such as the amount of throughput (material input amount) per unit time or per facility is reduced. Preferably, therefore, the crushed mixture is placed under pressure so as to avoid getting bulky and to have a proper bulk density. The application of pressure further allows the titanium compound and the lithium compound to easily come into contact with each other, so that a preferable lithium titanate precursor mixture having high reactivity between the lithium compound and the titanium compound can be more easily produced. Means for pressure (compression) forming and means for crushing under pressure (compression) can be used as the means for applying pressure.
[0048] A known pressure forming machine and a known compacting machine including a roller compactor, a roller crusher, and a pellet forming machine can be used as means for pressure (compression) forming of the mixed crushed powder after mixed crushing.
[0049] A pressure crushing machine and a compression crushing machine may be used as means for applying pressure concurrently with crushing. A crushing machine using pressure or compression may be appropriately used. At least one crushing machine selected from the group consisting of a Fret mill, a pan mill, an edge runner, a roller mill, and a Mix Muller may be used. The principle of crushing in a crushing machine is that high pressure applied to a specimen crushes the specimen.
[0050] In the case of a Fret mill, the operating mechanism is described as follows. The rotation of a heavy roller grinds a specimen under the roller. A plurality of compounds is ground under the roller for a predetermined time period so as to be concurrently mixed. The use of a crushing machine of the type allows the mixed powder to be placed under pressure concurrently with crushing, so that the process can be simplified without necessity of separately having a compression process.
[0051] The lithium titanate precursor mixture preferably has a bulk density of preferably 0.2 to 0.7 g/cm 3 , more preferably 0.4 to 0.6 g/cm 3 . A bulk density lower than the range reduces the contact between the titanium compound and the lithium compound, resulting in reduced reactivity. A bulk density higher than the range allows gas generated in the reaction during the heating process to hardly escape or inhibits thermal conductivity, also resulting in reduced reactivity. Consequently, the single-phase rate of the produced lithium titanate is reduced in both cases. The lithium titanate precursor having a bulk density in the range described above can be easily obtained under an applied pressure to powder of 0.6 t/cm 2 or less, more preferably less than 0.5 t/cm 2 , further preferably in the range of 0.15 to 0.45 t/cm 2 .
[0052] The frequency curve of the particle size distribution of the lithium titanate precursor mixture measured in a dispersed state in ethanol preferably has only one peak. Preferably the volume average particle diameter is 0.5 μm or less and the D 90 (diameter at a cumulative frequency of 90%) is 10 μm or less, more preferably the volume average particle diameter is 0.45 μm or less and the D 90 (diameter at a cumulative frequency of 90%) is 6 μm or less.
[0053] The particle size distribution is controlled in the range described above, so that a sub-phase having a different composition is less formed, less unreacted raw materials remain, sintering proceeds less rapidly, and the specific surface area is less reduced. A target lithium titanate can be reliably and stably produced at a heating temperature lower than that in a conventional method.
[0054] The compounding ratio of the lithium compound to the titanium compound may be set in accordance with the composition of the target lithium titanate. In the case of producing Li 4 Ti 5 O 12 as lithium titanate, compounding is performed to have a Li/Ti ratio of 0.79 to 0.85. The crushing is not necessarily required for all the lithium compound and/or the titanium compound. A portion of the compounds may be crushed and the remaining portion may be added thereto to produce a lithium titanate precursor mixture.
[0055] In heating and reacting at least the aforementioned (1) titanium compound, the (2) lithium compound having a volume average particle diameter of 5 μm or less, and the (3) lithium titanate compound having the same crystal structure as that of a target lithium titanate if needed, the raw materials are placed in a heating furnace, so as to be raised to a predetermined temperature and held at the temperature for a predetermined time period for reaction. Examples of the heating furnace for use include a fluidized furnace, a stationary furnace, a rotary kiln, a tunnel kiln. The heating temperature is preferably 700° C. or higher and 950° C. or lower. In the case of Li 4 Ti 5 O 12 , a temperature lower than 700° C. allows the single-phase rate of a target lithium titanate to be reduced, resulting in an increased amount of undesirable unreacted titanium compounds. On the other hand, a temperature higher than 950° C. allows undesirable impurity phases (Li 2 TiO 3 and Li 2 Ti 3 O 7 ) to be created. The preferable heating temperature in the range of 700° C. to 800° C. allows for the single-phase rate, which is described below, of 95% or more, in particular 97% or more, and stably produces the lithium titanate with suppressed sintering or grain growth. The heating time may be appropriately determined, in the suitable range of 3 to 6 hours. The heating atmosphere is not specifically limited. An oxidizing atmosphere such as air and oxygen gas, a non-oxidizing atmosphere such as nitrogen gas and argon gas, or a reducing atmosphere such as hydrogen gas and carbon monoxide gas can be used. In particular, an oxidizing atmosphere is preferable.
[0056] The lithium titanate thus produced may be disintegrated or crushed after cooling, if needed. The known crushing machine may be used for crushing. Sintering and grain growth are suppressed in the lithium titanate of the present invention, so that the lithium titanate particles are easily loosened by disintegration or crushing. Consequently, the lithium titanate particles are easily dispersed in a paste, suitable for manufacturing an electrode of an electric storage device.
[0057] The produced lithium titanate has a large specific surface area of, preferably 1.0 m 2 /g or more, more preferably 2.0 to 50.0 m 2 /g, further preferably 2.0 to 40.0 m 2 /g. The bulk density and the volume average particle diameter of lithium titanate may be appropriately set. The bulk density is preferably 0.1 to 0.8 g/cm 3 , more preferably 0.2 to 0.7 g/cm 3 . The volume average particle diameter is preferably 1 to 10 μm. The content of impurities is preferably low, more specifically in the following specific range: sodium (1000 ppm or less), potassium (500 ppm or less), silicon (1000 ppm or less), calcium (1000 ppm or less), iron (500 ppm or less), chromium (500 ppm or less), nickel (500 ppm or less), manganese (500 ppm or less), copper (500 ppm or less), zinc (500 ppm or less), aluminum (500 ppm or less), niobium (0.3% or less by weight), zirconium (0.2% or less by weight), SO 4 (1.0% or less by weight), and chlorine (1.0% or less by weight).
[0058] The present invention also relates to an electrode active material which includes the lithium titanate of the present invention. The present invention also relates to an electric storage device including the use of lithium titanate produced by the production method of the present invention. The electric storage device includes an electrode, a counter electrode, a separator, and an electrolyte. The electrode is produced by adding a conductive material and a binder to the electrode active material so as to be appropriately formed or coated. Examples of the conductive material include a conductive aid such as carbon black, acetylene black, and ketjen black. Examples of the binder include a fluorine resin such as polytetrafluoroethylene, polyvinylidene fluoride, and fluororubber, and a water-soluble resin such as styrene-butadiene rubber, carboxymethylcellulose, and polyacrylic acid. In the case of a lithium battery, the electrode active material is used for the positive electrode and metal lithium, lithium alloy, or a carbon-containing material such as graphite may be used for the counter electrode. Alternatively, the electrode active material may be used for the negative electrode, and a lithium-transition metal composite oxide such as a lithium-manganese composite oxide, a lithium-cobalt composite oxide, a lithium-nickel composite oxide, a lithium-cobalt-manganese-nickel composite oxide, and a lithium-vanadium composite oxide, and an olivine-type compound such as a lithium-iron phosphate composite compound may be used for the positive electrode. A porous polypropylene film or the like is used for any devices. A commonly used material such as a lithium salt such as LiPF 6 , LiCF 4 , LiCF 3 SO 3 , LiN(CF 3 SO 2 ) 2 , and LiBF 4 dissolved in a solvent such as propylene carbonate, ethylene carbonate, dimethyl carbonate, diethyl carbonate, ethylmethyl carbonate, γ-butyl lactone, and 1,2-dimethoxy ethane may be used as the electrolyte. The lithium titanate of the present invention may be used not only as an active material of a lithium secondary battery but also for attaching to the surface of an active material of another type, for compounding in an electrode, for being contained in a separator, or as a lithium ion conductor. Alternatively, the lithium titanate may be used as an active material of a sodium ion battery.
EXAMPLES
[0059] Examples of the present invention are described in the following. The present invention is, however, not limited to the examples.
Crushing of Lithium Carbonate
[0060] Sample a of lithium carbonate powder (purity: 99.2%) was used as a lithium compound. Sample a was crushed into Sample b having a volume average particle diameter of 4 μm or less, using a jet mill (STJ-200 made by Seishin Enterprise Co., Ltd). Sample c was obtained with enhanced crushing with a reduced feed rate compared to the rate in production of Sample b. Samples d and e having different particle diameters respectively were obtained with moderate crushing with an increased feed rate compared to the rate in production of Sample b.
(Evaluation 1)
[0061] The particle size distribution of the raw material samples a to e was measured with a laser diffraction/scattering particle size distribution measurement device (LA-950 made by Horiba, Ltd). In the measurement, using ethanol as a dispersion medium, the refractive indexes of lithium carbonate and ethanol were set as 1.500 and 1.360, respectively. The results are described in Table 1. The volume average particle diameter of each of Samples a to e was 8.1 μm, 3.7 μm, 2.1 μm, 5.0 μm or 7.7 μm. The D 90 (diameter at a cumulative frequency of 90%) of each was 13.0 μm, 6.2 μm, 3.1 μm, 8.1 μm or 12.0 μm.
[0000]
TABLE 1
Volume
average
particle
diameter
D5
D10
D20
D50
D80
D90
D95
Sample a
8.1
3.5
4.1
5.1
7.4
10.8
13.0
15.1
Sample b
3.7
1.4
1.8
2.3
3.3
4.9
6.2
7.5
Sample c
2.1
1.1
1.3
1.5
2.0
2.7
3.1
3.6
Sample d
5.0
2.1
2.4
3.0
4.5
6.6
8.1
9.6
Sample e
7.7
3.5
4.1
5.1
7.2
10.1
12.0
13.8
(All figures in μm)
Synthesis of Lithium Titanate, Li 4 Ti 5 O 12
Example 1
[0062] Titanium oxide powder (made by Ishihara Sangyo Kaisha, Ltd., purity: 97.3%, volume average particle diameter: 1.3 μm, specific surface area: 93 m 2 /g) as a titanium compound and Sample b as a lithium compound were sampled to obtain a Li/Ti molar ratio of 0.81. The raw materials were mixed in a Henschel mixer for 10 minutes at 1800 rpm so that a precursor mixture was prepared. Subsequently the precursor mixture was heated at 750° C. in the atmosphere for 3 hours, using an electric furnace, so that lithium titanate was synthesized. The produced lithium titanate was disintegrated with a jet mill, so that Sample 1 was obtained.
Example 2
[0063] Sample 2 was obtained in the same manner as in Example 1 except for the use of Sample c as the lithium compound.
Example 3
[0064] Sample 3 was obtained in the same manner as in Example 1 except for the use of Sample d as the lithium compound.
Comparative Example 1
[0065] Sample 4 was obtained in the same manner as in Example 1 except for the use of Sample a as the lithium compound.
Comparative Example 2
[0066] Sample 5 was obtained in the same manner as in Example 1 except for the use of Sample e as the lithium compound.
Comparative Example 3
[0067] Sample 6 was obtained in the same manner as in Comparative Example 1, except that the heating was performed at 800° C. in the atmosphere for 3 hours.
(Evaluation 2)
[0068] The powder X-ray diffraction pattern of each of the obtained Samples 1 to 6 was observed with a powder X-ray diffractometer (Ultima IV made by Rigaku Corporation, with Cu-Kα ray). The results of the powder X-ray diffiraction measurement of Samples 1, 4, and 6 are illustrated in FIG. 1 . Among the measured peak intensities, the peak intensity of Li 4 Ti 5 O 12 in the vicinity of 2θ=18° was used as X, and the peak intensity of rutile-type TiO 2 in the vicinity of 2θ=27°, the peak intensity of anatase-type TiO 2 in the vicinity of 2θ=25°, and the peak intensity of Li 2 TiO 3 in the vicinity of 2θ=44° were used as Y, so as to calculate the single-phase rate. The results are described in Table 2. Samples 1 to 3 with the use of crushed lithium carbonate having a volume average particle diameter of 5 μm or less produced lithium titanate Li 4 Ti 5 O 12 having a single-phase rate of 95% or more even at a heating temperature of 750° C. In contrast, the use of lithium carbonate having a volume average particle diameter of more than 5 μm did not produce lithium titanate Li 4 Ti 5 O 12 having a single-phase rate of 95% or more at a heating temperature of 750° C. (Samples 4 and 5). Lithium titanate Li 4 Ti 5 O 12 having a single-phase rate of 95% or more was eventually produced at a heating temperature of 800° C. (Sample 6). This proves that the production method of the present invention allows for the synthesis of lithium titanate having a single-phase rate of 95% or more even at a lower heating temperature for synthesizing lithium titanate, specifically lower than 800° C.
[0000]
TABLE 2
Lithium
Firing
Single-phase
compound
temperature
Lithium titanate
rate
Example 1
Sample b
750° C.
Sample 1
98%
Example 2
Sample c
750° C.
Sample 2
98%
Example 3
Sample d
750° C.
Sample 3
98%
Comparative
Sample a
750° C.
Sample 4
93%
example 1
Comparative
Sample e
750° C.
Sample 5
92%
example 2
Comparative
Sample a
800° C.
Sample 6
99%
example 3
(Evaluation 3)
[0069] The specific surface area of each of Sample 1 and Sample 6 having a single-phase rate of 95% or more was measured by single-point BET method (nitrogen adsorption, Monosorb made by Yuasa-Ionics Co., Ltd). As a result, the samples had a specific surface area of 4.9 m 2 /g and 3.0 m 2 /g, respectively. This showed that even in the case of synthesizing lithium titanate having a single-phase-rate of 95%, the production method of the present invention prevents lithium titanate particles from sintering with each other and allows for synthesis of lithium titanate which is easily crushed to achieve suppressed reduction in specific surface area.
(Evaluation 4)
Evaluation of Battery Characteristics
(1) Manufacturing of Electric Storage Device
[0070] Lithium titanate of Sample 1, acetylene black powder as a conductive material, and a polyvinylidene fluoride resin as a binder were mixed at a weight ratio of 100:5:7, and kneaded into a paste in a mortar. The paste was applied to an aluminum foil, dried at a temperature of 120° C. for 10 minutes, and then punched out into a circular form with a diameter of 12 mm, which was pressed at 17 MPa to form a working electrode. The weight of the active material contained in the electrode was 3 mg.
[0071] The working electrode was vacuum-dried at 120° C. for 4 hours, and then installed as a positive electrode into a closable coin-type battery in a glove box with a dew point of −70° C. or lower. The coin-type battery was formed of stainless steel (SUS 316) with an outer diameter of 20 mm and a height of 3.2 mm. The negative electrode was formed of metal lithium in a circular shape with a thickness of 0.5 mm and a diameter of 12 mm. LiPF 6 was dissolved in a mixed solution of ethylene carbonate and dimethyl carbonate (at mixing volume ratio of 1:2) at a concentration of 1 mole/litter so as to form a nonaqueous electrolyte.
[0072] The working electrode was placed on the lower can of the coin-type battery. A porous polypropylene film was placed thereon as a separator, and the nonaqueous electrolyte was dropped thereon. The negative electrode and a spacer with a thickness of 0.5 mm and a spring (both made of SUS 316) for thickness adjustment were placed further thereon. An upper can having a gasket made of polypropylene was placed as a cover, of which outer periphery was clinched for sealing. An electric storage device (Sample A) of the present invention was thus obtained.
[0073] An electric storage device (Sample B) in the comparative example was obtained in the same method as for Sample A of an electric storage device except for the use of Sample 6 as the lithium titanate.
(2) Evaluation of Rate Characteristics
[0074] The discharged capacity of the produced electric storage devices (Samples A and B) was measured for various current amounts so as to calculate a capacity retention rate (%). The voltage range was set to 1 to 3 V, the charging current was set to 0.25 C, the discharging current was set to the range of 0.25 C to 30 C for the measurement. The ambient temperature was set to 25° C. The capacity retention rate was calculated from an equation: (X n /X 0.25 )×100, where X 0.25 represents the measured discharged capacity at 0.25 C, and X n represents the measured value in the range of 0.5 C to 30 C. The term 1 C here means the current value for full charging in one hour. In the present evaluation, 0.48 mA is equivalent to 1 C. The higher the capacity retention rate is, the better the rate characteristics is. The results are described in FIG. 2 . It proves that the electric storage device (Sample A) of the present invention has more excellent rate characteristics, compared to the electric storage device (Sample B) in the comparative example.
INDUSTRIAL APPLICABILITY
[0075] According to the method for producing lithium titanate of the present invention, a target lithium titanate can be reliably and stably produced at a heating temperature lower than that in a conventional method at a low cost.
[0076] The use of the lithium titanate produced by the method as an electrode active material allows for production of an electric storage device excellent in battery characteristics, in particular, rate characteristics.
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Provided is a process for manufacturing, at a low cost and efficiently, lithium titanium oxides which are useful for electricity storage devices. A desired lithium titanium oxide can be obtained by heating at least both (1) a titanium compound and (2) a lithium compound that has a volume-mean particle diameter of 5 μm or less. The lithium compound is preferably obtained by adjusting the volume-mean particle diameter to 5 μm or less by pulverizing. It is preferable that the titanium compound and the lithium compound are heated together with (3) a lithium titanium oxide compound that has the same crystal structure as that of objective lithium titanium oxide. It is preferable that these materials are dry-blended prior to the heating.
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[0001] This application is a continuation of U.S. application Ser. No. 14/452,019, filed Aug. 5, 2014, which claims the benefit of U.S. Provisional Application Ser. No. 61/862,310, filed Aug. 5, 2013.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to the interlocking of stacked cargo containers and, more particularly, to automatic locks which are secured to and travel with the container.
[0003] The prior art includes various devices for interconnecting stacked cargo containers. These devices include manual locks, semi-automatic locks, and automatic locks. As will be recognized to those skilled in the art, manual locking devices must be manually installed within the corner fitting, are manually locked, are manually unlocked, and are then manually removed from the corner fitting. Semi-automatic devices must be manually installed in the corner fitting, provide automatic locking but must be manually unlocked, and are then manually removed from the corner fitting. Finally, automatic devices must be manually installed in the corner fitting, provide automatically locking and unlocking, and are then manually removed from the corner fitting.
[0004] Although the art has advanced from manual locks to semi-automatic locks to automatic locks, and although each new design has provided certain additional benefits, today's fully automatic locks still have certain drawbacks. First, many prior art automatic locks still require an operator to manually install and remove the device from the corner fitting of the container, resulting in additional time and cost during loading/unloading. Second, many prior art automatic devices are designed to release once a predetermined friction force is overcome during hoisting of the container. Due to such factors as tolerances, wear and abuse of the corner fittings, designs which rely upon release of friction forces can provide inconsistent results.
[0005] There is therefore a need in the art for an automatic lock which is capable of interconnecting two stacked containers, and of locking and unlocking without reliance upon the overcoming of a friction force to release the device. The same automatic lock is preferably affixed to the container, thereby eliminating the need to install and remove such device during loading/unloading of the container.
SUMMARY OF THE INVENTION
[0006] The present invention, which address the needs of the prior art, provides an automatic lock for a cargo container. The container has an upper surface and a lower surface. The lower surface defines a plane P. The container further includes at least one lower corner fitting located on the lower surface thereof. The lock includes a corner fitting mechanism sized and configured for location within an opening formed in the lower corner fitting. The mechanism includes a lower cone sized and located to releasably engage an adjacent corner fitting when the container is stacked upon another cargo container. The lock further includes a rack having first and second ends. The first end of the rack is connected to the corner fitting mechanism whereby movement of the rack actuates the corner fitting mechanism to move the lower cone between a released unengaged position and a locked engaged position. The second end of the rack extends outward from the lower corner fitting. The lock further includes a first linkage having first and second ends. The first end of the first linkage is pivotably connected to the second end of the rack. The lock further includes a foot. The second end of the first linkage is pivotably connected to the foot. The lock further includes a second linkage having first and second ends. The first end of the second linkage is pivotably connected to the foot. The second linkage is spring-loaded. The lock further includes a mounting point affixed to the lower surface of the container. The second end of the second linkage pivotably connected to the mounting point. The first and second linkages are sized and located such that the foot is suspended below plane P prior to the stacking of the cargo container on another cargo container whereby the contact of the foot with the upper surface of another cargo container causes upward movement of the foot and the resultant movement of the first linkage and of the rack thereby resulting in the actuation of the corner fitting mechanism.
[0007] As a result, the present invention provides an automatic lock which is capable of interconnecting two stacked containers, and of locking and unlocking without reliance upon the overcoming of a friction force to release the device. This same automatic lock is preferably affixed to the container, thereby eliminating the need to install and remove such device during loading/unloading of the container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a typical well car having two 53′ domestic cargo containers stacked thereon;
[0009] FIG. 2 is a schematical representation of the corner fittings of a domestic cargo container interacting with the retainers located on the floor of a well car;
[0010] FIG. 3 is a schematical end view of a well car showing two stacked domestic cargo containers;
[0011] FIG. 4 is a perspective view of a typical well car having a 53′ domestic cargo container stacked upon a 40′ ISO cargo container;
[0012] FIG. 5 is a schematical end view of a well car showing a domestic cargo container stacked upon an ISO cargo container;
[0013] FIG. 6 is a perspective view showing the automatic lock of the present invention;
[0014] FIG. 7 is a side elevation view showing an upper domestic cargo container incorporating the automatic lock of the present invention being landed upon a lower domestic cargo container;
[0015] FIG. 8 is a view similar to FIG. 7 showing the upper domestic cargo container landed upon the lower domestic cargo container;
[0016] FIG. 9 is an enlarged detail of the automatic lock of FIG. 6 , with the corner fitting removed for clarity;
[0017] FIG. 10 is a view taken along arrow A of FIG. 6 ;
[0018] FIG. 11 is a view taken along arrow B of FIG. 6 ;
[0019] FIG. 12 is a view showing the orientation of the components of the automatic lock of the present invention when the upper cargo container has been landed;
[0020] FIG. 13 is a view taken along arrow C of FIG. 12 ;
[0021] FIG. 14 is a cross-sectional view taken along lines D-D of FIG. 12 ;
[0022] FIG. 15 is a detail of the cam/cam follower arrangement of the automatic lock of the present invention;
[0023] FIG. 16 is a sectional view taken through the corner fitting mechanism of the automatic lock of the present invention;
[0024] FIG. 17 is a schematical top view of the cam/cam follower arrangement of the automatic lock of the present invention;
[0025] FIG. 18 is a flat pattern of the cam's profile and cam follower position, synchronized in time;
[0026] FIG. 19 is another sectional view taken through the corner fitting mechanism of the automatic lock of the present invention; and
[0027] FIG. 20 is a schematical view showing the interaction of one corner fitting of a domestic cargo container incorporating the automatic lock of the present invention with a retainer positioned on the floor of a well car.
DETAILED DESCRIPTION OF THE INVENTION
[0028] It is commonplace in the rail industry to use what are commonly referred to as well-cars (also known as double-stack cars) to transport cargo containers. A typical well-car 10 is shown in FIG. 1 . A lower container 12 sits within the well of the car, while an upper container 14 rests upon lower container 12 . Those skilled in the art will recognize containers 12 , 14 to be 53′ U.S. Domestic Containers, which is a common container used in the rail industry. These 53′ containers are all made with a standard size and configuration, including the location of four corner fittings on both the upper and lower surfaces.
[0029] Referring now to FIG. 2 , each of containers 12 , 14 is formed with a standard width of 8′-6″. As best seen in FIG. 1 , the corner fittings are located at the outer edges of the container, such that the distance from the outer edge of corner fitting 16 a to the outer edge of corner fitting 16 b is also 8′-6″. Each of the corner fittings located on the lower surface of a domestic container is formed with both an outboard opening 18 and an inboard opening 20 . Located at the bottom of each well-car are four retainers 22 , which are sized and located to engage and penetrate the inboard openings of the four corner fittings located on the bottom surface of container 12 when container 12 is lowered into the well of car 10 . The combination of retainers 22 and the walls of the well-car ensure that container 12 is secure for transport. When a second container, e.g., container 14 , is to be stacked upon container 12 , it is industry practice today to use a plurality of twistlocks to interconnect and lock container 14 to container 12 .
[0030] The stacking of two 53′ domestic containers is best illustrated with reference to FIG. 3 . As shown, retainers 22 affixed to the bottom of well car 10 penetrate inboard openings 20 in each of the four corner fittings located on the bottom surface of container 12 . The outboard openings 18 located in these same corner fittings are not used in this application. Four twistlocks 24 are then used to interconnect and lock container 14 to container 12 .
[0031] The rail industry also uses 8′ wide containers referred to as ISO standard containers. These ISO standard containers can be formed with lengths of 10′, 20′, 30′, 40′ and 49′. A 40′ ISO container 26 is shown in FIG. 4 . As shown, container 26 is positioned within the well of car 10 . A 53′ domestic container 28 is stacked thereon. This stacked relationship is best illustrated with reference to FIG. 5 . As illustrated in FIG. 5 , container 26 includes a plurality of corner fittings 30 , all of which are formed with a single opening 32 . Openings 32 are located to engage retainers 22 in the same manner that openings 20 of fittings 16 engaged retainers 22 . A plurality of twistlocks 24 are used to interconnect and lock container 28 to container 26 . Inasmuch as container 26 is narrower in profile, inboard openings 20 of corner fittings 16 receive one of the locking cones of the twistlocks. In this application, outboard openings 18 of corner fittings 16 are not used.
[0032] It has been discovered herein that the dual opening configuration of the corner fittings on the lower surface of domestic containers can be utilized in the design of an automatic lock for such containers. More particularly, the present invention provides a novel automatic locking system which can be installed on the lower surface of a domestic container, and which will cooperate with the outboard opening of each corner fitting located on such lower surface. As will be explained further hereinbelow, such an arrangement still allows the domestic container to be used in the applications described above. More particularly, the novel arrangement of the present invention will not interfere with retainers 22 of well-car 10 engaging inboard openings 20 of corner fittings 16 when the domestic container is placed within the well of car 10 . In such a scenario, the novel locking arrangement of the present invention will simply remain unused. In the arrangement shown in FIG. 5 , the novel locking arrangement of the present invention will also remain in unused condition without interfering with the usage of four twist locks to interconnect and lock container 28 to container 26 . However, in the common application shown in FIG. 3 (wherein a domestic container is stacked upon another domestic container), the novel automatic locking arrangement of the present invention will eliminate the need for twistlocks 24 , thus saving time and money during loading and unloading of the containers.
[0033] An automatic lock 100 formed in accordance with the present invention is shown in FIG. 6 . Lock 100 includes a corner fitting mechanism 102 , a rack 104 , a linkage 106 , a foot 108 , and a spring-loaded linkage 110 . As shown, mechanism 102 is located within outboard opening 112 of corner fitting 114 . The other end of automatic lock 100 , i.e., end 116 of linkage 110 , is pivotably connected to a mounting point 118 located on the bottom of the same container including corner fitting 114 . As will be more fully understood with reference to FIG. 7 , mounting point 118 is located on the bottom surface of the container 120 , container 120 being a domestic container. Foot 108 extends downward below the plane, i.e., plane P, defined by the bottom surface of corner fitting 144 . As container 120 is lowered upon container 122 (also a domestic container), foot 108 contacts the upper surface 124 of container 122 . The continued lowering of container 120 causes foot 108 to move generally upward, which in turn moves linkage 106 and linkage 110 . More particularly, movement of linkage 106 causes horizontal movement of rack 104 (to the left as viewed in FIG. 7 ). As shown in FIG. 6 , rack 104 extends through a flange 126 , which restricts movement of rack 104 to a horizontal left and right translation (as viewed in FIG. 7 ). The generally upward movement of foot 108 also causes spring-loaded linkage 110 to compress, thereby providing a biasing force tending to urge foot 108 downward to its “at-rest” position below the surface of plane P.
[0034] FIG. 8 shows domestic container 120 landed upon domestic container 122 . Foot 108 remains in contact with upper surface 124 of lower container 122 . As such, foot 108 has been moved toward the bottom surface of container 120 . This movement results in the translation of rack 104 to the left, which in turn causes lower cone 128 to move into its locking position within corner fitting 130 of container 122 . The movement of foot 108 also causes spring-loaded linkage 110 to compress into the biased position shown in FIG. 8 . When upper container 120 is unloaded, the action is reversed—that is, spring-loaded linkage 110 moves foot 108 downward, which in turn moves linkage 106 , and ultimately rack 104 to the right (as viewed in FIG. 8 ). It is further contemplated herein that foot 108 may be replaced with a spherical-shaped joint, which may be more resistant to inadvertent impact forces encountered during handling of the container.
[0035] To better illustrate the operation of mechanism 102 , corner fitting 114 has been removed from FIG. 9 . Like FIG. 8 , FIG. 9 shows lock 100 in its locked orientation. That is, foot 108 has been moved upward, spring-loaded linkage 110 has been moved into a biased position, and rack 104 has been translated to its left-most orientation. Lower cone 128 is shown in its rotated and locked orientation. In addition to lower cone 128 , corner fitting mechanism 102 includes a housing body 132 , a slider 134 , and a gear 136 . As shown in FIG. 6 , housing body 132 preferably includes a front body portion 132 a and a rear body portion 132 b . As will be more fully explained hereinbelow, the movement of rack 104 to the left causes rotation of gear 136 , which in turn causes vertical translation downward of slider 134 , as well as both vertical and rotational movements of lower cone 128 . Referring back now to FIG. 8 , slider 134 is shown extended downward into corner fitting 130 , and lower cone 128 is rotated to engage at least a portion of corner fitting 130 .
[0036] In FIG. 10 , rear body portion 132 b has been removed for clarity. As shown, a spline shaft 138 extends through and engages gear 136 . As a result, rotation of gear 136 causes simultaneous rotation of shaft 138 . Shaft 138 is preferably an integral component which extends through gear 136 into engagement with lower cone 128 such that rotation of shaft 138 causes simultaneous rotation of lower cone 128 . A pair of cam followers 140 a , 140 b are secured to opposing sides of spline 138 , and follow cam surfaces 142 a , 142 b formed in body portions 132 a , 132 b , respectively. As will be explained more fully hereinbelow, the lower edges of body portions 132 a , 132 b include skirts 144 . Skirts 144 extend around all four sides of mechanism 102 .
[0037] Referring back to FIG. 7 , in one preferred embodiment mechanism 102 is configured such that lower cone 128 is located outside of corner fitting 114 , even when in the “at-rest” condition. This design recognizes the limited vertical height within corner fitting 114 , as well as the need to vertically displace lower cone 128 downward into engagement with the corner fitting on the container therebelow. FIG. 11 (which is a view taken along arrow B of FIG. 6 ) shows lower cone 128 in its “at-rest” position. This will also be the position of lower cone 128 when a container has been hoisted for loading. As mentioned hereinabove, lower cone 128 is connected to spline shaft 138 . Moreover, lower cone 128 translates vertically downward together with slider 134 . As a result, lower cone 128 is rotating at the same time it is being displaced downward. To ensure that lower cone 128 will be in a suitable orientation to allow passage through the opening in the corner fitting of the lower container, lower cone 128 is initially positioned in the orientation in FIG. 11 . Thus, lower cone 128 can rotate through approximately 61 degrees from the initiation of translation to the point where lower cone 128 is within the corner fitting of the lower container. Once inside the corner fitting in the lower container, continued rotation of lower cone 128 will cause lower cone 128 to engage a portion of the corner fitting, thereby interconnecting the upper and lower containers.
[0038] Referring now to FIG. 12 , mechanism 102 further includes a vertical spring 146 . Spring 146 , which functions to urge cam followers 140 a , 140 b into engagement with cam surfaces 142 a , 142 b , will be described further hereinbelow. In one preferred embodiment, the vertical stroke of slider 134 is approximately 1⅜ inches. The orientation of lower cone 128 when in the fully rotated position is shown in FIG. 13 . As mentioned hereinabove, lower cone 128 rotates through approximately 61 degrees of rotation as it translates downward to penetrate the corner fitting in the lower container. As shown, once inside the corner fitting of the lower container, lower cone 128 continues rotating counterclockwise (as viewed in FIG. 13 ) approximately 15° such that bearing area 148 engages the corner fitting of the lower container. In one preferred embodiment, bearing area 148 provides the minimal bearing contact area of 400 mm 2 . Depending on the size and configuration of lower cone 128 , more or less rotation may be required to obtain the minimum bearing contact area. Is also contemplated herein that bearing area 148 may be configured to facilitate release of the lower cone from the lower corner fitting during unloading of the upper container. More particularly, bearing area 148 may be formed with a cross-sectional configuration which tends to rotate lower cone 128 in the clockwise direction (as viewed in FIG. 13 ) in the event that hoisting of the upper container causes lower cone 128 to contact the inner surface of the lower corner fitting.
[0039] Cam surfaces 142 a , 142 b and cam followers 140 a , 140 b will be explained in greater detail with reference to FIGS. 14-16 . Turning first to FIG. 14 , cam followers 140 a , 140 b are rotatably connected to spline shaft 138 via shafts 150 a , 150 b , respectively. As best seen in FIG. 15 , as spline shaft 138 rotates clockwise, cam follower 140 b will travel along cam surface 142 b . Simultaneously, cam follower 140 a will travel along cam surface 142 a . Referring now to FIG. 16 , one end of vertical spring 146 extends within spline shaft 138 , while the other end extends upward to contact the interior floor of the upper container. More particularly, spring 146 is arranged to contact a fixed surface of the upper cargo container such that spring 146 maintains a downward biasing force against shaft 138 . This downward biasing force will ensure that the cam followers remain in contact with the cam surfaces as spline shaft 138 is rotated. As best seen in FIG. 16 , shaft 138 includes a shoulder 152 . Slider 134 is accordingly captured between shoulder 152 and lower cone 128 . As a result, vertical displacement of spline shaft 138 causes simultaneous vertical displacement of slider 134 . Spline shaft 138 is also free to rotate with respect to slider 134 as it is vertically displaced. Due to the size limitations of the corner fitting, a portion of spline shaft 138 preferably extends above the height of gear 136 (see FIG. 10 ), such portion extending into opening 154 of the corner fitting shown in FIG. 16 . As a result, vertical spring 146 is preselected to have a length which extends through this same opening and contacts interior floor 156 of the container. Of course, is contemplated herein that vertical spring 146 could be configured to contact another fixed area of the corner fitting and/or upper cargo container.
[0040] FIGS. 17-18 provide further details regarding the cam/cam follower arrangement of the present invention. FIG. 17 provides a schematical cross-sectional view showing the connection of the cam followers to the spline shaft, as well as the front and rear cam surfaces. FIG. 18 is a flat pattern of the cam's profile, together with the cam follower position, synchronized in time. The front and rear patterns are substantially identical. At 0° (i.e., the initial position), the slider is an upper position. Vertical spring 146 is fully compressed between interior floor 156 and the contact surface within the spline shaft. The force exerted by spring 146 forces each of the cam followers into contact with their respective cam surfaces. At this point, foot 108 begins to contact a surface therebelow, e.g., the upper surface of a lower domestic container. From 0° to 5°, the upper domestic container is lowered downward. This in turn causes generally upward displacement of foot 108 , which in turn causes movement of the rack (to the left is viewed in FIG. 12 ), and in turn rotation of gear 136 . During this first 5° of rotation, downward translation of slider 134 is preferably restricted. The restriction of downward movement of slider 134 during this first 5° of rotation limits/eliminates unwanted movement of the cam followers due to vibrations/forces encountered at the initiation of landing, e.g., forces generated by the initial compression of spring-loaded linkage 110 . From 5° to an angle β=61°, the slider moves down, and the lower cone rotates in the clockwise direction (as viewed from above). Once angle β has been reached, lower cone 128 has penetrated the opening in the lower corner fitting and is positioned for locking rotation. During the same time, foot 108 has been translated upward, and spring-loaded linkage 110 has been compressed. The 61° angle mentioned above corresponds to the 61° angle discussed with reference to FIG. 11 . Depending on the configuration and design, this 61° angle may be increased or decreased. From angle β to 97°, the landing of the upper cargo container continues. During this time, the slider is in its lowest position, and lower cone 128 continues to rotate. From 97° to 120°, the lower cone rotates to its locked position, i.e., to provide the required bearing surface contact area. At 120°, the landing of the upper cargo container has been accomplished.
[0041] Referring now to FIG. 19 , and as mentioned hereinabove, body 132 is formed with a plurality of skirts 144 about its lower edges (see FIG. 10 ). Skirts 144 interact with chamfered edges 158 of the opening in the corner fitting. As such, mechanism 102 can be inserted into the opening until skirts 144 contact chamfered edges 158 . It will be appreciated that this contact occurs on all four sides of mechanism 102 , thus limiting any movement of mechanism 102 with respect to the corner fitting, other than downward vertical movement. To secure mechanism 102 within the corner fitting, a plurality of wedges 160 are employed. As shown, two wedges are attached on each side of mechanism 102 via clamping screws 162 . Wedges 160 are preferably formed with a conical shape such that tightening of screw 162 forces the individual wedge into greater contact with the interior surface of the corner fitting, thus urging mechanism 102 vertically upward, while at the same time fixedly securing mechanism 102 therein.
[0042] FIG. 20 shows a corner fitting of a domestic container containing the automatic lock of the present invention interacting with a retainer positioned on the floor of a well-car. As discussed hereinabove, the retainers located on the floor of the well-car penetrate and engage the inboard openings of the lower corner fittings. Plate 164 , which supports retainer 22 , typically has a thickness of approximately ½ inch. In one preferred embodiment, lower cone 128 is designed to extend approximately ½ inch below the surface of the corner fitting. As a result, the cargo container will rest upon plates 164 , and not upon lower cone 128 .
[0043] It is contemplated herein that a domestic container containing the automatic lock of the present invention may be landed on the ground. In this situation, the weight of the container will rest upon the four lower cones protruding from the lower corner fittings. The novel design of the current automatic lock ensures that the mechanism fitted within each corner fitting can support the weight of the container. In addition to the domestic containers described hereinabove, it is contemplated herein that the automatic lock of the present invention may be utilized with other standard containers used in the different forms of cargo transportation.
[0044] It will be appreciated that the present invention has been described herein with reference to certain preferred or exemplary embodiments. The preferred or exemplary embodiments described herein may be modified, changed, added to or deviated from without departing from the intent, spirit and scope of the present invention, and it is intended that all such additions, modifications, amendments and/or deviations be included in the scope of the present invention.
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An automatic lock affixed to a cargo container for interconnecting two stacked containers, and for automatically locking and unlocking without reliance upon the overcoming of a friction force to release the device.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to clock generation, and particularly, but not exclusively, relates to clock generation for power converters.
[0003] 2. Description of the Related Art
[0004] Power converters are well-known sources of electromagnetic interference. Switching converters and DC-DC converters, when clocked at frequencies in the order of megahertz, will generate substantial tones at the fundamental frequency and its harmonics.
[0005] These tones may cause problems for other components in the system. Electromagnetic (EM) pulses radiated from the chip may cause malfunction in other parts of the system. Further, in audio applications, the tones may react with non-linearities in the system and mix down in frequency, creating tones that are audible to the user.
[0006] FIG. 1 shows a standard power converter system 10 . An incoming voltage V in is input to a power converter 20 and converted to an output voltage V out , with the converter 20 being clocked at a frequency f c . V out may be greater than V in (as in boost converters) or less than V in (as in buck converters). The clock frequency f c is generated by dividing a signal of fixed frequency f REF in a ÷N block 30 .
[0007] FIG. 2 is a schematic graph showing the problem of tone generation in power converters. Sharp tones are created at the clock frequency f c and its odd harmonics. The generation of tones at the odd harmonics arises from the Fourier transform of the square wave clock. As aforementioned, these tones are undesirable.
SUMMARY OF THE INVENTION
[0008] According to a first aspect of the present invention, there is provided a frequency divider, comprising an input for receiving an input clock signal having a first frequency; a divider, for generating an output signal having an instantaneous frequency equal to the first frequency divided by an instantaneous division ratio; and a sequence generator, for generating a sequence of instantaneous division ratios by adding a sequence of instantaneous dither values to an integer value. The instantaneous division ratios in said sequence have a mean value that is equal to an integer desired ratio, but none of the instantaneous division ratios in said sequence is equal to the integer desired ratio.
[0009] According to a second aspect of the present invention, there is provided a frequency divider, comprising an input for receiving an input clock signal having a first frequency; a divider, for generating an output signal having an instantaneous frequency equal to the first frequency divided by an instantaneous division ratio; a word length reduction block, for receiving a fractional component of a non-integer desired ratio and outputting a sequence of instantaneous modulated outputs; and a sequence generator, for generating a sequence of instantaneous division ratios by summing a sequence of instantaneous dither values, said sequence of instantaneous modulated outputs and an integer value. The non-integer desired ratio is equal to the sum of an integer component and said fractional component, said fractional component being less than one. The instantaneous division ratios in said sequence have a mean value that is equal to the non-integer desired ratio. A partial sum of the integer value and the sequence of instantaneous dither values does not equal the integer component of the non-integer desired ratio.
[0010] According to a third aspect of the present invention, there is provided a method of frequency synthesis, comprising the steps of: receiving an input signal having a first frequency; generating a sequence of instantaneous division ratios by adding a sequence of instantaneous dither values to an integer value; generating an output signal having an instantaneous frequency equal to the first frequency divided by an instantaneous division ratio. The instantaneous division ratios in said sequence have a mean value that is equal to an integer desired ratio, but none of the instantaneous division ratios in said sequence is equal to the integer desired ratio.
[0011] According to a fourth aspect of the present invention, there is provided a method of frequency synthesis, comprising the steps of: receiving an input signal having a first frequency; receiving a fractional component of a non-integer desired ratio and outputting a sequence of instantaneous modulated outputs; generating a sequence of instantaneous division ratios by summing a sequence of instantaneous dither values, said sequence of instantaneous modulated outputs and an integer value; and generating an output signal having an instantaneous frequency equal to the first frequency divided by an instantaneous division ratio. The non-integer desired ratio is equal to the sum of an integer component and said fractional component, said fractional component being less than one. The instantaneous division ratios in said sequence have a mean value that is equal to the non-integer desired ratio. A partial sum of the integer value and the sequence of instantaneous dither values does not equal the integer component of the non-integer desired ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the following drawings, in which:
[0013] FIG. 1 is a block schematic diagram, illustrating the general form of a power converter circuit.
[0014] FIG. 2 illustrates tones generated in a power converter circuit.
[0015] FIG. 3 is a block schematic diagram, illustrating a clock modulation circuit, acting as a frequency divider.
[0016] FIG. 4 illustrates tones generated in the circuit of FIG. 3 .
[0017] FIG. 5 is a block schematic diagram, illustrating a further clock modulation circuit, acting as a frequency divider, in accordance with an aspect of the present invention.
[0018] FIG. 6 is a block schematic diagram, illustrating a further clock modulation circuit, acting as a frequency divider, in accordance with an aspect of the present invention.
[0019] FIG. 7 is a more detailed block schematic diagram, illustrating the frequency divider block in the circuits of FIGS. 5 and 6 .
[0020] FIG. 8 illustrates the operation of the frequency divider block of FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] One solution to the generation of the unwanted tones generated by the power converter is to modulate the clock frequency by applying some form of dither. Dither is a noise signal that is intentionally added to a signal. In some applications, dither is used to increase the accuracy of a truncated signal. In the present application, the dither is used to slightly spread the clock frequency so that not all of the energy radiated by the power converter is concentrated on the clock frequency and its harmonics. That is, the distribution of power is spread over a range of frequencies and hence the peaks are reduced.
[0022] FIG. 3 shows a first clock modulation circuit 40 .
[0023] The circuit 40 comprises a ÷N block 50 which receives an input signal at a reference frequency f REF . An adding element 60 adds a desired division factor N and a dither signal generated by a 1-bit dither block 70 , and outputs the sum to the ÷N block 50 .
[0024] The ÷N block 50 generates an output clock signal at an instantaneous frequency which is f REF divided by the output of the adding element 60 . This output signal is also used to clock the dither block 70 .
[0025] The dither block 70 may comprise one or more of a number of random number generators that will be familiar to one skilled in the art and need not be explained in great detail here. For example, the dither block 70 may comprise a linear feedback shift register, or a loop circuit with an unstable feedback loop.
[0026] Thus, in the one-bit case shown here, randomly generated 1s and 0s are added to N to shift slightly the output frequency of the system. The effect of this dither is to spread the peaks at the clock frequency and its harmonics, so that not all of the power of the system is concentrated at the discrete frequencies.
[0027] The circuit 40 has a drawback, however. The average output of the dither block 70 is approximately ½, so on average the division factor will increase to N+½, and the average output clock frequency of the system will be reduced. That is, the average output frequency of the first clock generation circuit 40 is in fact f c ′=f REF /(N+½).
[0028] FIG. 4 is a schematic graph showing this effect in more detail. The dashed lines show the previous positions of the tones. As can be clearly seen, the new clock frequency f c ′ and its harmonics are lower in frequency than they previously would have been. Such a reduction in frequency is also undesirable. However, the amplitude of the peaks is reduced and therefore the tones will not be as audible to an end user as they otherwise would have been.
[0029] One solution to the problem of reducing the frequency of the clock is to increase the number of bits of dither to at least two. In this instance, the possible dither outputs will be −1, 0 or +1, and the average dither output is zero. However, this does not reduce the amplitude of the peaks sufficiently.
[0030] FIG. 5 shows a second clock generation circuit 100 . The second clock generation circuit 100 is generally similar to the first clock generation circuit 40 . However, the dither is applied in a different way. Similar components in the two circuits 40 , 100 have similar reference numerals and therefore will not be described in further detail.
[0031] In this embodiment, the output of the dither block 70 is input to a multiplexer 80 , and the multiplexer 80 outputs the dither signal to the adding element 60 . The multiplexer 80 functions to receive the 1-bit output of the dither block 70 , and then select a dither signal of either −1 or +1. So, for example, if the output of the dither block is 0, the multiplexer may output −1, and if the dither is 1, the multiplexer may output +1.
[0032] As before, the ÷N block 50 generates an output clock signal at an instantaneous frequency which is equal to the input frequency f REF divided by the output of the adding element 60 . This output signal is also used to clock the dither block 70 . In this case, the average dither applied to the division factor is 0, and so the average frequency of the output clock signal is not shifted, and is equal to f REF /N.
[0033] However, a further important point of the circuit 100 is that none of the possible outputs of the multiplexer 80 is zero. So, although the average output is zero, none of the instantaneous outputs is zero. The instantaneous frequency output of the ÷N block 50 is therefore always slightly perturbed, either positively or negatively.
[0034] By never applying zero dither, the amplitudes of the tones at the central peaks of f c and its harmonics are minimized.
[0035] Variations on the circuit 100 may be thought of by one skilled in the art without departing from the scope of the invention. For example, advantageously, the applied dither may be +2 and −2, so that the peak is spread even further. If a two-bit dither signal was used, the dither outputs may be chosen as −5, −2, +2 and +5, for example. Higher numbers of bits of dither will allow the peaks to be shaped as required. However, such decisions are at the control of the system designer. The important point is that zero dither is never applied.
[0036] Of course, one skilled in the art will appreciate that the overriding principle is that the sum of the inputs to the adding element 60 never be equal to the desired ratio N. That is, an alternative approach would be to input a constant value of (N−1) to the adding element 60 instead of N, and apply dither values of 0 and 2, such that the mean division ratio is still N.
[0037] FIG. 6 shows a third clock generation circuit 200 wherein the clock frequency is synthesized using a fractional divide. That is, the overall division factor may not be an integer. In this case, the overall division factor is split into an integer part M and a fractional part y.
[0038] The fractional input y is input to a sigma-delta modulator 210 (SDM) as will be familiar to those skilled in the art. The fractional input y may initially be described with a high number of bits. The SDM 210 reduces y to a lower number of bits, but ensures that the average output is equal to y, accurate to a high accuracy. The output of the SDM 210 may be only one bit. Thus, although the instantaneous output of the SDM 210 may be inaccurate, the average output is highly accurate. The output of the SDM 210 is added to the dither in an adding element 220 , and this combined signal is added to the integer M in a further adding element 230 . The output of the adding element 230 is then used to modulate the clock frequency f c .
[0039] Thus, as before, the ÷N block 50 generates an output clock signal at an instantaneous frequency which is equal to the input frequency f REF divided by the output of the adding element 230 . This output signal is also used to clock the dither block 70 . Again, the average dither applied to the division factor is 0, and so the average frequency of the output clock signal is not shifted, and is equal to f REF /(M+y).
[0040] Sigma-delta modulation is one of several possibilities for modulating the fractional input y that will be readily apparent to those skilled in the art. In practice the SDM 210 may be any word length reduction block, such as a truncation or a noise shaper, for example. In the event that the word length reduction block is a truncation, dither may be applied to the fractional input y prior to truncation in order to improve the accuracy of the modulated output.
[0041] FIG. 7 is a schematic block diagram showing one realization of the ÷N block 50 in the circuits of FIGS. 3 , 5 and 6 .
[0042] The division is realized using a counter 240 and taking the most significant bit (MSB) of the count. An input k is fed to an adder 250 , and the signal from the adder 250 fed through a delay element 260 . The output from the delay element 260 is fed back to the adder 250 . The delay element 260 is clocked at a fixed frequency f REF which is typically much higher than the desired clock frequency. The delay/adder cycle effectively acts as a counter in steps of k. If the input k is R bits long, the highest number the count can reach before repeating is 2 R . The most significant bit (MSB) is extracted from the output of the delay element 260 by a MSB extractor 270 and this is used as the new clock signal. Thus the output frequency f c is the input frequency f REF divided by the number of ‘k’s in 2 R (f c =f REF ×k/2 R ). By adapting the input k, the output frequency of the MSB, f c , can be altered. Therefore in this embodiment the overall division factor N is 2 R /k.
[0043] This is shown in more detail in FIG. 8 . As the counter counts up, the MSB of the count is taken. The MSB output therefore has a lower frequency that may be adjusted by adjusting the size of the steps taken to reach the maximum value 2 R , i.e. k.
[0044] The frequency divider described herein preferably forms part of a power converter that is preferably incorporated in an integrated circuit. For example, the integrated circuit may be part of an audio and/or video system, such as an MP3 player, a mobile phone, a camera or a satellite navigation system, and the system can be portable (such as a battery-powered handheld system) or can be mains-powered (such as a hi-fi system or a television receiver) or can be an in-car, in-train, or in-plane entertainment system.
[0045] The skilled person will recognise that the above-described apparatus and methods may be embodied as processor control code, for example on a carrier medium such as a disk, CD- or DVD-ROM, programmed memory such as read only memory (firmware), or on a data carrier such as an optical or electrical signal carrier. For many applications, embodiments of the invention will be implemented on a DSP (digital signal processor), ASIC (application specific integrated circuit) or FPGA (field programmable gate array). Thus the code may comprise conventional program code or microcode or, for example code for setting up or controlling an ASIC or FPGA. The code may also comprise code for dynamically configuring re-configurable apparatus such as re-programmable logic gate arrays. Similarly the code may comprise code for a hardware description language such as Verilog TM or VHDL (very high speed integrated circuit hardware description language). As the skilled person will appreciate, the code may be distributed between a plurality of coupled components in communication with one another. Where appropriate, the embodiments may also be implemented using code running on a field-(re-)programmable analogue array or similar device in order to configure analogue/digital hardware.
[0046] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims. The word “comprising” does not exclude the presence of elements or steps other than those listed in a claim, “a” or “an” does not exclude a plurality, and a single processor or other unit may fulfil the functions of several units recited in the claims. Any reference signs in the claims shall not be construed so as to limit their scope.
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A frequency divider, comprising an input for receiving an input clock signal having a first frequency; a divider, for generating an output signal having an instantaneous frequency equal to the first frequency divided by an instantaneous division ratio; and a sequence generator, for generating a sequence of instantaneous division ratios by adding a sequence of instantaneous dither values to an integer value. The instantaneous division ratios in the sequence have a mean value that is equal to an integer desired ratio, but none of the instantaneous division ratios in the sequence is equal to the integer desired ratio.
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BACKGROUND OF THE INVENTION
The invention relates to a process for the recovery of the principal mineral elements contained in saline waters, such as sea water, salt water concentrates and brines, together with most of the water, which is recovered as potable water.
Saline waters, particularly sea water, contain a wide variety of dissolved minerals and chemicals, the bulk of which are present in the form of ions. In sea water, for example, the major ion constituents are sodium, magnesium, calcium, potassium, chlorine, sulfate, bicarbonate, and bromine ions. For many years, processes have been developed and attempts have been made to recover the major mineral or chemical constituents from sea water and other saline waters. Extensive efforts have been made in this direction in the last ten to fifteen years due to the availability of large quantities of brine by-product solutions obtained from commercial sea water desalination plants. Heretofore, commercially viable processes have been limited to the recovery of only a few of these valuable constituents, have produced substantial, unusable wastes, and have fallen far short of extracting the majority of the water in the feed. Thus, there is a need for a practical and economic process for the recovery of a substantial percentage of the principal minerals and chemicals in saline water together with most of the water and for a recovery process which produces only relatively minor amounts of unusable wastes.
SUMMARY OF THE INVENTION
The invention relates to a continuous process which may be used to recover most of the sodium, magnesium, calcium, potassium, chlorine, bromine and sulfate present in saline water, particularly desalination plant by-product brine solutions. In addition, most of the water in the saline water feed may be recovered as potable water.
In the process, a saline water feed initially is chemically treated to remove essentially all, 99% or more, of the magnesium and calcium in the form of salable compounds, such as magnesium oxide (magnesia) and calcium oxide (lime), or as compounds which may be converted to salable compounds. Advantageously, the sulfate and chloride ions associated with the magnesium and the calcium are converted to sodium sulfate and sodium chloride for recovery at later stages of the process. The magnesium and calcium depleted solution then is combined with recycled sodium chloride to form a sodium chloride fortified solution. Essentially pure sodium chloride crystals are obtained from the sodium chloride fortified solution by crystallizing sodium chloride from the solution and then separating the sodium chloride crystals from the filtrate or mother liquor. Advantageously, two stages of crystallization and separation are employed, each of which comprises evaporative crystallization followed by centrifugation. The crystals recovered from the first stage are dissolved between stages, with water for dissolution advantageously being provided by the second stage evaporative crystallizer. The redissolved sodium chloride then is recrystallized in the second stage to commercial quality sodium chloride.
At this point, the mother liquor stream, which includes potassium chloride, sodium sulfate, sodium bromide and unrecovered sodium chloride, is acidified and treated with chlorine to convert bromine ions to molecular bromine. The bromine then is removed from the stream by stripping. Next the stream is neutralized and sodium sulfate and sodium chloride crystals are crystallized. The crystal containing slurry is separated into a sodium sulfate crystal rich slurry and a sodium chloride crystal rich slurry, preferably by an elutriation classification. Both slurries contain uncrystallized potassium chloride. The sodium sulfate and sodium chloride then are separated from their respective slurries. The recovered sodium sulfate may then be dried to salable salt cake (sodium sulfate). The recovered sodium chloride is recycled to fortify the initial magnesium and calcium depleted solution.
The mother liquors remaining from the sodium sulfate and sodium chloride rich slurries are combined, and the combined solution then is treated to precipitate residual sulfate ions remaining in the combined solution. Next, most of the remaining sodium chloride is removed from the solution by thc crystallization and separation of sodium chloride crystals. These sodium chloride crystals are recycled to fortify the initial magnesium and calcium depleted solution. The mother liquor remaining from this last sodium chloride separation is vacuum crystallized to obtain potassium chloride crystals which are then separated from the crystallized solution and dried to salable potassium chloride. The solution from which the potassium chloride is separated may be recycled, preferably to the last sodium chloride crystallization step, since it still contains some sodium chloride and potassium chloride.
Significant quantities of potable water are obtained during various steps of the process, primarily as vapor condensate during the crystallization steps. As a result, virtually all of the water contained in the feed may be recovered as potable water.
The sodium chloride crystals obtained from the process may be dried and sold. Advantageously, a portion of the sodium chloride crystals are dissolved and then are electrolytically converted to an aqueous sodium hydroxide solution and to chlorine and hydrogen gases. Preferably, a portion of the sodium hydroxide solution is used in the process to remove magnesium from the saline water feed; the remainder is concentrated and flaked to salable flaked caustic. A portion of the chlorine gas is liquified; the remainder of the chlorine and part of the hydrogen are used to prepare hydrochloric acid. Preferably, part of the liquid chlorine and the hydrochloric acid are used in the process; the rest may be sold.
In a preferred embodiment of the invention, the flue gas from the boilers used to generate steam for the evaporators is reacted with sodium hydroxide to produce sodium carbonate. This chemical is then used in the calcium removal step. Preferably, all of the crystallization steps, except the vaccum crystallization, employ evaporative crystallizers which are combined into a large, integrated multiple effect evaporator system.
The principal advantages of the invention are the ability to economically recover as commercially salable compounds virtually all of the principal mineral and chemical constituents found in saline water and to simultaneously recover virtually all of the water in the feed as potable water. Heretofore, the simultaneous economical recovery of commercially salable sodium chloride, potassium chloride, sodium sulfate, calcium and magnesium compounds and sodium chloride derived products had not been achieved, particularly in combination with the recovery of significant quantities of potable water. Moreover, these extremely beneficial results may be achieved with only minimal waste production.
These beneficial results are achieved as a result of the synergistic processing sequence of the invention. This processing sequence removes hardness at the beginning and permits clean, unscaled operation during the remaining steps of the process. Moreover, hardness is most advantageously removed while the sulfate and chlorine ions associated with the calcium and magnesium are converted to recoverable sodium compounds. Since few of the steps employ an acidic environment, expensive, special alloy equipment is not necessary. The recycle of sodium chloride fortifies the feed solution to the first and largest crystallization steps, and thereby reduces the throughput volume, equipment size, and utility costs, while improving sodium chloride yield and purity. The dissolution of the initial, crude crystallization product with vapor condensate, insures purity and reduces the consumption of outside make-up water. The two stage sodium chloride crystallization sequence insures the production of a high quality sodium chloride product. All of the reactants added during the process may be obtained from the process. The processing sequence permits significantly greater quantities of sodium chloride to be produced per unit of saline feed than is possible with conventional processes, along with the production of a significantly smaller amount of unusable waste per unit of feed. The use of an integrated, multiple effect vapor system reduces steam consumption considerably. Moreover, the processing sequence effectively precludes the formation of large quantities of the complexes and sludges which, in most saline chemical recovery processes, tie up the valuable chemical constituents and significantly impair their recovery.
Additional features and advantages of the invention are described in and will appear from the description of the preferred embodiments and from the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 4 are a schematic flow diagram of the preferred embodiments of the invention described below.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention may be employed to recover the commercially valuable, principal dissolved chemical constituents in saline waters, such as sea water, salt waters, salt water concentrates, brines, and the like, where the combined concentration of the principal chemical constituents normally ranges from about 3 to 8% or more by weight. These principal constituents include sodium, chlorine, magnesium, calcium, potassium, sulfate and bromine. (Bicarbonate also is a principal constituent in most saline waters, but it is not recovered by the process of the invention since bicarbonate is usually removed by pH control prior to the saline water's introduction into the process of the invention.) Typically, these principal constituents are recovered as sodium chloride, potassium chloride, sodium hydroxide (caustic soda), hydrochloric acid, sodium sulfate (salt cake), magnesium oxide (magnesia), calcium oxide (lime), chlorine, bromine, and hydrogen, although not all of these products need be recovered. Substantial quantities of potable water also are recovered.
The invention is most advantageously employed to recover the chemicals contained in the brine or blow down solutions produced as a by-product in commercial saline water desalination plants. Such plants have become an important source of potable water in many arid countries, and today some desalination plants produce as much as 50 million gallons per day of fresh water. While many different methods are employed to desalinate sea water, all produce substantial quantities of salt containing brine wastes.
The preferred embodiment of the invention illustrated in the drawings and described below is especially adapted for use with desalination plant by-product brine solutions, such as those from multi-stage flash evaporation systems. The salt concentration in such a solution is typically about 5-7% or more. While the distribution of salts may vary somewhat, a brine solution containing about 6% salts typically would include about 4.5% dissociated sodium chloride, 0.65% magnesium chloride, 0.4% magnesium sulfate, 0.25% calcium sulfate, 0.13% potassium chloride and about 0.01% sodium bromide. Bicarbonates are normally not present in such brine solutions because the bicarbonate has been removed prior to desalination to minimize alkaline scale fouling in the desalination equipment.
In the preferred embodiment outlined in the drawings, the saline water feed solution 10, a desalination plant by-product brine solution containing about 6% dissolved salts, is withdrawn from feed storage trank 10 and charged to mixer-settler reactor 12. A sodium carbonate (soda ash) aqueous solution 13 is introduced into reactor 12. As will be explained below, this carbonate solution may be produced at another step in the process and recycled to reactor 12. The sodium carbonate solution 13 reacts with the calcium sulfate in the feed to produce sodium sulfate and insoluble calcium carb onate. Essentially all of the calcium carbonate, about 99% or more, preferably about 99.8% or more, settles out of the solution and is removed from reactor 12 at 14. The calcium carbonate 14 is then filtered in filter 15 and calcined in calciner 16 to convert the calcium carbonate to calcium oxide (quick lime), one of the commercially valuable products produced by the invention. The lime may be stored in storage bin 17. A portion of the lime may be used at a later point in the process, as will be discussed below.
A calcium depleted solution 18 is removed from reactor 12 and is introduced to mixer-settler reactor 19. Caustic soda (sodium hydroxide) 20 also is introduced to reactor 19. As with the sodium carbonate used in reactor 12, the sodium hydroxide used in reactor 19 may be produced at another point in the process. In reactor 19, caustic soda 20 reacts with the magnesium sulfate and magnesium chloride in the feed to produce sodium chloride, more sodium sulfate and insoluble magnesium hydroxide. Essentially all of the magnesium hydroxide, about 99% or more, preferably about 99.8% or more, settles out of the solution produced in reactor 19, and it then is removed at 21. The magnesium hydroxide 21 is filtered in filter 22 and calcined in calciner 23 to convert the magnesium hydroxide to magnesium oxide (magnesia). The magnesia, which is one of the commercially valuable products produced by the invention, may be stored in storage bin 24.
The removal of essentially all of the magnesium and calcium at the beginning of the process removes hardness from the feed. This minimizes scaling and fouling problems in the evaporation steps and eliminates the need for expensive, special alloy equipment, such as that made with titanium, Monel, etc. The conversion of magnesium chloride and the magnesium and calcium sulfates to sodium chloride and sodium sulfates also is highly advantageous since these sodium salts may be recovered at later stages of the process.
A magnesium and calcium depleted solution 25 is removed from reactor 19. Solution 25 is a nonsaturated solution which contains about 6% dissolved salt, if the preferred feed is employed. Solution 25 includes sodium chloride, sodium sulfate, potassium chloride, sodium bromide, and very minor concentrations of entrained calcium carbonate and magnesium hydroxide. Solution 25 is introduced into stirred mixer 26. Mixer 26 is employed to increase the salt concentration to about 7-8% or more immediately prior to the principal evaporation-crystallization steps in the process. This is accomplished by combining solution 25 with salt recycled from other points in the process. These recycled salt sources, identified by reference numerals 27, 28, are preferably crystallized salt cakes having a high concentration of sodium chloride and low concentrations of various other salts. The sources of this recycled salt will be described below. This recycle operation is employed to help reduce the throughput volume and utility cost per unit of product, to reduce equipment size and to help improve the yield and purity of the sodium chloride salt crystals produced in the immediately following processing steps.
The fortified evaporator feed 29 is fed to evaporator-crystallizer 30. Evaporator-crystallizer 30 concentrates the salts by a factor of from about 6:1 to 10:1, preferably from about 7:1 to 9:1, by evaporating and removing substantial quantities of water from the feed solution. This water, which is removed at 31, is condensed to form a large part of the potable water produced by the process. Evaporator-crystallizer 30 also crystallizes a substantial percentage of the sodium chloride contained in the feed. Both the crystallized and the uncrystallized salts are removed from evaporator-crystallizer 30 as a slurry 32 which contains about 25% by weight of crystallized salt. Approximately 95% of the salt crystals in slurry 32 are sodium chloride; the balance is primarily sodium sulfate and minor concentrations of previously unremoved magnesium hydroxide and calcium carbonate. Slurry 32 is charged to centrifuge 33 along with a minor amount of wash water 34, and slurry 32 is separated into a solid crystal containing cake 35 and a mother liquor 36, primarily composed of water and dissolved salts.
Crystal cake 35 then is charged to mixer-settler 37 and is dissolved in water to form a saturated salt solution. Preferably, the water used to form this saturated solution is obtained from the vapor condensate 38 from the second stage evaporator-crystallizer 39. It also may be obtained from other water vapor condensate streams so that the use of outside make-up water may be eliminated. Virtually all of the magnesium hydroxide and calcium carbonate present in cake 35 fails to dissolve in mixer-settler 37 and may be removed from the system at 40 as a discardable sludge.
The saturated brine solution formed in mixer-settler 37 is transferred via 41 to a second stage evaporator-crystallizer 39 in which the water added in mixer-settler 37 is removed (and recycled 38 to mixer-settler 37) and the sodium chloride is recrystallized. Both the crystallized and the uncrystallized salts are removed in a slurry stream 42 which then is centrifuged in centrifuge 43 with the aid of wash water 44. Slurry 42 contains about 25% by weight salt crystals. These crystals are virtually pure (about 99.99%) sodium chloride so that the cake 45 from centrifuge 43 may be dried in drier 46 to a commercial quality sodium chloride product. This product may be stored in storage bin 47. Preferably, a portion 48 of the pure sodium chloride cake product 45 is not dried to finished sodium chloride, but is redissolved and processed further to make additional products and some of the chemicals used in the process. These further sodium chloride cake processing steps are described below.
The mother liquor stream 49 from centrifuge 43 is combined with mother liquor stream 36 from centrifuge 33. This combined stream 50 contains potassium chloride, sodium sulfate, sodium bromide and the sodium chloride which remained in solution through the evaporative crystallization and centrifugation steps. Stream 50 is acidified, preferably with hydrochloric acid 51, and chlorine 52 is added to react with the sodium bromide to form bromine and more sodium chloride. This may be carried out in line and both the chlorine and hydrochloric acid may be supplied from other steps of the process. The bromine then is stripped from the system in stripper 53 which uses air 54 to entrain the molecular bromine. The bromine 55 recovered from stripper 53 is another one of the commercially valuable products produced by the invention.
The salt containing stripper output stream 56, which contains sodium chloride, sodium sulfate and potassium chloride, is neutralized at 57, preferably with sodium hydroxide, and then is charged to evaporator-crystallizer 60. Evaporator-crystallizer 60 further concentrates the remaining salts by the evaporation of water 61, which may be recovered as potable water, and crystallizes both sodium chloride and sodium sulfate crystals. The operating conditions in evaporator-crystallizer 60 are selected and maintained so that the evaporation is not carried to the point at which potassium chloride crystals would be formed. Preferably, the evaporation in evaporator-crystallizer 60 is controlled by monitoring slurry output stream 62 to maintain the potassium chloride concentration in stream 62 between about 6 to 8%, preferably about 7%. The slurry output 62 from evaporator-crystallizer 60 then is fed to an elutriation classifier column 63 which separates slurry 62 into a sodium sulfate crystal rich slurry 64 and a sodium chloride crystal rich slurry 65. This elutriation separation is possible because the sodium sulfate crystals are much smaller crystals than are the sodium chloride crystals. Of course, the sodium sulfate rich slurry 64 contains a minor concentration of sodium chloride crystals and the sodium chloride rich slurry 65 contains a minor concentration of sodium sulfate crystals.
The sodium sulfate crystal rich slurry 64 is centrifuged in centrifuge 66 with wash water 67. The cake 68 from centrifuge 66 is dried in drier 69 to form commercially salable anhydrous sodium sulfate (salt cake) which may be stored in bin 70. The mother liquor stream 71 from centrifuge 66 is split so that one portion 72 of stream 71 is recycled to classifier 63 to provide additional solution for the elutriation classification. The other portion 73 of mother liquor stream 71 is combined with a second mother liquor stream 74 to form a second combined mother liquor stream 75 which is the feed to mixer reactor 76. The second mother liquor stream 74 is obtained from centrifuge 77 in which the sodium chloride rich slurry 65 is separated into mother liquor stream 74 and cake 27 with the aid of wash water 78. Cake 27, which comprises sodium chloride crystals with a very minor concentration of sodium sulfate crystals, is one of the principal recycle salt sources for mixer 26, which precedes first evaporator-crystallizer 30.
Combined mother liquor stream 75 contains significant concentrations of sodium chloride, sodium sulfate and potassium chloride, with the sodium chloride concentration being much greater than the concentrations of the other two salts. If the preferred by-product brine solutions are used as the process feed, stream 75 typically will contain about 21% sodium chloride and 7% of both sodium sulfate and potassium chloride.
Mixer reactor 76 is used to remove the residual sulfate (sodium sulfate) from the system prior to the potassium chloride recovery steps. This removal is achieved by adding calcium hydroxide 79 to reactor 76 to convert the sodium sulfate to calcium sulfate and sodium hydroxide. The calcium hydroxide 79 used in reactor 76 may be obtained from the process itself by the conversion of a portion of the calcium oxide produced at the beginning of the process. Thus, calcium oxide may be withdrawn from storage tank 17 at 83 and charged to slaker 84 together with water 85 to convert the calcium oxide to calcium hydroxide. The calcium hydroxide product 79 then is used in reactor 76. The reaction product stream 80 from reactor 76 flows through filter 81 to remove an unusable calcium sulfate containing sludge 82 before further processing. At this point, stream 80 principally comprises sodium chloride, potassium chloride and sodium hydroxide in an aqueous solution.
The filtered reaction product stream 80 from reactor 76 is treated with hydrochloric acid 86 to convert the sodium hydroxide in the stream to sodium chloride and water. This produces a treated aqueous solution 87 which contains significant concentrations of only sodium chloride and potassium chloride. Treated solution 87 is fed to evaporator-crystallizer 89. Recycle stream 88 also may be fed to evaporator-crystallizer 89.
Evaporator-crystallizer 89 removes substantial quantities of the remaining water 90 and crystallizes a substantial portion of the sodium chloride in the crystallizer feed. The sodium chloride crystal containing slurry 91 from evaporator-crystallizer 89 then is charged to centrifuge 92 along with a minor amount of wash water 34, and slurry 91 is separated into a crystal containing cake 28 and a mother liquor stream 93. The mother liquor stream 93 comprises potassium chloride, a small concentration of dissolved sodium chloride, and the remaining water. Cake 28, which comprises sodium chloride crystals together with a minor concentration of potassium chloride, is the second principal recycle salt source for mixer 26, which precedes first evaporator-crystallizer 30.
Mother liquor stream 93 is charged to a vacuum crystallizer 94 which is operated at a relatively low temperature, on the order of about 100° F., in comparison to the operating temperature of the evaporator-crystallizers. In vacuum crystallizer 94, water 95 is removed under vacuum and potassium chloride crystals are formed to produce a potassium chloride crystal rich slurry 96. Adiabatic conditions are employed in vacuum crystallizer 94 to help prevent the crystallization of the sodium chloride contained in the feed. Slurry 96 is charged to centrifuge 97 along with wash water 98, and the slurry is separated into a potassium chloride crystal cake 99 and mother liquor stream 88. Mother liquor stream 88, which contains dissolved sodium chloride and potassium chloride, preferably is recycled to evaporator-crystallizer 89. The potassium chloride cake 99 is fed to drier 100 to remove remaining water. The dried potassium chloride may be transferred to storage bin 101 to await shipment.
In a preferred embodiment of the invention, a portion 48 of the sodium chloride produced by the process is treated to produce some of the chemicals consumed by the process, together with a variety of valuable commercial products. In accordance with this preferred embodiment, sodium chloride 48 is fed to a mixer 102 where it is redissolved in water 103. The dissolved sodium chloride 104 then is fed to an electrolytic cell system 105 which electrolyzes the solution to hydrogen and chlorine gases, 106 and 107 respectively, and to sodium hydroxide. The sodium hydroxide remains in solution and is removed from electrolytic cell system 105 as a 30-50% sodium hydroxide solution 108. A portion 20 of this solution 108 then may be used as a part of the sodium hydroxide feed to reactor-settler 19, in which a sodium hydroxide solution is added to convert magnesium salts to magnesium hydroxide. The remainder of solution 108 is fed to concentrators 109 and 110 which are connected in series. These concentrators are used to evaporate the water in which the sodium hydroxide is dissolved. The concentrated sodium hydroxide 111 obtained from the second concentrator 110 is transferred to a flaking drum 112 in which the sodium hydroxide is flaked to form the final flaked caustic product which may be stored in bin 113. This flaked sodium hydroxide is another of the many commercially valuable products which may be produced by the process.
The chlorine gas 107 produced in electrolytic cells 105 is advantageously used to produce two additional commercially valuable products, liquid chlorine and hydrochloric acid, both of which also may be used in the process itself. Thus, one portion 114 of the chlorine gas 107 is transferred to liquifier 115 in which the gaseous chlorine is liquified. This liquified chlorine is stored in storage tank 116. A portion of this liquid chlorine may be added to mother liquor stream 50 at 52 to convert sodium bromide to molecular bromine and sodium chloride. The other portion 117 of the chlorine gas is charged to a hydrochloric acid furnace 118 along with a portion of the hydrogen gas 106 produced in electrolytic cells 105. In furnace 118, the hydrogen and chlorine gases are converted to hydrogen chloride 119. Water is added to the hydrogen chloride 119 in absorber 120 to prepare a hydrochloric acid solution, preferably a concentrated solution containing about 32% hydrogen chloride. This solution may be stored in storage tank 121. While the concentrated hydrochloric acid solution is another of the salable products produced by the process, it also is consumed at two different points in the preferred embodiment disclosed herein. Thus, a portion 122 of the hydrochloric acid may be removed from tank 121 and may be added to mother liquor stream 50 at 51 and to the sulfate depleted stream 81 removed from reactor 76 at 86. The hydrogen gas 123 which is not needed for the production of hydrochlorine acid may be collected in storage tank 124. This hydrogen may be sold.
In the illustrated preferred embodiment, at least a portion of the sodium carbonate 13 used in reactor 12 may be produced from the flue gas given off by the boilers employed to generate the stream used in the evaporation steps of the process. Thus flue gas, 130 in FIG. 4, is charged to a reactor 131 along with water 132 and sodium hydroxide 20a to convert the ash in the flue gas to sodium carbonate 13 which then may be charged to reactor 12. The sodium hydroxide stream 20a used in reactor 131 preferably is obtained from the sodium hydroxide solution 108 produced by the electrolytic cells 105.
The temperatures, pressures, reaction conditions and other processing conditions employed in the process generally are not critical and will be known to those skilled in the art, given the processing sequence and other details described above, in light of the feed composition, utility costs and other factors related to any specific application of the process.
Advantageously, the slurry 32 removed from first evaporator-crystallizer 30 is at a temperature between about 200° F. and 219° F., the latter temperature being the upper limit at which the slurry may be removed. Preferably, the temperature of slurry 32 is about 212° F. The temperature of recrystallization in second evaporator-crystallizer 39 advantageously is between about 115° F. and 135° F., since this temperature should be as low as reasonably possible. Preferably this temperature is about 125°. The temperatures employed in the remaining evaporator-crystallizers advantageously is about 200° F. to 219° F., with a temperature about 212° F. being preferred. As noted above, the temperature of vacuum crystallizer 94 preferably is on the order of about 100° F. In addition, the temperature of the saline water feed preferably is on the order of about 105° F., although this temperature is by no means critical.
Similarly, the specific types of equipment that are employed to carry out the process generally are not critical and will be known to those skilled in the art, given the details described above and the volume of saline water that is to be processed, the cost of utilities, equipment availability and the various other factors known by those in the art. As noted above, special alloy equipment is not needed for the major steps in the process. Thus, commonly available chemical processing equipment generally may be employed. Preferably, all of the evaporative-crystallization steps are combined into an integrated, multiple effect evaporator system. This has the effect of substantially reducing the amount of steam needed for the water evaporation steps.
The principal advantage of the preferred embodiment of the invention described herein is the ability to economically recover commercially salable sodium hydroxide, hydrochloric acid, chlorine, sodium sulfate, sodium chloride, potassium chloride, bromine, and other compounds, such as magnesium oxide and calcium oxide, from desalination plant brine solutions, at the same time virtually all of the water in the brine solution is recovered as potable water.
With this process it is possible to recover much more sodium chloride and sodium chloride derived products per unit of feed than is possible with conventional processes. Moreover, the preferred embodiments of the process permit the recovery of all of the other chemicals noted above, large quantities of potable water and only a small amount of unusable wastes. As a result, the process produces a greater value of salable chemicals per day than is possible with conventional processes, even though the capital investment and operating costs are not significantly greater than for conventional sodium chloride recovery processes.
As an example, the following approximate amounts of products may be produced in a 2230 metric ton per day plant operated in accordance with the preferred embodiments described above, using a 6% salt desalination plant brine feed having the approximate composition set forth at the beginning of the description of the preferred embodiments: 100 tons per day (t/d) of 50% sodium hydroxide; 64 t/d of 32% hydrochloric acid; 43.5 t/d of chlorine; 13 t/d of sodium sulfate; 15 t/d of sodium chloride; 9 t/d of magnesium oxide; 3 t/d of potassium chloride; 2 t/d of calcium oxide; 1 t/d of hydrogen; 0.15 t/d of bromine; and 1970 t/d of potable water.
The embodiments described herein are intended to describe certain preferred embodiments of the saline water chemical recovery process of the invention. However, one skilled in the art would certainly be expected to be able to make many modifications and variations of these preferred embodiments without departing from spirit or the scope of the invention as it is defined in the following claims.
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A continuous process for the recovery of chemicals in saline water including the steps of converting the sulfates in the saline water feed to sodium sulfate; separating and recovering in the oxide forms essentially all of the magnesium and calcium from the saline water feed; then preparing a sodium chloride fortified solution by mixing the feed with recycled sodium chloride; crystallizing and re-crystallizing and then separating sodium chloride crystals, preferably in two evaporative crystallization processes; stripping bromine from the sodium chloride depleted solution; crystallizing and then separating sodium chloride and sodium sulfate crystals from each other and then from solution; recycling the separated sodium chloride to the first sodium chloride crystallization step; separating residual sulfates from the solution; crystallizing and then separating sodium chloride crystals; recycling the separated sodium chloride to the first sodium chloride crystallization step; crystallizing and then separating potassium chloride from the solution; and recycling the resulting solution to the last sodium chloride crystallization step. Substantial quantities of potable water are produced by the process. In a preferred embodiment, sodium chloride is electrolytically converted to sodium hydroxide, chlorine and hydrogen. Part of the sodium hydroxide is used in the process, the remainder is concentrated and flaked. Part of the chlorine is liquified, the remainder is combined with a portion of the hydrogen to form hydrochloric acid. Finally, the steam boiler flue gas may be combined with sodium hydroxide to produce the sodium carbonate used in the process.
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BACKGROUND OF THE INVENTION
The invention relates generally to fusible-plugholders, and more particularly to a fusible-element holder bracket device.
It is well known in the prior art for fusible-plug holders in the form of pipe or tube "T" fittings to have been connected in pressure fluid lines by oppositely disposed ends with the third end, normal to a common axis of said two ends, closed by a fusible plug. Such plug holders are used to vent fluid pressure in a line, in which it is connected, to atmosphere upon a predetermined rise in temperature over a set time period, and thereby activate any pressure monitored safety system. Their use required severing a fluid pressure line and sealing the two connections of the "T" fitting holder to the cut ends of the pressure line, which is supported by other means, to provide only one fusible plug per fitting against a possible failure in a much more reliable pressure monitored system.
The invention teaches a fusible-elements holder bracket device that includes a plurality of different fusible elements, rather than only one of a single kind, requires one sealed connection, rather than two, to install for use, and connects to and in, and where possible is supportable of, a pressure fluid line without severing it.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a fusible elements holder bracket device that more nearly equates a possibility of failure of the device to that of the pressure monitored system it activates.
Another object of the invention is to provide a fusible elements holder bracket device that fixes the device in a pressure fluid line and said line to a supporting structure.
The invention is more fully described below and more particularly pointed out in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a first embodiment of the invention taken along section lines 1--1 of FIG. 2;
FIG. 2 is a plan view of the first embodiment;
FIG. 3 is a cross sectional view of the second embodiment of the invention taken along section lines 3--3 of FIG. 4; and
FIG. 4 is a plan view of the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention is described in use with a pressure monitored fire control safety system, but it should be understood that it is just as usable with any pressure monitored safety system.
Referring to FIGS. 1 and 2, the first embodiment of the invention comprises a body 10 having a flat part 12 and a curved part 14 for respectively conforming to any flat supporting structure and a rounded upper surface of a pressure fluid line 16 defining a side opening 18. A pair of straight extentions 17 and 19 to the respective ends of curved part 15 are normal to flat part 12 and with extension 17 also contiguous with flat part 12, forming therewith a 90 degree angle 21. The extensions equate and limit engaging pressure of strap 10 on the pressure fluid line 16. A hollow open-ended cylinder 20 is integral with, and extends normal to, and above and below said curved part 14, for the lower end 22 of said cylinder to extend through and connect with said side opening 18 in said pressure fluid line, and the upper end 24 to extend to atmosphere. Strap flat part 12 defines a bolt hole 25 adjacent a free end 26 thereof for fixing strap 10 to any flat surface. A bolt 28 and nut 30 is adapted to bolt the invention to any flat surfaced supporting structure through said bolt hole 25 and a registering hole 31 in said structure, and with said cylinder lower end 22 registering in opening 18 of line 16. Supporting structure as shown in FIGS. 1 and 2 is a flat plate 32 extending between oppositely disposed ends 26 and 34 of body 10, but the structure could be any wall (not shown) available. A plurality of fusible elements provided by the invention comprise a fusible plug 36 mounted in hollow cylinder 20 for closing both said ends 22 and 24 at less then fusible temperatures, a fusible gasket 38 for sealing the connection of said cylinder to and in pressure fluid line 16 at less than fusible temperatures, and fusible bolt head 40 and fusible nut 30 of the bolt and nut for rigidly fixing the invention to the pressure pipe line and the supporting structure also at less than fusible temperatures. The melting of any of the fusible elements will cause the device to vent pressure fluid from line 16 to atmosphere. The first embodiment fusible elements are all eutetic alloy. Extension 19 of strap means 12 terminates in a free end 35 and does not engage flat plate 32 or other supporting structure if used.
Referring to FIGS. 3 and 4, the second embodiment of the invention resembles the first, differing only in having a longer straight extension 19' for defining near a free end a hole hole 50 for engaging a free end 34' of tensilely bendable flat plate 32' for clamping said body 10' around said pressure fluid line and said hollow cylinder 20' lower end 22 in said side opening 18. Second embodiment fusible elements comprise a fusible plug 36' of eutectic alloy as in the first, a fusible gasket 38' of fusible elastomeric coated with an adhesive plastic 46, also fusible, for ease in field installation, and a fusible plastic insert 48 in nut 30'.
In use, the first embodiment eutectic sealing gasket 38 of FIG. 1 is pressed over the lower end 22 of cylinder 20 and around the concave inner surface of strap curved part 14 and the convex surface of pressure fluid line 16, to fit therebetween and seal said end 20 in said side opening side opening 18 of line 16. Fusible plug 36 is mounted in said hollow cylinder 20, and bolt 28 with a fusible head 40 is engaged through registering bolt holes 25 and 31 with fusible nut 30, thereby fixing the invention in place for heat monitoring said pressure fluid line 16 to remain inactive so long as ambient temperature did not rise above the selected fusible temperature of the fusible elements. Above said selected temperature, the fusible elements melt together or in any sequence to vent pressure fluid from the pressure fluid line to activate said fire control safety system.
In use, the second embodiment with fusible elements differing little from those of the first embodiment, and then only in slightly less complicated arrangement, is secured on a tensile backing plate 30' at both ends of said body 10' respectively by engaging in hole 50 of straight extension 19' and by a bolt 28' and nut 30' in registering holes 25 and 31 in said back plate and strap. Securing body 10' at both ends equalizes the retaining pressure of the invention to and in the pressure fluid line 16.
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A heat activated device having a plurality of fusible elements for mounting in an aperture of a pressure fluid line which holds inactive safety fire control system which is actuated by loss of pressure in the pressure fluid line. The melting of any or all of the fusible elements at a preselected rise in temperature vents fluid pressure from the mounting aperture.
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This application is a continuation of application Ser. No. 08/478,996 filed Jun. 7, 1995, which was a continuation of application Ser. No. 08/288,165 filed Aug. 10, 1994, which was a continuation of application Ser. No. 07/888,278 filed on May 26, 1992, which was a continuation of application Ser. No. 07/663,198 filed on Feb. 28, 1991, which was a continuation of application Ser. No. 07/331,173 filed on Mar. 31, 1989, all now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a data communication apparatus and, more particularly, to a data communication apparatus capable of reserving data transmission.
2. Related Background Art
A facsimile machine is known as a conventional apparatus of this type to transmit, e.g., image data.
In particular, an apparatus incorporating a large-capacity memory or using an external memory device such as a magnetic disk is known whereby image data for a plurality of destinations are stored and sequentially transmitted.
In the above system for storing transmission images for the plurality of destinations in the image memory, destination telephone numbers and image data (and data pointers which indicate the image data) are stored as a set of data blocks, and each data block is accessed to perform transmission every transmission cycle.
In a conventional apparatus of this type, the telephone line must be disconnected upon every transmission cycle of one data block, and calling is made using a telephone number of the next block, thereby transmitting the next image data. According to this control, even if a plurality of transmission reservations are made for a given destination, i.e., even if the image data is read and the destination telephone number is input for a given destination, the communication line is disconnected between the adjacent data blocks even if these transmission cycles are successive. In transmission of the second data block, calling and communication procedures must be repeated from the beginning.
This also applies to the case wherein a transmission reservation is made for a given destination during transmission of image data to the given destination. This control prolongs the processing time and is disadvantage in communication cost in a case such as local communication in which communication charges are identical within a predetermined period of time.
There is available another conventional facsimile machine capable of performing a transmission reservation operation, i.e., an operation for transmitting an original image to a destination at designated time. In transmission reservation processing, an original is loaded on a reader unit, and an original image is read and transmitted in real time when the current time reaches the designated time. However, according to this system, the reader unit is occupied by the original until the designated time.
In order to solve the above problem, transmission image information is read and stored in an image memory in advance, and the stored image is transmitted at the designated time. In this transmission reservation by using memory transmission, the reader unit is not occupied by the original, and transmission reservations for a large number of destinations can be simultaneously performed.
FIG. 8 shows control procedures of a transmission reservation by memory transmission.
In step S51 of FIG. 8, it is determined by predetermined input operations at an operation panel 15 whether image transmission is selected. If YES in step S51, the flow advances to step S52. However, if NO in step S51, the flow advances to step S57.
It is then determined in step S52 whether a transmission "reserve" mode is set for transmitting information at reserved time. If NO in step S52, the read image is sequentially transmitted. That is, m pages of image data are read, and the read images are transmitted in step S54.
In the transmission reserve mode, n pages of image data are read in step S55, and a transmission reserving table is made in step S56. A structure of the transmission reserving table is shown in FIG. 10.
FIG. 10 shows a structure of a transmission reserving table set in part of a memory. The table consists of fields 71 to 74. Destination telephone numbers are stored in the field 71. Reserved times at which transmission is performed are stored in the field 72. Identification data of pages of the read image data are stored in the field 73. Start address data of the image memory for storing the image data of the pages in correspondence with the page identification data of the field 73 are stored in the field 74.
When the operation in step S56 is completed, the flow returns to step S51. If the transmission mode is determined in step S51 to be not designated, the flow advances to step S57 to check if a transmission reservation is made. This check is performed by checking the logical level of a flag.
If NO in step S57, the flow returns to step 51. However, if YES in step S57, it is determined in step S58 whether the time stored in the field 72 of FIG. 7 coincides with the time of the timer incorporated in a CPU. If the current time has not reached the reserved time, the flow returns to step S51. However, if the current time reaches the reserved time, the flow advances to step S59. The n pages of image data are transmitted in step S59. In this case, data readout operations are controlled by using data in the fields 73 and 74 in FIG. 7.
The transmission reserving table is removed from the memory in step S60, and the flow returns to step S51.
The basic transmission reserve control has been described above. When the first transmission reservation destination is called, this called station may be busy (during transmission). In this case, recalling is performed by the procedures shown in FIG. 9.
In step S61 of FIG. 9, it is determined whether the transmission mode is selected in the same manner as in step S51. When image transmission is performed, the flow advances to step S62, and the destination telephone number is settled in accordance with an input at a keyboard. In step S63, n pages of image data are read, and a new transmission reserving table is made in step S64. In this case, the structure of the transmission reserving table is the same as that shown in FIG. 10.
However, when image transmission is determined in step S61 to be not performed, the flow advances to step S70. It is determined in step S70 whether a transmission reservation is made. If NO in step S70, the flow returns to step S61. However, if YES in step S70, the flow advances to step 71 to determine whether the current time has reached reserved time. If No in step S71, the flow returns to step S61. However, if YES in step S71, the flow advances to step S65.
In step S65, the destination is called by using the telephone number data of the transmission reserving table in either the normal transmission mode or the transmission reserve mode. In step S66, it is determined whether the destination is busy.
If YES in step S66, the flow advances to step S69, and recalling is performed after a lapse of a predetermined period of time in the field 72 (2 minutes in this case) from the state of FIG. 10, as shown in FIG. 11.
However, if NO in step S66, the flow advances to step S67 and the stored image data is transmitted. The reserving table is removed from the memory in step S68. When the destination is determined to be busy, the reserved time is prolonged through step S69. The destination is called again at the updated time.
The following problems are posed by the above transmission reserve control by conventional memory transmission.
In the procedures of FIG. 8, the transmission reserved time of a destination B which is already reserved may pass during reading of the image data to be transmitted to a given destination A subjected to normal sequential transmission. In this case, the image data is transmitted to the destination B after the image data is transmitted to the destination A.
If the destinations A and B have the same telephone number, calling is performed to these destinations twice within a very short period of time. The communication procedures are repeated in either communication, and the communication time is prolonged. Therefore, utilization efficiency of the apparatus is degraded. In addition, the apparatus has a disadvantage in communication cost in a line to which a telephone charge is made in accordance with a line connecting time.
In the procedures shown in FIG. 9, the above problem occurs. That is, during a time period in which the destination A is called and recalling is to be made due to a busy state of the destination A, information can be transmitted to the destination B subjected to a transmission reservation unless the communication line is connected. In this case, if the destinations A and B are the same station, calling is performed twice. For this reason, the apparatus is not advantageous in efficiency and communication cost as described above.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve the above problems and to improve a data communication apparatus.
It is another object of the present invention to simultaneously transmit all reserved data for a single destination.
It is still another object of the present invention to simultaneously transmit the reserved data if the current time is almost the transmission reversed time and the current destination is the same as that reserved before.
The above and other objects, features, and advantages of the present invention will be apparent from the following detailed description of preferred embodiments in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an arrangement according to a first embodiment of the present invention;
FIG. 2 is a view showing a structure of transmission data blocks and an image memory in the first embodiment;
FIG. 3 is a flow chart showing control procedures of a control unit of the first embodiment;
FIG. 4 is a block diagram showing an arrangement according to a second embodiment of the present invention;
FIG. 5 is a flow chart showing a set of control procedures of the second embodiment;
FIG. 6 is a flow chart showing another set of control procedures of the second embodiment;
FIG. 7 is a view showing a transmission reserving table controlled by the set of control procedures shown in FIG. 6;
FIG. 8 is a flow chart showing a conventional set of control procedures;
FIG. 9 is a flow chart showing another conventional set of control procedures; and
FIGS. 10 and 11 are views showing general structures of transmission reserving tables, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
In the following descriptions, facsimile machines are exemplified as data communication apparatuses. However, the present invention is not limited to the facsimile machine but is applicable to other data communication apparatuses (e.g., teletex communication, wordprocessor communication, and personal computer communication) which allow transmission reservations.
FIG. 1 is a block diagram showing an arrangement of a first embodiment of the present invention.
Referring to FIG. 1, a control unit 1 controls the overall operations of the facsimile machine and comprises a microprocessor or the like. The control unit 1 is connected to respective memory means required for control and respective circuit components to be controlled through data and address buses.
More specifically, the control unit 1 is connected to a ROM la for storing permanent programs (to be described later) and constants required for control.
Original image data is read by a reader unit 2 constituted by a CCD sensor and an original convey system. The received image data or image data read by the reader unit 2 during copying is recorded by a recorder unit 7 constituted by a thermal printer or an ink-jet printer.
Transmission/reception of image data and a procedure signal with respect to a communication line 6 is performed through a communication control unit 3. The communication control unit 3 includes a modem for modulating/demodulating the image and procedure signals, and an NCU for performing line connection control with a line control telephone set (or handset) 5 or holding a loop.
Communication operations are controlled by the control unit 1 in accordance with key inputs at an operation unit 4. The operation unit 4 comprises a keyboard such as a ten-key pad and a display unit such as a liquid crystal display unit.
Referring to FIG. 1, the facsimile machine includes memories 31 and 32 comprised of programmable memories such as a RAM and a magnetic disk drive.
More specifically, the memory 31 is referred to as a transmission data block 31, and the memory 32 is referred to as an image memory 32. The transmission data block 31 stores data pointers in units of blocks for the image data stored in the image memory 32. The image memory 32 actually stores the image data. In this embodiment, two separate memories are used. However, these memories may be allocated in a single linear memory space.
FIG. 2 shows data structures of the transmission data block 31 and the image memory 32.
As shown in the left half of FIG. 2, the transmission data block 31 consists of six blocks #0 to #5. Block #0 is a transmission executive data block. Upon designation of transmission, image data designated by a register in block #0 is transmitted. Blocks #1 to #5 are transmission reserve data blocks. When the content of block #0 is transmitted, the contents of blocks #1 to #5 are sequentially transferred to executive block #0 and transmitted therefrom.
The structures of blocks #0 and #1 are illustrated at the center of FIG. 2.
The image memory 32 is a page memory for sufficiently storing image data of, e.g., an A4 size and has a memory area for 300 pages, i.e., 0th to 299th pages.
As shown in the center of FIG. 2, a telephone number register 31a for storing 20-digit destination telephone numbers is allocated at the start portion of the transmission data block #0. A page register 31b for storing pointers for designating the 0th to 299th pages of the image memory 32 is allocated after the telephone number register 31a. Data "0", "1", and "2" are stored at the start portion of the page register 31b, as shown in FIG. 2. These numbers represent the 0th, 1st, and 2nd pages of the image memory 32.
Data "-1" which represents the end of data is stored in the fourth register (3) of the page register 31b. The structures of data blocks #1 to #5 are the same as that of data block #0. For example, data block #1 stores the telephone numbers and page numbers (297) of the memory which store the image data.
With the above arrangement, when the control unit 1 reads data block (30) information to be transmitted, calling is performed using the content of the telephone number register 31a, and image data stored on the respective pages of the image memories which are represented by the registers of the page register 31b are transmitted to the destination.
An operation of the above arrangement will be described with reference to a flow chart of FIG. 3. The procedures of FIG. 3 are stored as a control program in the ROM 1a.
The known transmission reserve operations, i.e., input of the telephone number, and reading of the image data by the reader unit 2, are performed prior to actual transmission. Telephone number data and page designation data are sequentially stored in blocks #0 to #5 of the transmission data block 31. Image data read by the reader unit 2 are sequentially stored in empty pages of the image memory 32.
When an image data transmission command is input from the operation unit 4 by a predetermined key input operation, the destination is called using dial data stored in the telephone number register 31a of block #0 of the transmission data block 31 in step S1. In step S2, a pointer PP for designating a register in block #0 of the transmission data block 31 is reset, thereby selecting block #0 as a transmission executive block.
In step S3, the image data stored on the page of the image memory 32 which is identified by the register of the page register 31b which is designated by the pointer PP is transmitted.
In step S4, the pointer PP is incremented by one. The flow then advances to step S4'. In this step, the content of the register of the page register 31b which is identified by the pointer PP is read out. It is determined in step S5 whether the register value is "-1". If NO in step S5, the page block to be transmitted is stored in the image memory 32. The flow returns to step S3, and transmission of the page block is repeated. By the loop of steps S3 to S5, the image data stored on pages 0 to 2 of the image memory 32 is transmitted.
When data "-1" is read out in step S5 (i.e., when the content of register 3 of the page register 31b is read out), the flow advances to step S6. It is determined in step S6 whether the same telephone number data as that stored in the telephone number register 31a of data block #0 which currently transmits data is stored in the telephone number registers 31a of blocks #1 to #5 of the transmission data block 31. If NO in step S6, the line is disconnected in step S8, and transmission processing is ended. However, if YES in step S6, the flow advances to step S7.
In step S7, the content of the data block (i.e., one of blocks #1 to #5) which stores the same telephone number as that in the telephone number register 31a of data block #0 and which is detected in step S6 is transferred to data block #0. Therefore, the data block representing the destination subjected to transmission is transferred to block #0 as the executive data block. The flow then returns to step S2, and the above operations are repeated.
With the above arrangement, when the identical telephone number data are stored in the telephone number registers 31a of blocks #0 to #5 of the transmission data block 31, the data to the same destination are continuously transmitted by the loop of steps S2 to S7 without disconnecting the line.
Unlike the conventional apparatus, the line need not be disconnected in the presence of a transmission reservation to a given destination during transmission to the given destination, and communication cost is not increased. With an arrangement in which image transmission and transmission reserve operations are simultaneously performed, the line need not be disconnected by the procedures of FIG. 3 even if a transmission reservation is made for a given destination during transmission of data to the given destination. Therefore, the image data can be continuously transmitted to the given destination.
With the above arrangement, procedure time before and after communication can be shortened, and the communication cost can be reduced accordingly.
A second embodiment of the present invention will be described wherein a plurality of image data are simultaneously transmitted under the condition that the current transmission time is close to reserved time in addition to the condition that the transmission destination of the image data subjected to the transmission reservation is the same as that to which data is currently transmitted.
FIG. 4 is a block diagram showing an arrangement according to the second embodiment.
Referring to FIG. 4, a control unit 101 comprises a microprocessor or the like and controls the respective circuit components of a facsimile machine and performs image communication.
A line control unit 107 performs modulation and demodulation of procedure and image signals and line control, and includes a modem and an NCU. The line control unit 107 is connected to an automatic calling device 108 including a dial signal generator. The automatic calling device 108 receives telephone number data from the control unit 101 and transmits the corresponding dial signal to a telephone line through the line control unit 107.
An original is read by a reader unit 104. The reader unit 104 includes a CCD line sensor and an original convey system.
Communication operations are controlled through an operation panel 103.
The control unit 101 is connected to three memories 102, 105, and 106 which are referred to as a program memory 102, an image memory 105, and a memory 106 for data. Control programs are stored in the program memory 102 comprised of a ROM or the like. Image information read by the reader unit 104 and to be transmitted is stored in the image memory 105 comprised of a RAM or the like.
The memory 106 for data stores transmission reserving tables shown in FIGS. 10 and 11 and comprises a RAM or the like. In this embodiment, transmission reserving tables almost the same as those of FIGS. 10 and 11 are used. A timer 110 for controlling reserved time is arranged in the control unit 101.
An operation of the above arrangement will be described below.
FIG. 5 shows communication procedures of the control unit 101 which are stored in the program memory 102 shown in FIG. 4. The procedures in FIG. 5 aim at solving the conventional communication procedures shown in FIG. 8. Steps 124 to 127 are added to the procedures of FIG. 8 in FIG. 5.
The decision blocks in steps S51 and 52 in FIG. 5 are the same as those in FIG. 8. When transmission is designated on the operation panel 103 and a transmission reserve mode is selected, n pages of image data are read by the reader unit 104 and the read image are stored in the image memory 105 in steps S55 and S56 in the same manner as in the conventional apparatus. At the same time, a transmission reserving table shown in FIG. 10 is formed in the memory 106.
When image transmission is not designated, the memory 106 is accessed to determine in steps S57 to S59 whether a reservation is made and the current time has reached reserved time. If the current time has reached the reserved time, n pages of the image data reserved in step S59 are transmitted. Thereafter, the transmission reserving table is removed in step S60.
When the transmission reserve mode is not set, sequential transmission is performed. The flow advances from step S52 to step S53, and m pages of image data are read by the reader unit 104 in the same manner as in the conventional apparatus. It is then checked in step S124 whether a transmission reservation is made. This decision block is the same as that in step S57.
If YES in step S124, the reserved time in the memory 106 and time information of the timer 110 are referred to so as to determine in step S125 whether the current time has passed the reserved time. If YES in step S125, the content of the transmission reserving table corresponding to the reservation is referred to so as to determine whether the destination subjected to sequential transmission is the same as that subjected to the transmission reservation. This determination is performed by comparing the destination telephone number input from the operation panel 103 with the destination telephone number stored in a field 71 of the reserving table.
If NO in any of steps S124 to S126, m pages of image data read in step S53 are transmitted through the line control unit 107.
If YES in all steps S124 to 126, i.e., when the destination subjected to sequential transmission is determined to be the same as that subjected to the transmission reservation, the flow advances to step S127. The n pages of image data read in step S55 and the m pages of the image data read in step S53 are continuously transmitted in step S127. In this case, the telephone number of the destination is read from the field 71 of the transmission reserving table and is transferred to the automatic calling device 108. The automatic dialing device 108 transmits a dial signal on the basis of the input telephone number data.
That is, in step S127, the n and m pages of data to the given destination are continuously transmitted. For example, assume that a transmission reservation for a given destination is made for time 16:00, as shown in FIG. 10, and that reading of image for sequential transmission in step S53 is started at time immediately before time 16:00. Under these assumptions, when sequential transmission to the given destination in step S53 is ended at time 16:01 and the telephone number of the given destination subjected to sequential transmission is the same as that of the destination subjected to the transmission reservation, the line is not disconnected, and n and m pages of image data are continuously transmitted to the given station.
When transmission in step S127 is completed, the flow advances to step S60, and the transmission reserving table is removed from the memory 106. The flow then returns to step S51.
With the above arrangement, when sequential transmission is performed, whether a transmission reservation is made is checked. In addition, if the destination subjected to sequential transmission is the same as that subjected to the transmission reservation, all image data to the same destination are continuously transmitted by one call without performing a plurality of calls within a very short period of time. Therefore, utilization efficiency of the facsimile machine can be improved, and the communication cost can be reduced when the telephone charge is made on the basis of the time of use of the telephone line.
In step S125 of FIG. 5, if the current time measured by the timer 110 has not passed the reserved time, normal transmission is performed in step S54. However, if the current time is advanced from the reserved time by a predetermined period of time (e.g., a few minutes required for normal image transmission), the flow may advance to step S126 without going through step S54 to continuously transmit the two image data.
Different communication procedures are shown in FIG. 6. The procedures in FIG. 6 aim at solving the problem in the conventional communication procedures in FIG. 9. Steps S62-1, 62-2, and 62-3 are added to the procedures of FIG. 9 in FIG. 6.
It is determined in step S61 of FIG. 6 whether a transmission mode is designated. When sequential transmission is performed, the flow advances to step S62, and the telephone number is input. The flow advances to step S62-1. However, if the transmission mode is not set, it is determined in steps S70 and S71 whether a transmission reservation is made and the current time has reached the reserved time in the same manner as in the conventional case.
It is determined in step S62-1 whether the destination subjected to sequential transmission is the same as that subjected to transmission reservation. This determination is performed by comparing the input telephone number with the telephone number stored in the field 71 of the transmission reserving table as described above. If YES in step S62-1, the flow advances to step S62-2. However, if NO in step S62-1, the flow advances to step S63 in the same manner as in the conventional case.
In step S62-2, m pages of image data for sequential transmission are read by the reader unit 104, and the image data read in step S62-2 is added to the transmission reserving table in step S62-3. That is, as shown in FIG. 7, page identification data of (n+1) to (n+m) pages and start addresses of the corresponding page data are stored in page and address information of the fields 73 and 74, respectively.
The operations in steps S65 to S69 are the same as those in the conventional case. Calling is performed in step S65. Whether the destination is busy is determined in step S66. If NO in step S66, transmission is performed in step S67. The transmission reserving table is removed in step S68. If the destination is determined to be busy, the time in the transmission reservation table is changed in step S69 in the same manner as in the conventional case, and the flow returns to step S61.
According to the above control procedures, calling is performed on the basis of a given transmission reservation. When the destination is busy, the transmission reserved time in the transmission reservation table is delayed, and calling is interrupted. When sequential transmission is started prior to the delayed reserved time, the input telephone number is compared with the telephone number stored in the transmission reserving table in step S62-1. When the destination subjected to sequential transmission is the same as the transmission reserved destination, all the image data are transmitted to this destination by one call without disconnecting the line.
As shown in FIG. 7, for example, the transmission reserved time is delayed to time 16:01 due to the busy state of the destination, and sequential transmission is selected prior to time 16:01. In addition, if the input telephone number coincides with the stored telephone number, newly read image data are added to the fields 73 and 74 as image data.
According to the procedures in FIG. 6, even if the reserved time is delayed due to the busy state of the destination called on the basis of the transmission reservation, all the image data can be continuously transmitted by one call upon coincidence of the destination subjected to new sequential transmission and the reserved destination. The same effect as described above can be obtained.
In each embodiment described above, the image communication apparatus which performs communication through the telephone line is exemplified. However, the present invention is not limited to a line system communication apparatus, but is applicable to various data communication apparatuses.
The present invention is not limited to the particular embodiments described above. Various changes and modifications may be made within the spirit and scope of the invention.
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A data communication apparatus includes a reserving circuit for reserving transmission of data, a communicating circuit for performing data communication, and a communication control circuit for determining transmission destinations for a plurality of data reserved by the reserving circuit and simultaneously transmitting all data destined to a given transmission destination to this destination.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention deals with the field of airborne descent control devices such as parachutes and other gliding wing constructions which are attached to payloads therebeneath such as capsules used for return of individuals or equipment from space travel. Such parachute devices normally need to be reefed in order to restrict or at least control the inflation of the canopy thereof in order to assure a gradual properly formed movement of the canopy from the fully collapsed position within the parachute pack prior to deployment to the fully inflated position. Often multiple stages of such reefing are utilized in order to assure that the canopy gradually moves from the closed position to the fully inflated position to avoid excessive loads or the exposure thereof to improper inflation forces which might damage or otherwise inhibit the full canopy inflation.
Most parachute reefing is accomplished with a continuous line that is installed in the parachute skirt or mouth or lower surface and then is cut at a discrete time which is predetermined on the basis of load limitations and other aerodynamic considerations. Often mechanically actuated pyrotechnic reefing cutters are used for cutting this line. Normally these cutters are present with a specific time delay and cannot be adjusted for different conditions after installation or packing.
It should be appreciated that parachute reefing can occur in several multiple stages from one or two stages to as many as five stages or more. Reefing is used primarily for controlling the forces of canopy inflation. If a reefing line fails or if a reefing cutter operates prematurely, the canopy inflation can exceed design force levels. If a reefing line is not completely severed or if a cutter fails to operate, the canopy will not reach full inflation and excessive descent rates and and/or ground impacts can result. Redundant cutters and cutter activation signals herein are intended to provide back-up operation to this critical function. Also included within the present invention is an inhibiting feature to prevent disreefing beyond certain conditions.
2. Description of the Prior Art
Some parachutes which are used for controlling airborne descent of payloads include electrically actuated pyrotechnic reefing cutters which allow an electrical signal to provide flexibility and optimum performance. However, because the reefing cutters must be installed on the parachute skirt for proper inflation control, these electrical cables can become excessively heavy and risky to the reliability of operation of the parachute due to the length and necessary slack of the fairly heavy electrical cable. The present invention provides a unique means for controlling the disengagement of the reefing in one or multiple stages of such a parachute canopy. Parameters monitored by sensors on the payload are used to trigger the reefing disengagement mechanism located at the parachute skirt without requiring any such electrical cables. Some patents have been granted on remotely positioned control devices for parachutes all of which are significantly different from the present invention such as U.S. Pat. No. 2,427,979 patented Sep. 23, 1947 to A. J. Sorensen and assigned to The Union Switch & Signal Company on a “Communication And Control System For Airplanes”; and U.S. Pat. No. 2,490,844 patented Dec. 13, 1949 to E. M. Sorensen on a “Radio Remote-Control Aircraft System”; and U.S. Pat. No. 2,925,234 patented Feb. 16, 1960 to F. A. Wodal et al and assigned to Earle W. Wallick and Temple N. Joyce on an “Aircraft Remote Proportional Control Mechanism”; and U.S. Pat. No. 2,966,316 patented Dec. 27, 1960 to N. E. Ward et al and assigned to the United States of America as represented by the Secretary of the Navy on a “Missile”; and U.S. Pat. No. 3,146,976 patented Sep. 1, 1964 to M. J. Houdou on a “Parachute”; and U.S. Pat. No. 3,193,223 patented Jul. 6, 1965 to S. Davis on a “Parachute Release Control”; and U.S. Pat. No. 3,204,368 patented Sep. 7, 1965 to W. L. Effinger, Jr. et al and assigned to The A.C. Gilbert Company on a “Self-Powered Model Paraglider”; and U.S. Pat. No. 3,443,779 patented May 13, 1969 to F. M. Rogallo et al and assigned to the United States of America as represented by the Administrator of National Aeronautics and Space Administration; on “Aeroflexible Structures”; and U.S. Pat. No. 3,920,201 patented Nov. 18, 1975 to W. R. Battles on a “Pilotless Glider Construction”; and U.S. Pat. No. 4,175,722 patented Nov. 27, 1979 to M. W. Higgins on a “Control System For Ram Air Gliding Parachute”; and U.S. Pat. No. 4,180,221 patented Dec. 25, 1979 to D. E. Harris on a “Self Propelled Kite”; and U.S. Pat. No. 4,440,366 patented Apr. 3, 1984 to A. A. Keeler et al and assigned to Commonwealth of Australia on a “Parachute Control Apparatus”; and U.S. Pat. No. 4,601,443 patented Jul. 22, 1986 to A. W. Jones on a “Free Flyable Structure”; and U.S. Pat. No. 4,865,274 patented Sep. 12, 1989 to J. A. Fisher and assigned to United Technologies Corporation on a “Passive Control Assembly For Gliding Device”; and U.S. Pat. No. 4,934,630 patented Jun. 19, 1990 to S. L. Snyder on a “Powered Airfoil Canopy Aircraft”; and U.S. Pat. No. 4,948,071 patented to C. M. Summers on Aug. 14, 1990 on a “Deployment System For Parachute”; and U.S. Pat. No. 4,955,563 patented Sep. 11, 1990 to C. K. Lee et al and assigned to the United States of America as represented by the Secretary of the Army on an “Apparatus And Method For Controlled Simultaneous Opening Of Clustered Parachutes”; and U.S. Pat. No. 5,080,305 patented Jan. 14, 1992 to F. B. Stencel on a “Low-Altitude Retro-Rocket Load Landing System With Wind Drift Counteraction”; and U.S. Pat. No. 5,160,100 patented to S. s L. Synder on Nov. 3, 1992 on an “Airfoil Canopy Aircraft”; and U.S. Pat. No. 5,620,153 patented Apr. 15, 1997 to H. M. Ginsberg on a “Light Aircraft With Inflatable Parachute Wing Propelled By A Ducted Propeller”; and U.S. Pat. No. 5,678,788 patented Oct. 21, 1997 to W. Hetzer et al and assigned to Daimler-Benz Aerospace AG on a “Steering Device For A Glider”; and U.S. Pat. No. 6,042,056 patented Mar. 28, 2000 to J. P Chopard and assigned to Delegation Generale pour I'Armement on an “Air Carrier Steerage Control Device”; and U.S. Pat. No. 6,293,202 patented Sep. 25, 2001 to R. Woodall et al and assigned to The United States of America as represented by the Secretary of the Navy on a “Precision, Airborne Deployed, GPS Guided Standoff Torpedo”; and U.S. Pat. No. 6,322,021 patented Nov. 27, 2001 to J. A. Fisher et al and assigned to Advanced Systems Technology, Inc. on a “Deployable Wing With Propulsion For Range Extension”; and U.S. Pat. No. 6,343,244 patented Jan. 29, 2002 to H. Yoneda et al and assigned to Fuji Jukogyo Kabushiki Kaisha on an “Automatic Guidance System For Flight Vehicle Having Parafoil And Navigation Guidance Apparatus For The System”; and U.S. Pat. No. 6,364,251 patented Apr. 2, 2002 to J. H. Him on an “Airwing Structure”; and U.S. Pat. No. 6,416,019 patented Jul. 9, 2002 to D. P. Hilliard et al and assigned to The United States of America as represented by the Secretary of the Navy on a “Precision Parachute Recovery System”; and U.S. Pat. No. 6,503,119 patented to B. K. Lapointe on Jan. 7, 2003 on a “Parachute Toy”; and U.S. Pat. No. 6,505,793 patented Jan. 14, 2003 to H. J. Schwarzler and assigned to EADS Deutschland GmbH on an “Actuation System And Method For A Load-Bearing Paraglider”; and U.S. Pat. No. 6,587,762 patented Jul. 1, 2003 to H. B. Rooney and assigned to FXC Corporation on an “Automatic Guidance Unit For Aerial Delivery Unit”; and U.S. Pat. No. 6,622,968 patented Sep. 23, 2003 to D. S. Clair et al and assigned to Edward Strong on a “Guided Airborne Vehicle, Cargo And Personnel Delivery System”; and U.S. Pat. No. 6,676,084 patented Jan. 13, 2004 to J. Asseline et al and assigned to Institut de Recherche pour le Developpement on a “Small-Sized Radio-Controlled Flying Device”; and U.S. Pat. No. 6,830,222 patented to K. T. Nock et al on Dec. 14, 2004 and assigned to Global Aerospace Corporation on a “Balloon Device For Lowering Space Object Orbits”; and U.S. Pat. No. 6,845,948 patented Jan. 25, 2005 to P. J. Thomas and assigned to Paul J. Thomas on an “Adaptable Kite/Airfoil”; and U.S. Pat. No. 6,877,690 patented Apr. 12, 2005 to A. J. Bragg on a “Combination Powered Parachute And Motorcycle”; and U.S. Pat. No. 6,889,942 patented May 10, 2005 to D. Preston and assigned to Atair Aerospace, Inc. on a “Steerable Parachute Control System And Method”; and U.S. Pat. No. 6,923,404 patented Aug. 2, 2005 to D. D. Liu et al and assigned to ZONA Technology, Inc. on an “Apparatus And Methods For Variable Sweep Body Conformal Wring With Application To Projectiles, Missiles, And Unmanned Air Vehicles”; and U.S. Patent Publication No. US 2003/0164426 A1 to D. St. Clair et al on a “Guided Airborne Vehicle, Cargo And Personnel Delivery System”.
SUMMARY OF THE INVENTION
The present invention provides a unique method and apparatus for parachute reefing control which is usable with a payload attached solely through suspension lines to a parachute having a canopy and a multiply staged canopy reefing device and a reefing release mechanism for controlling canopy inflation and airborne descent after deployment. The parachute reefing control apparatus may include a plurality of sensors mounted with respect to the payload for monitoring parameters to facilitate determination of a release schedule for disengaging the reefing of the parachute canopy. The sensing mechanism can include a mission time clock which monitors the time elapsed since deployment of the parachute and the payload. The sensing devices can also include a global positioning system device for the purpose of instantaneously monitoring the position of the payload relative to the earth therebelow and to facilitate more precision in determining the location of landing of the parachute. With ongoing GPS monitoring, it is possible to disreef the parachute at the optimal altitude to account for wind drift and, in this manner, minimize the distance from a landing target. Furthermore the sensor array can include a pressure sensing mechanism for monitoring the dynamic pressure being exerted instantaneously on the payload. Also a load sensing means can be included in the sensing array for the purpose of sensing the load force of the canopy. Other conditions can be monitored for the purpose of providing information for determining continuously and instantaneously on an ongoing basis what the release profile or release schedule should be for the disengagement of the reefing mechanism for the canopy of the parachute.
A reefing control processor is also included which is mounted with respect to the payload and is operatively connected to the sensing means for receiving information on all the parameters sensed by the sensing array in order to utilize this to calculate a release schedule. This release schedule will generate one or more release signals which are operable to initiate disengagement of all or part of the reefing mechanism. A wireless transmitter means is also included mounted with respect to the payload and operatively connected to the reefing control processor. This wireless transmitter is responsive to receiving release signals from the reefing control means to transmit a wireless signal therefrom.
Further included in the present invention is a wireless receiver means attached with respect to the parachute canopy which is operative to be actuated responsive to sensing the generation of a wireless signal by the wireless transmitter to initiate operation of the reefing release mechanism. Normally this reefing release mechanism can include more than one individual stage and, as such, the wireless receiver will be responsive to receiving the individual wireless signals from the wireless transmitter to disengage each canopy reefing stage sequentially. When utilizing more than one stage the initial stage will allow partial inflation of the canopy by partial disreefing thereof and complete reefing will follow in the second or subsequent stages until full disengagement of the reefing mechanism is achieved which will then allow full inflation of the canopy.
The apparatus of the present invention can also include a parachute deployment inhibiting mechanism which is attached to the payload and is operatively positioned between the reefing control processor and the wireless transmitter to prevent deployment of the parachute unless all parameters being monitored by the sensing means are within predefined tolerance value limitations.
The apparatus of the present invention can also include a first signal and an additional signal wherein the second signal is a redundant backup signal to insure that full disreefing has occurred. The canopy release device preferably includes at least one line extending around the canopy such as to restrict parachute canopy inflation. Furthermore the reefing release mechanism further includes at least one electrically-fired cutter positioned adjacent to the line for cutting thereof responsive to actuation of the reefing release mechanism.
It should be further appreciated that the method of the present invention can be practiced in such a manner as to not require any direct connection between the payload and the parachute other than through solely the conventional suspension lines extending from the canopy to the payload. This is achieved by monitoring a plurality of parameters with a sensor array which is mounted on the payload. Thereafter a reefing control processor is provided mounted on the payload which continuously receives information on the monitored parameters from the sensor for instantaneously determining a release schedule for the reefing of the parachute canopy. Thereafter at least one wireless signal is transmitted from the payload to the reefing release mechanism mounted adjacent the reefing device at the parachute canopy. This signal is received at the canopy to facilitate actuation of a reefing release mechanism positioned adjacent to the canopy and preferably adjacent to the skirt of the canopy to allow at least partial inflation of the parachute canopy to facilitate control descent thereof with the payload attached thereto. If additional stages of reefing need to be disengaged then additional wireless signals can be generated by the reefing control processor and transmitted to the wireless receiver attached adjacent to the reefing release mechanism. In this manner once the final reefing is disengaged the canopy will be capable of full inflation to efficiently and effectively control airborne descent of the payload.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a smart reefing system responsive to continuously monitor parameters for fast and yet efficient full inflation of a parachute canopy.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a system which can quickly respond to real time changes in mission profile such as aborted missions and high winds and other unusual circumstances.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide the use of wireless technology including a wireless transmitter and a wireless receiver to preferably electrically initiate pyrotechnic cutters rigged on traditional reefing lines within the canopy.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a control processor which receives sensory input from load, altitude, mission time, pressure sensors and other parameters to determine the best time to operate the reefing release mechanism without requiring any physical connection for the control between the payload and the parachute.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a system which increases mission profile flexibility by building in known mission profiles that could be commanded by either a crew or a vehicle's flight computer.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a system which would not need to be over built to suit off nominal mission profile requirements.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a system which could utilize small power supplies installed adjacent to each electrically fired reefing cutter.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a system which allows for controlling operation of the reefing disengagement means to be mounted on the payload and to be continuously and instantaneously responsive to sensed conditions ongoing.
It is an object of the apparatus and method for parachute reefing control of the present invention to provide a system which allows for controlling operation of the reefing disengagement means of multiple parachutes which are all connected to the same payload, commonly known as a cluster of parachutes, and, wherein each of these parachutes are disreefed in a coordinated manner to facilitate uniform canopy inflation among all parachutes in the cluster.
BRIEF DESCRIPTION OF THE DRAWING
While the invention is particularly pointed out and distinctly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawing, in which:
The FIGURE shows a schematic illustration of an embodiment of the method and apparatus for parachute reefing control of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides an apparatus for parachute reefing control which includes a vehicle or payload 10 such as a space capsule which includes a parachute 16 attached thereto. Both the payload 10 and the parachute 16 are shown schematically in the FIGURE of the present invention. The parachute 16 includes a canopy 12 which is initially collapsed or packed and is reefed to restrict inflation thereof such that that movement toward the fully inflated state can be controlled. A plurality of suspension lines 14 extend from the canopy 12 of parachute 16 to the payload 10 . In one common usage of the apparatus of the present invention is where the payload 10 is a space travel capsule is returning from a mission wherein control of airborne descent thereof is provided by the parachute 16 or a cluster of such parachutes.
In the present invention a canopy reefing device 18 is shown schematically in the FIGURE extending around the lower surface or edge of the canopy 12 in order to selectively restrict inflation thereof until released. A reefing release mechanism 20 is also shown which may include one or more individual reefing release devices. As shown in the FIGURE, the first reefing release device 54 and the back up first reefing release device 57 are shown surrounding a reefing line 56 , or more particularly, extending around the first reefing line 72 , which restricts inflation of the canopy 12 until released.
Thus, when the first reefing release device 54 is activated it will cut the first line 72 in order to at least partially release the canopy 12 . The first reefing release device 54 can also be provided with a backup or redundant device to be operable to cut first reefing line 72 . The backup first reefing release device 57 provides this redundancy to assure that disreefing occurs despite any possible failure associated with the first reefing release device 54 . Such a back up system may also require a backup reefing release means 78 and a backup wireless receiver 76 .
Normally multiple stages of reefing of the canopy are provided and, as such, multiple reefing release devices are required to fully release the canopy to the full inflation. Such additional reefing release devices can be included such as second reefing release device 55 . This device 55 is shown in the FIGURE herein surrounding a second reefing line 74 to facilitate cutting thereof for disreefing the second stage of canopy reefing. It should also be appreciated that the present invention can be practiced with any number of different stages incorporated into the reefing release mechanism 20 . Use of as many as five or more stages is fairly common in some applications. Such reefing is shown schematically in the FIGURE wherein one frangible line 56 will usually be installed on the canopy skirt for each stage of reefing. In the FIGURE a first reefing line 72 and a second reefing line 74 are shown, as an example of two stage reefing but many others could be included, often configured with various sized lengths to facilitate staging of the reefing. Multiple stages of reefing configuration would normally be achieved by providing multiple independent reefing lines of successively increasing lengths for allowing the canopy to inflate in progressive stages to full inflation.
One of the unique optional aspects of the present invention is in the use of a plurality or array of sensing devices 22 which are mounted with respect to the payload 10 . The sensing devices 22 are for the purposes of continuously monitoring various conditions or parameters in an ongoing basis and providing this information to a reefing control processor 32 which normally is a digital device such as a computer. The reefing control processor 32 is operable to monitor the initially provided mission profile or reefing release schedule based upon the input from the various sensors in the array 22 . As shown in the schematic diagram of the present invention, the initial mission profile 28 is set prior to deployment of the parachute. This initial mission profile for release of the reefing mechanism can be modified by the control logic in the reefing control processor 32 in the continuous ongoing feedback basis based upon the information received from the various sensors in the array 22 .
The sensor array 22 can include a mission time clock 60 . It also can include an altitude sensor 62 . A global positioning system device 64 can be another sensor included on the sensing array 22 . Sensing array 22 can further include a pressure sensing means which monitors the dynamic pressure being exerted instantaneously on the payload. Another possible parameter to be sensed by array 22 is the load force of the canopy. Each of these parameters as well as other parameters which could be included and are still within the contemplation of the present invention will be continuously monitored in order to provide updated and current information to the reefing control processor 32 for the purpose of allowing the control processor through predetermined algorithms to modify the schedule or profile of actuation of the reefing release mechanism 20 . With this construction the release profile can be modified even at the very last split second prior to initiation of operation of the reefing release mechanism 20 .
It should be appreciated that the use of the array of sensors is an important optional aspect of the present invention but is not required in order to practice the basic concept. The reefing control processor will be initially programmed with one or more basic reefing release schedule. The processor can be preprogrammed with several choices of schedules, each of which is usable for different specific applications. Choice of the schedule or the programming of a customized schedule is facilitated because the reefing control processor is attached to the payload and is not packed within the parachute pack. Thus, the program can be chosen even after the parachute is completely packed.
The reefing control processor can contain only a simple timetable which will be set by an operator prior to use without requiring any input from any sensors. Thus the concept of the present invention allows for multiple and repeated use of a common parachute system across various mission profiles. It is very simple and easy to make modifications to any pre-defined disreefing schedule at the payload where the processor is located and at a time after the common parachute system has already been packed for use. Of course, the inclusion of the array of sensors with the input directed to the processor does provide a system which is adaptable to vary the disreefing schedule responsive to contemporaneous changes in flight conditions. The predesignated timetables for disreefing would also provide the reefing control processor with backup disreefing control timetables in those situations where the sensors fail to properly monitor flight conditions or fail to communicate their reading to the processor.
The profile or schedule determined by the reefing control processor 32 will be operative to generate one or more release signals such as first release signal 34 and/or second release signal 36 . At least one such release signal will be required in all operations and, in this embodiment, the first release signal 34 will then be communicated to the primary wireless transmitter 38 . This primary wireless transmitter 38 will then generate a primary wireless signal. It is important to appreciate that the reefing control processor 32 as well as the primary wireless transmitter 38 and any other wireless transmitter utilized with the apparatus of the present invention is attached with respect to the payload. In this example the primary wireless transmitter 38 will generate this primary wireless signal 42 which is adapted to be received by a primary wireless receiver 46 which is mounted with respect to the parachute. Preferably the primary wireless receiver 46 will be positioned immediately adjacent to the first stage reefing device 50 which in this case is shown as an electrically activated pyrotechnically fired cutter. As shown in the FIGURE of the present invention the first stage reefing means and the backup first stage reefing means are both shown in surrounding engagement to the first stage reefing line 72 surrounding the canopy and shown schematically in the FIGURE. Each is positioned immediately adjacent to a reefing release device. The first reefing release device 54 is positioned immediately adjacent to the first stage reefing means 50 and is operable for release thereof. Preferably the first reefing release device 54 will achieve partial or full disengagement of the canopy reefing device 18 but surely will achieve at least full releasing of the first stage reefing 50 .
Similarly the second reefing release device 55 is shown immediately adjacent to the second stage reefing means 52 . The second reefing release device 55 is operative responsive to receiving a secondary wireless signal 44 transmitted by a secondary wireless transmitter 40 attached to the payload 10 in order to initiate operation of the second reefing release device 55 .
It is an important consideration of the present invention to realize that the primary wireless transmitter 38 and the secondary wireless transmitter 40 will generate a primary wireless signal 42 and a secondary wireless signal 44 such as to be sensed by the primary wireless receiver 46 and, respectively, the secondary wireless receiver 48 and initiate operation, respectively, of the first reefing release device 54 and the second reefing release device 55 . It is also important to realize that the second reefing release device 55 can be constructed to release a second stage of reefing of the canopy. A backup release mechanism can also be provided for any or all of the stages to be assured that the main reefing release device for that stage works properly. It is also possible that more than two stages of disreefing may be required.
In utilizing the apparatus of the present invention, it is important to note that the only means of connection between the canopy 12 and the payload 10 is through the suspension lines 14 . These suspension lines extend toward the payload and are attached to the payload at an attachment point 24 as shown schematically in the FIGURE. Commonly the actual attachment between the suspension lines and the payload is through another physical means such as a riser or bridle. There is no need for any electrical lines or other hard wire communication between the payload 10 and the canopy 12 because the signal for initiation of operation of the reefing release mechanism 20 is provided by wireless transmitters and receivers as well as a continuously automatically adjustable reefing control processor 32 . The processor 32 should preferably include its own separate processor power supply 26 .
Two of the important sensors in the array of sensors 22 include the load force sensor 66 and the dynamic pressure sensor 68 . Each of these sensors monitor ongoing conditions which are very important in order to determine the proper time for disengagement of the canopy reefing. By positioning the primary wireless receiver 46 and, if needed, the secondary wireless receiver 48 in a position mounted on a canopy whereas the transmitters 38 and 40 are mounted on the payload, a physical disengagement between the payload and the electrically controlled operating means for disreefing in the canopy is provided. This is important since any such additional interconnections can often lead to improper loads or entanglements or other problems which can be of critical importance in the midst of a rapid airborne descent of a payload and parachute apparatus.
A parachute deployment inhibiting device 70 can also be included operatively positioned between the reefing control processor and the wireless transmitters 38 and 40 in order to prevent deployment and/or disreefing of the parachute unless the flight conditions are deemed acceptable as determined by the parameters being monitored by the array of sensing means which must be within predetermined tolerance limitations. It is also noted that in the preferred configuration, the configuration of the reefing mechanism includes at least one restricting line 56 which preferably can be cut by at least one electrically fired cutter 58 . However, other means of restricting the canopy are provided and other means of releasing the reefing mechanism can also be contemplated and still be within the metes and bounds of the present invention.
It is important to consider that the present invention provides a means for mounting a plurality of sensors and a reefing disengagement profile controller mounted to the payload rather than to the parachute. The parachutes are normally initially packed and, as such, access to controlling therewithin are severely restricted after packing. With the use of the apparatus of the present invention the sensors are mounted to the payload and the reefing control processor is also mounted on the payload and wirelessly transmits information regarding reefing release to the canopy. As such, those controls are external to the parachute when packed and are available for setting of the mission profile input or modifying of the algorithms in the reefing control processor 32 as needed even after the parachute canopy and suspension lines are completely packed. This added flexibility greatly enhances operational control of the canopy deployment.
The apparatus of the present invention also allows parachute reefing to be sequenced at optimal times in order to achieve a degree of trajectory control and in this manner further enhance the possibility of precise landings. Also, in the very unusual emergency circumstances, it may be needed to have a very short reefing delay. The system of the present invention allows for prompt inflation when the system is deployed at a low altitude or at low air speed while also allowing the system to be adaptable to obtain extended reefing delay and prolonged inflation when deployed at a high altitude or at high air speeds. Thus the array of sensors for monitoring continuously variable parameters allows the payload and parachute airborne descent control apparatus to be utilized in a much wider spread of possible operating conditions than has been available heretofore.
The present invention is particularly usable with payloads such as space capsules which often make use of a plurality or cluster of parachutes which are all simultaneously attached with respect to the same payload, namely, the capsule. Substantial uneven load distributions in the multiple parachutes can result with the current commonly used reefing cutters that are mechanically activated and which have pyrotechnic fuses for setting time delay. The concept of the present invention is very useful for such applications because it can broadcast the disreefing signal to all canopies in a cluster in a coordinated manner to maintain balanced inflation of the respect canopies. The concept of the present invention is particularly useful for applications involving the use of clusters of parachutes because a single processor can be used to fully control the operation of sets of wireless transmitters and receivers associated with each individual parachute in the cluster.
Optimization of the setting of the pre-designated time delay is an important improvement made possible by the apparatus of the present invention. Pyrotechnic reefing cutters commonly used at this time are mechanically-actuated and, as such, provide only a limited selection of delay times and accuracies. Currently used electrically-actuated reefing cutters may have unlimited delay selection capabilities, but are constrained by the bulk and mass of the wiring that is required. These problems are overcome by the improved reefing control system of the present invention since an essentially unlimited variation in the pre-set reefing schedule timing is made possible. The only constraints on the operation of the improved design present herein is the basic accuracy of the processor and the response characteristics of the wireless transmitting and receiving hardware.
While particular embodiments of this invention have been shown in the drawing and described above, it will be apparent that many changes may be made in the form, arrangement, and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
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An apparatus for controlling the drag area growth of a parachute canopy during airborne descent with sensors attached to the payload for facilitating modification of the schedule of release of a parachute canopy reefing mechanism. A control processor is included that can receive and/or calculate a schedule for disengaging the reefing on the parachute. One or more wireless transmitters at the payload transmit the releasing signal from the payload to the reefing mechanism normally located adjacent the parachute canopy. The control processor can also be configured to receive input information from multiple sensors attached to the payload that monitor parameters such as altitude, position, load force, dynamic pressure, time and others to facilitate instantaneous recalculation of the disreefing schedule responsive to such conditions.
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CROSS REFERENCE TO RELATED APPLICATION
This application is entitled to and claims the benefit of German Application No. DE 10 2011 122 059.7 and U.S. Provisional Application No. 61/579,254, both filed Dec. 22, 2011, the disclosures of which, including the specification, drawings and abstract, are incorporated herein by reference in its entirety.
FIELD
The invention relates to a system and a method for repairing a structural component, in particular an aircraft structural component.
BACKGROUND
At present, damage in the region of the outer skin of aircraft is repaired by removing the damaged outer skin region and riveting on a repair patch. The repair patch is riveted to the outer skin region adjacent to the damaged outer skin region in such a manner that an opening in the aircraft outer skin resulting from removing the damaged outer skin region is covered. A riveting method of this kind is described, for example, in DE 10 2006 057 255 B4. Recently, efforts have been made to use adhesive bonding methods in aircraft construction when repairing damage to the aircraft outer skin, i.e. after removing the damaged outer skin region a repair patch is to be adhesively bonded onto a region of the aircraft outer skin adjacent to the damaged outer skin region in such a manner that an opening resulting from removing the damaged outer skin region is covered.
SUMMARY
The invention is directed at the object of providing a system and a method for repairing a structural component, in particular an aircraft structural component, which enable simple and reliable monitoring and/or checking of the quality of the repair.
This object is achieved by a system having the features of the attached system claims and a method having the features of the attached method claims.
A system according to the invention for repairing a structural component comprises a repair patch which is connected to the structural component in such a manner that it covers an opening in the structural component resulting from removing a damaged region of the structural component. A structural component is understood here to mean a load-bearing component, i.e. a component which is subjected to mechanical loads during operation. The structural component is preferably an aircraft structural component, in particular a component constituting a section of the aircraft outer skin. The structural component and the repair patch may, in principle, be made of any desired suitable material, but preference is given to metals, in particular aluminium or aluminium alloys, and also fibre-reinforced plastic materials, in particular carbon fibre-reinforced plastic materials. According to requirements, the structural component and the repair patch may also be made of the same material or of different materials. In principle, the repair patch may be connected to the structural component in any suitable manner, i.e. the repair patch may, for example, be riveted or screwed to the structural component. Preferably, however, the repair patch is adhesively bonded to the structural component, i.e. the repair patch is adhesively bonded onto a region of the structural component adjacent to the opening in the structural component in such a manner that the opening in the structural component is completely covered by the repair patch.
The repair system according to the invention further comprises a sensor which is fastened to the repair patch in a region of the repair patch covering the opening in the structural component. The sensor is adapted to detect strains and/or stresses occurring in the repair patch. On use of the structural component as a load-bearing component, stresses introduced into the structural component are also transmitted to the repair patch. The stress transmission to the repair patch is all the better, the higher the mechanical strength the connection between the structural component and the repair patch. Conversely, fewer stresses are transmitted to the repair patch if the connection between the structural component and the repair patch is less strong or even defective. Consequently, the strains and/or stresses in the repair patch which are measured by means of the sensor allow conclusions to be drawn regarding the mechanical strength the connection between the structural component and the repair patch. The sensor may be configured in the form of a stress sensor and be adapted to directly measure stresses occurring in the repair patch, Alternatively to this, however, the sensor may also be configured in the form of a strain sensor and measure material strains occurring in the repair patch, which for their part allow calculation of the stresses present in the repair patch.
The system according to the invention for repairing a structural component further comprises an evaluating device which is adapted to evaluate the strain values and/or stress values detected by the sensor. In dependence on the result of this evaluation, the evaluating device outputs a signal which is characteristic of the quality state of the connection between the structural component and the repair patch. In particular, with the aid of the strain values and/or stress values measured by means of the sensor, the evaluating device determines whether the connection between the repair patch and the structural component meets the desired quality requirements.
For example, the evaluating device may be adapted to compare the strain values and/or stress values measured by means of the sensor with corresponding predetermined threshold values. The threshold values may, for example, be strain values and/or stress values characteristic of a desired mechanical strength of the connection between the structural component and the repair patch. If the evaluating device ascertains that the strain values and/or stress values measured by the sensor lie below the corresponding strain values and/or stress values characteristic of a desired mechanical strength of the connection between the structural component and the repair patch, the evaluating device can then output a signal that indicates that the connection between the structural component and the repair patch does not have the required quality, i.e. the required strength. Furthermore, the evaluating device may be adapted to take into account strain values and/or stress values determined immediately after the structural component has been repaired, when outputting the signal which is characteristic of the quality state of the connection between the structural component and the repair patch. In particular, the evaluating device may be adapted to output a corresponding warning signal if the strain values and/or stress values determined by the sensor lie by a predetermined difference amount below the strain values and/or stress values determined immediately after the structural component has been repaired, and thereby indicate a loss of strength of the connection between the structural component and the repair patch.
The system according to the invention enables simple checking and, if necessary, also continuous monitoring of a repaired structural component. In particular, a weakening of the connection between the repair patch and the structural component can be detected very early. The system according to the invention is therefore particularly suitable for use in the repair of an aircraft structural component by means of an adhesive bonding method. At present, the approved methods for repairing aircraft outer skin components are restricted to riveting methods. However, adhesive bonding methods are easier to carry out, since it is not necessary to make a damaged aircraft outer skin section accessible from the inside, i.e. from the interior of the aircraft, in order to connect a repair patch to the damaged aircraft outer skin component. Moreover, when using an adhesive bonding method for repairing a damaged aircraft outer skin region, an increase in the structural weight due to additional rivets can be avoided. Furthermore it is possible to eliminate the need for additionally making rivet holes in the component to be repaired. It is thereby no longer necessary to keep to corresponding minimum thicknesses of aircraft outer skin components. The system according to the invention can thus help to spread the use of adhesive bonding methods when repairing aircraft structural components.
The sensor is preferably fastened to the repair patch in the region of an inner surface of the repair patch. The inner surface of the repair patch here is understood to mean a surface of the repair patch facing away from the outside environment. If the structural component is, for example, a component constituting a section on an aircraft outer skin, the inner surface of the repair patch faces the interior of the aircraft. The sensor is then protected from environmental influences.
The sensor may be integrated into a measuring module which, for example, is fastened to the repair patch in the region of an inner surface of the repair patch. The sensor integrated into the measuring module is preferably in direct contact with the surface of the repair patch, i.e. bears, for example, directly against the inner surface of the repair patch. Besides the sensor, the measuring module may further comprise a data store for storing the strain values and/or stress values detected by the sensor. The data store may also be designed to store a threshold value for the strain values and/or stress values in the repair patch. Furthermore, in the measuring module there may be provided an accumulator which supplies the sensor and/or further components of the measuring module with electrical energy. Finally, a transmitter for wireless transmission of signals may be integrated into the measuring module. The transmitter may, for example, comprise a processor and/or signal conditioner and also an antenna. A transmitter for wireless signal transmission enables cabling of the measuring module to be dispensed with.
The evaluating device for evaluating the strain values and/or stress values detected by the sensor and for outputting a signal which is characteristic of the quality state of the connection between the structural component and the repair patch may be integrated into the measuring module. The transmitter is then preferably adapted to transmit the signal, outputted by the evaluating device and characteristic of the quality state of the connection between the structural component and the repair patch, to a receiving device. The receiving device may, for example, be configured in the form of a mobile hand-held device. For monitoring or checking the repaired structural component, the receiving device can then be brought into the transmitting range of the transmitter, in order to receive the signal transmitted by the transmitter in a convenient and time-saving manner. An assessment of the quality state of the connection between the structural component and the repair patch is then possible immediately.
Alternatively to this, the evaluating device may also be integrated into a receiving device which, in turn, as described above, may be configured in the form of a mobile hand-held device. The transmitter is then preferably adapted to transmit the strain value and/or stress value, detected by the sensor and/or stored in the data store, to the receiving device. The evaluating device integrated into the receiving device then evaluates the signals transmitted by the transmitter to the receiving device and in turn immediately and conveniently delivers a signal which is characteristic of the quality state of the connection between the structural component and the repair patch.
The system according to the invention may comprise further components which enable the system to be used for immediate checking of the quality of the repair of the structural component, i.e. the quality of the connection between the structural component and the repair patch. For this purpose, the system preferably comprises a bridge element which is temporarily connectable to the structural component in such a manner that it spans a section of the structural component comprising the repair patch. The bridge element may, for example, comprise a base and a carrier supported by the base. The base is able to keep the carrier at a desired distance from the surface of the repair patch or of the structural component.
The shape of the carrier is preferably adapted to the shape of the section of the structural component repaired by means of the repair patch. If the structural component is a component constituting an aircraft outer skin section, the shape of the carrier of the bridge element is consequently preferably adapted to the curvature of the structural component constituting the aircraft outer skin section. For this purpose, the carrier may either be formed in a correspondingly curved manner or be provided with a joint which enables adaptation of the shape of the carrier to the shape of the structural component. A carrier provided with a joint is usable particularly flexibly in cooperation with differently shaped structural components. Preferably, the bridge element is provided to be temporarily connected to an outer surface of the structural component, an outer surface being understood here to mean a surface of the structural component facing the outside environment.
The system may further comprise a sealing system which is adapted to seal a space, defined by the bridge element and the section of the structural component spanned by the bridge element, against the outside atmosphere. Furthermore, the system may comprise a negative pressure-generating device which is adapted to generate, in the space sealed against the outside atmosphere by the sealing system, a pressure which is reduced relative to the ambient pressure. The negative pressure-generating device may, for example, be configured in the form of a vacuum pump and/or be provided with a pressure measuring device, for example, configured in the form of a manometer.
When a pressure, which is reduced relative to the ambient pressure, is generated with the aid of the negative pressure-generating device in the space sealed against the outside atmosphere by the sealing system, this reduced pressure also acts on an outer surface, i.e. a surface of the repair patch lying opposite the inner surface, of the repair patch. The outer surface of the repair patch faces the carrier of the bridge element in the state of the structural component when connected to the bridge element and faces the outside environment in the state of the structural component when not connected to the bridge element. The ambient pressure is in this case taken up by the bridge element and thereby decoupled from the inner surface of the repair patch. By contrast, the ambient pressure continues to act on the inner surface of the repair patch, on which the sensor for detecting the strains and/or stresses occurring in the repair patch is mounted. Consequently, the repair patch and in particular the connection between the repair patch and the structural component is loaded with the difference between the ambient pressure and the reduced pressure generated by the negative pressure-generating device.
Preferably, the negative pressure-generating device generates, in the space sealed against the outside atmosphere by the sealing system, such a reduced pressure that the differential pressure acting on the repair patch and hence the connection between the repair patch and the structural component is approximately 640 mbar. This corresponds roughly to the differential pressure acting, when an aircraft is flying at cruising altitude, on a repair patch which has been used to repair an aircraft outer skin component. The stresses and/or strains occurring in the repair patch can now be detected by the sensor and evaluated by the evaluating device. Moreover, a problem with the build-up of a negative pressure in the space sealed against the outside atmosphere by the sealing system indicates an untight and consequently defective connection between the repair patch and the structural component. This enables simple and reliable checking of the repaired structural component, i.e. in particular of the connection between the repair patch and the structural component under real mechanical loads.
The sealing system may comprise a vacuum film covering the bridge element and connected to the structural component, and a sealing element for sealing the vacuum film against the structural component. A sealing system of this kind is comparatively easy to handle and can be removed from the structural component again comparatively easily after the connection between the repair patch and the structural component has been checked.
A method according to the invention for repairing a structural component, in particular an aircraft structural component, comprises connecting a repair patch to the structural component in such a manner that the repair patch covers an opening in the structural component resulting from removing a damaged region of the structural component. A sensor is fastened to a region of the repair patch covering the opening in the structural component and is adapted to detect strains and/or stresses occurring in the repair patch. The strain values and/or stress values detected by the sensor are evaluated by means of an evaluating device. Finally, a signal which is characteristic of the quality state of the connection between the structural component and the repair patch is outputted in dependence on the result of this evaluation by the evaluating device.
The sensor is preferably fastened to the repair patch in the region of an inner surface of the repair patch.
The method may further comprise storing the strain values and/or stress values detected by the sensor in a data store, it being possible for the data store to be integrated into a measuring module also comprising the sensor. Furthermore, provision may be made for wirelessly transmitting signals by means of a transmitter which may be integrated into a measuring module also comprising the sensor.
The strain values and/or stress values detected by the sensor may be evaluated by means of an evaluating device integrated into the measuring module. The transmitter may then transmit the signal, outputted by the evaluating device and characteristic of the quality state of the connection between the structural component and the repair patch, to a receiving device.
Alternatively to this, the strain values and/or stress values detected by the sensor may be evaluated by means of an evaluating device integrated into a receiving device. The transmitter may then transmit the strain values and/or stress values, detected by the sensor and/or stored in the data store, to the receiving device.
The method according to the invention for repairing a structural component may further comprise checking the repair quality, i.e. in particular checking the quality of the connection between the repair patch and the structural component. For this purpose, a bridge element may be temporarily connected to the structural component in such a manner that the bridge element spans a section of the structural component comprising the repair patch. Subsequently, a space, defined by the bridge element and the section of the structural component spanned by the bridge element, may be sealed against the outside atmosphere. Finally, in the space sealed against the outside atmosphere by the sealing system, a pressure which is reduced relative to the ambient pressure may be generated.
The space defined by the bridge element and the section of the structural component spanned by the bridge element is preferably sealed against the outside atmosphere by means of a sealing system which comprises a vacuum film covering the bridge element and connected to the structural component, and a sealing element for sealing the vacuum film against the structural component.
An above-described system and/or an above-described method for repairing a structural component is/are usable particularly advantageously for repairing an aircraft structural component, in particular an aircraft structural component constituting a section of an aircraft outer skin.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be explained in more detail with reference to the appended schematic drawings, of which
FIG. 1 shows a system for repairing a structural component,
FIG. 2 shows a detail illustration of a measuring module employed in the system according to FIG. 1 ,
FIG. 3 shows a sectional view of a system for repairing a structural component, in which a bridge element is temporarily connected to the structural component,
FIG. 4 shows a plan view of the system according to FIG. 3 ,
FIG. 5 shows the system according to FIG. 3 , in which a space, defined by the bridge element and the section of the structural component spanned by the bridge element, is sealed against the outside atmosphere and connected to a negative pressure-generating device,
FIG. 6 shows a plan view of the system according to FIG. 5 , and
FIG. 7 shows the system according to FIG. 5 when the negative pressure-generating device generates, in the space sealed against the outside atmosphere, a pressure which is reduced relative to the ambient pressure.
DETAILED DESCRIPTION OF EMBODIMENTS
In FIG. 1 , a system 10 for repairing a structural component 12 is illustrated. In the embodiment shown, the structural component 12 is configured in the form of a component constituting a section of an aircraft outer skin and has an inner surface 14 facing an interior of the aircraft and an outer surface 16 facing the outside environment. Formed in the structural component 12 is an opening 18 which has resulted from removing a damage region of the structural component 12 . The structural component 12 is made of metal, in particular of aluminium or an aluminium alloy, or from a fibre-reinforced plastic material, in particular a carbon fibre-reinforced plastic material.
The opening 18 produced in the structural component 12 by removing the damaged region of the structural component 12 is covered by a repair patch 20 . The repair patch 20 , which is made of the same material as the structural component 12 , is adhesively bonded in the region of its edge to a region of the structural component 12 adjacent to the opening 18 . In particular, the repair patch 20 is adhesively bonded to the outer surface 16 of the structural component 12 .
During the operation of an aircraft in which the structural component 12 is installed, mechanical loads act on the structural component 12 . In particular, when the aircraft in flight, a differential pressure acts on the structural component 12 , since the interior of the aircraft is kept under an increased pressure relative to the ambient pressure. The mechanical loads acting on the structural component 12 are also transmitted to the repair patch 20 . The load transmission here functions all the better, the higher the mechanical strength of the connection between the structural component 12 and the repair patch 20 . In other words, material elongations and stresses which occur in the repair patch 20 during the operation of the aircraft are all the greater, and ideally correspond to the material strains and stresses occurring in the structural component 12 , the higher the strength of the adhesive bond between the structural component 12 and the repair patch 20 .
The system 10 further comprises a sensor 22 which is fastened to the repair patch 20 in such a manner that it bears against an inner surface 24 of the repair patch 20 . As with the inner surface 14 of the structural component 12 , the inner surface 24 of the repair patch 20 faces the interior of the aircraft, whereas an outer surface 26 of the repair patch 20 , as with the outer surface 16 of the structural component 12 , faces the outside environment. The sensor 22 is configured in the form of a strain sensor, i.e. it is capable of measuring material strains occurring in the repair patch 20 . From the material strains occurring in the repair patch 20 , it is possible to calculate the stresses which are transmitted by the structural component 12 to the repair patch 20 .
As can best be seen in FIG. 2 , the sensor 22 is integrated into a measuring module 28 which is fastened in a region of the repair patch 20 covering the opening 18 in the structural component 12 , so that the sensor 22 bears against the inner surface 24 of the region of the repair patch 20 covering the opening 18 in the structural component 12 . Besides the sensor 22 , the measuring module 28 comprises a data store 30 for storing the strain values detected by the sensor 22 . Furthermore, a transmitter 32 for wireless transmission of signal is present, which transmitter comprises a processor and/or signal conditioner 34 and also an antenna 36 . The components of the measuring module 28 are supplied with electrical energy by an accumulator 38 .
The system 10 further comprises a receiving device 40 configured in the form of a mobile hand-held device (see FIG. 1 ) which serves to receive the signals transmitted by the transmitter 32 . Into the receiving device 40 is integrated an evaluating device 42 which is adapted to evaluate strain values detected by the sensor 22 . For this purpose, the evaluating device 42 processes the strain values which are detected by the sensor 22 and transmitted to the receiving device 40 by the transmitter 32 . The strain values detected by the sensor 22 may be strain values detected directly by the sensor 22 , but also strain values stored in the data store 30 .
The evaluating device 42 compares the measured strain values with a stored threshold value. The threshold value may, for example, be a strain value which is characteristic of a desired mechanical strength of the connection between the structural component 12 and the repair patch 20 . If the measured strain value falls short of the threshold value, the evaluating device 42 evaluates this as an indication of insufficient transmission of mechanical stresses by the structural component 12 to the repair patch 20 , which is caused by a lack of strength of the connection between the structural component 12 and the repair patch 20 . In other words, strain values lying below the threshold value are judged to be an indication of an (imminent) detachment of the repair patch 20 from the outer surface 16 of the structural component 12 . Consequently, the evaluating device 42 outputs a signal which is characteristic of the quality state of the connection between the structural component 12 and the repair patch 20 .
The evaluating device 42 may also be integrated into the measuring module 28 . The transmitter 32 then transmits merely the signal, outputted by the evaluating device 42 and characteristic of the quality state of the connection between the structural component 12 and the repair patch 20 , to the mobile receiving device 40 . In any case, it is sufficient to bring the mobile receiving device 40 into the transmitting range of the transmitter 32 . This can be done from outside the aircraft, i.e. the receiving device 40 can be brought closer to the outer surface 16 of the structural component 12 or the outer surface 26 of the repair patch 20 until it comes into the transmitting range of the transmitter 32 . This may be done, for example, after each flight of the aircraft.
FIGS. 3 to 7 illustrate how the system 10 can be extended in order to be able to carry out a quality control of the connection between the structural component 12 and the repair patch 20 by means of the system 10 . For this purpose, the system 10 is extended by a bridge element 44 which is temporarily connected to the structural component 12 . The bridge element 44 comprises a base 46 and a carrier 48 supported by the base 46 . In the arrangement illustrated in FIGS. 3 to 7 , the carrier 48 of the bridge element 44 has an oval contour, as does the repair patch 20 . The bridge element 44 is connected to the outer surface 16 of the structural component 12 in such a manner that it spans a section of the structural component 12 comprising the repair patch 20 , the base 46 keeping the carrier 48 at a defined distance from the outer surface 16 of the structural component 12 and the outer surface 26 of the repair patch 20 . The shape of the carrier 48 of the bridge element 44 is adapted to the shape of the structural component 12 . For this purpose, the carrier 48 is provided with a joint 50 which enables the shape of the carrier 48 to be adapted to the curved shape of the structural component 12 .
When the bridge element 44 , as shown in FIGS. 3 and 4 , is connected to the structural component 12 , a space 52 , defined by the bridge element 44 and the section of the structural component 12 spanned by the bridge element 44 , is sealed against the outside atmosphere, see FIGS. 5 and 6 . For this purpose, a sealing system 54 comprising a vacuum film 56 covering the bridge element 44 is used. The vacuum film 56 is sealed against the outer surface 16 of the structural component 12 by means of a sealing element 58 . Finally, the space 52 sealed against the outside atmosphere is connected to a negative pressure-generating device 60 . In the embodiment shown in the figures, the negative pressure-generating device 60 is configured in the form of a vacuum pump equipped with a manometer 62 .
As illustrated in FIG. 7 , a pressure P r which is reduced relative to the ambient pressure P u is now generated in the space 52 sealed against the outside atmosphere by means of the negative pressure-generating device 60 . The ambient pressure P u then acts on the inner surface 24 of the repair patch 20 , whereas the reduced pressure P r in the space 52 sealed against the outside atmosphere acts on the outer surface 26 of the repair patch 20 facing the bridge element 44 , since the ambient pressure P u , which would otherwise act on the outer surface 26 of the repair patch 20 is taken up by the bridge element 44 . Consequently, the connection between the repair patch 20 and the structural component 12 is loaded with the differential pressure between the ambient pressure P u and the reduced pressure P r in the space 52 sealed against the outside atmosphere.
In order to simulate mechanical loads which act, when the aircraft is flying at cruising altitude, on the repair patch 20 , i.e. the connection between the repair patch 20 and the structural component 12 , the negative pressure-generating device 60 generates, in the space 52 sealed against the outside atmosphere, such a pressure P r which is reduced relative to the ambient pressure P u that a differential pressure of approx. 640 mbar acts on the repair patch 20 . If problems already occur in the space 52 sealed against the ambient atmosphere when the pressure P r which is reduced relative to the ambient pressure P u is generated, this means that the connection between the repair patch 20 and the structural component 12 is not tight and consequently has a lack of strength. If the generation of the desired negative pressure P r in the space 52 sealed against the outside atmosphere is unproblematical, the material strains in the repair patch 20 measured by the strain sensor 22 are used to assess the quality of the connection between the repair patch 20 and the structural component 12 .
After completion of the quality check, the space 52 can be put under ambient pressure P u again. Furthermore, the sealing system 54 and the bridge element 44 can be removed from the structural component 12 again.
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A system for repairing a structural component, in particular an aircraft structural component, includes a repair patch which is connected to the structural component in such a manner that it covers an opening in the structural component resulting from removing a damaged region of the structural component. A sensor is fastened to the repair patch in a region of the repair patch covering the opening in the structural component and is designed to detect strains and/or stresses occurring in the repair patch. An evaluating device is adapted to evaluate the strain values and/or stress values detected by the sensor and, in dependence on the result of this evaluation, output a signal which is characteristic of the quality state of the connection between the structural component and the repair patch.
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FIELD OF THE INVENTION
[0001] The present invention relates to control valves, and more particularly to a valve operator for manually operating a control valve.
BACKGROUND OF THE INVENTION
[0002] Flow control valves, including plug valves, are used in a number of different applications. Some guiding principles in designing and implementing control valves include the desire to employ a simple and efficient valve and operator having a relatively low number of parts, with the assembled valve being cost effective, efficient, and reliable in operation.
[0003] Current implementations of control valves often utilize an automated actuator to actuate the control valve. The automated actuator can have a pneumatic or electric source of power.
[0004] The possibility of the control valve actuator failing at some point during its lifetime varies with each control valve. Because the possibility exists, it is desirable in many instances to provide a manual backup valve operator, or an auxiliary valve operator, to duplicate the function of the automated valve actuator during a failure. The valve operator can also be used in instances where the automated valve actuator is properly functioning, and for other reasons (such as manual override), it is desirable to have the ability to open and close a control valve without using the actuator.
SUMMARY OF THE INVENTION
[0005] There is a need in the art for a valve operator having a fewer number of parts, a relatively low manufacturing cost, and a high operating efficiency relative to known valve operators in use today. The present invention is directed toward further solutions to address this need.
[0006] In accordance with one example embodiment of the present invention, a valve operator includes a rotatable spindle extending along an axis. The rotatable spindle is rotatable about the axis. The rotatable spindle is additionally pivotable about a first pivot point. A pivotable linkage operably couples with the spindle. The pivotable linkage is pivotably movable about a second pivot point, such that rotation of the spindle about the axis moves the pivotable linkage in a pivoting motion about the second pivot point. Rotation of the spindle can additionally pivotally move the spindle about the first pivot point.
[0007] The valve operator can be mounted in combination with an automated valve actuator on the same control valve. The automated valve actuator can have a number of different power sources, including pneumatic and electronic.
[0008] In accordance with one aspect of the present invention, a bearing forms the first pivot point. A reaction force from the pivotable linkage can push a first end of the spindle against the bearing. A structure fixed to a yoke of an actuator coupled to the valve operator supports the bearing.
[0009] According to another aspect of the present invention, a support bracket for supporting the pivotable linkage is fixed to a yoke of the actuator. The support bracket includes a first bracket arm and a second bracket arm. Each of the first and second bracket arms can extend to the second pivot point from the yoke of the actuator.
[0010] In accordance with further embodiments of the present invention, the pivotable linkage generally forms about a 90° angle between each of first and second ends and the pivot point. Alternatively, the pivotable linkage can form greater than or less than about a 90° angle between each of first and second ends and the second pivot point.
[0011] In accordance with still another aspect of the present invention, a pivot pin extending through a pivot bore within the pivotable linkage forms the second pivot point. In addition, a threaded fixture operably coupling the rotatable spindle with the pivotable linkage mounts within a bore of a first end of the pivotable linkage. A bearing mounted within the bore supports the threaded fixture. The threaded fixture can take the form of a nut, in addition to other structures.
[0012] In accordance with still further aspects of the present invention, the threaded fixture rotatably mounts in a manner enabling the rotation of the threaded fixture about a rotation axis perpendicular to the axis of the threaded spindle and parallel to a rotation axis of the second pivot point. This arrangement allows the threaded fixture to be pivotable about the first pivot point, wherein the first pivot point is distal from the threaded fixture.
[0013] In accordance with still another aspect of the present invention, a second end of the pivotable linkage extends to couple with a stem. The stem can be an actuator stem or a valve stem. The actuator stem and valve stem can likewise couple together.
[0014] In accordance with still another aspect of the present invention, a rounded tip is disposed at a first end of the threaded spindle. The rounded tip facilitates the pivoting and rotating movements of the threaded spindle.
[0015] In accordance with still another aspect of the present invention, a wheel is disposed at a second end of the threaded spindle for actuating a rotation force on the threaded spindle.
[0016] In accordance with yet another embodiment of the present invention, a pivotable lock nut is disposed to receive the threaded spindle. The lock nut is disposed to lock the threaded spindle to prevent rotation.
[0017] In accordance with still another embodiment of the present invention, a valve operator is provided having a rotatable threaded spindle. The spindle extends along an axis and is rotatable thereabout. The spindle is pivotable about a first pivot point. A pivotable linkage having a first end, a second end, and a second pivot point is also provided. A bore extends at least partially through the first end of the linkage. A threaded fixture rotatably mounts at the bore for receiving the threaded spindle. The threaded fixture is rotatable about an axis parallel to an axis of the second pivot point. The second end of the pivotable linkage couples to a stem, such that rotation of the spindle causes the linkage to pivot about the second pivot point to effect movement of the stem.
[0018] In accordance with another embodiment of the present invention, a system is provided for actuating a valve. The system includes an automated valve actuator. In addition, a valve operator is provided. The valve operator includes a rotatable spindle having a first end, a second end, and a center line axis extending therebetween. The first end rotatably couples to a bearing and the spindle is pivotable about a first pivot point at the bearing. A pivotable linkage having a first end, a second end, and second pivot point therebetween, is also provided. The first end supports a rotatable threaded fixture that receives the rotatable spindle, and the second end extends to communicate with a stem.
[0019] The present invention provides a side mounted valve operator. The assembly of the valve operator can be configured so that the pivotable linkage in one mode can push a valve stem downward, and in another mode the assembly can be inverted so the operator pushes a valve stem upward. No additional parts are required between each of the two modes.
[0020] Furthermore, the present invention provides for a mechanism using manually induced motion and lifting forces applied to valve and actuator stems at a greatly increased mechanical efficiency over known art, and using a reduced number of bearings. Known manual valve operators have at least one additional bearing within the operator mechanism relative to the operator of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The aforementioned features and advantages, and other features and aspects of the present invention, will become better understood with regard to the following description and accompanying drawings, wherein:
[0022] [0022]FIG. 1 is a diagrammatic cross-sectional view of a valve operator in combination with a valve actuator capable of moving an actuator stem in an upward motion according to the teachings of the present invention;
[0023] [0023]FIG. 2 is a cross-sectional view taken at section A-A of FIG. 1 according to the teachings of the present invention;
[0024] [0024]FIG. 3 is a diagrammatic cross-sectional view of a valve operator in combination with an actuator capable of moving an actuator stem in a downward motion according to the teachings of the present invention;
[0025] [0025]FIG. 4 is a cross-section at section B-B of FIG. 3 according to the teachings of the present invention;
[0026] [0026]FIG. 5 is an enlarged diagrammatic illustration of a bearing according to the teachings of the present invention; and
[0027] [0027]FIGS. 6A through 6C are diagrammatic illustrations of motivated linkages according to aspects of the present invention.
DETAILED DESCRIPTION
[0028] An illustrative embodiment of the present invention relates to a valve operator for use with a control valve. The valve operator includes a handwheel attached to a rotatable and pivotable threaded spindle. The threaded spindle pivots about a first pivot point. Rotation of the handwheel causes a motivated linkage having an extended link portion to pivot about a second pivot point and push against the stem of an actuator. The direction of motion is typically against a spring force from an actuator spring.
[0029] The threaded spindle engages a nut, which can rotate in a bore within the motivated linkage. A second bore retains a pivot pin, which is further engaged in a support structure, to form the second pivot point. The support structure fastens to a yoke of the actuator. The reaction force applied to the threaded spindle as a result of the turning of the handwheel is absorbed by a needle-bearing, which is supported within a portion of the structure.
[0030] The nut moves along the spindle and makes a radial excursion around the second pivot point as the threaded spindle rotates and pivots. A spherical tip on the end of the spindle, which seats in the bearing, facilitates the pivotal movement in addition to the rotational movement.
[0031] The components of the valve operator can be inverted to push a valve stem downward rather than pushing the valve stem upward. The overall operator design utilizes a reduced number of parts, thereby reducing the overall cost. The components of the operator are reversible without the use of additional parts, and the low friction of the pivoted and rotating spindle unit, together with a lower number of bearings, provides a high operating efficiency.
[0032] [0032]FIGS. 1 through 6C, wherein like parts are designated by like reference numerals throughout, illustrate example embodiments of a valve operator according to the teachings of the present invention. Although the present invention will be described with reference to the example embodiments illustrated in the figures, it should be understood that many alternative forms can embody the present invention. One of ordinary skill in the art will additionally appreciate different ways to alter one or more parameters of the embodiments disclosed, such as the size, shape, or type of elements or materials, in a manner still in keeping with the spirit and scope of the present invention.
[0033] [0033]FIG. 1 is a diagrammatic cross-sectional view of a valve operator 10 in accordance with one embodiment of the present invention. A force generator or handwheel 12 is provided for applying a rotational force to a threaded spindle 24 . The invention is not limited to the handwheel 12 for providing the rotational force to the threaded spindle 24 . Alternative mechanisms such as differently shaped levers, an additional automated actuator, a belt and pulley system, or the like, that can generate the requisite rotational force, can be used instead of the illustrated handwheel 12 .
[0034] The threaded spindle 24 couples to a motivated linkage 14 by way of a rotatable nut 26 . The nut 26 rotatably mounts within a first bore 28 of the motivated linkage 14 . Internal threads of the nut 26 engage with the threads of the threaded spindle 24 . The rotatable nut 26 can take the form of a number of different structures having a threaded internal passage for receiving the threaded spindle 24 and a fitting, or able to be coupled with a fitting, for rotatable mounting within the first bore 28 , as understood by one of ordinary skill in the art.
[0035] The motivated linkage 14 further includes a second bore 30 having a pivot pin 32 passing therethrough. The motivated linkage 14 also includes an extended link 16 that couples with an actuator stem 18 of an actuator 20 . The extended link 16 can couple with the actuator stem 18 in a number of different ways, such as by using different fastening devices, pins, bearings, fixtures, or simply pressing against the actuator stem 18 when applying a force thereon. The actuator stem 18 can connect with a valve stem 22 to enable the motivated linkage 14 to effect movement of the valve stem 22 as later described herein.
[0036] A support structure 34 connected to an actuator yoke 36 supports the valve operator 10 . The support structure 34 can be fixedly attached to the actuator yoke 36 by a number of different fastening methods, including adhesive, welding, riveting, clamping, bolting, screwing, or the like. The support structure 34 is able to withstand the weight of the valve operator 10 assembly, as well as the reaction forces generated by the operator 10 as the threaded spindle 24 pushes against a needle bearing 38 , and as the motivated linkage 14 moves the actuator stem 18 .
[0037] The threaded spindle 24 includes a generally spherical tip 40 , which mounts in the needle-bearing assembly 38 A supported by the support structure 34 . The spherical tip 40 of the threaded spindle 24 allows for either or both rotational and pivotal motion of the threaded spindle 24 .
[0038] A lock nut 46 , couples to a spherical portion of the motivated linkage 14 , and serves to prevent movement of the threaded spindle 24 when not in use. The lock nut 46 has an internal thread that engages with the thread of the threaded spindle 24 . The lock nut 46 additionally has a perimeter profile that matches the perimeter profile of the motivated linkage 14 , such that the lock nut 46 can slide along the perimeter edge of the motivated linkage 14 when not in a locked position. If a user desires to lock the threaded spindle 24 in a particular arrangement, the user rotates the lock nut 46 to compress the lock nut 46 against the perimeter edge of the motivated linkage 14 , which prevents rotational and pivotal movement of the threaded spindle 24 as well as pivotal movement of the motivated linkage 14 .
[0039] [0039]FIG. 2 is a cross-sectional illustration of the valve operator 10 taken along section A-A of FIG. 1. The support structure 34 of FIG. 1 supports the threaded spindle 24 and the nut 26 . The support bracket 34 includes a pair of arms 48 extending from the actuator yoke 36 . However, the support bracket 34 can have a number of different configurations extending between the actuator yoke 36 and the nut 26 . For example, the support bracket 34 can have a different number, and differently shaped, arms 48 where the arms can be relatively straight, curved, angled, or the like. The arms can be solid, or can contain a series of openings to reduce the weight of the support bracket 34 . Other support bracket configurations are possible as will be understood by one of ordinary skill in the art.
[0040] [0040]FIG. 2 also provides a cross-sectional top view of the coupling connection between the handwheel 12 , the threaded spindle 24 , and the nut 26 . As can be seen, the threaded spindle 24 passes through the nut 26 and terminates at the needle-bearing 38 in the form of the spherical tip 40 . The needle-bearing 38 receives the spherical tip 40 in a seat and allows for the rotation and pivoting of the threaded spindle 24 . Also visible in this view is the pivot pin 32 .
[0041] The support bracket 34 mounts to the actuator yoke 36 and is affixed thereto with bolts 50 , which hold the support bracket 34 fixedly in place. The support bracket 34 can mount in a number of additional ways, including adhesive, welding, riveting, or the like.
[0042] [0042]FIG. 2 also illustrates the extended link 16 being coupled with the actuator stem 18 . A pair of pins 54 forms the connection between the extended links 16 and the actuator stem 18 . However, one of ordinary skill in the art will understand that any number of different mechanical couplings can couple the extended link 16 of the motivated linkage 14 with the actuator stem 18 .
[0043] [0043]FIG. 3 illustrates an alternative embodiment of the valve operator 10 ′ in accordance with the teachings of the present invention. Like parts are designated with like reference numerals. The embodiment illustrated is an inverted form of the embodiment shown in FIGS. 1 and 2. The handwheel 12 couples with the threaded spindle 24 , which terminates in the spherical tip 40 seated within the needle-bearing 38 . The threaded spindle passes through the nut 26 , which mounts within the first bore 28 of the motivated linkage 14 . Rotation of the handwheel 12 causes the motivated linkage 14 to travel along the length of the threaded spindle 24 , while pivoting about a pivot point formed by the second bore 30 and the pivot pin 32 .
[0044] [0044]FIG. 4 illustrates a cross-sectional view of the valve operator 10 ′ taken at section B-B of FIG. 3. As illustrated herein, the handwheel 12 couples with the threaded spindle 24 . The spindle 24 passes through the threaded nut 26 . The support bracket 34 has a slotted portion 55 to receive the motivated linkage 14 , and fixedly mounts to the yoke 36 of the actuator with the use of two bolts 50 . The pins 32 pass through the slotted portion 55 , allowing the motivated linkage 14 to rotate about the shared axis of the pins 32 . In addition, the pins 54 couple the extended link 16 of the motivated linkage 14 to the actuator stem 18 .
[0045] The valve operator 10 of FIGS. 1 and 2 pushes the actuator stem 18 upward with movement of the handwheel 12 , while the arrangement valve operator 10 ′ illustrated in FIG. 3 pushes the actuator stem 18 downward with rotation of the handwheel 12 . Each component of the valve operator can be rearranged into the valve operator 10 ′ configuration of FIG. 3 without requiring any modification to the actual components. The specific arrangement of operator components relates to the direction of the spring force on the actuator stem 18 . If the actuator stem 18 experiences a constant spring force pushing the actuator stem 18 downward, the valve operator configuration of FIGS. 1 and 2 is appropriate. If the actuator stem 18 experiences a constant spring force pushing the actuator stem 18 upward, the valve operator configuration of FIG. 3 is appropriate. The direction of the spring force is determined as a specification of the particular valve construction, and typically makes use of a valve spring (not shown) surrounding the actuator stem 18 , or the valve stem 22 , as is understood by those of ordinary skill in the art.
[0046] [0046]FIG. 5 illustrates a close-up of the needle bearing assembly 38 A illustrated in FIGS. 1 and 3. The needle bearing assembly 38 A includes a screw 42 , which screws into the spherical tip 40 of the threaded spindle 24 . The screw 42 holds the spherical tip 40 of the threaded spindle 24 in place during times at which the valve operator 10 is not connected to the actuator, and/or there is no force pressing the threaded spindle 24 against the needle-bearing 38 , i.e., during shipping. The needle bearing 38 further receives a base 43 coupled with a cap 39 that is part of the support bracket 34 . When the valve operator 10 is coupled with an actuator, the reaction force of a properly installed motivated linkage 14 pushes the spherical tip 40 of the threaded spindle 24 towards, or into base 43 and therefore compresses the bearing 38 . Thus, there is no need for the screw 42 to withstand any pulling load from the threaded spindle 24 .
[0047] [0047]FIGS. 6A, 6B, and 6 C illustrate several embodiments of the motivated linkage 14 in accordance with the teachings of the present invention. The illustrated linkage includes the first bore 28 , the second bore 30 , and the extended link 16 . The angle between the extended link 16 to the second bore 30 and the second bore 30 up to the first bore 28 is approximately 90° in FIG. 6A. However, in FIG. 6B the angle is an obtuse angle (i.e., approximately greater than 90°), while the angle in FIG. 6C is an acute angle (i.e., less than approximately 90°). One of ordinary skill in the art will understand that varying the angle of the linkage will have different affects on the power and range of the motivated linkage 14 . In addition, one of ordinary skill in the art will appreciate that the motivated linkage 14 can have a number of different shapes and angles in addition to those depicted herein. FIGS. 6A through 6C illustrate the underlying angular relationship possibilities between each end of the motivated linkage, regardless of the actual linkage shape.
[0048] In operation, the valve operator 10 works generally as follows in accordance with the teachings of the present invention. Referring to FIG. 1, a user rotates the handwheel 12 in either a clockwise or a counterclockwise direction, depending on the desired movement of the actuator stem 18 . Rotation of the handwheel 12 rotates the threaded spindle 24 and causes the nut 26 to travel along the axis of the threaded spindle 24 , and at the same time move along an arcuate path defined by the distance between the pin 32 and the bearing 26 , where the axis of the pin 32 is the focal point. The movement of the nut 26 through the arcuate path in turn causes the axis of the spindle 24 to be angularly displaced. The angular displacement is enabled by a rotation about a pivot point at the spherical tip 40 . Rotation of the handwheel 12 in one direction moves the nut 26 in one direction, and rotation in the other direction moves the nut 26 in the opposite direction. The nut 26 couples with the first bore 28 of the motivated linkage 14 . Therefore, movement of the nut 26 results in movement of the motivated linkage 14 . For example, if rotation of the handwheel 12 results in the nut 26 traveling in the direction toward the handwheel 12 , the nut 26 moves the motivated linkage 14 in that direction.
[0049] The motivated linkage 14 is also pivotally mounted at the second bore 30 with the pivot pin 32 to form a first pivot point. The force generated by the nut 26 pivots the motivated linkage in a clockwise direction about the pivot pin 32 . The clockwise rotational movement of the motivated linkage 14 causes the extended link 16 to push up against the actuator stem 18 , vertically lifting the actuator stem 18 and the valve stem 22 coupled thereto. The vertical action of the actuator stem 18 opens or closes a valve. The valve is not illustrated for purposes of clarity. One of ordinary skill in the art will understand that a number of different valves can connect with the type of actuator illustrated herein, such as gate valves, plug valves, and needle valves.
[0050] When the manual valve operator 10 is not in use, and the automated actuator 20 is in use, the actuator 20 automatically lifts the actuator stem 18 off the extended link 16 . Thus, the motivated linkage 14 does not interfere with automated movement of the actuator stem 18 and the corresponding movement of the valve stem 22 to open and close the valve. Locking the nut 46 can lock the motivated linkage 14 in place to prevent interference from the valve operator 10 .
[0051] The valve operator 10 in the configuration depicted in FIG. 3 is useful for implementation with a valve actuator 20 having a spring normally pulling the actuator stem 18 in an upward direction. In such an arrangement, the actuator 20 and the motivated linkage 14 each push in a opposite, downward, direction on the actuator stem 18 to open and close the valve attached thereto.
[0052] Referring again to FIG. 1, as the motivated linkage 14 rotates in a clockwise direction, the motivated linkage 14 at the location of the first bore 28 and the nut 26 moves along an arcuate path. In order for such a path to occur, the threaded spindle 24 pivots about a pivot point generally located at the spherical tip 40 . Therefore, as the motivated linkage 14 moves along the arcuate path, the threaded spindle 24 pivots downward to follow the path. The threaded spindle is provided with the spherical tip 40 to allow the pivotal movement to occur. Further, the nut 26 rotates within the first bore 28 to maintain alignment with the threaded spindle 24 and allow the threads to engage appropriately.
[0053] The lock nut 46 is additionally provided to lock the threaded spindle in place against the motivated linkage 14 . To lock the operator in place, the lock nut is tightened, which results in a friction force between the lock nut and the edge of the motivated linkage 14 . The friction fit prevents the pivotal movement of the threaded spindle 24 , as well as the rotational movement of the threaded spindle 24 . The lock nut 46 must be loosened and removed a sufficient distance from the motivated linkage 14 so as to not interfere during the normal operation and use in the range of movement of the motivated linkage 14 .
[0054] The valve operator according to the teachings of the present invention offers a unique arrangement of linkages and a spindle to achieve a cost effective and efficient design for movement of a valve actuator and stem with a minimum amount of friction. The components of the valve operator are reversible, such that the same parts can be used in an upward force-generating configuration or a downward force-generating configuration by simply re-arranging individual components. Movement of the handwheel, or some other source of rotational force, causes the threaded spindle to rotate and slightly pivot as the motivated linkage moves to motivate the actuator stem and open or close the attached valve.
[0055] Numerous modifications and alternative embodiments of the present invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode for carrying out the present invention. Details of the structure may vary substantially without departing from the spirit of the present invention, and exclusive use of all modifications that come within the scope of the appended claims is reserved. It is intended that the present invention be limited only to the extent required by the appended claims and the applicable rules of law.
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A valve operator is provided having a rotatable spindle extending along an axis. The rotatable spindle is rotatable about the axis. The rotatable spindle is additionally pivotable about a first pivot point. A pivotable linkage operably couples with the spindle. The pivotable linkage is pivotably movable about a second pivot point, such that rotation of the spindle moves the pivotable linkage in a pivoting motion about the second pivot point. Rotation of the spindle additionally pivotally moves the spindle about the first pivot point. The inventive valve operator has a fewer number of parts, a relatively low cost of manufacture, and a high operating efficiency relative to known valve operators.
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to the art of vaccinating birds, including but not limited to pullets.
[0002] More particularly, the invention relates to a rotating bird vaccinating device in the form of a rotating drum or carosel turned by an electric motor and having means, such as shackles, which hold the birds upside down by the legs, in order to present the bird to the vaccinator, where said drum turns before successive fixed stations, including a first station to attach the bird, one or several vaccination stations for the vaccinators, and a releasing station where the bird is released from the drum.
[0003] The invention also relates to a method which makes use of the improved device according to the invention.
[0004] Presently such kind of pullet vaccinating devices are on public use. These machines comprise a cylindrical drum turning on a vertical shaft and chain driven by an electrical motor connected to a power source.
[0005] Such known devices need an important staff, to attach the pullet, to vaccinate the birds and to release the vaccinated pullets.
[0006] Using such machines leads sometime to inaccurate vaccination, for example in the event the drum must be suddenly stopped, which requires one operator to disconnect the power source and there is a risk of vaccinating some birds twice or just omitting to vaccinate them because of the time needed for the drum to stop. Further, the vaccinators cannot know how many birds are vaccinated, unless they try to count the birds.
[0007] Some of these known machines have a cylindrical drum surface to which the pullet can be backed on by the vaccinator, which may result in some stress to the animal.
[0008] These machines are often cumbersome and are not very practical for the vaccinators who generally have to stand during the whole vaccination sequences.
SUMMARY OF THE INVENTION
[0009] It is an object of the invention to provide bird vaccinating devices which results in more accurate vaccination of the birds, even if several distinct vaccines are administered.
[0010] Another object of the invention is to reduce the stress of the birds during the vaccination step.
[0011] Another object is to allow each operator or vaccinator to stop and restart the machine immediately.
[0012] Another object is to allow an accurate and simple counting of the vaccinated birds.
[0013] Another object is to reduce the staff needed to operate the vaccinating device.
[0014] Another object is to speed up the vaccination rate of birds.
[0015] Another object is to allow the vaccinators to work in a comfortable position.
[0016] According to a first embodiment of the invention, the bird vaccinating device comprises a frame, a drum or carosel rotatable on a vertical axis on this frame, schackle means for attaching birds, and being angularly spaced on said drum, motor means to rotate said drum, to present the bird successively to different operating stations, wherein said drum has a polygonal shape, preferably octagonal, each lateral side of the polygon providing a flat surface, said schackle means protruding from said surface so that an attached bird can be backed on to this flat surface by the vaccinator for proper vaccination.
[0017] By providing such a polygonal, preferably octagonal, shape of the drum with flat surfaces, for example vertical plates forming said lateral sides, the pullet can be backed on to a flat surface whereby the stress on the pullet is reduced compared to the stress of being pressed against the usual convex cylindrical surface of a drum.
[0018] This octagonal or polygonal shape also allows, if needed, to provide more than one schackle means per lateral side, whereby more than one, for example two pullets can be attached on one lateral side for increasing the rate of vaccination without increasing the rotation speed.
[0019] According to another improvement, a bird vaccinating device according to the present invention comprises a frame, a drum or carosel rotatable on a vertical axis on this frame, schackle means for attaching birds, being angularly spaced on said drum, motor means to rotate said drum, to present the birds successively to different operating stations, wherein said drum or carosel is cinematically driven by the motor means through drive disconnecting means able to be actuated by any member of a staff, to immediately stop the drum while the motor continues to run, and to immediately restart the rotation of the drum, if wanted.
[0020] This rotation disconnecting means can, for example, comprises clutch means with various clutch control means angularly spaced around the frame to be actuated from each working station.
[0021] But, according to a preferred embodiment, this disconnecting means comprises friction means, such as, for example, frictionnaly mutually engaged discs, whereby the drum can be immediately stopped by an operator grasping the drum and immediately restarted when the operator releases the drum.
[0022] This allows to immediately stop the drum by the proper operator if needed and to have it restarted after a short time, without disconnecting the power source. Further once an operator, for example a vaccinator, stops the drum, he keeps the side of the polygon with the relevant pullet in front of him, instead of having the drum continuing to rotate for a short time while he goes to disconnect the power source.
[0023] It also prevents risks or injuries if the drum is blocked accidentally.
[0024] According to another embodiment of the improved vaccinating device according to the invention, the device comprises a frame, a drum or carosel rotable on a vertical axis on this frame, schackle means for attaching birds, said schackle means being angularly spaced on said drum, motor means to rotate the drum, to convey a bird successively to different operating stations, wherein said schackle means are responsive to a schackle release means fixed at a precise angular location of the frame to release automatically the bird once the schackle means reaches an angular location corresponding to said schackle releasing means.
[0025] In such embodiment there is preferably provided a slide or other receiving and transportation means which gently receives the falling pullet to transport the pullet away from the device.
[0026] According to another embodiment of the present invention, the bird vaccinating device comprises a frame, a drum or carosel rotatable on a vertical axis on this frame, a schackle means for attaching birds, said schackle means being angularly spaced on said drum, motor means to rotate said drum, to present the bird successively to different operating stations, wherein there is provided a pullet counter which automatically counts the number of pullets released from the schackle. Preferably this counter is a mechanichal counter.
[0027] In a preferred embodiment, this counter is located either on the frame, at the bird release station, or on the slide or other transportation means for the released bird.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Examples of the invention are illustrated in the drawings.
[0029] [0029]FIG. 1 is general view of a bird vaccinating device according to a preferred embodiment of the invention,
[0030] [0030]FIG. 2 is a side elevation of another embodiment where the lateral plates are omitted,
[0031] [0031]FIG. 3 is a front elevation corresponding to FIG. 2,
[0032] [0032]FIG. 4 is a schematic top view of the device (with a decagonal drum) corresponding to FIG. 2,
[0033] [0033]FIG. 5 is a general view of the preferred drum where the lateral plates are omitted,
[0034] [0034]FIG. 6 is a view of the slide of the device.
[0035] [0035]FIG. 7 is a schematic view of the slide with a counting pallet.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] While the preferred embodiment is shown on FIGS. 1, 5, 6 , 7 , FIGS. 2, 3, 4 are used to show the driving and sliding disc means and the shape of the shackles.
[0037] With reference to the figures, there is provided a rotating bird vaccinating device comprising a frame 1 and a rotating carosel like drum 2 . Frame 1 has vertical legs 3 , provided with wheels 4 for rolling the device. Frame 1 rigidly supports a motor and gear box assembly having an electrical motor 5 and a gear box 6 whose output vertical shaft is rigidly fastened to a hub 7 whereby the hub 7 is driven by the output shaft. Hub 7 rigidly supports a lower horizontal disc 8 which is thereby rotatively driven with the shaft (FIG. 2). Frame 1 supports a control panel 9 having switching means to connect or disconnect electrical power to motor 5 . Means can also be provided on the panel to vary the rotation speed of the electrical motor 5 , as well as the clockwise or counterclockwise direction of the rotation. Further a remote system pause can be provided, for example a foot pedal actuated switch to allow a designated operator to pause the rotation.
[0038] Drum 2 has the shape of an octogon having eight vertical lateral sides 10 , each side arboring a rectangular vertical metal plate 11 . As better seen on FIG. 5, the structure of wheel 2 comprises upper and lower octagonal assemblies 12 , 13 being connected at each apex by vertical legs 14 . A central disc 15 is rigidly mounted centrally in this octagonal cage by a pair of oblique bracings 16 whose proximal ends are secured to the periphery of disc 15 and whose distal ends are respectedly secured to apexes of the upper and lower polygons 12 , 13 . Plates 11 are welded or otherwise secured to the octagonal drum sides to form the lateral sides thereof.
[0039] While the upper side of disc 15 is flat, its lower side has a large central recess surrounded by a peripheral rim, which recess has a diameter slightly larger than the diameter of the lower disc 8 . As better seen on FIG. 2, when a drum is mounted on the frame, upper disc 15 engages lower disc 8 which penetrates into the central large recess. The peripheral rim of disc 15 would prevent any substantial lateral displacement of one disc with respect to the other. The friction between the upper side of the lower disc 8 and the internal side of the recess of the upper disc 15 is such that when lower disc 8 is rotated by the motor-gear box assembly, the upper disc 15 , and, accordingly, the drum 2 , is driven at the same speed. However if the rotation of the drum is hindered, for example by an operator grasping the drum, the discs will slide with respect to each other. In other words, disc 8 and 15 provide a kind of frictional clutch which allows the upper disc to be easily disconnected from the rotation of the lower disc by an operator which retains the drum.
[0040] Disc 15 has a central bore through which the upper end of the vertical output shaft can freely extend and a means can be provided, such as a nut screwed on the upper end of the shaft to prevent disc 15 to be vertically removed from disc 8 while allowing both discs to slide respectively if needed.
[0041] As best seen on FIG. 5, the horizontal sides of the upper octagonal assembly 12 , which are formed of bars 17 , provide radial brackets 18 which protrude radialy outside from the plate 11 . As better seen on FIG. 2, brackets 18 provide also a lower part forming a horizontal hinge for shackles. Shackle 19 comprises a rigid metal wire having a M form having a central V shaped part 20 and two radial end parts 21 . Accordingly there is provided between each end part 21 and the central V shaped part 20 , a tapered recess 22 in which a leg of a pullet can be introduced in such a way that the pullet can be maintained upside down by its two legs in the recesses 22 of a shackle 19 . As the shackles 19 are normally in an oblique position with their external parts pointing upwardly, one understands that the legs of the pullet, whose feet prevent it from falling down, will be urged to the apexes of the shackle due to the weight of the pullet. On the other side, if bracket 19 is tilted down and points obliquely and downwardly, the legs of the pullet will slide out of recesses 22 and the pullet will be released from the wheel.
[0042] The shackles 19 are normally oriented outwardly and upwardly according to FIG. 2, and are maintained in this orientation by a latch hook 23 having a lever form which is journalled on the upper octogonal assembly. Lever 23 is hinged to a lever rod 24 which is hinged to the end of a short lateral arm 25 secured to a shaft 26 having a lever form which is journalled at respective ends on the lateral bar 27 of the lower polygon 13 and on a hinge affixed on the disc 15 (FIG. 5). A lateral tab 28 extends from the shaft in a direction opposite to arm 25 . During rotation of the drum 2 , when this tab 28 encounters a static cam mounted at proper location on frame 3 , shaft 26 will be rotated, whereby lever 23 is tilted, which allows the corresponding shackle 19 to tilt downwardly and release the bird. After the bird is released the shackle reverts to its upper oriented position and once the tab 28 escapes the cam, the latch hook 23 engages the shackle. Of course, rod arrangement 24 can be replaced by equivalent pull means, such as a pull cable, which allows more flexibility for the location of the shackle actuation control means.
[0043] With reference to FIG. 6, there is provided a funnel like slide 30 mounted on a wheeled frame, which is adapted to be located radially with respect to drum 2 in such a position that a pullet which is released from shackle 19 at the corresponding angular releasing station, will fall on the slide and slide downwardly to be finally released. Preferably, a mechanical counter is fixed on the slide 30 in such a position that each pullet which slides downwardly on slide 30 , actuates the counter by one increment. Preferably, the counter comprises a lightweight pivoting pallet 31 at the top of slide 30 which is biased to its horizontal rest position by a counterweight 32 . As a bird is released from the shackle it falls on pallet 31 and causes it to deflect. The deflection is counted by a microswitch 33 . The dimension of the pallet is enough to allow birds falling from each direction to be counted accurately.
[0044] The operation is as follows:
[0045] The device according to the invention can be introduced in a poultry farm through normal doors as it can have an external diameter which is less than usual form door width. This also allows transportation on an usual pick-up. Once the device is at the proper place, it provides eight working stations A to H (assuming the drums of FIG. 3 is modified to an octagonal drum). Assuming the cam is located at the angular position corresponding to location H, location H will form the pullet releasing station and the slide 30 will be accordingly located under the drum at location H. As the device is clockwised rotated, the next station, namely A, will be the station where an operator hangs the pullet on the shackle 19 .
[0046] Locations B to G can be used for vaccinators. If needed, location B, which is directly downstream location A, could be used for a second operator to hang a pullet on a shackle. In this event location B will not be available for a vaccinator.
[0047] Once the drum is rotated with a pullet, maintained upside down close to a lateral plate 11 , the pullet will reach a successive station, for example station C, where the vaccinator administers the vaccine, for example, a parenteral or an ocular vaccine. It is easy for the operator to gently press the pullet against plate 11 to maintain it motionless with one hand in order to vaccinate it with the other hand according to any suitable administration route, for example wingweb transfixion or eye drop administration. As the pullet is gently pressed on a flat surface, it would not be stressed as it would on a cylindrical convex drum. Once the pullet reaches location H, the shackle is tilted by the cam and the pullet is released and counted.
[0048] If one of the operators or vaccinators needs to temporarily stop the wheel he just grasps the drum at any location and the drum will stop while the motor and the lower disc will still rotate. As soon as he releases the drum, the slight frictional engagement between plate 8 and 15 will drive the drum to rotate.
[0049] The frame 1 is preferably designed to maintain the drum at a vertical level which allows the vaccinators to seat on foldable chairs at the relevant vaccinating station, instead of standing during the whole vaccination campaign. As an alternative, seats can be directly mounted on the frame.
[0050] The vertical dimension of the drum can be adapted to the size of the bird to be vaccinated. For example, one can provide a drum having a sufficient height for maintaining and vaccinating turkeys or other big birds. In such event the same drum could be used for smaller fowls like pullets. A larger octagonal drum can be provided with large lateral sides, with several shackles per side in order to maintain several birds close to a same plate 11 .
[0051] The device according to the invention gives easy access to all its components. Accordingly it can be readily disinfected before use. Preferably its components are made of easy to disinfect materials, for example stainless steel.
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The bird vaccinating device comprises a frame, a drum or carosel rotatable on a vertical axis on this frame, schackle means for attaching birds, and being angularly spaced on said drum, motor means to rotate said drum, to present the bird successively to different operating stations, wherein said drum has a polygonal shape, preferably octagonal, each lateral side of the polygon providing a flat surface, said schackle means protruding from said surface so that an attached bird can be backed on to this flat surface by the vaccinator for proper vaccination. Preferably means are provided to cause the drum to stop if grasped by a vaccinator and to release automatically the vaccinated bird, preferably on a slide, as well as to count the vaccinated birds.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to provisional application Ser. No. 62/335,782, filed May 13, 2016, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The disclosure relates generally to monomer purification needed to perform chemical reactions. More particularly, but not exclusively, the disclosure relates to a standalone system for purifying reactants with a high degree of purity.
BACKGROUND OF THE INVENTION
[0003] In conventional purification methods, monomers and/or other reactive chemicals are reacted with highly oxidative reagents, i.e. alkyl lithium or alkyl magnesium, forming insoluble salts with the inhibitors and impurities. The monomers are then distilled off and the process is repeated several times until the desired purity is achieved. The use of alkyl lithium or alkyl magnesium, labeled as “highly flammable”, can catch fire spontaneously if exposed to air, can be fatal if swallowed, can cause severe skin burns and eye damage, may cause drowsiness or dizziness, can be very toxic to aquatic life with long lasting effects, and has caused many lab accidents (from minor burns to even deaths) when exposed to air, water, or other protic chemicals. Additionally, conventional cleaning procedures require experienced personal to get best results.
[0004] Therefore, there is a need in the art for a monomer purification system, method, and/or apparatus that purifies monomers and other reagents with a high degree of purity with improved safety, shortened time, and being economical.
SUMMARY OF THE INVENTION
[0005] It is therefore a primary object, feature, and/or advantage of the present disclosure to improve over the state of the art.
[0006] It is another object, feature, and/or advantage of the disclosure to provide an economical and safe system, method, or apparatus for purifying monomers and other reagents.
[0007] It is still another object, feature, and/or advantage of the disclosure to provide a purification system that can be portable.
[0008] It is yet another object, feature, and/or advantage of the disclosure to provide a purification system that purifies reagents in a shortened time.
[0009] It is a further object, feature, and/or advantage of the disclosure to that can be used to purify a broad range of reactive chemicals.
[0010] It is still a further object, feature, and/or advantage of the disclosure to provide a system that does not require dedicated training.
[0011] These and/or other objects, features, and advantages of the disclosure will be apparent to those skilled in the art. The disclosure is not to be limited to or by these objects, features and advantages. No single embodiment need provide each and every object, feature, or advantage.
[0012] The present disclosure presents an economical, standalone system that replaces conventional monomer (and other reactive chemical) purification methods needed to perform chemical reactions (e.g. anionic polymerizations, RAFT polymerizations, ATRP, ROMP) that require reactants with a high degree of purity. Chemical reactions, such as anionic polymerization, can produce highly monodisperse homopolymers and block copolymers, however, to do so they require very high purity reactants along with a moisture, oxygen, and protic free environment.
[0013] The approach uses traditional column purification methods used by industry, but incorporates them into an economical, standalone, compact, and hazard free system. This method is different in view of safety, cost of cleaning procedure, time commitment, space availability, design and operational ease; helping researchers save time by cutting down the operating commitment by 90% and most importantly making it safer. The disclosure also eliminates the concern of dedicating a large amount of lab space for the purification system, giving the user option of collecting the purified monomer air free; all at a very economical and facile way.
[0014] The system according to aspects of the disclosure allows for replacing components (e.g., columns) in an easier and user friendly manner, while reducing the time needed and minimizing the exposure of the components of the system to outside atmosphere. Still further, the disclosure provides for apparatus, systems, and/or methods for refilling the chemical holding reservoir in a way that improves upon what is currently offered.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a depiction of a system used for the purification of monomers (styrene) according to aspects of the present disclosure.
[0016] FIG. 2 is a diagram of a purification system according to aspects of the disclosure.
[0017] FIG. 3 is an isometric view of a column system for use with the purification system according to aspects of the disclosure.
[0018] FIG. 4 is an isometric view of a reservoir refilling system according to aspects of the disclosure.
[0019] FIGS. 5A and 5B are graphs showing 1-Hydrogen Nuclear Magnetic Resonance of styrene monomer before and after passage through a purification system according to aspects of the present disclosure.
[0020] FIG. 6 is a graph showing Size Exclusion Chromatography of polystyrene synthetized via anionic polymerization from styrene purified through the purification system, methods, and apparatus of the present disclosure.
[0021] Various embodiments of the invention will be described in detail with reference to the drawings, wherein like reference numerals represent like parts throughout the several views. Reference to various embodiments does not limit the scope of the invention. Figures represented herein are not limitations to the various embodiments according to the invention and are presented for exemplary illustration of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 shows a depiction of an exemplary purification system 10 according to aspects of the disclosure that is used to purify monomers, such as styrene. Accordingly, the purification system 10 comprises an enclosed system containing a reservoir tank 12 , one or more activated alumina columns/column systems 14 or other types of cleaning agents, as will be disclosed, and a series of valves connected through high pressure rated stainless steel tubing. An exemplary set up of a purification system 10 is shown in FIG. 2 . The system 10 facilitates purging, collecting and storing the purified contents air and moisture free. Moreover, this system 10 can be easily carried around on a small cart that can be on wheels or other means for easy movement of the system and can be stored in chemical storage freezers.
[0023] An aspect of the purification system 10 of the present disclosure provides that the system is refrigerated during operation. The refrigeration of the system prevents or otherwise mitigates the reaction of the reagents (e.g., monomers) being purified by the components disclosed herein. The columns and cleaning agents 14 associated therewith will remove inhibitors associated with the reagents and the refrigeration will mitigate these inhibitor-free materials from reacting. As will be understood, a refrigerant tank or other source 16 can be operatively connected to the system 10 to provide for the refrigeration of the system, which allows for the purification of the reactive chemicals without the volatile inputs of conventional purifying system. The purification system 10 could be refrigerated in a number of ways. Furthermore, the unit could be built into a small refrigerated unit which will be on wheels for mobility.
[0024] Many monomers and/or other reactive chemicals are shipped from suppliers loaded with good amount of inhibitors. These inhibitors would prolong the life of the material by preventing side reactions and auto-polymerization side effects. According to aspects of the present disclosure, the packed columns 14 may have some uninhibited monomer susceptible to side reactions and cause damage to packing in the column (most of the cases the column should just be replaced with a new one). Tests of the purification system of the present disclosure have been successful in keeping the column safe from side reactions and also store the monomer in the reservoir in safe conditions by storing the whole system in a refrigerator.
[0025] As shown in FIG. 2 , the reservoir tank 12 contains an amount of a monomer to be purified by the system 10 . The reservoir 12 can be generally any holding device for holding an amount of material (i.e., monomer) that is to be purified via the system. The reservoir tank 12 shown in the figure can hold approximately 1-2-gallons. It is a stainless steel tank equipped with inlet and outlet (with gas sparger) valves 19 , 20 , a pressure relief valve 21 , and a handle to facilitate input of the monomer to be cleaned, inert gas purging, output of the monomer to columns, and maintain air-tight environment for extended periods of time. There may also be one or more additional valves that can be used, in part, for refilling the reservoir 12 . Any tank 12 with capabilities can be utilized as part of the present disclosure. An inert gas 24 , such as argon as shown in the figure, is operatively connected to the reservoir 12 . For example, steel tubing can be used to connect the inert gas 24 and the reservoir 12 , with one or more valves positioned therebetween to control the flow/pressure of the inert gas. A pumping mechanism, such as any type of pump, can be included to aid in controlling the flow of the inert gas into and/or through the system. The connection between the gas source 24 and the purification unit 10 can be via quick connects to allow for quick and easy hookup of the system to perform the purification process. However, it should be appreciated that other types of connectors used with gases and/or liquids could be used as part of the present disclosure. Furthermore, it is contemplated that the quick connects be utilized with the columns to be able to swap out columns as needed. For example, the columns will have a life span and after which, they will need to be refurbished or otherwise replaced. Utilizing the quick connect couplings would allow the columns to be quickly removed and replaced without much downtime.
[0026] For example, FIG. 3 shows an isometric view of a column system 14 according to aspects of the disclosure. As shown in FIG. 3 , the columns 15 holding the adsorbent material can be replenished/replaced after they are spent (meaning the adsorbent material gets exhausted and needs to be replaced with new adsorbent material). To ease the column replacement process for the user, reduce the time needed to replace the columns 15 , and minimize the exposure of the system to outside atmosphere (system should always be maintained inert), the disclosure includes a method of column replacement. Columns 15 containing the adsorbent material are connected to the system 10 using a sequence of valves 18 and quick connects 26 . Spent columns can be removed from the system by operating the quick connects 26 . Presence of quick connects 26 makes it easy to remove the columns 15 from the system 14 . Once the spent columns 15 are removed, the purification system is shut-off up to the point 17 because of the presence of three-way valve 28 as shown in the Figure. New columns will be sealed by pressurizing the columns with inert gas. The user connects the new columns to the system via the quick connects 26 , opens the three-way valve 28 to exhaust and opens the two-way valve 30 on the new columns. The pressurized inert gas will purge the exposed lines. Once the purge is completed, the valves will be directed in a way to guide the chemical flow into the columns and the system is ready to be used again.
[0027] The columns 15 comprise a stainless steel tube with two caps positioned at each end. For example, the caps can be welded or screwed at each end, or can otherwise be positioned. The columns 15 for use with the disclosure as presently disclosed can be fabricated on an as-needed basis, or can purchased already made and generally ready-to-use.
[0028] Returning to FIGS. 1-3 , it is contemplated that the columns used in the disclosure could incorporate different cleaning agents, as will be understood. Particular cleaning agents/column combinations could be better used to purify particular reagent/inhibitor combinations. Therefore, according to some aspects of the disclosure, the columns could be swapped out via the quick connects to pair the desired cleaning agent with the reagent that is being purified with the system disclosed herein.
[0029] However, it should also be appreciated that the quick connects not be utilized in all embodiments, and traditional connection methods (clamps, nut and bolts, etc.) could also be utilized with the system disclosed.
[0030] The inert gas is used to push the chemical stored in the reservoir through the purification system. The use of an inert gas ensures that the interaction between the inert gas and the chemical to be purified will not interact to contaminate the chemical. As inert gases are non-reactive, they are ideal to be used to aid in moving the purifying chemical through the system.
[0031] The valves of the system are generally one-way valves that prevent the backflow of the inert gas, the chemical to be purified, and/or any combination of the same from flowing backwards through the system. The number of valves used can be determinative upon many factors, including, but not limited to, the size of the system, the amount of product (chemical) to be purified, the required pressure to move through the system, the inert gas used, the type of chemical to be purified, the temperature of the system, among others. For example, it may be desired to maintain a pressure in the system during the purification process. Having more valves allows for smaller segments of pipes to be pressurized, which reduces the pressure burden of the system. This also provides a failsafe, should one or more of the valves fail. The valves may be check valves, butterfly valves, ball valves, diaphragm valves, solenoids, angle valves, or any combination of the same. It should be noted that the system can become automated with the use of solenoids connected to an intelligent control, such as a central processing unit (CPU), server, or other computing device. A user interface could also be connected to the intelligent control to aid in the automation process.
[0032] It should also be appreciated that the system could include, at either or both of the inlet and the outlet ports to attach to a Schlenk line or other vacuum gas manifolds.
[0033] Also shown in FIGS. 1-3 are first and second activated alumina columns 14 a, 14 b. While two of the columns are shown in the figure, it should be appreciated that this is not a requirement for the disclosure, and instead, the setup is shown for exemplary purposes. As will be appreciated, the number of columns may be determined based upon the particular use/need of the purification system, and can include generally any number of columns to complete the purification process.
[0034] As disclosed, the columns can comprise activated alumina. Activated alumina is manufactured from aluminum hydroxide by dehydroxylating it in a way that produces a highly porous material; this material can have a surface area significantly over 200 m 2 /g. The compound is used as a desiccant (to keep things dry by absorbing water from the air) and as a filter of fluoride, arsenic and selenium in drinking water.
[0035] While alumina columns are shown in the figures, it should be appreciated that other types of cleaning agents could be used in place thereof. For example, it is contemplated that oxygen scavengers (Q5 catalyst), silica sand, molecular sieves, silica gel, etc., could be used in place of or in conjunction with the alumina columns. Still further, it is to be appreciated that other types of “cleaning agents” that are able to purify monomers, reactants, and/or other chemicals could be used and should be considered as part of the disclosure.
[0036] Still further, the disclosure provides for methods, apparatus, and/or systems for refilling the reservoir 12 of the purification system 10 . As shown in FIG. 1 , the reservoir tank 12 connected to the columns 14 a, 14 b holds the chemical to be purified. When the level of reservoir tank 12 reaches approximately 10% of the total volume, a new batch of chemical can be added using a siphon pump mechanism 32 . To enhance the safety of the system, the tank 12 has been designed as a completely enclosed system with no lids. Because of this, new batch of chemical should be input to the system via use of a hand operated siphon pump 32 . The pump 32 has attachments that can be secured directly to the chemical bottle and can input a gallon of chemical in as little as 3-minutes.
[0037] Initial tests on the purity of the monomer were done using hydrogen nuclear magnetic resonance ( 1 H-NMR), see FIGS. 5A and 5B , where the bottom spectra shows the reduction in intensity of the inhibitor at around 1.5 and 7.2 ppm. FIG. 5A includes 1H-NMR showing styrene (H c ) and 4-tert-butylcatechol (BHT, stabilizer) (H a and H b ) before passing through the purification unit. All unlabeled peaks correspond to styrene. FIG. 5B includes 1H-NMR showing styrene (Hc) and 4-tert-butylcatechol (BHT, stabilizer) (Ha and Hb) after passing through the purification unit. All unlabeled peaks correspond to styrene. Size exclusion chromatography (SEC), see FIG. 6 , was done after polymerizing the purified monomer using anionic polymerization showing a single narrow peak (low polydispersity, no secondary shoulders) with targeted molecular weight achieved.
EXAMPLE
[0038] A purification system was assembled and used for testing. The testing was for the purification of monomers. Table 1 lists dates the monomer purification system was used to dispense monomer, styrene, used for anionic polymerizations; and it also lists the targeted and obtained molecular weight of the polymers. These numbers show that the system, after 21 months, still is capable of purifying the monomer for anionic polymerization purposes.
[0000] TABLE 1 List of different polystyrene anionic polymerization reactions with the target and the obtained molecular weights are listed. Poly(Styrene) Target Poly(Styrene) Obtained Date Molecular Weight, [Da] Molecular Weight, [Da] June 2014 15,000 15,000 July 2014 13,900 14,900 July 2014 14,000 17,000 September 2014 12,700 12,700 September 2014 13,500 16,000 December 2014 54,000 50,000 March 2015 15,000 15,500 April 2015 15,000 16,000 February 2016 2,000 2,000 March 2016 2,000 2,200
Table 1 List of different polystyrene anionic polymerization reactions with the target and the obtained molecular weights are listed.
[0039] Therefore, the system as shown and described provides for the purification of a chemical, such as a monomer, that improves on or provides advantages over that previously known. In addition, the system of the present disclosure also greatly reduces the amount of time for the process. It has been shown that the purification process using aspects of the present disclosure can be completed in 0.5-1 hour, while conventional methods have taken 8-10 hours.
[0040] The compactness of the system provides additional advantages. This would allow the system to be standalone and portable, such that it can be easily implemented into a lab, while taking up a fraction of the space when compared to traditional processes.
[0041] Additional aspects of the system include that the process could be adapted to use the process for a broad range of reactive chemicals, including monomers.
[0042] It should also be noted that, while the disclosure has included the example of styrene herein, it is to be appreciated that generally any type of reactive chemical and/or reactant could be purified via the disclosed. The disclosure should not be limited to the purification of certain types of chemicals and instead, should be considered for substantially any and all purification.
[0043] Therefore, a system, method, and/or apparatus for purifying monomers has been shown and described. It is to be appreciated that any number of changes be contemplated by the disclosure, and that the disclosure need not be limited to the exemplary aspects disclosed herein. That which has been described is merely exemplary. The present invention contemplates numerous variations, options, and alternatives fall within the spirit and scope of the invention.
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Herein disclosed is an economical standalone system that replaces conventional monomer purification methods needed to perform chemical reactions that require reactants with a high degree of purity. Chemical reactions, such as anionic polymerization, can produce highly monodisperse homopolymers and block copolymers, however to do so they require very high purity reactants along with a moisture and oxygen free atmosphere. The system and method uses traditional column purification methods, but incorporates them into an economical, standalone, compact, and hazard free system. This method is different in view of safety, cost of cleaning procedure, time commitment, space availability, design and operational ease; helping researchers save time by cutting down the operating commitment by 90% and most importantly making it safer.
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CLAIM FOR PRIORITY
[0001] This application claims priority to International Application No. 10235013.2 which was filed in the German language on Jul. 31, 2002, which is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a method for determining a boost pressure setpoint in an internal combustion engine, and in particular, an internal combustion engine with an exhaust gas turbocharger.
BACKGROUND OF THE INVENTION
[0003] In combustion engines with exhaust gas turbochargers and wastegate, the boost pressure is controlled through the bypass in the exhaust gas duct being opened or closed to varying degrees. The exhaust gas mass flow through the turbine, and hence the turbine power output, varies depending on the position of the wastegate. Depending on the varying turbine power output there is a change in the compressor power output and hence the boost pressure.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a method for determining a boost pressure setpoint in an internal combustion engine, and in particular, an internal combustion engine with an exhaust gas turbocharger which has a bypass line running parallel to the turbine in the exhaust gas duct, the bypass line having a wastegate which is set via a pneumatically operated actuator.
[0005] The invention also relates to types of internal combustion engines in which the pressure actuator for the wastegate is controlled pneumatically by means of air from the compressor. As a result of this control of the pressure actuator, a situation can arise in which there is not sufficient boost pressure present to control the wastegate. In this case, the boost pressure is no longer sufficient to open the wastegate, with the result that the power output from the compressor cannot be reduced.
[0006] The invention provides a method for controlling the boost pressure, particularly to provide a boost pressure setpoint, in an internal combustion engine in order to enable reliable and stable control of the boost pressure.
[0007] In one embodiment according to the invention, the setpoint for the boost pressure is limited to a minimum value when the wastegate is deactivated. According to the invention, the minimum value is made up of the sum of the environmental pressure and one or more pressure constants. In the invention, the control of the internal combustion engine is limited to the extent that a minimum setpoint for the boost pressure is determined. The minimum value depends on the environmental pressure, the setpoint for the boost pressure not being less than the environmental pressure. The further pressure constants which are taken into account for determining the minimum pressure are dependent on the actual design of the exhaust gas turbocharger, more particularly of the actuator for the wastegate. The invention maintains the boost pressure at a minimum pressure which provides a certain basic power for the system. The basic power ensures that the wastegate is in a closed state such that a sufficiently large pressure is built up in front of the turbine wheel so that the turbine power output which is then delivered is great enough to produce an increase in pressure in the compressor which is used mainly to boost the internal combustion engine but also acts in turn as control pressure for the actuator.
[0008] Another embodiment of the invention determines the basic boost pressure which is produced even when the wastegate is actuated via, for example, an electrical or hydraulic wastegate actuator or a pressure actuator which is open in the pressureless state. In these cases, an increase in pressure will generally arise via the wastegate, leading to an undesirable boost pressure (basic boost pressure). This increase in pressure is explained also by the throttle effect of the open wastegate.
[0009] In a preferred embodiment of the invention, a speed-dependent basic value is added to the environmental pressure. The speed-dependent basic value is preferably generated by a characteristic curve recorded for a reference system.
[0010] An additional pressure constant is preferably determined with the throttle valve open and the wastegate closed, the additional pressure constant being added to the value for the environmental pressure and the basic value. The additional pressure constant ensures that the setpoint does not drop so far that no further control can be effected.
[0011] In a preferred embodiment of the invention, the additional pressure constant is corrected adaptively as a function of the measured boost pressure. The adaptive correction of the additional pressure constant ensures that the difference between boost pressure actual value and boost pressure setpoint does not diverge as a result of a limitation over time.
[0012] A diaphragm box which is controlled by overpressure and underpressure and which is mechanically linked to the wastegate is preferably used as an actuator for the wastegate. Pressure can be applied to different sides of a diaphragm box of this type, with the result that the movement of the diaphragm is converted into the setting of the wastegate. The pressure box is preferably pretensioned toward the closed wastegate position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Exemplary embodiments of the invention are explained in more detail below with reference to the drawings, in which:
[0014] [0014]FIG. 1 shows a schematic view of an internal combustion engine with exhaust gas turbocharger.
[0015] [0015]FIG. 2 shows a schematic view of a wastegate with pressure diaphragm box.
[0016] [0016]FIG. 3 shows the invention as a block diagram.
[0017] [0017]FIG. 4 shows a schematic view of a switching valve.
DETAILED DESCRIPTION OF THE INVENTION
[0018] [0018]FIG. 1 shows a schematic view of an internal combustion engine 10 . At the beginning of the intake duct the incoming air is filtered (air filter 12 ) and can be measured via an air mass sensor 14 . A turbocharger compressor 16 is placed downstream in the intake duct, followed by a boost air cooler 18 and optionally by a second air mass sensor 20 . A reflow channel 22 is provided parallel to the compressor 16 . The reflow channel 22 is varied in terms of its throughflow rate via a reflow flap which may also be implemented as a reflow valve.
[0019] Located downstream from the second air mass sensor 20 is a throttle valve 22 which controls the air mass entering the internal combustion engine 10 . The second air mass sensor 20 also is merely optional. A proportion of exhaust gas can be mixed with the compressed air introduced into the internal combustion engine via an exhaust gas recirculation unit 26 . The exhaust gas proportion is dependent on the position of an exhaust gas recirculation valve 28 .
[0020] An exhaust gas turbine 32 is provided in the exhaust gas duct 30 . It is understood that the exhaust gas turbine 32 is mechanically linked to the compressor 16 , wherein the power extracted from the exhaust gases is converted with mechanical losses into a compressor power output 16 . An additional secondary air inlet 34 can be provided up-stream of the turbine 32 .
[0021] Provided in the exhaust gas duct 30 and running parallel to the turbine 32 is a bypass line 36 , through which parts of the exhaust gases or mixture of exhaust gases and secondary air can be directed past the turbine 32 . The amount of air directed past is determined by a wastegate 38 . If the wastegate 38 is closed, this leads to a maximum exhaust gas flow through the turbine 32 , which then leads to a maximum compression of the fresh air in the intake duct. The boost pressure is increased as a result. If, on the other hand, the wastegate 38 is opened to the maximum, as many exhaust gases as possible flow through the bypass channel 36 , whereupon the turbine power taken up by the turbine 32 drops. In parallel with this there is a decrease in the power delivered by the compressor 16 and consequently in the boost pressure.
[0022] [0022]FIG. 2 shows the actuation of the wastegate 38 in schematic form. The wastegate 38 possesses a wastegate flap 40 which covers an inlet opening 42 . Toward that end, the flap 40 is mounted about a swiveling axis 44 .
[0023] The varying distance between the throttle flap 40 and the opening 42 produces a reduced throughflow area in terms of flow rate, with the result that a varyingly large proportion of the exhaust gases flows through the bypass line 36 .
[0024] The wastegate flap 40 is mechanically linked to a diaphragm box 46 . The diaphragm box 46 has two mutually separate chambers 48 and 50 to which pressure is applied via the lines 52 and 54 . Additionally provided in the chamber 48 is a spring 56 which is in contact with a diaphragm 58 separating the chambers 48 and 50 . The diaphragm 58 is linked to the wastegate flap 40 on the side facing the chamber 50 via a push rod 60 . In response to an actuation of the push rod 60 the retainer arm of the wastegate flap 40 swivels about the swiveling axis 44 .
[0025] In the position in which pressure is not applied, the diaphragm 58 is pretensioned by the spring 56 such that the spring resistance and the power of the exhaust gases flowing through the opening 42 act upon the throttle valve 40 . The wastegate position results from the equilibrium of forces arising from spring resistance 56 and exhaust gas pressure force.
[0026] If a pressure difference is now applied to the two chambers, the pressure force exerted on the wastegate flap 40 increases or reduces, leading told change in the position of the throttle valve. Pressure is applied to the chambers of the diaphragm box for example by means of timing valves which are controlled by means of pulse width modulation. The timing valves can be designed such that they switch back and forth between a high pressure value, for example the boost pressure, and a low pressure value, for example the environmental pressure. In an alternative embodiment it is also conceivable that operation switches back and forth between a low pressure value, for example lower than the environmental pressure, and the environmental pressure or a higher pressure value. Thanks to the pulse width modulation, virtually any pressure value between the low and the high pressure value can be applied to each chamber.
[0027] [0027]FIG. 3 shows the execution sequence of the method according to the invention. A value of a basic boost pressure 64 is added to a measured value of the environmental pressure 62 . The basic value is determined with the aid of a reference system and is dependent on the speed 66 . The sum of environmental pressure and basic value leads to a minimum value 68 for the boost pressure. An additional pressure constant 70 is added to the sum of the values 62 and 64 . The additional pressure constant 70 is determined iteratively, so that in the illustrated nth step of the method the additional pressure constant from the (n−1)th iteration step is added.
[0028] The minimum boost pressure value 68 ensures that when the timing valves are used there is a sufficient pressure difference between boost pressure and environmental pressure to ensure that the wastegate flap can be controlled.
[0029] In order to determine the additional pressure constant, the sum of environmental pressure and basic value is reduced by the current boost pressure 72 . The additional pressure constant 74 for the nth step is formed from the standard deviation formed in this way as a function of the speed 66 . For this purpose the pressure constants are stored in a characteristic map 76 .
[0030] The additional pressure constant 74 is determined in the case where both the throttle flap is open and there is control of the timing valves. This condition is specified by the pressure quotient 78 at the throttle valve. The condition for the open throttle valve results in this case from the fact that the pressure quotient at the throttle valve is greater than a predetermined constant. By suitable redefinition of the pressure quotient it is of course possible that this condition can also be formulated as a comparison to determine whether the pressure ratio is less.
[0031] The control of the timing valves is determined in that their control signal 82 is compared with a constant 84 . The additional pressure constant 74 is calculated in the case where the throttle valve is open and the actuator for the wastegate is controlled via the control valves. To this end, both conditions are applied to a switch 86 via a logical AND operation. If a signal is present at the center input of the switch 88 , the control difference is forwarded to the characteristic map 76 . If not, the determination of the additional pressure constant is omitted.
[0032] [0032]FIG. 4 shows an example of a timing valve 90 which can be used to apply different pressures to the chambers 48 and 50 . In the position shown in FIG. 4, the output line 92 of the timing valve 90 , which operates according to the principle of a switching valve with two inputs and one output, is linked to its input line 94 . In the second setting, the input line 96 is linked to the output line 92 . If different pressures are now applied to the two input lines 94 and 96 , any intermediate value can be generated at the output line 92 by means of appropriate switching back and forth between the first and the second position.
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The invention relates to a method for determining a boost pressure in an internal combustion engine having an exhaust gas turbocharger in which a wastegate is actuated via the compressed boost air. Since a basic force is required in order to enable actuation of the wastegate, the setpoints for the boost pressure are limited to a minimum value.
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FIELD OF THE INVENTION
This invention relates to a method and system for controlling the amount of formation fines that are produced from a heavy oil reservoir that is stimulated by thermal means and is penetrated by and in communication with a well that is highly deviated from the vertical.
BACKGROUND OF THE INVENTION
This invention is concerned with producing hydrocarbons from hydrocarbon-bearing formations. More particularly it is concerned with controlling the amount of particulate matter, often referred to as sand, formation fines, or fines which are produced along with hydrocarbons from a hydrocarbon-bearing formation into a well that penetrates and communicates with the hydrocarbon-bearing formation.
There are many methods and equipment available for reducing or preventing the production of fines along with fluids and in particular along with hydrocarbons that are produced from earth formations into a well that penetrates the formation. Such methods and equipment include the use of sand screens, filters, perforated liners and slotted liners. Such equipment may be subjected to high temperatures and fluids having low and/or high pH values. Such conditions are encountered particularly when fluids are produced from hydrocarbon-bearing formations that are stimulated by thermal recovery techniques, such as steam and fire secondary and tertiary techniques. Also, fluids such as acids are often injected down a well and out through such equipment and into the formation to clean the equipment and/or the formation that communicates with the well.
A device for controlling the production of fines into a well is described in U.S. Pat. No. 4,811,790 which device is resistant to shock and which can withstand harsh conditions encountered with thermal enhanced oil recovery techniques. This device is referred to hereafter as a "refractory tube".
SUMMARY OF THE INVENTION
This invention is directed to a method and system for controlling the production of fines from a heavy oil reservoir that is stimulated by thermal means and which reservoir is penetrated by a wellbore. A wellbore is formed which has a first portion that extends essentially vertically from a surface location into the earth's crust, and a second portion that extends from the first portion and is deviated from the first portion at an angle of sixty degrees or greater which second portion extends into the heavy oil reservoir. The wellbore is thereafter cased to provide a well for producing hydrocarbons from the reservoir. A production string is extended down the well which production string has a first vertical portion and a second portion connected to the lower end of the first portion. The second portion of the production string is formed of flexible tubing and is deviated to conform with the second portion of the wellbore and has connected therein at least one refractory tube.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an embodiment of this invention for controlling fines produced into a highly deviated well.
FIG. 2 is a schematic view illustrating other embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention is directed to a technique of completing a wellbore that is drilled into a hydrocarbon reservoir to control or reduce the amount of formation fines, sometime referred to as fines or sand, that is produced or transported along with fluids from the reservoir into the wellbore. More particularly this invention is directed to controlling the production of fines from a heavy oil reservoir that is stimulated by thermal means and which reservoir is penetrated by a wellbore completed as a well that is deviated from the vertical at an angle of sixty degrees or greater.
Earth formations which contain viscous hydrocarbons are often referred to as heavy oil reservoirs. Such heavy oils often have an API gravity less than 15 and have a viscosity that is sufficiently high that production of such heavy oils from the reservoir without assistance by some secondary recovery means is difficult and slow and may be uneconomical. Thermal secondary recovery means is often used inasmuch as heat, which may be introduced, for example, by injecting steam into the reservoir or conducting a fire flood both lowers the viscosity of the heavy oil and provides secondary energy that assists in producing the heavy oil from the reservoir into a well.
For a more detailed description of the invention reference is made to FIG. 1 wherein there is shown a schematic view of a wellbore 1 that is extended through overburden earth formations 3 and penetrates a heavy oil reservoir 5. A first portion 7 of the wellbore 1 is shown schematically extending essentially vertically from the earth's surface (not shown) and a second portion 9 of the wellbore 1 extending from the first portion 7 at an angle of 60 degrees or greater into the heavy oil reservoir 5. In FIG. 1 the second portion 9 of the wellbore 1 is shown extending from the first portion 7 an an angle of about 90 degrees into the heavy oil reservoir 5. This configuration is sometimes referred to as a horizontal well. Within wellbore 1 there is shown a production or tubing string 11 that extends down the vertical portion of the wellbore and into the second deviated portion of the wellbore. The production string is comprised of a first vertical portion 13 and a second deviated portion 15. The second deviated portion 15 of the production string is formed of flexible tubing. Suitable flexible tubing that can be used in accordance with this invention is marketed under the name of COFLEXIP and can be obtained through Coflexip & Services Inc., 7660 Woodway, Suite 390, Houston, Tx 77063. The second deviated portion of the production string has at least one refractory tube 17 connected thereto through which hydrocarbons can flow from the heavy oil reservoir 5 into the production string 11 through perforations 20 and be produced to the surface of the earth and recovered. A guide shoe 19 will normally be connected to the lower end of the second deviated portion of the production string to seal the lower end thereof such that fluids that flow from the heavy oil reservoir into the wellbore will flow through the refractory tube to enter the production string. The second deviated portion of the production string ma be made up of multiple refractory tubes interconnected by flexible tubing in order to efficiently produce the heavy oil reservoir.
The wellbore 1 will normally be cased and completed in a conventional manner. Centralizers such as bow spring centralizers 21 will normally be used to space the production tubing from the well or casing wall.
With reference to FIG. 2 there is provided a schematic illustration of other embodiments of this invention. A wellbore 23 is shown extending from the earth's surface 25 through earth overburden 27 and penetrating a heavy oil reservoir 29. The first portion 31 of the wellbore 23 extends essentially vertically from the earth's surface to a kickoff point 35 where a second portion 33 of the wellbore deviates from the first portion 31 at an angle of 60 degrees or more. The second portion 33 of the wellbore extends into the heavy oil reservoir 29 and is deviated at a sufficiently high angle such that it exits through the uppermost portion of the heavy oil reservoir and into the earth overburden 27 where it is then deviated downward to repenetrate the heavy oil reservoir 29 and extend therethrough and may exit the lower portion of the heavy oil reservoir. A method of providing such a wellbore is shown in U.S. Pat. No. 4,386,665 and the subject matter thereof is incorporated herein by reference. In accordance with this invention the wellbore 23 is completed by using flexible tubing with refractory tubes interspersed therein as previously described with reference to FIG. 1.
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This specification relates to the control of earth fines that are produced with hydrocarbons from a hydrocarbon-bearing formation into a well that penetrates the hydrocarbon-bearing formation. More particularly this specification relates the control of fines from a heavy-oil reservoir that is stimulated by thermal techniques and penetrated by and in communication with a well that is highly deviated from the vertical.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to athletic footwear in general and more specifically to stiffening means for stabilizing pronation of the foot by providing support to the rear half of the first metatarsal bone.
2. Description of the Prior Art
The stabilization requirements of feet differ from foot to foot and from activity to activity. Present day shoe design does not adequately cover the range of variability. In consequence, devices such as arch supports and heel cups are expected to do more than should be expected of them insofar as stabilizing the foot is concerned. Flexible devices are often inadequate, while rigid devices are often uncomfortable and therefore intolerable for athletic use.
Most devices employed to stabilize the foot are designed for street shoes. However, problems of foot instability are more apparent and are more frequently encountered in connection with jogging, running and other athletic sports.
During the course of the last few years several devices have been disclosed for improving the stability of athletic shoes. This may be the result of an increased interest in running sports. For example, U.S. Pat. No. 3,992,788 issued to William P. Orien discloses an athletic shoe structure which features padded subtalar support and relatively dense sole construction under the subtalar joint. Edward H. Phillips, in U.S. Pat. No. 4,155,180 discloses a running shoe featuring compressible orthotic support upon a rigid base situated in the rearfoot and shank portions of the sole.
U.S. Pat. No. 3,466,763 issued to Victor Herbert Levin discloses a football shoe of interest including a combined heel counter and lateral counter. U.S. Pat. No. 3,726,287 issued to Simon J. Wikler discloses a construction of medial and lateral abutments adapted to prevent the foot from sliding in the shoe. Of particular interest is the lateral abutment situated by the shaft of the fifth metatarsal bone. U.S. Pat. No. 3,145,486 issued to Constantinos Petalas discloses a shoe having a combined counter support and insole.
U.S. Pat. Nos. 3,997,984 and 4,112,600 issued to George J. Hayward disclose an athletic shoe which provides wide medial arch support and which tends to inhibit pronation by means of a flexible sole which extends fully under the medial arch, curves upwardly in that region and includes a medial heel wedge.
Outer soles for running shoes are known to include a variety of stability aiding features. In U.S. Pat. No. 4,130,947 the inventor, Francis Denu, discloses a sole with deep transverse ribs. U.S. Pat. No. 4,098,011 issued to William J. Bowerman discloses a sole including large medial and lateral cleats on the heel and ball of the shoe. The Osaga Model KT-26 running shoe includes elongated side cleats perpendicular to the perimeter of the sole. Hiking shoes have long been made with this feature. The outer sole of the Adidas "tobacco" Model, a casual shoe, has greater continuity in the medial arch region than elsewhere.
The advantages of different distributions of midsole compressibility are set forth in U.S. Pat. No. 3,103,931 issued to Hans C. Knellwolf and in U.S. Pat. No. 3,738,373 issued to John J. Glancy.
While various prior art shoes disclose some features which assist in stabilizing pronation, none of them appear to disclose the specific features of the present invention which provide support for the rear half of the first metatarsal bone.
SUMMARY OF THE INVENTION
The act of walking or running includes several phases. Pronation is one of the normal phases of gait found in walking or distance running. In these activities, pronation is the means by which the foot absorbs shock. No shoe sole of conventional thickness can absorb all, or nearly all, of the force of a vigorous foot strike. Thus, pronation should not be abnormally restricted because a certain amount of it is healthy and useful. Problems associated with pronation should be treated by the use of footwear which affords stability for the foot structures throughout that phase of gait.
The running shoe of the present invention has a basic structure in which the shank of the shoe is shaped and stiffened so as to provide stable support for the rear portion of the first metatarsal bone. In addition, the upper may be reinforced and an insert provided to further insure stability. In running shoes and in most other athletic shoes the shank is not stiffened. Some running shoes do include a stiff shank. Such shoes tend to be stiff overall even at the ball of the foot. This invention, by contrast, includes specific stiffeners while allowing flexibility where it is otherwise required to achieve an overall stabilizing effect.
Unlike basic orthopedic shoes and most running shoes, the shoe of this invention is constructed to meet changing requirements during gait cycle. In particular, the sole is moderately compressible on the lateral side to provide a gentle landing and stiffer under the medial arch in order to resist inward rotation of the foot and shoe. Also, the shoe is unusually wide under the first metatarsal bone in order to provide improved stabilization when the foot is pronated.
This invention permits even a relatively weak foot to be supported in a stable manner through soft cushioning inside the shoe. Also, by means of a strong lateral counter, it overcomes the common problem of lateral slipping of the foot caused by support for the medial arch.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a bottom perspective view of an athletic shoe adapted for wear on the right foot according to the preferred embodiment of the invention.
FIG. 1B is a cross-sectional view of the preferred embodiment illustrated in FIG. 1A, together with an insert to provide special support for the navicular bone. The cross-section is at the level of the navicular bone.
FIG. 1C is a skeletal view of the bones of the right foot as seen from below (plantar projection) in which some of the bones are emphasized for clarity.
FIG. 2A is a bottom plan view of the shoe of FIGS. 1A and 1B illustrating the relative location of the large medial cleat with respect to the rear half of the first metatarsal bone.
FIG. 2B is a longitudinal cross sectional view of the bottom sole of FIG. 2A showing a stiffening element included in the medial arch cleat.
FIG. 3 is a top plan view of the upper surface of the midsole of the shoe of FIGS. 1A and 1B contrasted with that of a conventional running shoe, shown with the bone structure of the right foot superimposed thereon.
FIG. 4 is a side elevational view of the medial portion of a running shoe which includes an add-on stiffening component to widen and stiffen the medial border of the shank of the shoe.
FIG. 5 is a schematic representation of average densities of the midsole of the preferred embodiment of the invention as shown in FIGS. 1A and 1B.
FIG. 6A is a cross sectional view of an adjustable midsole of an alternative embodiment as seen from above, showing cavities for the reception of removable stiffeners and one stiffener in a cavity.
FIG. 6B is a cross sectional view of a cavity such as found in the adjustable midsole of FIG. 6A showing the insertion of a removable stiffener into the cavity by means of a suitable tool.
FIG. 6C is a cross sectional view of an adjustable midsole as shown in FIG. 6A which discloses a tool and method for removing a removable stiffener from the cavity.
FIG. 7 is a side elevational view of the lateral portion of a shoe showing a lateral counter-shank stiffener included thereon.
FIG. 8A is a top plan view of the upper surface of the shoe insert of FIG. 1B which is rigidly reinforced in the region of the navicular bone, shown in relation to the bone structure of the right foot and to the supporting surface of the shoe sole.
FIG. 8B is a side elevational view of the medial portion illustrating the form and location of the insert illustrated in FIGS. 1B and 8A.
FIG. 8C is a side elevational view of the lateral portion further describing the nature and location of the insert illustrated in FIGS. 1B and 8A.
FIGS. 9A and 9B illustrate an embodiment of the invention in which the medial arch cleat and the medial stiffener are continuous and integral as shown in the context of the two different perspective bottom views of a left foot athletic shoe.
FIGS. 10A and 10B illustrate an embodiment of the invention in which the heel counter is continuous and integral with the lateral counter and medial counter.
DETAILED DESCRIPTION OF THE INVENTION
During the course of this description like numbers will be used to identify like elements according to the different drawings which illustrate the invention.
The foot bones of concern in this invention are illustrated in detail in FIG. 1C. FIG. 1C is the plantar view of the right foot 100, that is to say, the view of the bone structure that would be seen if the bones could be viewed from below. The bones which are included in the articular structure of the big toe include the distal phalanx 48, the proximal phalanx 46, and the first metatarsal bone 40. The first metatarsal bone 40 includes a posterior base 42, an anterior head 44 and a shank 62. The navicular bone 50 is situated two bones behind the first metatarasal bone 40. It is a primary concern of the present invention to provide stable support to the rear half of the first metatarsal bone 40 including the posterior base 42 thereof, and in many cases to the navicular bone 50. In order to support the first metatarsal bone 40 and the navicular bone 50 in the manner described it may be necessary to additionally provide a lateral counter because of foot slippage. The bones that would be affected by the preferred lateral counter are the cancaneous or heel bone 90, the cuboid bone 92, and the fifth metatarsal bone 94.
The preferred embodiment of the invention is in the context of a running shoe 10. It may be basically understood with reference to FIGS. 1A and 1B. The outer sole 12 includes a large medial arch cleat 14, several transverse first toe cleats 16 and numerous complementary cleats 18. Outer sole 12 is combined with a medial shank stiffener 24 which is also indicated in phantom by the dotted lines 24 of FIG. 2A. The midsole 20 is shaped so that its upper surface extends fully under the first metatarsal bone 40 as shown on the anatomical drawing of FIG. 1C.
The midsole of the midfoot region includes a moderately firm region 26 and a complementary comparatively soft lateral region 28. The shoe upper 22 has heel counter reinforcement 25 and is additionally reinforced by means of a lateral counter 30 such as shown in FIG. 7. Lateral counter 30 also serves to longitudinally stiffen the lateral border of the shoe sole in the shank region thereby giving it substantial additional stiffness against forces perpendicular to the longitudinal axis of the shoe. The foot of the wearer rests on cushioning 38 found inside of shoe 10. An optional insert 32 is recommended if the foot has a collapsed or loosened arch. Option insert 32 includes a rigid base 34 under cushioning 38 for the support of the navicular bone 50 shown in the anatomical diagram of FIG. 1C. A lateral and backward continuation 36 of base 34 serves to anchor insert 32. Other details of the preferred embodiment may be appreciated from the description of the embodiments as illustrated in FIGS. 2A-10B.
FIG. 2A illustrates the position of the large medial cleat 14 relative to the bones of the foot 100. The large medial arch cleat 14 extends under at least the medial half of the base 42 of the first metatarsal bone 40 and is at least 3 centimeters long in the typical adult shoe and preferably longer. As described previously, the shank stiffener 24 is illustrated with a phantom line and is located within or directly above cleat 14. The drawing of FIG. 2A illustrates a rounded shape which has worked well, but the exact size and shape may be altered somewhat. The cleat 14 should preferably not extend anteriorly, i.e. ahead of, the head 44 of the first metatarsal bone 40, nor should it extend laterally any closer than 2 centimeters from the lateral border of the outer sole 12. However, under some circumstances the cleat 14 might extend posteriorly, i.e. rearwardly, to the back edge of sole 12. If stabilization in the region of the navicular bone 50 is desired, it is recommended that the medial arch cleat 14 extend posteriorly under the navicular bone 50 as shown in FIG. 2A. The transverse first toe cleats 16 extend fully across the articular bone structure of the first toe which includes the distal phalanx 48, the proximal phalanx 46 and the anterior portion of the first metatarsal bone 40. Separate sequential cleats 16 are desirable in that region to provide some longitudinal flexibility there. The number, size and shape of the toe cleats 16 can be altered to fit the requirements of the wearer. In addition the cleats 16 may extend laterally most or even all the way to the lateral border of the sole. Or, they might be slightly curved and angled instead of straight as shown in the drawings. Or the cleats 16 might be 10° or 15° off the transverse axis instead of strictly transverse to the long axis of the foot as shown.
Complementary cleats 18 are distributed over the remainder of the bottom sole 12 in order to give an even ride. Their specific size, location and orientation may be dictated by other shoe requirements.
The large medial arch cleat 14 and the transverse first toe cleats 16 may incorporate on their surfaces a secondary cleat or tread structure in order to improve the grip of the outer sole 12.
The outer soles of most present day running shoes are made of natural or synthetic rubbers. Some are made from plastic materials. Such materials are suitable for use in the outer sole 12 of the preferred embodiment of the invention, although the large medial arch cleat 14 and the transverse first toe cleats 16 are preferably made at least in part of a composition material which is harder, stiffer, and more durable than rubber, and which has better traction properties than conventional rigid plastic. An example of a composition material suitable for this purpose is a mixture of Shoe Patch® and pulverized rubber. Shoe Patch® is the trademark of a product produced by the KiWi Polish Company of Pottstown, Pennsylvania 19464 and is intended primarily for the repair and maintenance of shoe soles. A suggested ratio is, by volume, two (2) parts Shoe Patch® to one (1) part pulverized rubber. Whether or not this specific material would be suitable in large scale production has not been determined. Ideally, the medial arch cleat 14 and the first toe cleats 16 would be molded integrally with the structure of the bottom sole.
The invention includes a means for providing medial longitudinal stiffening to the shank. This may be achieved simply by constructing most or all of the large medial arch cleat 14 out of a rather stiff material, such as the material described in the previous paragraph. Alternatively, or in addition thereto, a separate stiffener 24, made, for instance, of Nylon® or other rigid plastic, may be included as shown in FIGS. 1A and 2A. Nylon® is a trademark of the E. I. DuPont Company of Wilmington, DE. Such a stiffener 24 preferably has one of the following three forms. Firstly, it could be approximately horizontal and combined with the large medial arch cleat 14 of the outer sole 12 as indicated by element 24 in FIG. 2B and by the dotted line in FIG. 2A. This is the form of the preferred embodiment. Or, secondly, it could be approximately vertical and situated along the lower medial side of the sole. Or, thirdly, it could include regions of both types. In the last two embodiments, the stiffener preferably joins the outer sole 12 and may be molded integrally with the outer sole. The exact nature of the additional stiffening is largely determined by the properties that the sole would have without the extra stiffening. In general a very flexible sole needs a horizontal stiffener. On the other hand, a thick soft sole would need a vertical stiffener along the medial border of the shank.
The large medial arch cleat 14 and the first toe cleats 16, by virtue of their resistance to stretching, impart to the corresponding regions of the sole a predetermined resistance to bending, which depends, of course, upon the construction of the sole itself. In general, the cleat structure increases the transverse stiffness of the medial arch and first toe regions of the sole. Transverse stiffness is greatest if the cleats themselves are constructed of stiff material or, in the shank region, if the medial arch cleat is combined with a horizontal shank stiffener. The effect of medial transverse stiffness depends upon the geometry of the medial border of the sole. When weight is borne on a shoe having the structure of the preferred embodiment, the shoe sole resists inward rotation of the shoe about the medial border. This resistance occurs in the region of the shank or toe where the weight is applied. Since the shank is wide medially, as shown in the drawings, the transversely stiffened shank provides strong resistance to inward rotation about its medial border. In this manner, resistance to pronation is provided by the structure of the lower shoe sole. The construction does not create torque when weight is borne on the lateral side of the shoe. Also, the structure does not provide resistance to either supination or normal forward roll of the foot.
A wide shank is recommended also for general support of the foot. Indeed, it is known that support for the anterior half of the first metatarsal bone promotes medial stability. However, in running shoes such support is often inadequate because it is soft and because the posterior half of the bone, not being fully supported or adequately contained, rotates over the soft edge of the midsole when the foot pronates. Thus, support for the posterior half of the first metatarsal bone is essential. Accordingly, fairly wide support for other parts of the medial arch is also preferred. The outer outline of FIG. 3 represents a preferred shape for the upper surface of the midsole 20. The shaded area represents a portion which is typically omitted from the upper part of the midsole in present day running shoes. Some present day running shoes are built on a straight last and have a midsole whose medial arch border lies between the two shown in FIG. 3. FIG. 3 also illustrates that full lateral support, especially for the 3rd, 4th and 5th toes, is recommended.
It is another aspect of the present invention that a shoe which provides medial support and longitudinal stiffening of the shank as already described might be constructed by starting with a suitable conventional running shoe and adding a part to the medial side of the shank of the sole. Such a part, or add-on stiffener 56, is illustrated in FIG. 4. The upper part 58 of the add-on stiffener 56 is made of midsole material and the lower part 60 includes a longitudinal shank stiffener which might comprise a long piece of stiff plastic such as Nylon®. The upper part 58 should be at least 0.3 centimeters wide at the base of the first metatarsal bone, preferably wider. The shank stiffener 56 should extend longitudinally at least from the shaft 62 of the first metatarsal bone 40 to the navicular bone 50. If such a stiffener 56 were made for the typical running shoe sole, its convex side would then be made of midsole material so that it may be readily shaped to fit the concavity of the medial arch region of the sole of the existing shoe. Its bottom edge would preferably be cut to come even with either the bottom of the midsole, 20, or with the bottom of the outer sole 12 as shown in FIG. 4. In the latter case, the bottom of the outer sole 12 might need reinforcement at the juncture. A suitable reinforcing material would be Shoe Patch® as previously described. The upper surface of add-on stiffener 56 is shaped to come even with the upper surface of the existing sole. The add-on stiffener 56 is attached to the sole with suitable cement, such as Barge, a product of Barge Cement Division, Pierce and Stevens Chemical Company, Buffalo, N.Y., or Shoe Patch®, and perhaps with nails cemented in. The procedure would best be preformed by a shoe repairman, although the typical consumer could, with care, do an adequate job. Unfortunately, not all running shoes are adaptable to receive such a part. For example, the Adidas TRX has a midsole which incorporates a circumferential groove in the side and is made of a synthetic foam crepe-like material which cannot be bonded to an add-on stiffener 56 with readily available, conventional cement.
According to the preferred embodiment, midsole construction which is of somewhat lower compressibility in the medial arch region than in other regions promotes medial stability and helps prevent the midsole of the medial arch region from "bottoming out," i.e. permanently squashing down. As suggested in FIG. 1B, this problem can be solved by joining a wedge 26 of moderately firm midsole material to a complementary wedge 28 of comparatively soft midsole material. An alternative solution is to provide holes in the midsole material where greater softness is desired.
Other variations of midsole compressibility can be beneficial to the athlete. FIG. 5 represents two distributions which are recommended. Compressibility is rated "1" for moderately firm, "3" comparatively soft and "2" for intermediate values. According to the diagram, region 64 is the heel region, region 66 is the toe region, region 68 is approximately the medial arch region and region 70 is the remaining region. The two recommended relative distributions are: region 64--"3", region 66--"3", region 68--"1" and region 70--"3", or region 64--"3", region 66--"3", region 68--"1", and region 70--"2". A third recommended distribution, not illustrated, is like the second of the foregoing distributions except that the region of intermediate density "2" extends forward to include the medial side of the toe region 66. This feature provides control of forefoot pronation and helps prevent "bottoming out" of the midsole under the big toe.
Optimal distribution of midsole compressibility depends upon such factors as the body weight of the runner, his foot structure, his running speed, the terrain, and so on. Thus, for general use, it would be desirable to construct a midsole 20 to have adjustable compressibility. Accordingly, FIG. 6A illustrates an alternative embodiment of the present invention which comprises a resilient midsole 72 including a plurality of cavities 74 adapted to receive one or more removable stiffening elements 78. A typical cavity 74 is cylindrical in cross section but has conical end portions. The cavity 74 communicates with the exterior of the sole through a small opening 76 in the external wall. The stiffener 78 includes a body portion 80 which fits into cavity 74 and a small loop portion 82 connected to one end of body 80. The body 80 is preferably formed of a light-weight plastic and the loop 82 is preferably formed of a strong thin line such as Nylon® fishing line. A conventional tool or applicator 84 is used for inserting and removing the stiffener 78. A suitable tool 84 comprises a common flat headed nail-like object at least 2" long. The tip 88 of tool 84 may be passed through the loop 82 for removal of the stiffener 78. The head 86 of tool 84 may be used to push the stiffeners 78 into cavities 74. Alternatively, a pair of small household pliers or a kitchen fork could be used in place of the preferred embodiment of the tool 84. The tip 88 of tool 84 may be rounded for safety purposes. As shown in FIG. 6B, the stiffener 78 is inserted into the cavity 74 by means of force applied with the head 86 of the preferred tool 84. The small opening 76 of the cavity 74 is easily expanded by the leading pointed end of the stiffener 78. Once the body 80 of the stiffener 78 is entirely inserted, the opening 76 contracts to keep the stiffener 78 from falling out. As shown in FIG. 6C the stiffener 78 may be removed from the cavity 74 by inserting the tip 88 of the tool 84 through the loop 82 and applying outward force to draw the stiffener 78 out in the direction of the arrow illustrated in FIG. 6C. The opening 76 of the cavity 74 is easily expanded by the tapered head of the insert 78 adjacent to the loop 82.
A stiffener 78 may include, in addition to a body 80 and a loop 82, a small stiff extension at right angles to the body, located at the same end as the loop. The function of such an extension would be to prevent the stiffener from becoming lost in a hole which is too deep for it. However, this possibility can be minimized by color coding the cavity 74 and stiffener 78 or by making all cavities 74 of the same depth and internal construction. In any event, a lost stiffener 78 can be retrieved with a small crochet hook or similar item. A small hook might even be provided at the end of tool 84 if desired.
The midsole material which includes the cavities 74 should be rather stiff, both for durability and because the empty cavities 74 increase the compressibility of the midsole. The cavities 74 should be preferably about 3/16" in diameter and should be situated in the rearfoot and/or shank regions, where the midsole is fairly thick. For simplicity, the cavities 74 should all have the same diameter and at most two different lengths. However, the stiffeners 78 might have different degrees of transverse compressibility or of longitudinal stiffness. For example, a hollow stiffener and a solid stiffener might have about the same transverse compressibility, but the hollow one may be made of more rigid material and therefore have less longitudinal flexibility. Hence it is possible to vary the resistance to bending somewhat independently of compressibility.
In the preferred embodiment, medial arch support is provided. However, it is known that the use of a conventional arch support in a sneaker or similar shoe frequently causes the foot to slide laterally and fall off the lateral side of the shoe sole. The problem is reduced with the use of larger, stiffer heel counters such as used in some present day running shoes, but there continue to be many failures.
The preferred embodiment of the invention includes a good heel counter and a lateral counter 30, such as shown in FIG. 7, which is constructed and installed so as to longitudinally stiffen the lateral border of the shoe sole. Counter 30 is preferably made of a plastic material. The plastic material is somewhat flexible when thin, but becomes quite rigid in thicknesses of 1/2 a centimeter or more. Counter 30 is relatively thin, hence somewhat flexible, but unlike conventional counters it is attached to the sole not horizontally, but vertically, (See FIG. 1B) along a height of at least 1/2 centimeters, that is to say the counter 30 is attached to the vertical side of the sole rather than to the horizontal top of the sole. By this technique the counter imparts a longitudinal stiffness to the lateral border of the shank region of the sole.
In practice, excellent results have been achieved by attaching a lateral counter to the outside of an existing running shoe. The shoes employed had a suede material secured to the upper of the shoe in the region to be stiffened. A successful method is as follows: Several small applications of Shoe Patch® are spread over the suede and over an upper horizontal strip of the midsole. Generally two pieces of fiberglass cloth are applied separately between applications of Shoe Patch®. Alternatively, a corresponding piece of plastic, or fiberglass reinforced plastic, might be cemented in place to give similar results. The piece might be covered with fabric or leather for the purpose of improving its appearance, although weight is minimized if no covering material is used.
The lateral counter is preferably located adjacent the anterior part of the calcaneous bone 90, the cuboid bone 92 and the posterior part of the fifth metatarsal bone 94. Its height is such that it restricts only the bottom part of the side of the foot.
It is another aspect of the present invention to continue the lateral counter backwards around the heel and forward along the navicular bone 50 provided that the shank is fairly wide as illustrated in FIG. 3. This embodiment 200 is illustrated in FIG. 10A and 10B. The height of the counter 200 rises around the back of the heel and declines downwardly toward the shank of the shoe. The height of the counter 200 also depends upon the height of the anticipated shoe insert or inlay, so that it contains but does not irritate the foot. For a foot having a fallen or weakened arch, it is possible to achieve acceptable results, without the use of a rigid insert under the navicular bone, by employing both the extended continuous counter construction 200 of FIGS. 10A and 10B and the lower longitudinal medial stiffening element 56 as attached to the medial side of the shank.
According to the preferred embodiment of the invention the cushioning 38 on which the foot rests may comprise any one or all of the following elements: a flat cushioned insole; a mass produced contoured cushioned insole; a continuous cushioned insole which the wearer fashions himself; or, preferably, a cushioned insert custom made by a capable professional. All of the foregoing are considered "inserts" whether or not they are cemented into the shoe.
As previously described, if the foot of the wearer has a collapsed or loosened arch, it is the recommendation of this invention to provide a rigid support base 34 for the navicular bone 50 as described in FIGS. 1B, 8A-8C. According to the preferred embodiment, such a structure 34 is part of an insert 32 as shown in FIGS. 1B and 8A-8C where element 36 is a lateral and backward continuation of element 34. Since the insert 34 is fairly wide the shoe must also be wide to accomodate the insert 34. The insert 32 is similar in some respects to so-called plastic orthotics, but differs in at least the following three major respects. First, it is intended for use with a soft orthotic covering. Secondly, it may be mass produced, because exact support is accomplished by precise construction of the soft orthotic covering. Thirdly, no rigid part of insert 32 extends anteriorly to the posterior half of the first metatarsal bone 40. See FIG. 8A. This third difference is fundamental and reflects a very important structural aspect of the shoe. The sole is wide at the base of the first metatarsal bone 40 and will thus support the anterior portion of the wide rigid region 34 of insert 32. FIG. 8B suggests that region 34 might be reinforced at its two ends like a bridge. If desired, insert 32 might be cemented into the shoe or its bottom surface could be provided with a plurality of spikes to anchor it in the shoe bed.
Insert 32 could be sold separately from the shoe since a majority of wearers would not need it. As mentioned, it may be mass produced, but it might also be made individually or in small numbers for podiatrists or other qualified professionals. It is recommended that the cushioned support 38 above insert 32, i.e. the soft orthotic covering, be custom made by a capable professional. A professional may wish to combine the two structures into a single insert.
The use of an insert in the foot receiving cavity of a shoe imposes certain new conditions upon the shoe upper 22. Specifically, the upper and the counters need to be a little higher than if no insert were used. That is because the insert raises the foot. However, care should be taken that no stiff counter is so high as to cause irritation during athletic activity.
As we have seen, according to this invention the foot is in all cases directy supported by a good layer of cushioning, and no rigid portion of the structure will interfere with the normal flexing of the foot at the ball. In particular, activities such as sprinting and jumping can be comfortably pursued.
As described in great detail above, the primary purpose of the invention is to provide stable cushioned support to the posterior half of the first metatarsal bone 40 including the base 42. Accordingly, the specific preferred embodiment is as shown in FIG. 1A wherein a large medial arch cleat 14 includes above it a shank stiffener 24 which provides support to the critical area. The arch cleat construction 14 may be employed with or without an additional medial stiffener 56. Under some circumstances the medial stiffener 56 may be added on separately (See FIG. 4) or could be incorporated into the structure of the sole 12 itself (See FIGS. 9A and 9B). The support for the rear half of the first metatarsal bone 40 and other parts of the medial arch may cause the foot to slide outwardly and therefore a lateral counter-shank stiffener 30 may be employed. Finally, an insert 32, such as illustrated in FIG. 1B and 8A-8C, might also be employed to enhance the effect of the invention. Therefore, while FIGS. 1A and 1B describe the preferred embodiment it will be understood by those who have studied this disclosure that under some circumstances the lateral counter-shank stiffener 30 and the insert 32 can be used independently of the medial stiffener means. The alternative embodiment of FIGS. 6A-6C could be used without any of the other features.
As previously described the stiffener 56 can be of the add-on variety as illustrated in FIG. 4. Alternatively, the stiffener 56 may be made integral and continuous with the cleat 14 as shown in the perspective views of FIGS. 9A and 9B.
While the invention has been described with reference to a preferred embodiment thereof it will be appreciated by those of ordinary skill in the art that changes may be made to the structure and function of the elements without departing from the spirit and scope of the invention.
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An improved running shoe includes several means for stabilizing pronation and for promoting and maintaining favorable positioning of the foot while running or jogging. The bottom of the sole has cleats which resist inward rotation of the shoe during certain phases of weight bearing. The sole provides basic support through a wide shank, rigid longitudinal shank reinforcement and relative incompressibility in the medial arch region. The central part of the foot is contained and directly supported by a strong lateral counter and an insert which cooperates with the foregoing elements. A primary purpose of the invention is to provide stable support for the rear half of the first metatarsal bone in a practical and novel manner.
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RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Patent Application No. 61/864,958 filed Aug. 12, 2013, and entitled “WASHABLE ANALYTE METERS, SEALED CONNECTORS, AND METHODS OF MANUFACTURING AND USING SAME” (Attorney Docket No. BHC124017US) which is hereby incorporated herein by reference in its entirety for all purposes.
FIELD
[0002] The invention relates to analyte meters that may be used to detect an analyte concentration level in a bio-fluid sample, analyte sensor electrical connectors, and methods of using and manufacturing thereof.
BACKGROUND
[0003] The monitoring of analyte concentration levels in a bio-fluid may be an important part of health diagnostics. For example, an electrochemical analyte sensor may be employed with an analyte meter for monitoring a patient's blood glucose level as part of diabetes treatment and care. Other types of analytes may be measured as well. An electrochemical analyte sensor may be employed, for instance, for detecting an analyte concentration level in a bio-fluid sample, such as from a single sample of blood or other interstitial fluid. The bio-fluid may be obtained from the patient using a lancet (e.g., by a pinprick or needle). Typically, after a bio-fluid sample has been obtained, the sample may then be transferred to an analyte sensor (e.g., typically an analyte sensor strip) for measurement of the bio-fluid sample's analyte concentration level (e.g., a glucose analyte level).
[0004] As part of the process, electrodes formed on the analyte sensor are placed in electrical contact with an electrical connector of the analyte meter. Typically, the analyte sensor (e.g., sensor strip) is inserted into a sensor port of the sensor connector. However, portions of the sensor connector housing may be partially open to the inside of the analyte meter and the electrical connection takes place within the interior of the analyte meter. Once the connection is established, the bio-fluid is applied to a receiving end of the sensor strip and the analyte measurement is carried out. During this process, bio-fluids such as blood may contaminate portions of the outside of the meter, such as near the port. Further, the port and the internal electrical connections may become contaminated.
[0005] Accordingly, there is a need to provide an analyte meter configured for bio-fluid analyte testing that may overcome certain issues due to contamination.
SUMMARY
[0006] In a first aspect, an analyte meter is provided. The analyte meter includes an analyte sensor electrical connector having a sensor port configured to receive an analyte sensor in a port entryway, and at least one wash port coupled to the sensor port and separate from the port entryway, the at least one wash port configured to receive a cleaning fluid.
[0007] In another aspect, another analyte meter is provided. The analyte meter includes a meter housing having a first part and a second part interfacing with each other to form an internal chamber, an electronic circuit within the internal chamber, and an analyte sensor electrical connector including a sealed electrical connection through the first part or the second part into the internal chamber, a sensor port configured to receive an analyte sensor in a port entryway, and at least one wash port coupled to the sensor port and separate from the port entryway, the at least one wash port configured to receive a cleaning fluid.
[0008] In a method aspect, a method of cleaning an analyte meter is provided. The method includes providing an analyte meter having a sensor port configured to receive an analyte sensor, the sensor port having a port entryway and a wash port, and flowing a cleaning fluid through the wash port to clean the sensor port.
[0009] In another method aspect, a method of manufacturing an analyte meter is provided. The method includes providing an analyte meter housing having an internal chamber, providing an analyte sensor electrical connector having at least two electrodes, providing an analyte meter battery connector, forming a sealed connection between the analyte sensor electrical connector and the internal chamber, and forming a sealed connection between the analyte meter battery connector and the internal chamber.
[0010] In another aspect, another analyte meter is provided. The analyte meter includes a meter housing having a first part and a second part interfacing with and sealed to one another to form an internal chamber, an electronic circuit within the internal chamber, a sensor port configured to receive an analyte sensor in a port entryway, an analyte sensor electrical connector in the sensor port including a sealed electrical connection through the first part or the second part into the internal chamber, a screen display sealed to one of the first part and a second part, a keypad sealed to one of the first part and a second part, and a removable battery pack including a sealed electrical connection through the first part or the second part into the internal chamber.
[0011] In another aspect, another analyte meter is provided. The analyte meter includes a display screen, a keypad, an analyte sensor port, and battery pack interfacing with an electronic circuit located in an internal chamber of a meter housing wherein the internal chamber is entirely sealed and liquid impermeable such that the analyte meter is washable and immersable.
[0012] Still other aspects, features, and advantages of the invention may be readily apparent from the following detailed description wherein a number of example embodiments and implementations are described and illustrated, including the best mode contemplated for carrying out the invention. The invention may also be capable of other and different embodiments, and its several details may be modified in various respects, all without departing from the scope of the invention. Accordingly, the drawings and descriptions are to be regarded as illustrative in nature, and not as restrictive. The invention covers all modifications, equivalents, and alternatives falling within the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The drawings, described below, are for illustrative purposes only and are not necessarily drawn to scale. The drawings are not intended to limit the scope of the invention in any way.
[0014] FIG. 1A illustrates a top plan view of a washable analyte meter including a washable sensor connector according to embodiments.
[0015] FIG. 1B illustrates a partial cross-sectioned side view of the analyte meter of FIG. 1A taken along section line “ 1 B- 1 B.”
[0016] FIG. 1C illustrates a partial perspective view of the washable analyte meter including the washable sensor connector according to embodiments.
[0017] FIG. 1D illustrates a front view of the washable sensor connector of FIG. 1C , shown in isolation.
[0018] FIGS. 1E-1H illustrates various perspective views of certain components of the washable analyte meter including the washable sensor connector according to embodiments.
[0019] FIG. 2 illustrates a flowchart of a method of using an analyte meter according to embodiments.
[0020] FIG. 3 illustrates a flowchart of a method of manufacturing an analyte meter according to embodiments.
[0021] FIGS. 4 and 5 illustrate perspective views of a washable analyte meter including a replaceable battery cartridge according to embodiments.
[0022] FIGS. 6 and 7 illustrate perspective views of battery cartridge housings according to embodiments.
[0023] FIGS. 8 and 9 illustrate cross-sectional and top plan views, respectively, of a replaceable battery cartridge according to embodiments.
[0024] FIGS. 10 and 11 illustrate cross-sectional and top plan views, respectively, of another replaceable battery cartridge according to embodiments.
[0025] FIG. 12 illustrates a perspective view of a battery cartridge connector and printed circuit board according to embodiments.
[0026] FIG. 13 illustrates a perspective view of a battery cartridge housing according to embodiments.
[0027] FIGS. 14 and 15 illustrate cross-sectional views of an assembly of a replaceable battery cartridge into the battery cartridge housing of FIG. 13 according to embodiments.
[0028] FIGS. 16 and 17 illustrate cross-sectional views of an assembly of another replaceable battery cartridge into the battery cartridge housing of FIG. 13 according to embodiments.
[0029] FIGS. 18-21 illustrate schematic circuit diagrams illustrating the electrical connections between a replaceable battery cartridge and an analyte meter according to embodiments.
DESCRIPTION
[0030] Reference will now be made in detail to the example embodiments of this disclosure, which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0031] Certain regulatory requirements regarding cleaning and disinfection efficacy in a clinical setting are becoming more stringent. Moreover, in cases of high levels of contamination, the analyte measurement itself taken by an analyte meter may be adversely affected because the electrical connection between the analyte (e.g., an analyte sensor strip) and one or more electrodes of the electrical connector may be contaminated or adversely affected in some way.
[0032] In view of this concern, embodiments of the invention may provide an entirely hermetically sealed analyte meter that may be washable and, in some embodiments, may even be immersed in a liquid without damage. Accordingly, the sealed analyte meter may be washed in a washing fluid, such as a disinfecting liquid, or the like. In one or more embodiments, the one or more electrical connections of the analyte meter may be sealed. Some may be washable, such as, e.g., the analyte sensor port. Other electrical connections may be sealed and/or washable and/or removable such as a communication connector (e.g., a universal serial bus (USB) port) and/or a battery connection. In some embodiments, the analyte meter itself is entirely washable and all connections thereof may be sealed and washable, including the sensor port, enabling electrical connection with an analyte sensor.
[0033] The analyte meter, in accordance with one or more embodiments, may be used to measure any number of analytes, such as glucose, fructose, lactate, keytone, microalbumin, bilirubin, total cholesterol, uric acid, lipids, triglyceride, high density lipoprotein (HDL), low density lipoprotein (LDL), hemoglobin Alc, and the like. These analytes may be detected in, for example, whole blood, blood serum, blood plasma, interstitial fluid, urine, etc. Other types of analytes may be measured provided a suitable reagent exists.
[0034] These and other embodiments of washable analyte meters, washable analyte sensor electrical connectors, and methods of using and manufacturing and using the analyte meter are described below with reference to FIGS. 1A-21 .
[0035] FIGS. 1A-1D illustrates various views of a first example of an analyte meter 100 that is washable according to one or more embodiments. The analyte meter 100 may include a meter housing 102 that may be made of two parts, such as first part 104 and second part 106 that engage each other to form an internal chamber 108 ( FIG. 1B ). The internal chamber 108 may be configured to contain various internal components of the analyte meter 100 , such as a printed circuit board 110 (shown dotted in FIG. 1A ), which may contain all or part of an internal electronic circuit. Internal chamber 108 may be entirely sealed and liquid impermeable such that the analyte meter 100 is washable and immersable. The first part 104 and second part 106 may be sealed to each other at their contact surfaces in order to form the internal chamber 108 as a sealed chamber that is sealed from the outside environment. Internal chamber 108 may be hermetically sealed. The first part 104 and second part 106 of the meter housing 102 may be formed of an insulating material such as plastic injection-molded pieces, for example. Sealing may be provided by ultrasonic welding of the first part 104 and second part 106 , or by providing a sealant (e.g., a curable sealant), o-ring, gasket, or the like between the first part 104 and the second part 106 . Other suitable sealing methods may be used. Connection of the first part 104 to the second part 106 may be made by screws, rivets, snap fit connectors molded on the first part 104 and second part 106 , or the like when using a sealant, o-ring, gasket, or the like.
[0036] The printed circuit board 110 may reside within the confines of the internal chamber 108 . The printed circuit board 110 may include conventional electronic components such as a power supply, processor, memory, and the like that are conventional for carrying out analyte measurements and display thereof. The printed circuit board 110 may be retained in a defined position within the internal chamber 108 by projections and/or recesses formed in one or both of the first part 104 and second part 106 . Other suitable positioning features may be used.
[0037] The meter housing 102 may have a first end 112 and a second end 113 opposite the first end 112 . The first end 112 may include an analyte sensor electrical connector 115 that is fully washable having a sensor port 116 configured to receive an analyte sensor 105 in a port entryway 119 thereof. The analyte sensor electrical connector 115 may also have a one or a plurality of wash ports 118 coupled to sensor port 116 that are separate from port entryway 119 . Wash ports 118 may be configured to receive a cleaning fluid there through. The analyte sensor electrical connector 115 may include a connector body 117 that may be received in a recessed pocket 114 of the first part 104 and/or the second part 106 . In some embodiments, the connector body 117 of the analyte sensor electrical connector 115 may include a first wall receiving two or more electrodes 121 , and a second wall opposite the first wall and including one or more wash ports 118 . Two or more electrical connectors 122 may be coupled to two or more electrodes 121 at the first wall. In some embodiments, the two or more electrical connectors 122 may be electrical connector pins. A sealing layer 123 may be provided in some embodiments between a surface of the analyte sensor electrical connector 115 and the first part 104 and/or second part 106 , such as in the recessed pocket 114 .
[0038] In some embodiments, the wash ports 118 may cooperate with the port entryway 119 to form a fluid flow channel enabling flushing of the sensor port 116 . The wash ports 118 may be formed through a first wall of the analyte sensor electrical connector 115 . As shown best in FIG. 1C , the wash ports 118 may be configured as elongated slots. The wash ports 118 may be one or more in number.
[0039] The analyte meter 100 may further include a display screen 120 that may be sealed to the first part 104 and/or second part 106 such that fluids are prevented from entering the internal chamber 108 from between the display screen 120 and the first part 104 and/or second part 106 . Similar sealing methods as described above may be used. For example, a sealing material layer 124 may be provided around the periphery of the display screen 120 .
[0040] The analyte meter 100 may still further include a keypad 125 that may be sealed to the first part 104 and/or second part 106 such that fluids are prevented from entering the internal chamber 108 from between the keypad 125 and the first part 104 and/or second part 106 . The seal between the keypad 125 and the first part 104 and/or second part 106 may be provided by employing a thin layer 126 covering over the keys of the keypad 125 . The thin layer 126 may be sealed to the first part 104 and/or second part 106 and may be adhered thereto. The thin layer may be a plastic sheet in some embodiments and may include indicia printed or otherwise marked thereon. Other means for sealing the keypad 125 or individual keys may be used.
[0041] In some embodiments, the analyte meter 100 may include a battery connector 127 that is sealed to the first part 104 and/or second part 106 such that fluids are prevented from entering the internal chamber 108 from between the battery connector 127 and the first part 104 and/or second part 106 . The battery connector 127 allows the use of a removable battery pack 128 , as will be described herein.
[0042] The analyte meter 100 may also include a universal serial bus (USB) port sealed to the first part 104 and/or second part 106 on a side, for example, such that fluids are prevented from entering the internal chamber 108 from between the USB port and the first part 104 and/or second part 106 . Sealed connection for the universal serial bus (USB) port may be the same as for the battery connector 127 . A connection seal 127 S, such as an elastomer seal, may be provided on the connector or on the first part 104 and/or second part 106 to seal the connection interface.
[0043] As further shown in FIGS. 1E-1H and as otherwise described herein, the analyte meter 100 may eliminate any opening allowing liquid ingress into to the internal chamber 108 , and may be configured to drain and dry the analyte sensor electrical connector 115 upon washing or cleaning thereof with a cleaning fluid or other liquid. In some embodiments, the analyte sensor electrical connector 115 may be seated within the recessed pocket 114 in the first part 104 of the analyte meter 100 . In some embodiments, the electrical connectors may project through one or more apertures in the first part 104 and may be configured to be connected to (e.g., plugged into or otherwise contact) conducting receptacle features on the printed circuit board 110 . Other suitable electrical connectors may be used such as bendable leaf spring contacts that contact conducting pads on the printed circuit board 110 . In some embodiments, the electrical connectors may be insert-molded in the analyte sensor electrical connector 115 forming a seal between plastic (e.g., the first part 104 ) and metal. In some embodiments, a sealing layer 123 such as a gasket-type sealing arrangement or other sealing arrangement (sealing compound) may be used between the analyte sensor electrical connector 115 and the surface(s) of the first part 104 and/or second part 106 . In some embodiments, the surfaces within the analyte sensor electrical connector 115 may be sloped and/or ventilated as needed to facilitate fluid egress after washing.
[0044] FIG. 2 is a flowchart illustrating a method 200 of cleaning an analyte meter in accordance with one or more embodiments. At process block 202 , method 200 may include providing an analyte meter (e.g., analyte meter 100 ) having a sensor port (e.g., sensor port 116 ) configured to receive an analyte sensor (e.g., analyte sensor 105 ), the sensor port having a port entryway (e.g., port entryway 119 ) and a wash port (e.g., wash port 118 ). At process block 204 , method 200 may include flowing a cleaning fluid through the wash port to clean the sensor port. The method 200 of cleaning may be accomplished without adversely affecting the analyte meter.
[0045] FIG. 3 is a flowchart illustrating a method 300 of manufacturing an analyte meter in accordance with one or more embodiments. At process block 302 , method 300 may include providing an meter housing (e.g., meter housing 102 ) having an internal chamber (e.g., internal chamber 108 ). At process block 304 , method 300 may include providing an analyte sensor electrical connector (e.g., analyte sensor electrical connector 115 ). The analyte sensor electrical connector may include at least two electrodes (e.g., electrodes 121 ). Analyte sensor electrical connector 115 may be attachable to the meter housing 102 . At process block 306 , method 300 may include providing an analyte meter battery connector (e.g., battery connector 127 ). At process block 308 , method 300 may include forming a sealed connection between the analyte sensor electrical connector and the internal chamber. And at process block 310 , method 300 may include forming a sealed connection between the analyte meter battery connector and the internal chamber. Any suitable means for accomplishing the sealed connection may be used.
[0046] The above process blocks of method 300 may be executed or performed in an order or sequence not limited to the order and sequence shown and described. For example, in some embodiments, process block 304 may be performed after or in parallel with process block 306 . Similarly, process block 308 may be performed after or in parallel with process block 310 .
[0047] FIGS. 4-6 illustrate an embodiment of a removable or replaceable battery cartridge 428 of an analyte meter 400 that includes a sealed battery connector 429 that may protect against liquid ingress into the internal chamber 108 . The sealed battery connector 429 may be provided via the use of a sealed or potted interface in accordance with one or more embodiments. In some embodiments, the replaceable battery cartridge 428 may be configured to attach to an meter housing 402 via slideable insertion.
[0048] As shown in FIGS. 5 and 6 , some embodiments may include retention features, such as a pair of T-shaped retention rails 430 on opposite sides of a surface of an meter housing 402 ( FIG. 5 ) and a corresponding pair of retention slots 432 in the battery cartridge housing 428 H configured to receive the T-shaped rails.
[0049] FIGS. 7-11 illustrate a battery cartridge housing 728 H ( FIG. 7 ) configured to receive battery cartridge inserts of different battery chemistries in accordance with one or more embodiments. FIGS. 8 and 9 illustrate a battery insert assembly 832 including coin cell batteries and FIGS. 10 and 11 illustrate a battery insert assembly 1032 including a prismatic battery cell, each configured to be inserted in battery cartridge housing 728 H.
[0050] FIG. 12 illustrates a printed circuit board (PCB) 1200 that may be affixed to the inserts at locations 825 and 1025 (of FIGS. 8 and 10 , respectively) in accordance with one or more embodiments. In some embodiments, potting compound may be used to encapsulate the electronics creating a fluid-tight seal (e.g., a water-tight seal). A gasket or potting compound may additionally be used in some embodiments to seal the prismatic battery. Battery electrical connector 1227 extending from the printed circuit board (PCB) 1200 may couple to and provide a sealed connection (e.g., with connection seal 127 S) with the meter housing of the analyte meter, for example. Optionally, sealed electrical connectors may be the same as for the analyte sensor electrical connector 115 . Thus, power may be readily provided to the analyte meter and the internal chamber 108 may remain entirely hermetically sealed.
[0051] As shown in FIGS. 13-17 , battery insert assemblies 832 , 1032 may be slid into the battery cartridge housing 728 H first at an angle such that the interface battery connector slides through an access hole 1335 (see FIG. 13 ) and then the battery insert assemblies 832 , 1032 may be snapped down into the battery cartridge housing 728 H. In addition, in some embodiments, the battery insert assembly 832 , 1032 may be secured in the battery cartridge housing 728 H with potting or an adhesive. In the case of the battery insert assembly 1032 this may also protect the prismatic battery and the battery compartment against liquid ingress.
[0052] Embodiments of the battery cartridge housing 728 H may allow multiple battery chemistries to be used while maintaining an identical mechanical envelope for an analyte meter (or other suitable battery-powered device). In some embodiments, the electronics in the battery cartridge may be protected against liquid ingress such that the IP22 standard is met. The IP22 standard is part of the Ingress (or International) Protection Rating code published by the International Electrotechnical Commission (IEC). Embodiments of the replaceable battery cartridge may also allow an analyte meter (or other suitable battery-powered device) to meet the IP22 standard for liquid ingress. Embodiments of the replaceable battery cartridges may be user replaceable, thus reducing the cost of replacing a replaceable battery cartridge when the battery/batteries expire(s). In some embodiments, the coin cell batteries of the battery insert assembly 832 of the replaceable battery cartridge may be user replaceable.
[0053] FIGS. 18-21 illustrate the electrical interface between a replaceable battery cartridge and an analyte meter (or other suitable battery-powered device). FIGS. 18 and 19 illustrate less complex circuit topologies of electrical interfaces wherein power management circuitry common to all battery chemistries may be contained in an analyte meter (or other suitable battery-powered device), while the power management circuitry unique to a battery chemistry may be contained in the battery cartridge. FIGS. 20 and 21 illustrate full cartridge electrical interface topologies wherein all power management circuitry may be contained in the battery cartridge.
[0054] Accordingly, battery cartridges of different battery chemistries may be mechanically and electrically interchangeable, allowing an analyte meter (or other suitable battery-powered device) to be powered from different battery chemistries.
[0055] The foregoing description discloses only example embodiments of analyte meters, sensor connectors, battery cartridges, and methods of manufacturing and using the analyte meters. Modifications of the above-disclosed analyte meters, sensor connectors, and methods, which fall within the scope of the invention, will be readily apparent to those of ordinary skill in the art. Accordingly, while the invention has been disclosed in connection with example embodiments thereof, it should be understood that other embodiments may fall within the scope of the invention, as defined by the following claims.
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An analyte meter to detect an analyte concentration level in a bio-fluid sample may be cleaned and disinfected with a cleaning liquid without harming electrical and internal meter components. In some embodiments, the analyte meter is washable and immersable and may include a sealed sensor connector, sealed battery connector, and possibly a sealed USB connector that may be subjected to a cleaning liquid without the liquid entering an internal chamber of the analyte meter and contacting internal electronic components. In some embodiments, a sealed display screen and sealed keypad are provided such that liquids are prevented from entering the internal chamber. Manufacturing methods and systems utilizing the analyte sensors are provided, as are numerous other aspects.
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FIELD OF THE INVENTION
This invention relates to a guide that can be secured to a wall for guiding a concrete cutting saw in cutting a desired straight cut in the wall.
BACKGROUND OF THE INVENTION
A concrete cutting chain saw is heavy and unwieldy and making straight cuts, e.g., to create a window or door opening in a concrete wall, is a difficult task. Such a task often requires a guide system that supports and guides the saw as the cut is being made. Heretofore such guide systems have been complex in both structure and mounting and it is desirable to find a more simple apparatus that can be easily mounted, e.g., to a wall, and still function as a guide that assists an operator in making a straight wall cut.
BRIEF DESCRIPTION OF THE INVENTION
The present invention in a preferred embodiment includes an elongated track member that is secured to a wall to be cut. It is laid alongside the desired cut line. The track member includes protruding hinge cradles spaced sequentially along the track. The saw is provided with a hinge post that is mated to the hinge cradles. With the track member secured to the wall and starting, e.g., at a point just below the top of the cut line, the hinge post of the saw is nested in a cradle of the track member and the saw blade is pivoted inwardly and downwardly along the cut line. When the cutting procedure at that cradle position is completed, the saw is lifted off the cradle and dropped into a lower subsequent cradle and the procedure repeated. The track member and hinge post are cooperatively designed so that the cut can be made at either side of the track.
The invention will be more fully appreciated upon reference to the following detailed description having reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a chain saw guide;
FIG. 2 is a view of the chain saw guide of FIG. 1 showing a mounting bracket for the chain saw and a mounting tube;
FIG. 3 is a view illustrating a chain saw mounted to the guide and in the process of making a cut;
FIG. 4 is another view of the chain saw mounted to the guide and in the process of making a cut;
FIG. 5 illustrates an accessory bracket for the chain saw guide of FIG. 1;
FIG. 6 is a view as viewed on view lines 6 — 6 of FIG. 8;
FIG. 7 is a perspective view of the accessory bracket; and,
FIG. 8 is a view showing the accessory bracket mounted to the saw guide of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a track member or guide 10 for accurately guiding and maintaining a chain saw 12 in position during a sawing operation. The guide 10 is particularly suited for sawing aggregate material. The guide 10 has a base 16 that is an elongate member having slots 18 . Side members 20 are fixedly attached to the base 16 by fasteners 22 . Each side 20 has formed slots (hinge cradles) 24 that serve as pivotal mounts as will later be explained. As shown, the slots 24 are spaced at intervals along each of the sides 20 .
The guides 10 are provided in varying lengths to suit and may be abutted in an end to end relation for longer lengths as required. While the illustrations show the guide 10 in a vertical position, they are equally suited for horizontal or angular placement.
A bracket 30 as seen in FIG. 2 is mounted to the chain saw 12 by conventional fasteners. (However, it will be appreciated that it could be integrated into the design of the saw.) A mounting tube 32 is provided on one end of the bracket 30 and is arranged to receive a post 34 . The post 34 has spools 36 mounted in a spaced arrangement.
The post 34 is arranged to be inserted or mounted in the tube 32 in two different arrangements. As shown in FIG. 2, the end 38 of the post 34 is inserted into the end 40 of the tube 32 and is retained in position by a fastener 42 . Conversely the post 38 may be inserted into the end 44 of the tube 32 to position the spools 36 on the opposite side of the bracket 30 . This provides the ability of providing a saw cut on either side of the guide 10 . When the post is inserted into end 40 , the guide bar 50 when the chain saw 12 is installed on the guide 10 will be positioned on one side of the guide 10 and when the post 34 is inserted into end 44 , the guide bar 50 will be positioned on the opposite side of the guide 10 . The post 34 serves as a complimentary pivotal mount that is matable with the slots 24 of the guide 10 .
Refer now to FIG. 3 of the drawings. FIG. 3 illustrates a typical operation for making a saw cut in aggregate material by the chain saw 12 . The chain saw 12 is of a type that has a guide bar 50 on which a saw chain 52 is mounted and is driven by a power head 54 of the chain saw 12 . In this embodiment, the bracket 30 and the post 34 are mounted to the chain saw 12 in the manner illustrated in FIG. 1 . This positions the guide bar 50 and the saw chain 52 to right of the bracket as shown in the figures. The guide 10 is secured in a desired position on the material to be cut by fasteners 60 . The fasteners 60 are inserted through the slot 18 of the guide 10 and are secured to the material in a conventional manner. The slots 18 , which are elongated permit adjusting the guide 10 to accurately position the guide 10 relative to the desired cut line.
FIG. 1 illustrates the chain saw 12 being inserted into one pair of slots 24 . The slots 24 are configured to receive the posts 34 and are sized to accommodate the diameter of the post 34 . The slots 24 have a formed hook 26 that defines a recess 28 . FIG. 1 illustrates the post 34 in the process of being inserted into the slots 24 and FIGS. 3 and 4 show the post 34 being fully seated in the recess 28 . The sides 20 of the guide 10 are received in the spools 36 . The spools 36 prevent lateral movement of the post 34 mounted to the chain saw 12 . The hook portion 26 of the slot 24 will retain the post 34 and thus the chain saw 12 in position on the guide 10 . As seen in FIGS. 3 and 4, the post 34 provides an axis of pivot for the guide bar 50 and the guide bar 50 may be pivoted about the post 34 in the direction indicated by arrow 66 .
Refer now to FIG. 3 of the drawings. The chain saw 12 is initially pivoted upward to facilitate making the initial cut in the aggregate material. The chain saw 12 is positioned on the guide 10 with the sides 20 being received in the center of the spools 36 and the post 34 fully seated in the recess 28 . The chain saw 12 is pivoted on the post 34 which moves the guide bar 50 in the direction indicated by arrow 66 . The post 34 being fully seated in the recess 28 maintains the position of the chain saw 12 relative to the bracket 10 and thus to the desired path of cut in the material. The chain saw 12 is continued to be pivoted on the post 34 and the cut will progress such as shown in FIG. 4 . When the guide bar 50 has been pivoted downward (in the direction indicated by arrow 66 ) a desired degree, the saw 12 is removed from the pair of slots 24 in which it was mounted and is moved to a next pair of slots 24 . The sawing operation continues until the full length of cut has been completed.
FIG. 5 illustrates an accessory bracket 100 that is mountable to the saw guide 10 . The bracket 100 is mountable to the guide 10 and provides a support for the chain saw 12 . The bracket 100 is of the I-beam type having upstanding legs 102 , 104 . The legs 102 , 104 are in the same spacial distance as the sides 20 of the guide 10 . An L-shaped bracket 106 is fixedly mounted to the bracket 100 . The bracket 106 has a slot 108 which is provided to facilitate mounting the bracket 100 to the guide 10 . A mounting pin 112 has a shoulder 116 sized to fit in the recess 28 of the guide 10 . The shank 118 of the pin 112 is sized to fit in the slot 108 of the bracket 106 .
The pin 112 sized to fit in the recess 28 of the sides 20 of the guide 10 and the slot 108 secures the bracket 100 to the guide 10 . The bracket 100 is mounted between the sides 20 of the guide 10 with the L-shaped bracket 106 fitting against the base 16 of the guide 10 . The bracket 100 is adjusted upwardly or downwardly as required to a desired position and the pin 112 is inserted into a recess 28 and through the slot 108 and into the opposite recess 28 of the opposite side 20 . A washer 110 having a shoulder portion 120 sized to fit the recess 28 (FIG. 6) is fitted on the end of the pin 110 and is secured by a nut 114 . The pin 110 fitting in the slot 108 of the bracket 100 permits the bracket 100 to be adjusted upwardly and downwardly to a final adjustment. When the bracket 100 is in its final adjusted position, the nut 114 is tightened which forces the shoulder 116 of the pin 112 and the shoulder 120 of the washer 110 against the L-shaped bracket 106 to fixedly secure the bracket 100 to the guide 10 .
The bracket 100 is particularly suited for making a plunge cut into the material to be sawn and is most often used to make a square cut or a straight cut into the material. Referring to FIG. 8, the chain saw 12 is fitted to the bracket 100 with the spools 36 riding on the legs 102 , 104 of the I-beam bracket 100 . The chain saw 12 thus may be moved toward and away from the guide 10 on the bracket 100 .
Those skilled in the art will recognize that modifications and variations may be made without departing from the true spirit and scope of the invention. The invention is therefore not to be limited to the embodiments described and illustrated but is to be determined from the appended claims.
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A guide for a concrete cutting chain saw. The guide has multiple paired slots which receive a post of a bracket mounted to the chain saw. The slots provide multiple pivotal mounts for the chain saw. The chain saw is mounted on the guide with the post being received in a pair of slots. The multiple slots provide sequential pivotal mounts for moving the saw to complete the cut. The post is mountable on either end of the bracket so the guide may be mounted on either side of the cut line.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Appl. No. 62/020,286 for “System and Method for Automatic Use-After-Free Exploit Detection” filed Jul. 2, 2014, herein incorporated by reference in its entirety for all purposes.
GOVERNMENT LICENSE RIGHTS
[0002] This invention was made with government support under FA8750-12-C-0161 awarded by the United States Air Force. The government has certain rights in this invention.
BACKGROUND
[0003] Computer networks and the devices and services that reside on them are often the subject of attacks by parties that are attempting to improperly access information and resources or to introduce malicious code to the networks. The attackers who are threats to information technology infrastructure assets and to the confidentiality of information stored in them may come from a wide variety of different sources, with different motives, levels of sophistication, available resources, and expertise.
SUMMARY
[0004] In accordance with certain aspects of the present invention, a process and system are shown for automatically detecting a use-after-free exploit based attack that includes receiving crash dump data relating to a fault event and determining whether an instruction that caused the fault event is a call type instruction. If the faulting instruction is a call type instruction, the process calls for identifying a use-after-free attack by checking whether the faulting instruction includes a base address in a first register and the first register has stored therein a pointer to a portion of memory whose status is free and generating a use-after-free alert if a use-after-free attack is identified. A further refinement of the process and system involves, if the faulting instruction is a call type instruction, identifying a use-after-free attack by checking whether the faulting instruction includes a base address in the first register and includes a pointer in a second register that points to a memory location associated with the base address, where a status of the memory location is free. In another refinement of the process and system, generating a use-after-free alert involves generating a use-after-free exploit factor data as input to a heuristic including multiple exploit detection factors including the use-after-free exploit factor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Various embodiments in accordance with the present disclosure will be described with reference to the drawings, in which:
[0006] FIG. 1 is a schematic diagram depicting an example of a computer network based system that may be subject to attack and may be suitable for utilization of certain aspects of the present invention;
[0007] FIG. 2 is a schematic diagram illustrating an example of a V-table structure;
[0008] FIG. 3 is a schematic diagram illustrating an example of a V-Table based attack on the V-table structure of FIG. 2 ;
[0009] FIG. 4 is a control flow diagram illustrating one example of a process for automatically detecting a V-table based attack in accordance with certain aspects of the present invention;
[0010] FIG. 5 depicts aspects of elements that may be present in a computer device and/or system configured to implement a method, system and/or process in accordance with certain aspects of the present invention.
[0011] Note that the same numbers are used throughout the disclosure and figures to reference like components and features.
DETAILED DESCRIPTION
[0012] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.
[0013] FIG. 1 is an architecture diagram that depicts aspects of an example of a computer network system with communication among multiple devices. In this example, network 106 , which can be one network or multiple networks, provides communication between server 110 connected to database 112 and several client devices, such as printer 120 , personal computer 122 , and interactive terminal 124 . The architecture of FIG. 1 is a simplified representation of an enterprise environment having a multitude of different computing devices that may represent a target for an attack. A gateway 130 provides a communications link between the network 106 and other networks, such as the internet, through which an attacker may launch an attack. The open nature of computer networks exposes code vulnerabilities that are frequently targeted for attack by hackers and malicious actors to gain improper access to systems.
[0014] Referencing memory after it has been freed can cause a program to crash, use unexpected values, or execute code. For example, a segment of memory allocated to a first pointer may be validly allocated to a second pointer at some point after the memory segment has been freed. Then the first pointer to the freed memory is used again and points to a location within the new allocation to the second pointer. As the data in the memory segment indexed by the first pointer is changed, the validly allocated memory is corrupted, which induces undefined behavior in the process that may be exploited to take control of a machine that is the subject of an attack. For example, if the newly allocated data happens to hold a C ++ class, then various function pointers may be scattered within the head data. If one of these function pointers is overwritten with an address to valid shellcode, then execution of arbitrary code may be achieved.
[0015] FIG. 2 is a graphical depiction of an example of a heap showing a relationship between an object d 150 allocated on the heap at address 0x00574720 and V-tables 152 and 154 that object d references. The first Dword of the d object 150 points to a B1 class V-table 154 that resides in a read-only .rdata section of memory and includes pointers to functions f 0 and f 1 . The second Dword of object d 150 points to a B2 class V-table 152 that also resides in the read-only .rdata section of memory and includes pointers to functions f 2 and f 3 .
[0016] In this example, in order to use a V-table pointer overwrite exploit to hijack a call to d->f 1 ( ) a “fake V-table” and attacker code must be in place in memory before executing the call. For this example, assume the “fake V-table” is at 0xDEADBEEF and the attacker code is at 0x41414141. This can be achieved by memory spraying to establish the following: 1) Address 0xDEADBEEF has already been allocated and is readable; 2) The DWORD at 4 bytes past 0xDEADBEEF, e.g. 0xDEADBEF3, is the address of attacker code that the exploit is trying to execute; and 3) the attacker code exists at 0x41414141. The exploit is to overwrite the pointer, which is stored in the heap-allocated object, to the B1 class V-table 154 with the value 0xDEADBEEF. Here, the pointer to the B1 V-table, which is stored at 0x00574720, is overwritten with the value 0xDEADBEEF. FIG. 3 illustrates the resulting overwritten V-table pointers with sprayed fake V-table 170 and attacker code 172 . (See http://neilscomputerblog.blogspot.com/2013/02/attacking-v-table-pointers.html for further details relating to this example.)
[0017] FIG. 3 is a control flow diagram illustrating an example of a process 200 for exploiting a use-after-free vulnerability, i.e. the Internet Explorer UAF vulnerability CVE-2013-3893, that exploits the ability of a JavaScript object to take or relinquish control over mouse events in a browser window using the functions setCapture( ) and releaseCapture( ). At step 202 , a malicious payload is stored at a known address in memory. At step 204 , the target device is heap sprayed with the execution address of the payload in step 202 . In order to create the freed memory to be used in the use-after-free exploit, at step 210 , a large number of items are created in the web page used for the exploit all having the same known title string. At step 212 , the title for many of the items created in step 210 is set back to a blank string in order to free the memory for those items. At step 214 , two items are created with a parent-child relationship. At step 216 , an Onclosecapture event is set for the child item to create the same large number of items as in step 210 with the same known title as used in step 210 . At step 218 , the target is heap sprayed with the payload execution address, e.g. large blocks of data containing repeated instances of the execution address. At step 220 , the setCapture( ) function is called from the child item created at step 214 . At step 222 , setCapture( ) is called from the parent item, which causes the Onclosecapture( ) event created at step 216 to be called in the child item.
[0018] The steps 210 and 216 permit the attacker to control the content of a register ECX in the processor and cause an exception to occur when system library MSHTML.DLL tries to run the instruction MOV EDX, [ECX], which causes the processor to fetch the value at the memory address stored in ECX and store it in register EDX. This instruction is following in code by the instructions MOVE EAX, [EDX+C4] and CALL EAX, which fetches the contents of the address C4 bytes beyond the address in ECX and calls it as a subroutine. This causes an exception to occur because there is no memory allocated at the address location indicated by the ASCII value of the title used in the steps 212 and 216 .
[0019] The memory that was freed at step 212 was re-used by Internet Explorer to store data that control the flow of execution in MSHTML.DLL and then wrongly re-used again for saving the text strings created at step 216 giving rise to a use-after-free (UAF) vulnerability. The UAF vulnerability is used by the attackers to cause the browser to use untrusted data from the attackers' web page to jump to the next location in memory. The attackers are thus able to execute their malicious payload at the heap spray address of step 204 using this UAF vulnerability.
[0020] At step 220 , the child item calls setCapture( ) followed by step 222 , which calls setCapture( ) from the parent item, which causes the onclosecapture( ) event from step 216 to be called in the child item. This causes execution to load the contents of an address in memory with the goal that the address might be one of the locations populated by the heap spray from step 204 , which contains the execution address of the payload introduced at step 202 . The memory freed up at step 212 is re-used by the Internet Explorer browser application to store data that controls the flow of execution in the rendering engine, mshtml.dll, and then re-used again for saving the texts strings created in step 216 , i.e. the name “user-after-free”. The attacker can thus gain remote code execution on the targeted device.
[0021] Use-after-free (UAF), denoting a scenario in which a block of memory reported to the operating system as no longer in use continues to be used by the executing program for the purpose for which it was originally allocated, is a common software vulnerability. In particular, if an attacker can cause the same region of memory to be reallocated for some other purpose that allows an attacker to influence the contents of that memory, or to influence the contents of that memory after it has been freed, than there exists an exploitable software vulnerability. In particular, an attacker may overwrite a segment of memory that was previously allocated in such a way that it should be interpreted as a list of offsets of functions to which execution may be branched (e.g. a jump table or vtable) and then cause the program to use that data (e.g. by calling a method in a freed object). This scenario can be detected in the program state as the branch occurs because the address to which execution will branch will be contained within a region of memory marked as being not currently in use. It is possible to infer an exploitable software bug, and to a limited degree, evidence of that bug being exploited, where this scenario exists.
[0022] If a UAF vulnerability exists in an application and an attacker is attempting to exploit it, then the exploit may fail because the address that the attacker attempted to redirect execution to is incorrect or invalid, e.g. a program call that causes a fault. The fault will typically cause a crash dump to be generated indicating that the application faulted on a call instruction, using a particular register as the base address (e.g. a vtable call, as a call to an array of pointers, is generally of the form base+index*displacement). Generally, in memory, there will also be a pointer to the object in which a method is being called.
[0023] The presence of a UAF exploit may be inferred from two conditions. First, if the faulting instruction is a call with the base address in a register, and that register contains a pointer to a chunk of memory that is marked as free on the heap, then a UAF exploit event is indicated. Secondly, if the faulting instruction is a call with the base address in a register, and in some other register is a pointer to a memory location containing this base address (e.g. the second register points to the object being dereferenced, the first component of which is a vtable address), then a vtable call may be inferred. If the object pointer in the second register also points to a free region on the heap, then the object whose vtable is being called has been deleted. A UAF exploit is indicated because the program faulted when it was attempting to execute a method on an object that resides in memory that is marked as free.
[0024] One aspect of the present invention involves checking the values of registers in a snapshot of program state, such as a crash dump, against a list of memory regions to determine whether any registers are acting as pointers to a jump table residing in a block of memory that is marked as free. Another aspect of the present invention involves checking the offset in memory of the base address of a function call to a jump table against a list of memory regions to determine whether the base of that jump table resides within a block of memory that is marked as free. Yet another aspect of the present invention involves inferring the existence or exploitation of a software vulnerability from the existence of pointers into blocks of memory marked free or from the use of operands to branch instructions located within blocks of memory marked free, or the use of this data as input to a heuristic comprised of this and other factors.
[0025] FIG. 4 is a control flow diagram illustrating one example of a process 300 for processing a crash dump to detect an attempted UAF exploit based attack in accordance with certain aspects of the present invention. At step 302 , a crash dump for a fault event is received and is analyzed. The crash dump data may be reverse assembled or similarly processed such that the code instructions in the crash dump are recovered along with their parameters, e.g. pointers, base address, branch with destination address or index.
[0026] At step 304 , the instruction that caused the fault event is analyzed to determine if it is a call instruction with a base address in a register and the register contains a pointer to a portion of memory that is marked as free on the heap. If it is, then the fault event is highly likely to have been caused by a UAF exploit attempt and control branches to step 310 to flag the event for action or further analysis. The alert may be used to automatically send a message to a network administrator, such as an email with the crash dump data, the reverse compiled code and text indicating the type of attack and the code module or instruction that faulted. The alert may be used to automatically trigger system defenses to respond to the attack, such as limiting or blocking access to the vulnerable code module. The alert may be used for a variety of responses.
[0027] If not, then control branches to step 306 , where the faulting instruction is analyzed to determine if it is a call instruction using a base address in a register and another register contains a pointer to a memory location associated with the base address and that the corresponding memory portion is marked as free on the heap. If so, then this fault is highly likely to have been the result of a UAF exploit attempt and control branches to step 310 . If not, then a UAF event is unlikely and control branches to step 312 with no alert.
[0028] In accordance with at least one embodiment of the invention, the system, apparatus, methods, processes and/or operations described herein may be wholly or partially implemented in the form of a set of instructions executed by one or more programmed computer processors, such as a central processing unit (CPU) or microprocessor. Such processors may be incorporated in an apparatus, server, client or other computing device operated by, or in communication with, other components of the system. In accordance with another embodiment of the invention, the system, apparatus, methods, processes and/or operations described herein may be wholly or partially implemented in the form of a set of processor executable instructions stored on persistent storage media.
[0029] FIG. 5 depicts aspects of elements that may be present in one example of a computer device and/or system 400 configured to implement at least some elements of a method, system and/or process in accordance with some embodiments of the present invention. The subsystems shown in FIG. 5 are interconnected via a system bus 402 . Additional subsystems include a printer 404 , a keyboard 406 , a fixed disk 408 , and a monitor 410 , which is coupled to a display adapter 412 . Peripherals and input/output (I/O) devices, which couple to an I/O controller 414 , can be connected to the computer system by any number of means known in the art, such as a serial port 416 . For example, the serial port 416 or an external interface 418 can be utilized to connect the computer device 400 to further devices and/or systems not shown in FIG. 5 including a wide area network such as the Internet, a mouse input device, and/or a scanner. The interconnection via the system bus 402 allows one or more processors 420 to communicate with each subsystem and to control the execution of instructions that may be stored in a system memory 422 and/or the fixed disk 408 , as well as the exchange of information between subsystems. The system memory 422 and/or the fixed disk 408 may embody a tangible computer-readable medium.
[0030] It should be understood that the present invention as described above can be implemented in the form of control logic using computer software in a modular or integrated manner. Based on the disclosure and teachings provided herein, a person of ordinary skill in the art will know and appreciate other ways and/or methods to implement the present invention using hardware and a combination of hardware and software.
[0031] Any of the software components, processes or functions described in this application may be implemented as software code to be executed by a processor using any suitable computer language such as, for example, Java, C++ or Perl or using, for example, conventional or object-oriented techniques. The software code may be stored as a series of instructions, or commands on a computer readable medium, such as a random access memory (RAM), a read only memory (ROM), a magnetic medium such as a hard-drive or a floppy disk, or an optical medium such as a CD-ROM, where the code is persistently stored sufficient for a processing device to access and execute the code at least once. Any such computer readable medium may reside on or within a single computational apparatus, and may be present on or within different computational apparatuses within a system or network.
[0032] All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and/or were set forth in its entirety herein.
[0033] The use of the terms “a” and “an” and “the” and similar referents in the specification and in the following claims are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “having,” “including,” “containing” and similar referents in the specification and in the following claims are to be construed as open-ended terms (e.g., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely indented to serve as a shorthand method of referring individually to each separate value inclusively falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation to the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to each embodiment of the present invention.
[0034] Different arrangements of the components or steps depicted in the drawings or described above, as well as components and steps not shown or described, are possible without departing from the scope of the invention. Similarly, some features and subcombinations are useful and may be employed without reference to other features and subcombinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will be apparent to one of ordinary skill in the art. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications can be made without departing from the scope of the invention.
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Systems, methods and media are shown for automatically detecting a use-after-free exploit based attack that involve receiving crash dump data relating to a fault event, determining whether the fault event instruction is a call type instruction and, if so, identifying a UAF attack by checking whether it includes a base address in a first register that stores a pointer to free memory and, if so, generating a UAF alert. In some examples, generating a use-after-free alert includes automatically sending a message that indicates a UAF attack or automatically triggering a system defense to the UAF attack. Some examples may include, for a call type faulting instruction, identifying a UAF attack, checking whether a base address in the first register includes a pointer in a second register to a free memory location associated with the base address.
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