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BACKGROUND
[0001] The health care industry continues to search for ways to reduce medical errors. Medical errors cause tens of thousands of patient injuries and deaths every year. One class of these errors is medication delivery error that is, giving a patient a wrong medication or a wrong dosage of a medicine.
[0002] One subset of medication delivery error involves injected medications. Typically medication is injected via a syringe. A typical syringe is a simple pump consisting of a plunger that fits tightly inside a cylindrical tube, also referred to as a “barrel”. The plunger can be pulled and pushed inside the cylindrical tube. The pulling and pushing allow the syringe to take in and expel a liquid medication through an orifice at an open end of the tube. For medical uses, the open end of the syringe is typically fitted with a needle. Another typical medical use for the syringe is to inject medication into an intravenous fluid infusion set. Generally, syringes are prepared, that is, filled with a medication close to the time that the medication is to be delivered. There is, however, typically a time gap, or delay, and sometimes a personnel gap between the time that the syringe is prepared and the time when the medication is injected into a patient. In these gaps, syringes can become confused by the person who performs the injection and the wrong medication can be delivered.
[0003] One attempt to prevent medical error in injected medications is syringe labeling. Types of syringe labeling include both affixing labels to the syringe and writing directly on the syringe, either onto a “labeling strip” already applied to the syringe or directly onto the syringe barrel with a pen. Compliance with syringe labeling has been generally found to be low apparently because of the time and effort involved in the labeling process.
[0004] It remains desirable to have innovative medication delivery mechanisms that can reduce the propensity for medication delivery error, that can be readily adopted by health care institutions, and that have convenience and ease of use that will encourage compliance.
SUMMARY
[0005] The present invention is directed to a syringe adapted to inhibit medication delivery error thereby addressing the problems articulated above.
[0006] Syringes having various tactile and visual differentiation features are provided. The tactile and visual differentiation elements act as a labeling system and an alert to the user. For example, the user may be alerted to a “high-alert” medication by the tactile surface elements on the syringe barrel. The visual and tactile differentiation can be used to alert the user to different medications in a group of filled syringes. Essentially, the tactile and visual differentiation is a way of alerting the user to pay attention and is a quick cue to syringe contents.
[0007] The tactile and visual differentiation elements include ribbing on the tube, or “barrel” of the syringe. Alternatively, the tube has tactile strips. In a system employing the embodiments presented here, the user is alerted to the type of medication in the syringe .
[0008] In one embodiment, the vertical ribs on the outside of the tube create the impression of a square or triangular shape on the hand holding the syringe. In further alternative arrangements, the syringe tube is hexagonal or decahedronal or dodecahedronal in cross-section.
[0009] In an alternative embodiment, ribs arranged on the outside surface of the syringe tube provide a tactile difference between syringes. In a first arrangement, the outside surface of the tube has at least one vertical rib. In a second arrangement, the outside surface of the tube has at least one horizontal rib, also referred to as a “circumferential rib”.
[0010] The ribs provide both visual as well as tactile differentiation to syringes. This differentiation provides a safety improvement in that easily distinguishable differences between syringes will discourage medicine delivery errors. Specifically, medications designated as “high-alert” medications such as muscle relaxants, narcotics, and insulin could be more easily distinguished from other medications. A differently configured syringe would be a tactile indicator to a health care provider, often working in an environment that is hurried and full of distractions, of the type of drug that the syringe holds. Further, syringe differentiation would be a strong safety enhancement in the production and use of pre-filled syringes which are expected to be used for a wide range of medications, including vaccines, anticoagulants, anti-infectives, anti-inflammatory agents, hematological agents, multiple sclerosis therapies, hormone therapies, obstetric agents, cancer therapies, pain relievers, vasopressors, local anesthetics, and hypnotic agents.
[0011] In another alternative embodiment, the ribs on the syringe tube are provided as part of the syringe labeling. Together these innovations have the potential to add an extra margin of safety for patients against the potentially harmful consequences of being administered a wrong drug. Embodiments of the present invention provide the advantages of reducing medication delivery errors and their associated costs, both human and financial.
[0012] Another embodiment is a barrel for a syringe where the barrel is a tube that has an outer surface. This embodiment further includes a tactile element on the outer surface configured such that the tactile element acts as a tactile label for the syringe whereby a user of the syringe is able to perceive an alert to the contents of the syringe. A barrel with a tactile labeling element on a syringe could be used to alert a syringe user to a particular medication contained in the syringe thereby tending to reduce medical error.
[0013] In a first alternative embodiment, the tactile element is a plurality of vertical ribs. In a one arrangement, the plurality of ribs are arranged and configured to create an impression of a particular geometric figure in cross-section such as a square or a triangle. This embodiment retains the underlying configuration of a syringe with a cylindrical barrel and further including a non-rounded shape superimposed over the familiar arrangement. This embodiment provides the user with a tactile alert to the user differentiating the syringe of the present embodiment from a conventional syringe.
[0014] Another embodiment is a barrel for a syringe where the barrel is a tube that has an outer surface. This embodiment further includes a tactile element of circumferential ribs on the outer surface configured such that the tactile element acts as a tactile label for the syringe whereby a user of the syringe is able to perceive an alert to the contents of the syringe. In an alternative arrangement, the plurality of circumferential ribs are located and arranged as a plurality of groups on the outer surface of the syringe barrel.
[0015] Another embodiment is a barrel for syringe where the barrel is a tube that has an outer surface. The outer surface of the tube includes a tactile element where the tactile element is a spiral ridge.
[0016] Another embodiment is a barrel for a syringe where the barrel is a tube that has an outer surface. The outer surface includes a tactile element that is a plurality of bumps. In an alternative arrangement, the tactile element is a plurality of dimples.
[0017] Another embodiment is a syringe for delivery of a medication where the syringe includes a barrel having a cylindrical tube. The cylindrical tube has an outer surface. The outer surface includes a tactile element configured such that the tactile element acts as a tactile label for the syringe whereby a user of the syringe is able to perceive an alert to the contents of the syringe.
[0018] In one alternative embodiment of the syringe, the tactile element is a plurality of vertical ribs. In one arrangement, the plurality of vertical ribs are arranged and configured to create an impression of a particular geometric figure in cross-section such as a square or a triangle.
[0019] Another embodiment is a syringe for delivery of a medication where the syringe includes a barrel having a cylindrical tube. The cylindrical tube has an outer surface. The outer surface includes a tactile element where the tactile element is a plurality of circumferential ribs.
[0020] Another embodiment is a syringe for delivery of a medication where the syringe includes a barrel having a cylindrical tube. The cylindrical tube has an outer surface. The outer surface includes a tactile element where the tactile element is a spiral ridge.
[0021] Another embodiment is a syringe for delivery of a medication where the syringe includes a barrel having a cylindrical tube. The cylindrical tube has an outer surface. The outer surface includes a tactile element where the tactile element is plurality of bumps. In an alternative embodiment, the tactile element is a plurality of dimples.
[0022] In another embodiment, the syringe includes a plunger having a thumb plate. The thumb plate further includes a second tactile element configured such that the second tactile element forms a second non-textual tactile label. From this second non-textual tactile label, a user of the syringe is able to perceive an alert to contents of the syringe. In one arrangement, the second tactile element is a geometric configuration of the thumb plate. In a second arrangement, the second tactile element is at least one raised structure locating on the upper surface of the thumb plate.
[0023] In another embodiment, the syringe includes an adapter cap. The adapter cap includes a third tactile element configured such that it forms a third non-textual tactile label. Through this third non-textual label, a user of the syringe is able to perceive an alert to contents of the syringe.
[0024] In another embodiment, the syringe includes a barrel, a plunger with a thumb plate and an adapter cap. The barrel includes a tactile element that forms a non-textual tactile label. The thumb plate further a second tactile element formed and configured as a second non-textual tactile label. The adapter cap further include a third tactile element formed and configured as a third non-textual tactile label. The tactile elements on the barrel, the thumb plate and adapter cap match providing the user with an alert to contents of the syringe.
[0025] Another embodiment is a syringe for delivery of a medication where the syringe includes a barrel having a cylindrical tube. The cylindrical tube has an outer surface. The outer surface includes a tactile element where the tactile element is a flexible sheet with tactile labeling elements. The flexible sheet is affixed to the outer surface of the tube.
[0026] The present invention together with the above and other advantages may best be understood from the following detailed description of the embodiments of the invention illustrated in the drawings, wherein:
DRAWINGS
[0027] FIG. 1 is a side view of a syringe with a tube having a plurality of vertical ribs according to principles of the invention;
[0028] FIG. 2 is a cross-sectional view of the syringe of FIG. 1 ;
[0029] FIG. 3A is a cross-sectional view of a first alternative embodiment of ribs on a syringe tube according to principles of the invention;
[0030] FIG. 3B is a cross-section view of a second alternative embodiment of ribs on a syringe tube according to principles of the invention;
[0031] FIG. 4 is a side view of a syringe with a tube having an alternative type of vertical rib on the syringe tube according to principles of the invention;
[0032] FIG. 5 is a side view of a syringe having circumferential ribbing along the syringe tube according to principles of the invention;
[0033] FIG. 6 is a side view of a syringe having a spiral ridge according to principles of the invention;
[0034] FIG. 7 is a side view of a syringe having tactile strips according to principles of the invention;
[0035] FIG. 8 is an illustration of a label having ribs according to principles of the invention,
[0036] FIG. 9 is a cross-section view of a syringe where the ribs are arranged to form a square shape around the syringe barrel according to principles of the invention;
[0037] FIG. 10 is a cross-section view of a syringe where the ribs are arranged to form a triangle shape around the syringe barrel according to principles of the invention;
[0038] FIG. 11 is a side view of a syringe having a surface with a plurality of protrusions according to principles of the invention;
[0039] FIG. 12 is a top view of an embodiment of a thumb plate according to principles of the invention;
[0040] FIG. 13 is a top view of an alternative embodiment of a thumb plate according to principles of the invention;
[0041] FIG. 14 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0042] FIG. 15 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0043] FIG. 16A is a top view another alternative embodiment of a thumb plate according to principles of the invention;
[0044] FIG. 16B is a side view of the thumb plate of FIG. 16A ;
[0045] FIG. 17 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0046] FIG. 18 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0047] FIG. 19 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0048] FIG. 20 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0049] FIG. 21 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0050] FIG. 22 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0051] FIG. 23 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0052] FIG. 24 is a top view of another alternative embodiment of a thumb plate according to principles of the invention;
[0053] FIG. 25 is a top view of another alternative embodiment of the thumb plate according to principles of the invention;
[0054] FIG. 26 is a top view of another alternative embodiment of the thumb plate according to principles of the invention;
[0055] FIG. 27 is a top view another alternative embodiment of a thumb plate according to principles of the invention; and
[0056] FIG. 28 is a side view of an embodiment of a syringe including an adapter cap according to principles of the invention.
DESCRIPTION
[0057] Embodiments of the present invention include syringes adapted to reduce instances of medication delivery error. Syringes according to embodiments of the present invention have barrels that are variously configured such that they provide non-textual tactile differentiation. . The tactile elements on the syringes are formed and configured such that the tactile elements form a non-textual tactile label. The tactile elements provide alerts to users of the syringes to be aware of the syringe contents. The different syringe configurations also provide visual differentiation beyond text labeling. The syringes are typically in the range of sizes from 1 milliliter to 60 milliliters, however the present invention is not limited to this range.
[0058] FIG. 1 is a side view of a syringe according to one embodiment. The syringe 100 has a cylindrical tube 110 . The tube 110 is also referred to as a “barrel.” The tube 110 includes a flange 120 at one end and an adapter 102 at the other end. The adapter 102 in some arrangements holds a needle as shown in FIG. 1 . In alternative arrangements, the adapter 102 is mateable with an intravenous fluid infusion set. The syringe 100 further has a plunger 115 . The plunger 115 is inserted into the flanged end of barrel 110 and is configured to slide inside the barrel 110 . The end of the plunger 115 inside has a plunger seal (not shown in this figure) to maintain a tight fit between the plunger and the inner surface of the barrel. The end of the plunger 115 outside the barrel has a thumb plate 104 .
[0059] Typically, a syringe user grips the barrel between the second and third fingers of one hand and presses on the plunger with the thumb of that hand to push a fluid out of the adapter end of the syringe.
[0060] The syringe 100 has a plurality of vertical ribs 125 , also referred to as “ridges”, arranged on the outer surface of the tube 110 around the tube's circumference. The ribs 125 are substantially parallel to the vertical axis 127 of the tube 110 . Further, the ribs 125 are arranged substantially equidistantly around the tube 110 .
[0061] In a first arrangement, the ribs 125 are formed as part of the tube 110 in, for example, an extrusion process. In a second arrangement, the ribs 125 are applied to the tube 110 . The ribs are applied, for example, as part of a flexible sheet affixed to the outer surface of the tube 110 . In the flexible sheet, the ribs form a part of a medication label to be located on the outer surface of the tube thereby providing both a tactile and visual differentiation to the syringe. The ribs may also be applied individually. The present embodiment is not limited to those methods of forming the ridges provided here.
[0062] The ribs 125 provide a tactile alert to the person using the syringe to deliver medication. The ribs 125 are a surface element on the syringe barrel that differentiates the barrel of the present embodiment from a conventional syringe having no tactile differentiation elements. The user of the syringe of the present embodiment would have a tactile alert when handling the syringe beyond any text labeling. If, for example, “high-alert” medications are used only in syringes having a tactile alert on the barrel and other types of medications are used in conventional syringes, the tactile alert would tend to make a user aware of the high-alert medication and medication delivery errors would tend to be averted. The tactile differentiation is not related to any text, for example, in the way that Braille represents letters and can be used to form words. The tactile differentiation provides a quick and simple alert to the user. In addition to the non-textual tactile alert, the ribs 125 provide a visual difference between the syringe of the present embodiment and conventional syringes. The visual difference may be enhanced by ribs having a color different from that of the syringe barrel.
[0063] FIG. 2 is a cross-sectional view of the syringe of FIG. 1 . The tube 110 of the syringe has ribs 125 arranged around the outer surface 130 . In this embodiment, the ribs 125 are rounded ridges. Alternative configurations and forms are possible within the scope of the invention. For example, in one alternative embodiment, there is only one vertical rib. In another arrangement, the vertical ribs are arranged in groups, for example, the groups of three ribs shown in FIG. 3A . In other alternative embodiments, for example, the vertical ribs on the outside of the tube create the impression of a square or triangular shape in the hand holding the syringe. These embodiments are shown in FIGS. 9 and 10 respectively and will be described in greater detail below. In further alternative arrangements, the syringe tube has additional vertical ribs on the outside surface such that it creates the impression of a hexagonal or decahedronal or dodecahedronal shape in the hand holding the syringe. Examples of further alternative embodiments are shown in FIGS. 3A and 3B .
[0064] FIG. 3A is a cross-sectional view of an alternative embodiment of ribs on a syringe tube 138 . In this embodiment, groups 140 of vertical ribs are arranged around the outer surface of the syringe tube 138 . This alternative arrangement of ribs provides both tactile and visual differentiation both from syringes without ribbing and from the embodiment shown in FIGS. 1 and 2 .
[0065] FIG. 3B is a cross-sectional view of a further alternative embodiment of a syringe having ribs 150 on the outer surface of the syringe tube 148 . In this embodiment, the ribs 150 are not rounded and instead are triangular in cross-section and arranged in a manner where an edge is presented to a user gripping the syringe.
[0066] FIG. 4 is a side view of a syringe 200 with a tube 210 having an alternative type of vertical rib 215 on the syringe surface 220 . The vertical ribs 215 have gaps along each rib. This arrangement provides tactile differentiation as well as visual differentiation.
[0067] FIG. 5 is a side view of a syringe 300 having an alternative rib arrangement. In this embodiment, circumferential ribs 320 are located on the outer surface of the syringe tube 310 . In this embodiment, only four ribs are shown. The ribs 320 are arranged in two groups. A first group is located closer to the needle end of the tube 310 . A second group is located closer to the plunger end of the tube 310 . Alternative embodiments of rib number and location are possible. The alternative embodiments provide both tactile and visual differentiation from other configurations.
[0068] FIG. 6 is a side view of an alternative embodiment of a syringe 350 . In this embodiment, the syringe tube 355 has a spiral ridge 360 on the surface 365 of the tube 355 .
[0069] FIG. 7 is a side view of an alternative embodiment of a syringe 400 . In this embodiment, the syringe tube 410 has a tactile strip 415 located on the surface 420 of the tube 410 . The tactile strip 415 has, for example, a roughened surface that is semi-random like sandpaper. Alternatively, the tactile strip 415 has a regularly roughened surface having a pattern such as a diamond pattern. Other types of roughening are possible within the scope of the invention. In alternative embodiments, the syringe tube 410 has more than one tactile strip 415 . The tactile strip may be formed as a part of the manufacture of the tube. Alternatively, the tactile strip may be applied after the tube is formed, for example as a separate sheet, or for example, through a printing process. In a further alternative embodiment, the tactile strip incorporates medication information and acts as a text label in addition to a tactile label.
[0070] FIG. 8 is an illustration of a sheet having ribs according to one embodiment. The sheet 500 is made of a flexible material such as a plastic. The sheet 500 includes a number of ribs, or “ridges”, 510 . The sheet 500 further includes text information 520 so that it may also function as a text label. The sheet is also capable of being adhered to plastic or glass so that it is capable of being adhered to a syringe tube to provide both visual and tactile cues about the contents of the syringe. The sheet 500 shown in this embodiment has the ribs equivalent to those shown in FIG. 1 , however, other types of surface element can be accomplished on the sheet as well such as the circumferential rib, the spiral rib, and the tactile strip. The differentiating tactile surface elements available on the sheet 500 are not limited to those listed above. Other types of surface element are within the scope of the invention.
[0071] FIG. 9 is a cross-sectional view of an alternative embodiment of ribs on a syringe tube 550 . In this embodiment, four vertical ribs 555 are arranged around the outer surface of the syringe tube 550 . The four vertical ribs 555 are arranged and configured around the syringe tube 550 such that the impression on the hand of the syringe user is that of a syringe that is square in cross-section.
[0072] FIG. 10 is a cross-sectional view of an alternative embodiment of ribs on a syringe tube 560 . In this embodiment, three vertical ribs 565 are arranged and configured around the syringe tube 560 such that the impression on the hand of the syringe user is that of a syringe that is triangular in cross-section.
[0073] The configurations shown in FIGS. 9 and 10 are merely exemplary. Other rib configurations forming other shapes in cross-section such as a hexagon or an octagon are possible within the scope of the invention.
[0074] FIG. 11 is a side view of an alternative embodiment of a syringe 600 . In this embodiment, the syringe 600 has a surface 605 including a plurality of protrusions, also referred to as “bumps” 610 . The bumps 610 in this embodiment are formed on the surface 605 of the syringe barrel. In alternative embodiments, the bumps 610 are part of a label applied to the tube for example with adhesive. In an alternative arrangement, the bumps are concave, or “dimples.” Various arrangements of dimples or bumps are possible in order to provide tactile differentiation. The placement, distance between, number and arrangement of bumps are all possible variations on the syringe tube surface. For example, there may be in one arrangement a single vertical line of bumps on the surface of the syringe. In an alternative arrangement, there are two lines of bumps. Further alternative shapes of bumps are within the scope of the invention. For example, the bumps may be round, oval, square, triangular, pointed or pyramid-shaped. The alternatives provided here are merely exemplary. The form and configuration of the bumps is not limited to those described here. The bumps may also be of a different color than the syringe tube thereby providing a visual differentiation element as well as a tactile differentiation element.
[0075] The thumb plate of a syringe is another location where tactile differentiation may be effectively used to provide non-textual cues to syringe users about the syringe's contents. FIGS. 12-27 show embodiments of various embodiments of thumb plates with tactile differentiation. The tactile differentiation of the thumb plate could be used alone or in combination with differentiation on the surface of the syringe barrel.
[0076] FIG. 12 is a top view of a thumb plate 620 that is substantially square in shape. FIG. 13 is a top view of a thumb plate 625 that is substantially triangular in shape. FIG. 14 is a top view of a thumb plate 630 that is substantially a six-sided polygon in shape. FIG. 15 is a top view of a thumb plate 635 that is substantially hexagonal in shape. The thumb plate shapes provided here are merely exemplary. Other shapes are possible within the scope of the invention.
[0077] FIG. 16 a is a top view of a thumb plate 640 that is substantially circular. FIG. 16 b is a side view of the thumb plate 645 shown in FIG. 16 a . The thumb plate 640 has a top surface. A round protrusion 645 is located on the top surface. In this embodiment, the protrusion has a radius that is somewhat smaller than that of the thumb plate. In FIG. 21 , a round protrusion 695 is located on the top surface of the thumb plate 690 . The protrusion in FIG. 21 has a radius that is not much smaller than the radius of the thumb plate 690 .
[0078] FIG. 17 is a top view of a thumb plate 650 having two protrusions 655 on its top surface. The two protrusions are located off the center of the thumb plate 650 in this embodiment however, the protrusions may be centered in an alternative arrangement. FIG. 18 and FIG. 19 are top views of thumb plates 660 , 670 . Each thumb plate 660 , 670 has three protrusions 665 , 675 . The protrusions 665 in FIG. 18 are centered and are arranged in a triangular shape. The protrusions 675 are centered but are arranged in a line. FIG. 20 is a top view of a thumb plate 680 having four protrusions 685 . The protrusions 685 are centered and arranged in a square shape. The arrangements discussed here are merely exemplary. Other arrangements of the protrusions are possible within the scope of the invention.
[0079] FIGS. 21 , 22 and 23 are top views of thumb plates 690 , 700 , 710 with a single relatively large protrusion on the top surface of each. FIG. 21 has a circular protrusion 695 . FIG. 22 has a square protrusion 705 and FIG. 23 has a triangle-shaped protrusion 715 .
[0080] FIG. 24 is a top view of a thumb plate 720 that has a ridge 725 on the top surface. FIG. 25 is a top view of a thumb plate 730 having a raised “X” shape 735 . FIG. 26 is a top view of a thumb plate 740 having an arrangement of three ridges 745 . FIG. 27 is a top view of a thumb plate 750 having an arrangement of two ridges 755 .
[0081] The raised elements on the thumb plates in FIGS. 16-27 may be formed and configured in various alternative ways, some already described above. Additional alternative configurations include variations in height of the feature with regard to the top surface of the thumb plate.
[0082] FIG. 28 is a side view of a syringe according to an alternative embodiment. The syringe 100 has a cylindrical tube 110 . The tube 110 is also referred to as a “barrel.” The tube 110 includes a flange 120 at one end and an adapter at the other end. The adapter is not visible in this view. The adapter is covered by an adapter cap 775 . The adapter cap 775 is also referred to as a hub cover or a plug cap. The adapter cap 775 covers the open end of the barrel 110 . The adapter cap 775 is another location on the syringe that includes non-textual tactile elements to alert the user to the syringe contents. In this embodiment, the adapter cap 775 has a plurality of vertical ridges 780 or “ribs” similar to the plurality of vertical ribs 125 on the syringe barrel 110 .
[0083] As described above with regard to the syringe barrel, the ribs 780 provide a tactile alert to the person using the syringe to deliver medication. The ribs 780 are a surface element on the adapter cover that differentiates the adapter cover of the present embodiment from a conventional adapter cover without tactile differentiation. The user of the syringe of the present embodiment would have a tactile alert when handling the ridged adapter cover beyond any text labeling. The tactile differentiation described above with regard to the syringe barrel may be applied similarly to the adapter cap. In one embodiment, the tactile differentiation elements on the adapter cap match that provided on the syringe barrel. In an alternative embodiment, the tactile differentiation on the adapter cap and on the barrel are different. In a further alternative embodiment, there is tactile differentiation on the adapter cap only and not on the syringe barrel. In a further alternative embodiment, the tactile differentiation elements on the syringe barrel, thumb plate and adapter cap match. This embodiment has the benefit of maximizing the alert to the user.
[0084] Other variations from the syringes described above include using different colors for the plunger seal to provide visual differentiation of the syringes.
[0085] Embodiments of the invention described above provide tactile labels that alert the users of syringes in a medical setting to particular contents of the syringes. This differentiation of the syringes with tactile labeling from conventional syringes and also from other syringes with tactile labeling provides a significant safety improvement in that easily distinguishable differences between syringes will discourage medicine delivery errors. Specifically, medications designated as “high-alert” medications such as muscle relaxants, narcotics, and insulin could be more easily distinguished from other medications. A differently configured syringe would be a tactile indicator to a health care provider, often working in an environment that is hurried and full of distractions, of the type of drug that the syringe holds. Further, syringe differentiation would be a strong safety enhancement in the production and use of pre-filled syringes which are expected to be used for a wide range of medications, including vaccines, anticoagulants, anti-infectives, anti-inflammatory agents, hematological agents, multiple sclerosis therapies, hormone therapies, obstetric agents, cancer therapies, and pain relievers.
[0086] It is to be understood that the above-identified embodiments are simply illustrative of the principles of the invention. Various and other modifications and changes may be made by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.
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Syringes having various tactile and visual differentiation features are provided. Elements of differentiation ribs of various shapes and configurations are located on the syringe tube. The different configurations provide tactile cues and to some extent visual cues that enable a user to quickly and easily identify different syringes and accordingly the syringe contents thereby encouraging greater precision in the delivery of correct medications.
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FIELD OF THE INVENTION
[0001] The present invention relates to a mammogram workstation and a method for using such a workstation.
BACKGROUND OF THE INVENTION
[0002] Breast cancer is one of the most common types of cancer afflicting Western society. It is estimated that the spread of the disease has risen in the United States, from one in twenty women being afflicted in 1940, to one in eight in 1995. The American Cancer Society estimated that 183,000 new cases of breast cancer were reported during 1995. In the United States, some 46,000 women die from the disease per year. Today, it is accepted that the best way to detect breast cancer in its early stages is by annual mammography screening of women aged 40 and up.
[0003] Today, radiologists generally interpret mammograms visually, using a light box, and their analysis is largely subjective. Film masking is used to highlight additional detail. In many cases, the radiologist employs supplementary tools such as a magnifying glass and bright light sources to evaluate very dark regions. If the mammogram is not conclusive the radiologist must recall the patient for an additional mammogram using one or more of the following techniques:
[0004] 1. adding a view with a different projection;
[0005] 2. performing a magnification mammogram by changing the distance between the breast and the film;
[0006] 3. locally compressing the breast in the area of suspected abnormality;
[0007] The analysis, even after using the above techniques, still remains mainly subjective.
[0008] In order to aid radiologists in reducing the false negative rate in mammographic screening, computer systems using specialized software and/or specialized hardware have been developed. These systems, often called computer-aided detection systems, hereinafter often denoted as “CAD systems”, have been known for many years and have been reported extensively. As noted below, their use in evaluating mammograms has been discussed at length in both the patent and professional literature.
[0009] CAD systems are typically used as follows. A radiological technician or a radiologist takes a set of radiological film images of the patient following a predetermined protocol. A radiologist views the film images and reaches a preliminary diagnosis. The radiologist next views separate, second images that are generated by the CAD system after processing the scanned and digitized set of film images. Typically, suspected abnormalities detected by the CAD system through computer analysis of the digitized version of the respective radiological film images appear as marked locations on the second images. After a reexamination of the areas of the original film images that correspond to the positions of the suspected abnormalities displayed on the CAD system, the physician makes a final diagnosis and determines a course of further action.
[0010] [0010]FIG. 1 to which reference is now made shows a block diagram of a simplified prior art CAD system designated as 100 . Radiological films 110 taken by a radiologist or technician are scanned into and digitized by a digitizer 114 . The digitized image produced is then fed into a processor 142 , which uses any of many known algorithms to detect suspected abnormalities on the mammogram. Typical algorithms used for detecting abnormalities on the mammogram can be found in many of the references cited below. The digitized image is displayed on display 134 . The displayed image shows the abnormalities detected, a location marker typically marking each abnormality. The image can be manipulated through a keyboard or other input device. Using a keyboard 138 , the user instructs the processor to send the displayed images to a printer 118 for printing. The printout of the displayed digitized images includes location markers indicating suspected abnormalities on the images.
[0011] Computer-aided detection (CAD) mammography systems, and algorithms for use therewith, have been discussed extensively in many issued patents. An overview of the field can be obtained by reviewing U.S. Pat. Nos. 5,729,620 (Wang); 5,815,591 (Roehrig et al); 5,828,774 (Wang); 5,854,851 (Bamberger et al); 5,970,164 (Bamberger et al); 6,075,879 (Roehrig et al); 6,198,838 (Roehrig et al); 6,266,435 (Wang); and 6,434,262 (Wang). These patents, including references cited therein, are hereby incorporated by reference in this specification as though fully set forth herein.
[0012] Generally, a radiologist reads and analyzes several sets of mammograms one after another, each set relating to a different patient. The radiological films of the patients are often commingled during the digitizing process, as are the printed reports generated by the printer. Significant time is required by the staff of a radiology department to sort and collate the films with their respective printouts for insertion into the patient's physical files. The commingling of film and printed reports allows for the possibility of misplacement, error or even loss. In addition, the separation of films and printed reports, and then their subsequent collation generally requires a large work area.
[0013] While many prior art patents discuss collation of medical records, to the best of the inventors' knowledge they almost always pertain to collating digital records and do not relate to the collation of physical records. Typical, prior art medical data management and collating systems and methods can be found, for example, in U.S. Pat. Nos. 6,272,481 (Lawrence et al); 6,336,903 (Bardy); and 6,368,284 (Bardy). All appear to be computer-based systems and methods dealing with digital records, and they do not provide for collating and filing physical records.
[0014] In the case of mammograms the retention and organization of the physical radiological films is mandated. A workstation and method for retaining, organizing and assisting in the filing of radiological film mammograms together with related digitally produced printouts is required but lacking. Such a workstation and method would require less time for data management and would prevent errors.
SUMMARY OF THE PRESENT INVENTION
[0015] It is an object of the present invention to provide a system and method for collating radiological films and their associated physical data generated during mammogram screening.
[0016] It is a further object of the present invention to provide a method and a system for collating mammogram films and printouts that is useful in both large and small environments, e.g. hospitals and radiological clinics.
[0017] An additional object of the present invention is to provide a system and method for collating and filing mammogram films and data that can be carried out in smaller work areas. Today collating and filing requires relatively large areas to collate and file the physical records produced by mammogram screening.
[0018] An additional objective of the present invention is to provide a mammogram display having a pre-selected order for the displayed digitized images, irrespective of the order in which the film mammograms have been fed into the scanner.
[0019] A further objective of the present invention is to provide a method for automatically isolating, that is separating, the digitized images generated from analog film mammograms of one patient from another. Additionally, it is an object of the invention to keep the film mammograms and their associated physical data, e.g. digitized image printouts, of one patient physically separate from those of another. This separation simplifies filing the mammograms in physical storage containers. Both of these separation objectives are achieved with separator films described in the present invention.
[0020] There is thus provided in accordance with the present invention a method of separating and collating mammogram records, the method including the steps of: scanning one or more radiological film mammograms relating to a patient thereby obtaining one or more digitized images; storing the one or more digitized images in a memory; providing and scanning a separator film having identifiable features which when scanned identify the film as a separator film, and positioning the separator film immediately after the one or more radiological films of a patient; and repeating the scanning, storing and providing steps for all remaining film mammograms of all patients in a film mammogram queue. The digitized images generated subsequent to each scanned separator film are stored separately from the stored digitized images obtained from prior scanned film mammograms.
[0021] In yet another embodiment of the invention, the method further includes a printing step, the printing step providing a printout of the one or more digitized images of the one or more film mammograms of a patient. The printing step also includes conveying and positioning the printout together with the one or more film mammograms. The one or more film mammograms and printout form a collated package of physical data relating to a single patient. Generally, the printout contains location markers indicating anatomical abnormalities found on each mammogram. Sometimes the printing step is effected prior to the providing step, more often the printing step is effected after the separator film has been scanned and identified as a separator film. When a printing step is included, it is also repeated in the above mentioned repeating step
[0022] In yet another embodiment of the invention, the method includes an inputting step where patient identifier data are entered. Sometimes the inputting step is effected prior to the providing step as discussed previously. More often the inputting step is effected prior to the scanning step. When an inputting step is included, it is also repeated in the above mentioned repeating step.
[0023] In other embodiments of the invention, the step of inputting enters identifier data for every patient having a set of mammograms in the mammogram queue before any scanning begins and the repeating step includes repeating only the scanning, storing, providing, and printing steps.
[0024] In another aspect of the present invention there is provided a method for separating and collating mammogram records, the method includes the steps of: scanning a set of film mammograms relating to a patient thereby to obtain at least one digitized image of the set of film mammograms; moving the scanned set of mammograms to a collating station; providing and scanning a separator film, and positioning the separator film immediately after the at least one radiological film of a patient; positioning the separator film so that it is the last film of the scanned set of film mammograms located at the collating station; repeating the scanning, moving, providing and positioning steps for all N sets of film mammograms in a film mammogram queue, where N≧1; and transferring each of the N sets of film mammograms positioned between separator films to its own individual storage container for storage.
[0025] In another preferred embodiment of this aspect of the invention, the method further includes: a printing step, the printing step providing a printout of the at least one digitized image; and a conveying step, the conveying step conveying and positioning the printout together with the set of film mammograms at the collating station, whereby the set of film mammograms and printout form a collated package of physical data relating to a single patient. Generally, the printout generated by the printing step contains location markers indicating anatomical abnormalities found on each mammogram. Sometime the printing and conveying steps are effected prior to the providing step, but more often the printing and conveying steps are effected prior to the positioning step. When printing and conveying steps are included, they are also repeated in the repeating step.
[0026] In yet another embodiment of this aspect of the invention, the method may further include an inputting step wherein patient identifier data are entered. Sometimes the inputting step is effected prior to the providing step while more often times the inputting step is effected prior to the scanning step. When an inputting step is included, it is also repeated in the repeating step. More often when there is an inputting step, the inputted identifier data for every patient having a set of mammograms in the mammogram queue is entered prior to beginning the scanning step and the repeating step includes only the scanning, moving, providing, positioning, printing and conveying steps.
[0027] In yet another aspect of the invention, there is provided a method for displaying digitized images of film mammograms on the display of a mammogram workstation, where the method includes the steps of: scanning a set of radiological film mammograms relating to a patient, thereby to obtain digitized images of the set of film mammograms; storing the digitized images in a memory; analyzing the digitized images to determine the view of each digitized image; and using the determined views of each image to display the digitized images in a pre-selected order irrespective of the order in which the film mammograms were scanned.
[0028] There is provided in accordance with another aspect of the present invention a workstation system for collating radiological film mammograms and other physical records. The system includes a scanner which receives and digitizes radiological film mammograms of a patient and a separator film carrying identifiable features for identifying the film as a separator film. It also includes a collating station for receiving the scanned films from the scanner. The system has a processing means for receiving digitized images from the scanner. The processing means is operative to evaluate the digitized images of the film mammograms so as to detect suspicious lesions. It also generates output data indicative of such lesions, the data being stored in association with the digitized images. The processing means is further operative to detect the scanned separator film and to assign all subsequent scanned radiographic film mammograms to other patients. The system further includes a printer in communication with the processing means for producing a printout of the digitized images, identifying data, and output data relating to the patient. The printer includes a conveyor for conveying the printout to the collating station. Finally, the system contains a means for synchronizing the scanner and the printer so that the printout is laid on the scanned films prior to the delivery of the separator film to the collating station.
[0029] Additionally, in accordance with a preferred embodiment of the present invention, the system further includes a display for displaying the digitized images of scanned radiological film mammograms received from the processing means which is in electronic communication with the display.
[0030] Additionally, in accordance with a preferred embodiment of the present invention, the processing means of the system operates the display so that the digitized images are displayed in a pre-selected order irrespective of the order in which the film mammograms were scanned by the scanner.
[0031] In yet another embodiment of the invention, the system further includes an input device for entering identifier data relating to the patient.
[0032] In some embodiments of the invention the conveyor includes a set of rollers, while in others, the conveyor is a paper guide.
[0033] There is provided in accordance with another aspect of the present invention a separator film for use with a mammogram workstation where the workstation includes a scanner and a processing means. The film has one or more identifiable characteristics recognizable by the processing means which determine that the film is a separator film. The determination of the film as a separator film indicates to the processing means that all subsequently scanned film mammograms relate to patients other than patients whose film mammograms were scanned prior to the separator film. In another embodiment of the separator film, the separator film is for use with any of the embodiments of the workstation system described above.
[0034] In another embodiment of the present invention, the one or more identifiable characteristics are chosen from among the following: graphical indicia; a marker; a textured edge, and a serrated edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:
[0036] [0036]FIG. 1 is a block diagram of a prior art CAD system;
[0037] FIGS. 2 A- 2 C are three schematic views of a mammogram workstation constructed in accordance with an embodiment of the present invention;
[0038] [0038]FIG. 2D is a schematic view of the conveyor and conveyance of the printout constructed according to an embodiment of the present invention;
[0039] FIGS. 3 A- 3 B are isometric cut-away and enlarged cut-away views respectively of a body of a workstation constructed in accordance with another embodiment of the present invention; and
[0040] FIGS. 4 A- 4 D show flow charts of four embodiments of the method of the present invention.
[0041] Similar elements in the Figures are numbered with similar reference numerals.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0042] FIGS. 2 A- 2 C, to which reference is now made, show various schematic views of a workstation of the present invention, generally referenced as 200 , constructed according to an embodiment of the present invention. FIG. 2A is a full front view, FIG. 2B is a cut-away front view and FIG. 2C is a side view of the workstation. Workstation 200 includes a display 234 , a keyboard 238 and a computer processor 242 , the latter located within the body 212 of workstation 200 . It also may include an input device (not shown), which may be a computer mouse, touch screen or other such devices.
[0043] Integrated with body 212 of workstation 200 is a scanner 221 which is in electronic communication with processor 242 . A film feed 220 of scanner 221 is shown at the top of workstation 200 . Radiological films containing mammogram images are placed in film feed 220 and scanned through scanner 221 from which digitized images are transferred to processor 242 and then displayed on display 234 . The scanned films then drop into a collating station 224 of workstation 200 . Without being limiting, a scanner that can be used is the Mammography Pro™ scanner produced by Vidar Systems Corporation.
[0044] The films of a patient are scanned one after the other by scanner 221 and after each film is scanned they fall onto the previously scanned film already lying in collating station 224 . Generally four films of a patient, representing craniocaudal (CC) and mediolateral oblique (MLO) views of each breast, are scanned. Processor 242 receives the scanned digital images from scanner 221 and processes them so that they are all simultaneously displayed on display 234 . It should readily be evident to one skilled in the art that in other workstation configurations a plurality of scanned films relating to a single patient can be processed and displayed sequentially one-by-one or in pairs or in a pre-determined manner.
[0045] When the four films are displayed together, the films are regularly placed in preselected positions. For example, the upper two pictures on display 234 can be the right and left craniocaudal (CC) views respectively while the bottom two views, the right and left mediolateral oblique (MLO) views, can be lined up directly below the respective CC views. Alternatively, films of the right breast can be displayed above the left breast with the right CC view over the left CC view and the right MLO view over the left MLO view. Other display orders are also possible.
[0046] In general an algorithm used by the processor recognizes each of the scanned films as a CC or MLO view. It also recognizes if the film relates to the left or right breast of the patient. After recognition, the processor then displays the views in the pre-selected order on display 234 . This automatic sequencing replaces time-consuming sorting by a technician, with a reduction in human error.
[0047] Each of the displayed films include location markers circumscribing suspected abnormalities. Processor 242 , using any of many algorithms known in the art, determines the existence of abnormalities. Examples of algorithms which can be used are discussed in U.S. Pat. Nos. 5,854,581 and 5,970,164 both to Bamberger et al, and both incorporated herein by reference in their entirety. The radiologist examines the displayed views, particularly the areas marked as suspicious lesions, before making a final diagnosis and/or prescribing a course of action.
[0048] Generally, prior to scanning a new set or sets of films, i.e. films relating to one or more patients, the operator, using keyboard 238 , enters the one or more patients' identifier data. This typically includes but is not limited to name, age, identifier number, etc. This step obviates the need for using bar codes or adhesive stickers containing identifier data as is currently being done. After the digitized images of the scanned film mammograms of a patient have been stored in processor 242 they can be retrieved at any time by a radiologist for re-viewing by inputting the previously inputted patient identifier data.
[0049] Typically, a separator film is placed immediately after a patient's set of film mammograms in film feed 220 . The separator film contains a preprinted pattern, graphical indicia, design or other identifier recognizable by the scanner and/or processor as indicating a separator film. In addition, or alternatively to a preprinted pattern, the separator can have a predefined edge, such as a textured or serrated edge, which differs from the edges of the previously scanned set of radiological films. The different shaped edge can be discriminated by the scanner as indicating a separator film.
[0050] After the separator film is scanned, processor 242 recognizes that the end of the set of film mammograms relating to patient Jones has been reached and that the next mammogram relates to patient Smith. Processor 242 then automatically instructs printer 232 to print the digitized images of patient Jones displayed on display 234 , including the marked suspected abnormalities shown thereon. The printout of the displayed digitized images is then delivered directly and automatically to collating station 224 by a conveyor 236 . The conveyor 236 used in FIG. 2C is a system of rollers 236 . In collating station 224 , the printout falls onto its associated set of film mammograms that have been scanned previously and from which the displayed digitized images have been generated. Finally, the separator film drops from scanner 221 onto collating station 224 where it forms a complete collated package with the film mammograms and associated printout for patient Jones. The procedure is then repeated for patient Smith and all succeeding patients.
[0051] It should be noted that the separator film has two functions. It indicates to the processor that the next film to be scanned relates to a different patient and should be associated with different identifier data. Additionally, at a later stage after film/printout collation has been completed at collating station 224 , it indicates to the technician filing the radiological films and their associated printout that the collated material for one patient has ended and data for a new patient lies below. Accordingly, the technician knows to file the data between a pair of separator films in a single storage container, generally a physical folder, for storage in the medical records department, the radiology department, or elsewhere.
[0052] Processor 242 can be pre-programmed to stop scanner 221 from scanning when it determines that no identifier data has been supplied.
[0053] In another embodiment, identifier data could be entered during the process of generating the film mammograms. Such data could be inputted and coded directly and automatically onto the film mammograms as they are being processed. When scanner 221 scans the films, the identifier data can be read and stored in processor 242 with the digitized images.
[0054] In yet another embodiment, a set of film mammograms may be scanned by scanner 221 , digitized and displayed on display 234 . Then using keyboard 238 , the radiologist or technician instructs printer 232 , which is in communication with processor 242 , to print the digitized images displayed on display 234 , including the marked suspected abnormalities shown thereon. The displayed image printout is then delivered directly and automatically to collating station 224 by a conveyor 236 . The conveyor used in FIG. 2C is primarily a system of rollers 226 . In collating station 224 , the printout falls onto its associated set of films that have been previously scanned and from which the displayed digitized images have been generated. After the printout of the digitized images has automatically been placed on the set of scanned films, a separator film is inserted into film feed 220 and scanned. The processor detects the separator film and knows that any subsequent film mammograms belong to another patient. The separator then drops onto the film mammograms and printout lying in collating station 224 .
[0055] While the separator film that has been discussed above, and will be discussed below, has been described in terms of radiological films having predetermined designs or patterns or films having distinctive edges, separators with other distinguishing features or marks may also be used.
[0056] It should be noted that for purposes of simplicity, processor 242 has been shown in FIGS. 2 B- 2 C (and below in FIGS. 3 A- 3 B), and described in conjunction therewith, as a single unit. In reality it represents a complete “processing means” that includes both hardware and software systems which are in electronic communication with scanner 221 , printer 232 , and display 234 , coordinating their activities. Processor 242 also includes a “means for synchronizing” which synchronizes the scanning done by scanner 221 and printing done by printer 232 . Processor 242 also contains a memory for storing digitized images and patient input data, the latter provided inter alia by an input device such as keyboard 238 . In what is described herein, including in the claims, “processor” and “processing means” will be used synonymously without any intent at distinguishing between them.
[0057] [0057]FIG. 2D to which reference is now made shows in a schematic fashion the conveyance of the printout from printer 232 over a series of rollers 236 into collating station 224 where rollers 236 serve as the conveyor 236 of the printout.
[0058] Reference is now made to FIG. 3A which shows an isometric view of workstation 200 with a cut-away view of its body 212 and FIG. 3B which shows an expanded view of printer 232 , conveyor 236 , which here is a simple paper guide 243 , and collating station 224 .
[0059] [0059]FIG. 3A shows printer 232 , including paper station 246 , which generates a printout of the scanned digitized images. Paper guide 243 guides the printout from printer 232 to collating station 224 . FIG. 3B shows an expanded isometric view of printer 232 , paper guide 243 , and collating station 224 . Paper guide 243 acts as a conveyor 236 just as roller 236 does in FIGS. 2C and 2D. It should be evident that constructions other than rollers 236 shown in FIGS. 2C and 2D and paper guide 243 shown in FIGS. 3A and 3B can also serve as a conveyor of the printout from printer 232 to collating station 224 . For example, and without being limiting, the many different types of paper conveyor systems in photocopier machines can be adapted for use in workstation 200 .
[0060] Reference is now made to FIGS. 4 A- 4 D, where several embodiments of the method of the present invention are illustrated.
[0061] In FIG. 4A, a flowchart is presented where the method is generally referenced 400 . A set of radiological films, usually four films including a craniocaudal (CC) and a mediolateral oblique (MLO) view of each breast of a patient, patient X, are scanned (step 420 ) by a mammogram scanner. The scanned analog film mammograms are converted into digitized images. The scanned digitized film images are delivered to the processor of the workstation where they are stored (step 425 ) in memory. The scanned films then drop into a collating station of the workstation.
[0062] A technician then provides a separator film to the scanner in providing step 440 . The separator film contains a preprinted pattern, design or other identifier recognizable by the scanner and/or processor as indicating a separator film. In addition, or alternatively to a preprinted pattern, the separator can have a predefined edge, such as a textured or serrated edge, which differs from the edges of the previously scanned set of radiological films. The different shaped edge can be discriminated by the scanner as indicating a separator film. After being scanned the separator film falls into the collating station on top of the original mammogram films. In practice, in providing step 440 , a separator film generally is placed simultaneously in the film feed of the scanner and positioned as the last film in a set of one or more radiological films relating to patient X.
[0063] In repeating step 450 , scanning step 420 , storing step 425 and providing step 440 are repeated for as many sets of patient film mammograms as desired. The sets of films inputted forms a queue of mammograms for N, where N≧1, patients which are to be reviewed by a radiologist.
[0064] Generally, several sets of radiological films are placed in the workstation film feed simultaneously, each set separated from subsequent sets by a separator film. A set of mammogram films consists of one or more films. Each set relates to a different patient and is recognized as such by the processor when a separator film is detected.
[0065] Practically, the film feed of the scanner limits the number of sets of films that can be inputted serially at one time. The flowchart of FIG. 4A indicates that the maximum number of patients for which films may be scanned and collated as N. In theory, method 400 allows for collation of an unlimited number of mammograms.
[0066] All digitized images generated after a scanned separator film has been recognized are stored separately from all prior digital images stored in storing step 425 . In effect when the entire film mammogram queue is stored the digitized images of each patient are stored separately from all of the other patients.
[0067] In FIG. 4B a flowchart is presented showing another embodiment of the method of the invention. In FIG. 4B the method is generally referenced as 401 and is very similar to the one shown in FIG. 4A. A set of radiological films, usually four films of a patient, patient X, is placed in the film feed of a mammogram scanner and scanned (step 420 ). The scanner converts the analog film images to digitized images. The digitized images generated by the scanner are fed into the processor of the workstation and stored (step 425 ). The scanned films then drop into a collating station of the workstation.
[0068] A technician then provides a separator film to the scanner in providing step 440 . As in the embodiment discussed in conjunction with FIG. 4A, the separator film contains a preprinted pattern, design or other identifier recognizable by the scanner and/or processor as indicating a separator film. In addition, or alternatively to a preprinted pattern, the separator can have a defined edge different from the edges of the previously scanned set of radiological films. In practice, in providing step 440 , a separator film generally is placed simultaneously in the scanner and positioned as the last film in a set of one or more radiological films relating to patient X.
[0069] When the processor recognizes that a separator film is or has been scanned, a printing step 430 is automatically initiated. In printing step 430 , a printer produces a printout on at least one sheet of paper of the digitized images of the scanned radiological films together with any processor-detected abnormalities. Scannable identifier data associated with the original radiological films may also be included on the sheet. The sheet is conveyed automatically to the collating station and placed on top of the scanned radiological films. The scanned separator film then drops from the scanner to the collating station on top of the collated printout and radiological films relating to a single patient, patient X.
[0070] In repeating step 450 , scanning step 420 , storing step 425 , providing step 440 and printing step 430 are repeated for as many sets of patient film mammograms as desired. The sets of films inputted forms a queue of film mammograms relating to N patients which are to be reviewed by a radiologist.
[0071] Generally, several sets of radiological films are placed in the workstation film feed simultaneously, each set separated from subsequent sets by a separator film. A set of mammogram films consists of one or more films. Each set relates to a different patient and is recognized as such by the processor of the workstation when a separator film is detected.
[0072] The flowchart of FIG. 4B indicates the maximum number of patients for which films may be scanned and collated as N, where N≧1. In theory, however, the number is not limited.
[0073] All digitized images generated after a scanned separator film has been recognized are stored separately from all prior digital images stored in storing step 425 . As in FIG. 4A above (and FIGS. 4C and 4D to be discussed below), in effect when the entire film mammogram queue is stored the digitized images of each patient are stored separately from all of the other patients.
[0074] In FIG. 4C a flowchart is presented showing another embodiment of the method of the invention. In FIG. 4C the method is generally referenced as 402 and is very similar to the one shown in FIGS. 4 A- 4 B. A set of radiological films, usually four films, is placed in the film feed of a mammogram scanner which scans (step 420 ) the analog film mammograms and converts them to digitized images. The digitized images generated by the scanner are fed into the processor of the workstation and stored (step 425 ) in memory. The scanned films then drop into a collating station of the workstation.
[0075] The operator then initiates a printing step 430 in which the scanned films together with any processor detected abnormalities are printed on at least one sheet of paper. Scannable identifier data associated with the original radiological films may also be included on the sheet. The sheet is conveyed automatically to the collating station of the scanner and placed on top of the scanned radiological films.
[0076] A technician then provides a separator film into the film feed in providing step 440 . As in the embodiments discussed in conjunction with FIGS. 4 A- 4 B, the separator film contains a preprinted pattern, design or other identifier recognizable by the scanner and/or processor as indicating a separator film. In addition, or alternatively to a preprinted pattern, the separator can have a defined edge different from the edges of the previously scanned set of radiological films. After being scanned the separator film falls into the collating station of the scanner on top of the one or more printout sheets and the original mammogram films.
[0077] In repeating step 450 , scanning step 420 , storing step 425 , printing step 430 and providing step 440 are repeated for as many sets of patient film mammograms as desired. The sets of films inputted forms a queue of film mammograms for N patients which are to be reviewed by a radiologist. The flowchart of FIG. 4C indicates the maximum number of patients for which films may be scanned and collated as N, where N≧1. In theory, however, the number is not limited.
[0078] All digitized images generated after a scanned separator film has been recognized are stored separately from all prior digital images stored in storing step 425 . In effect when the entire film mammogram queue is stored the digitized images of each patient are stored separately from all of the other patients.
[0079] In FIG. 4D a flowchart is presented showing another embodiment of the method of the invention. In FIG. 4D the method is generally referenced as 403 and is very similar to the one shown in FIG. 4B.
[0080] An operator of the workstation first inputs 410 patient identifier data into the processor, typically by using a keyboard. The identifier data includes name, age, identifying number etc. and is stored in the processor of the workstation.
[0081] A set of radiological films, usually four films, is placed in the film feed of a mammogram scanner and scanned (step 420 ). The scanner converts the analog mammogram films to digitized images. The digitized images are fed into the processor of the workstation where they are stored (step 425 ) in memory. The scanned films then drop into a collating station of the workstation. The stored digitized images provided by the scanner are associated with the identifier data inputted in input step 410 .
[0082] A technician then provides a separator film to the scanner in providing step 440 . As in the embodiment discussed in conjunction with FIG. 4A, the separator film contains a preprinted pattern, design or other identifier recognizable by the scanner and/or processor as indicating a separator film. In addition, or alternatively to a preprinted pattern, the separator can have a defined edge different from the edges of the previously scanned set of radiological films. In practice, in providing step 440 , a separator film generally is placed simultaneously in the scanner and positioned as the last film in a set of one or more radiological films relating to a single patient.
[0083] When the processor recognizes that a separator film is or has been scanned, a printing step 430 is automatically initiated. In printing step 430 , a printer produces a printout of the digitized images of the scanned radiological films together with any processor detected abnormalities on at least one sheet of paper. The printout also includes identifier data entered in step 410 and stored in the processor as described above. The sheet is conveyed automatically to the collating station and placed on top of the scanned radiological films. The scanned separator film then drops from the scanner to the collating station on top of the collated printout and radiological films relating to a single patient.
[0084] Similar to the methods discussed in conjunction with FIGS. 4 A- 4 C, in repeating step 450 , inputting step 410 , placing step 420 , storing step 425 , separating step 440 , and printing step 430 are repeated for as many patients as desired. The number of films inputted forms a queue of patients for review by the radiologist.
[0085] All digitized images generated after a scanned separator film has been recognized are stored separately from all prior digital images stored in storing step 425 . In effect when the entire film mammogram queue is stored the digitized images of each patient are stored separately from all of the other patients.
[0086] In another embodiment similar to the one shown and discussed in conjunction with FIG. 4D, inputting step 410 is not repeated in repeating step 450 . Instead inputting step 410 consists of inputting identifier data for all of the patients having a set of mammograms in the film mammogram queue before any scanning of the sets of mammograms begins. This obviates the need for repeating inputting step 410 in repeating step 450 .
[0087] The embodiment discussed in conjunction with FIG. 4D is essentially the same as the embodiment shown and discussed with FIG. 4B except for the addition of an inputting step. It should readily be understood by one skilled in the art that an inputting step can also be added to the embodiments shown in and discussed with FIGS. 4A and 4C.
[0088] In the above description of the method, the internal separation aspect, that is the processor separation aspect, of the invention has been emphasized. The digitized images of the different sets of film mammograms are stored separately in the memory of the processor. In another aspect of the invention already mentioned above, the present invention allows for the collation of physical data and facilitates filing and storage of the physical records generated in mammogram screening.
[0089] Embodiments of this collating aspect of the invention include the following steps, which, as can readily be seen, are essentially the same as those discussed in conjunction with the embodiments of FIGS. 4 A- 4 D. However, this aspect of the invention makes no mention of the processor digitized image storage aspect of the invention and relates solely to the physical records, the film mammograms and printout, of individual patients.
[0090] The steps include:
[0091] 1. Scanning a set of radiological film mammograms of a patient, patient X, using a mammogram scanner.
[0092] 2. Moving the scanned set of film mammograms to a collating station of the workstation.
[0093] 3. Providing and scanning a separator film.
[0094] 4. Positioning the separator film on top of the scanned set of film mammograms in the collating station.
[0095] 5. Repeating the scanning, moving, providing and positioning steps for each of the N sets of patient film mammograms to be scanned. The N inputted sets of films inputted forms a queue of film mammograms for N patients, where N≧1, which are to be reviewed by a radiologist.
[0096] 6. Transferring the collated packages of each of the N sets of film mammograms positioned between separator films to their N individual storage containers for storage.
[0097] Generally, several sets of radiological films are placed in the workstation film feed simultaneously, each set separated from subsequent sets by a separator film. As mentioned previously, a set of mammogram films consists of one or more films. Each set relates to a different patient and is recognized as such by the processor when a separator film is detected.
[0098] In effect, all scanned film mammograms dropping onto a scanned separator film and then covered by another scanned separator film are recognized as relating to a single patient. When the entire film mammogram queue is scanned the film mammograms positioned between two separators are filed separately from the other sets of film mammograms in their individual storage containers.
[0099] In addition to the above steps, other steps, taken singly or together, may be used with the above steps.
[0100] When the processor recognizes that a separator film is, or has been, scanned, a printing step may be automatically initiated. In the printing step, a printer produces a printout on at least one sheet of paper of the digitized images of the scanned radiological films of patient X, where X is patient 1 to N. the printout also includes any processor-detected abnormalities. Scannable identifier data associated with the original radiological films may also be included on the sheet. In a conveying step, the printout is conveyed automatically to the collating station and placed on top of the scanned radiological films. The scanned separator film then drops from the scanner onto the collating station on top of the collated printout and radiological films which together form a collated set of physical data relating to a single patient, patient X.
[0101] The method may also include an inputting step. An operator of the workstation may initiate an input step by inputting identifier data into the processor, typically by using a keyboard. The identifier data includes name, age, identifying number etc. and is stored in the processor of the workstation.
[0102] The printing step can be effected both prior to the providing step or prior to the positioning step. When a printing step is used it is generally included in the repeating step.
[0103] Similarly when their is an inputting step the inputting step can be effected prior to the providing step but more often prior to the scanning step. When an inputting step is used it is generally included in the repeating step.
[0104] In another embodiment, the inputting step is not repeated in the repeating step. Instead the inputting step consists of inputting identifier data for all of the patients having a set of mammograms in the film mammogram queue before any scanning of the sets begins. This obviates the need for repeating the inputting step in repeating step.
[0105] In other embodiments of the method, there is an additional step that is not indicated in the flowcharts of FIGS. 4 A- 4 D. It serves as the final step of the embodiment of the methods discussed in conjunction with FIGS. 4 A- 4 D. After the radiological films and printout are collated and separated between two separator films, a technician files the scanned radiological films and their associated printout in a single physical storage container. Only collated films and printouts located between two nearest separator films are filed in a single physical storage container. The storage container is typically, but not necessarily, a medical records or radiology department folder.
[0106] Whenever a radiologist wishes to review a patient's records he can review the contents of the patient's physical storage container, which contains the radiological films and display printout of the patient. Alternatively, he may return to the list of patients whose scanned digitized film mammograms are stored in the system's processor and which can be viewed on the system's display. The radiologist indicates on the display, typically by using a computer mouse or keyboard, the patient for which he wishes to review the stored, scanned images.
[0107] It should readily be evident to one skilled in the art that in addition to identifier data the printout may contain diagnostic data provided by the processor's algorithm. This may include, but is not limited to, an overall evaluation of the likelihood of malignancy determined by the algorithm used by the processor.
[0108] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the invention is defined by the claims that follow.
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A method of separating and collating mammogram records, the method including the step of providing and scanning a separator film having identifiable features which when scanned identify the film as a separator film, thereby assisting in the separation of mammograms of different patients. A separator film for use with a mammogram workstation the film having at least one identifiable characteristic recognizable by the workstation's processing means so that the film is identified as a separator film separating mammograms of different patients. A workstation system for collating radiological film mammograms which includes a scanner which digitizes radiological film mammograms and scans a separator film carrying identifiable features for identifying the film as a separator film usable to separate mammograms of different patients.
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RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/933,183 filed Jun. 5, 2007.
BACKGROUND
[0002] The invention is directed to expandable casing packing element systems for use in oil and gas wells and, in particular, expandable casing packing element systems having extrudable sealing elements for sealing open-hole wells.
[0003] Expandable casing having a sealing element such as a packer have been used to seal the annulus of open-hole wells. In operation, after the well is drilled into the earth formation, the expandable casing is run into the well. The expandable casing has disposed on it, or as part of the expandable casing string, a sealing device such as a packer. The packer is designed to divide the well by sealing against the well formation, thereby isolating a lower portion of the well from an upper portion of the well.
[0004] After the expandable casing is run into the desired location in the well, a cone or other device can be transported through the bore of the expandable casing. As the cone, such as a swage, travels downward, the expandable casing is expanded by the cone. The expansion of the expandable casing causes the sealing device to contact the formation and separate the open-hole well into at least two isolated regions, one above the sealing device and one below the sealing device.
[0005] The expandable casing and sealing devices disclosed herein include components that, to the inventors' knowledge, are novel and non-obvious from previous expandable casing and sealing devices.
SUMMARY OF INVENTION
[0006] Broadly, the expandable casing packing element systems disclosed herein include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. In one embodiment, both retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of the a wellbore in three locations. The wellbore may be an opened-hole wellbore or a cased wellbore. In another embodiment, both of the two retainer rings include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.
[0007] Also disclosed is a method comprising the steps of: (a) running an expandable casing string having a packing element system attached thereto into a wellbore defined by an inner wall surface, the packing element system having a sealing element and at least two retainer rings, at one of the at least two retainer rings overlapping the sealing element; (b) applying a radial load to expand the expandable casing, causing the sealing element to be extruded outwardly by at least one of the at least two retainer rings applying an inward force to the sealing element; and (c) continuing to apply the radial load causing the sealing element to move radially outward into sealing engagement with the inner wall surface of the wellbore. In one particular embodiment, the wellbore is cased. In another specific embodiment, the wellbore is an opened-hole wellbore.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 is a cross-sectional view of one embodiment of an expandable casing having a sealing device, FIG. 1 showing the expandable casing as it is being expanded from its run-in position to its expanded or set position.
[0009] FIG. 2 is a cross-sectional view of another specific embodiment of an expandable casing having a sealing device, FIG. 2 showing the expandable casing in its run-in position.
[0010] FIG. 3 is a cross-sectional view of the expandable casing shown in FIG. 2 shown in its expanded or set position.
[0011] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0012] Referring now to FIG. 1 , in one specific embodiment, expandable casing 30 is disposed within well 20 that has been drilled into formation 26 . Well 20 is defined by well inner wall surface 22 . Expandable casing 30 has upper end 32 , lower end 34 , bore 36 defined by inner wall surface 38 , outer wall surface 39 , and axis 40 . Expandable casing 30 includes run-in diameter 42 , set diameter 44 , and transitional diameter 46 . Run-in diameter 42 is less than set diameter 44 and transitional diameter 46 illustrates the location of a cone (not shown) or other device used to expand expandable casing 30 from the run-in diameter 42 to the set diameter 44 . Although a cone is described as being used to expand expandable casing 30 from the run-in diameter 42 to the set diameter 44 , it is to be understood that any device or method known to persons of ordinary skill in the art may be used to expand expandable casing 30 .
[0013] As illustrated in FIG. 1 , disposed on outer wall surface 39 of expandable casing 30 are upper sealing device 50 and lower sealing device 60 . In this embodiment, upper sealing device 50 is identical to lower sealing device 60 except that upper sealing device 50 is shown in the set position and lower sealing device 60 is shown in the run-in position. It is to be understood, however, that expandable casing 30 may have only one sealing device 50 , 60 , or more than two sealing devices 50 , 60 . For convenience, both upper and lower sealing devices 50 , 60 will be discussed in greater detail with reference to like numerals.
[0014] Sealing devices 50 , 60 include annular deformable sealing elements 51 having upper ends 52 and lower ends 54 , upper retainer ring 56 , and lower retainer ring 58 . Sealing element 51 is a deformable element formed from an deformable material so that radial outward movement of sealing element 51 away from axis 40 and into upper and lower retainer rings 56 , 58 causes sealing element 51 to extrude into sealing contact with inner wall surface 22 of well 20 . Suitable materials for forming sealing element 51 include, but are not limited to, elastomers, rubbers, polymers, or thermoplastics.
[0015] Additionally, sealing element 51 may have any shape desired or necessary to provide the requisite compression, deformation, or “extrusion” to form the seal with inner wall surface 22 of well 20 . As shown in FIG. 1 , in this specific embodiment, sealing element 51 is formed in the shape of a sleeve having a thicker center portion as compared to upper and lower ends 52 , 54 . This thicker portion is disposed between upper and lower retainer rings 56 , 58 and, as shown with reference to sealing device 60 , has an outer diameter that is equal to the outer diameter of both upper and lower retainer rings 56 , 58 when in the run-in position. It is to be understood, however, that sealing element 51 may have an outer diameter that is less than the outer diameter of one or both of upper or lower retainer rings 56 , 58 when in its run-in position or it may have an outer diameter that is greater than the outer diameter of one or both upper or lower retainer rings 56 , 58 when in its run-in position.
[0016] Further, in the embodiment shown in FIG. 1 , upper and lower ends 52 , 54 are shown protruding above and below upper and lower retainer rings 56 , 58 ; however, upper and lower ends 52 , 54 are not required to protrude above and below upper and lower retainer rings in this manner.
[0017] Sealing element 51 is maintained against outer wall surface 39 of expandable casing 30 using any device or method known to persons of ordinary skill in the art. For example, sealing element 51 may be chemically bonded to outer wall surface 39 . Alternatively, sealing element 51 can be maintained solely by upper and lower retainer rings 56 , 58 .
[0018] Upper retainer rings 56 and lower retainer rings 58 are expandable members disposed around the outer diameter of sealing element 51 and, thus, can maintain or assist in maintaining sealing element 51 along outer wall surface 39 . In this embodiment both upper retainer ring 56 and lower retainer ring 58 have a relatively flat vertical cross-section parallel or substantially parallel to the axial length of the expandable casing 30 . As additionally shown in FIG. 1 , both upper and lower retainer rings 56 , 58 have an axial length greater than their width so that the inner diameter surface area of both upper and lower retainer rings 56 , 58 are in contact with sealing element 51 to facilitate extrusion of sealing element 51 during expansion of expandable casing 30 .
[0019] Although the shape of upper and lower retainer rings 56 , 58 are discussed with reference to FIG. 1 , it is to be understood that upper and lower retainer rings 56 , 58 may have any shape desired or necessary to provide the necessary force against sealing element 51 during expansion of expandable casing 30 so that sealing element 51 is extruded to seal against inner wall surface 22 of well 20 .
[0020] Further, upper and lower retainer rings 56 , 58 may be formed from any material known to persons of ordinary skill in the art. For example, one or both of upper and lower retainer rings 56 , 58 may be formed from stiffer elastomers, polymers, or metals such as steel.
[0021] After expandable casing 30 is properly located within well 20 , a cone (not shown) or other expanding device is run through bore 36 of expandable casing 30 . As the cone travels downward, i.e., downhole, expandable casing 30 is forced radially outward from axis 40 . In so doing, run-in diameter 42 is radially expanded to transition diameter 46 and ultimately to set diameter 44 . As a result of the radial expansion of expandable casing 30 , sealing element 51 is forced into upper and lower retainer rings 56 , 58 . Although upper and lower retainer rings 56 , 58 are radially expandable, they are formed from a material that is stronger, i.e., more resistance to expansion, compared to the material used to form sealing element 51 . As a result, as expandable casing 30 is expanded, sealing material 51 is compressed, deformed, or extruded in between outer wall surface 39 of expandable casing and the inner wall surfaces of upper and lower retainer rings 56 , 58 defined by the inner diameters of upper and lower retainer rings 56 , 58 . Due to the compression of sealing element 51 between outer wall surface 39 of expandable casing 30 and the inner wall surfaces of upper and lower retainer rings 56 , 58 , the center portion of sealing element 51 is extruded outwardly in between upper and lower retainer rings 56 , 58 ; upper end 52 of sealing element 51 is extruded outwardly above upper retainer ring 56 ; and lower end 54 of sealing element 51 is extruded outwardly below lower retainer ring 58 until all three portions of sealing element 51 form a seal against inner wall surface 22 of well 20 . The distance between the outer diameter of upper and lower retainer rings 56 , 58 and inner wall surface 22 of well 20 is referred to as the extrusion gap.
[0022] Referring now to FIGS. 2-3 , in another embodiment, expandable casing 130 has upper end 132 , lower end 134 , bore 136 defined by inner wall surface 138 , outer wall surface 139 , and axis 140 . Expandable casing 30 includes run-in diameter defined by run-in radius 142 ( FIG. 2 ) and set diameter defined by set radius 144 ( FIG. 3 ). Run-in radius 142 and, thus, the run-in diameter, is less than set radius 144 and, thus, the set diameter. Expandable casing 130 is radially expanded using a cone (not shown) or other device used to expand expandable casing 130 from the run-in diameter defined by run-in radius 142 to the set diameter defined by set radius 144 in the same manner as the embodiment discussed above with respect to FIG. 1 .
[0023] As illustrated in FIG. 2 , expandable casing 130 is in the run-in position. Disposed on outer wall surface 139 of expandable casing 130 is sealing device 150 . Although only a single sealing device 150 is shown, it is to be understood that more than one sealing device may be disposed on outer wall surface 139 of expandable casing 130 .
[0024] Sealing device 150 includes annular sealing element 151 , upper retainer ring 156 and lower retainer ring 158 . Annular sealing element 151 is a deformable element formed from a deformable material such as those discussed above with respect to sealing element 51 . In this embodiment, sealing element 151 has a trapezoid section such that the inner surface of sealing element 151 has a longer axial length along outer wall surface 139 than the axial length of the outer surface defined by the outer diameter of sealing element 151 .
[0025] Upper retainer ring 156 has upper flare portion 157 and lower retainer ring 158 has lower flare portion 159 thereby forming a cavity between upper retainer ring 156 and lower retainer ring 158 with a gap between the lowermost end of upper retainer ring 156 and the uppermost end of lower retainer ring 158 . Sealing element 151 is disposed within the cavity. In one specific embodiment, sealing element 151 is maintained along outer wall surface 139 through any device or method known to persons of ordinary skill in the art, such as through chemical bonding or by upper and lower retainer rings 156 , 158 .
[0026] As with the embodiment shown in FIG. 1 , upper and lower retainer rings 156 , 158 may be formed from any material known to persons of ordinary skill in the art. For example, one or both of upper and lower retainer rings 156 , 158 may be formed from stiffer elastomers, polymers, or metals such as steel.
[0027] Upper flare portion 157 and lower flare portion 159 may have any shape or angle relative to the remaining vertical portions of upper and lower flare portions. For example, upper and lower flare portions 157 , 159 may be at an angle in a range greater than 0 degrees and less than 90 degrees relative to the vertical portions of upper and lower flare portions 157 , 159 . Additionally, the angle at which upper flare portion 157 intersects the remaining portion of upper retainer ring may be different from the angle at which lower flare portion 159 intersects the remaining portion of lower retainer ring 158 . In one specific embodiment, both of these angles are within the range from 30 degrees to 60 degrees so that sufficient inward force can be applied to sealing element 151 during expansion of expandable casing 130 to extrude sealing element 151 through the gap between the lowermost and uppermost ends of upper retainer ring 156 and lower retainer ring 158 , respectively. In the embodiment shown in FIGS. 2-3 , upper and lower flare portions 157 , 159 are reciprocally shaped to receive sealing element 151 so that a portion of both upper and lower flare portions 157 , 159 contact sealing element 151 during run-in.
[0028] Upper and lower retainer rings 156 , 158 can be secured to outer wall surface 139 through any device or method known to persons of ordinary skill in the art. For example, upper and lower retainer rings 156 , 158 may be welded or epoxied to outer wall surface 139 . Alternatively, upper and lower retainer rings 156 , 158 may be secured or formed integral with an expandable mandrel (not shown) that is then secured such as through threads to an expandable casing string.
[0029] As shown in FIG. 2 , sealing element 151 of sealing device 150 is in its run-in position such that it does not protrude outwardly from outer wall surface 139 past upper or lower retainer rings 156 , 158 . It is to be understood that although sealing element 151 is shown as having an outer diameter equal to the outer diameters of upper and lower retainer rings 156 , 158 , sealing element 151 may have either an outer diameter that is less than the outer diameter of one or both of upper or lower retainer rings 156 , 158 when in its run-in position, or an outer diameter that is greater than the outer diameter of one or both of upper or lower retainer rings 156 , 158 when in its run-in position.
[0030] After expandable casing 130 is properly located within well (not shown), a cone (not shown) or other expanding device is run through bore 136 of expandable casing 130 . As the cone travels downward, i.e., downhole, expandable casing 130 is forced radially outward from axis 140 . In so doing, the run-in diameter illustrated by run-in radius 142 is radially expanded to a transition diameter (not shown) and ultimately to set diameter illustrated by set radius 144 ( FIG. 3 ). As a result of the radial expansion of expandable casing 130 , sealing element 151 is forced into upper and lower flare portions 157 , 159 of upper and lower retainer rings 156 , 158 . As with upper and lower retainer rings 56 , 58 , upper and lower retainer rings 156 , 158 are radially expandable; however, they are formed from a material that is stronger, i.e., has more resistance to expansion, compared to the material used to form sealing element 151 . As a result, as expandable casing 130 is expanded, upper and lower flare portions 157 , 159 bend inward toward axis 140 as expandable casing 130 expands and, thus, compress, deform, or extrude sealing element 151 within the cavity in between outer wall surface 139 of expandable casing 130 and upper and lower flare portions 157 , 159 . In other words, upper flare portion 157 and lower flare portion 159 become more straightened in line with the remaining portions of upper retainer ring 156 and lower retainer ring 158 , respectively, so that sealing element 151 is forced radially outward.
[0031] Due to the compression of sealing element 151 between outer wall surface 139 of expandable casing 130 and the upper and lower flare portions 157 , 159 , sealing element 151 is extruded outwardly from the cavity through the gap located between the lowermost end of upper retainer ring 156 and the upper most end of lower retainer ring 158 until sealing element 151 forms a seal against the inner wall surface of the well. This distance between the outermost diameters of upper and lower retainer rings 156 , 158 and the inner wall surface of the well is referred to as the extrusion gap.
[0032] It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. For example, the sealing devices may be disposed on an expandable mandrel that is placed within an expandable casing string. Additionally, the expandable casing may have one or more sealing devices 50 or 60 together with one or more sealing devices 150 . Moreover, a spacer may be disposed in between outer wall surface 39 of expandable casing 30 and the inner diameter of sealing element 151 to assist in extrusion of sealing element 151 during expansion of expandable casing 130 . Further, the inner diameter of upper retainer ring 56 is not required to be equal to the inner diameter of lower retainer ring 58 . Likewise, the shape of upper flare portion 157 is not required to be the same shape as lower flare portion 159 . Additionally, the expandable casing 30 , 130 may be disposed in a cased wellbore as opposed to an open-hole wellbore. Thus, the term “wellbore” as used herein includes a cased wellbore as well as an opened-hole wellbore. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
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The expandable casing packing element systems for cased and open-hole wellbores include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. In one embodiment, both retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of a wellbore in three locations. In another embodiment, both of the two retainer rings include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national stage filing under 35 U.S.C. 371 of International PCT/US2011/064375, filed Dec. 12, 2011, which claims priority to European Application No. EP 10196464.1, filed Dec. 22, 1010. The disclosures of both applications are incorporated by reference in their entirety herein.
FIELD OF THE INVENTION
The invention relates to a dispensing device for a dental substance and to a method of making the device. The dispensing device has a valve member and may be switched between a storage mode and a use mode. The device is preferably adapted to hermetically encapsulate at least one component of the dental substance during storage.
BACKGROUND OF THE INVENTION
Dental substances are often provided in dispensing devices which allow for storing of the substances over a time, but also enable the substances to be dispensed directly from such devices. Such dispensing devices are often designed for single use and thus typically disposed after. Therefore there are devices which are entirely pouched for storing of the dental substances. Such devices are typically only removed from the pouch directly before use. Other devices are designed for multiuse, and accordingly may contain a sufficient amount of substance for two or more uses. Some of such multiuse devices have an openable closure which enables to reclose the device between two uses.
For example WO 2010/123800 discloses a dispensing device for a dental substance which has an outlet for the dental substance, and a valve for opening and closing the outlet. The device is switchable between a storage mode and an operative mode. In the storage mode a cannula is locked in the device and the valve opens the outlet, and in the storage mode the cannula can be released from the device and the valve closes the outlet.
Although there is a variety of dispensing devices for dental substances there is still a desire for a device which is reusable, but which also provides a maximized shelf life for the substance contained therein after initial use. Further such a device is desirably inexpensive and easy to use.
SUMMARY OF THE INVENTION
The invention in one aspect relates to a method of making a dispensing device for dispensing a substance, in particular a dental substance. The method comprises the steps of:
providing a mold which is adapted to form a mold space for receiving a solidifyable material; providing a valve member having a first portion formed between first and second areas of an outer surface of the valve member; placing the valve member into the mold space such that the first area is isolated from the mold space and at least part of the second area is within the mold space; displacing the first portion of the valve member at least partially relative to another portion of the valve member and thereby applying a pre-load on the first portion; solidifying the material in the mold space and thereby fixing the displaced first portion in place under the pre-load; and providing the flowable material in the mold space.
The invention is advantageous in that it preferably provides for manufacturing of a device for dispensing material which allows a substance to be stored over a maximized time period. Such a device may particularly be capable of hermetically encapsulating a substance stored under different temperature and pressure conditions, as they occur for example during transportation of the device from the manufacturing site to a user. Further the invention may help reducing manufacturing costs, for example may minimize costs for assembly of the valve member in the device.
An isolation of a surface area (for example the first area) from the mold space may be achieved by avoiding direct contact of that surface area with the mold space. For example the surface area may be covered by a mold component. Further a surface area may be regarded as being within the mold space if that surface area forms at least part of a boundary of the mold space. For example the surface area may be exposed to the mold space.
In one embodiment the method comprises the step of displacing the first portion together with the first and second areas of the valve member relative to another portion of the valve member. Thus the first portion, or part of the first portion, may be predominantly displaced as a whole rather than compressed as such. The first portion may be partially displaced together with the first and second areas of the valve member relative to another portion of the valve member. For example the first portion may be connected with the remainder of the valve member at a transition region, and the valve member may be deflected so that it is more displaced in a region further remote from the transition region than towards the transition region itself. In one example the first portion is a membrane which is circumferentially connected to the remainder of the valve member. The membrane preferably has a smaller thickness than the portion of the valve member to which the membrane is connected in the same dimensions. The first portion may be displaced in a direction from the second area toward the first area.
In a further embodiment the first and second areas of an outer surface of the valve member are arranged opposite of each other. For example the first and second areas may face away from each other.
In one embodiment the flowable material is injected or pressed in the mold space. The step of providing the flowable material in the mold space may cause the first portion to displace.
In another embodiment the method comprises the step of urging at least one of the valve member and a mold component toward the other one of the valve member and the mold component and thereby causing the first portion to displace. For example the mold component may be urged toward the valve member, particularly to the first portion, and thereby the first portion may be caused to displace. Thereby at least part of the second area may be within the mold space and the remaining part may be outside of the mold space. For example the remaining part of the second area may be covered by the mold component (for example with a mold core). The mold component may further be movable relative to other mold components and used to displace the first portion. Thus a well controlled displacement of the first portion may be achieved.
In one embodiment the method further comprises the step of supporting the valve member in the mold, and suspending support at the first area. For example the valve member may be held in place by a mold component which also seals the first area from the mold space. In an embodiment the valve member has a blind hole defined by an interior wall and an end wall forming the first area. The method may comprise the step of inserting a mold core in the blind hole to support the valve member, but with leaving a space between the first area and the mold core. Thus the valve member may be securely held in place and the first area may be effectively sealed from the mold space. Further thus the first area may be spaced from any mold component enabling the first portion to be displaced into that space.
In one embodiment the method further comprises the step of displacing a second portion of the valve member relative to another portion of the valve member. Thereby the other portion of the valve member may not comprise the first portion. The second portion may be formed between third and fourth areas of the outer valve surface. Thus the valve member may have the first and the second portions which preferably are configured generally identical relative to each other. Further all embodiments described in relation to the first portion only are considered possible embodiments for the first and second portions as well as for only the second portion. A valve member having the first and second portions may be used in combination with a device for dispensing a substance from two individually stored components of the substance. The skilled person will recognize that further embodiments of the device may comprise a valve member having more than two displaceable portions, for example for making devices for dispensing a substance from more than two individually stored components of the substance.
The term “another portion” of the valve member for the purpose of this specification may correspond to a portion of the valve member other than the first and second portions, and particularly a portion adjacent the first or second portions. Such another portion may for example correspond to a part or the remainder of the valve member not including the first and second portions.
In a further aspect the invention relates to a device for dispensing a substance. The device comprises:
a cartridge; a valve member having a first portion formed between first and second areas of an outer surface of the valve member; the valve member being accommodated within the cartridge such that the first area is in non-direct contact relationship with the cartridge and at least part of the second area is in direct contact with the cartridge; the first portion of the valve member being under pre-load which prevents the first portion from displacing relative to another portion of the valve member; and wherein the first portion is fixed in place under pre-load by the cartridge.
Thus a device of the invention may be generally characterized by being made using the method of the invention.
In one embodiment the cartridge is monolithically formed and encases the valve member such that the valve member and the cartridge are non-detachably interlocked with one another.
In a further embodiment the device has at least one chamber. The chamber preferably has an outlet which is openably closed by at least part of the first portion. In particular the device may have a longitudinal axis parallel to which or along the at least one chamber extends. The chamber may extend between a front end and an opposite rear end of the chamber and may open into the outlet. Thus the outlet is arranged adjacent the front end. The chamber may extend with a generally uniform cross-section, for example may be formed by a generally cylindrical chamber wall. Further the chamber is preferably adapted to receive a piston through the rear end which is movable within the chamber in a direction between the front and rear ends of the chamber. Preferably the valve member with the first portion openably closes the outlet. In particular a part of the second surface may block the outlet and the remaining part of the second surface may surround the outlet. The remaining part of the second surface may urge toward the cartridge due to a pre-load provided to the first portion. Thus the first portion may exert a sealing force to the cartridge. This preferably helps maximizing the seal between the cartridge and the valve member. Further this may provide for a maximized shelf life of the device filled with the substance.
In one embodiment the device is adapted such that the valve member is movable generally laterally to the longitudinal axis for opening the outlet. The valve member may for example be rotatable about a rotation axis that is oriented parallel to or in line with the longitudinal axis. The valve member may have a generally cylindrical shape and may comprise a blind hole extending from a first cylinder end face into the valve member. The first area is preferably formed by an end face of the blind hole, and the second area is formed by a second cylinder end face. The first portion thus is preferably formed between the first and second areas. Further the first and second areas are preferably opposing areas which face away from one another.
In one embodiment the second area has a raised portion. The raised portion may protrude from the second cylinder end face. Such raised portion may form a sealing pad. The sealing pad may have a cross-sectional shape which generally corresponds to the cross-sectional shape of the outlet. Therefore the sealing pad may mate with the outlet in the closed position of the valve member. Thus the seal between the valve member and the cartridge may be further maximized.
In a further embodiment the blind-hole is formed at least by a stepped interior wall of a generally cylindrical shape and the first area. For example the first area may form the end face of the blind hole. Further the blind-hole may extent into the valve member with a first diameter, and may continue towards the first area with a smaller second diameter. Thus for molding the cartridge the valve member may be held by a mold component penetrating into the blind hole. Further this mold component may be prevented from getting into contact with the first area by the step formed within the blind-hole.
In one embodiment the device has two chambers for holding components of a substance. Each of the chambers preferably has an outlet which is openably closed by the valve member. The valve member is preferably movable relative to both outlets for opening the outlets. Further the device may have at least one plunger for extruding the substance from the chambers through the outlets. The plunger may have a piston which seals the chamber at their rear ends. Embodiments described with regard to a chamber, an outlet and a first portion therefore are not limited to one chamber, one outlet and one portion only.
Therefore in another embodiment the device comprises:
a cartridge; a valve member having a first portion formed between first and second areas of an outer surface of the valve member and a second portion formed between third and fourth areas of the outer surface of the valve member; the valve member being accommodated within the cartridge such that the first and third areas are in non-direct contact relationship with the cartridge and at least part of the second and fourth areas are in direct contact with the cartridge; the first and second portions of the valve member being under pre-load and urging toward the cartridge to a greater extent than another portion of the valve member; and the cartridge fixes the pre-loaded first and second portions in place.
The device may have two chambers each having an outlet which is openably closed by at least part of the first and second portions, respectively. Each chamber may extend between a front and a rear end parallel to the longitudinal axis of the cartridge. Each of the outlets may be arranged adjacent the front end of the respective chamber. The valve member may have a generally cylindrical shape with two blind-holes extending from a first cylinder end face into the valve member. The first and third areas may be formed by end faces of the blind-hole, and the second and fourth areas may be formed by a second cylinder end face. Further the second and fourth areas each may have a raised portion protruding from the second cylinder end face. Each of the blind-hole may be formed at least by a stepped interior wall of a generally cylindrical shape and the first or third area respectively.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of a dispensing device according to an embodiment of the invention;
FIG. 2 is a perspective view illustrating details of the dispensing device shown in FIG. 1 .
FIG. 3 is a perspective view of further details of the dispensing device shown in FIG. 1 .
FIG. 4 is a perspective view of a valve member according to an embodiment of the invention;
FIG. 5 is a partial cross-sectional view of the dispensing device according to a further embodiment of the invention;
FIGS. 6-8 are schematic cross-sectional views illustrating a molding process according to a further embodiment of the invention; and
FIG. 9 is a cross-sectional view of a dispensing device obtained from the process illustrated in FIGS. 6-8 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a dispensing device 10 for a dental substance. The device 10 has a nozzle appliance 11 , a cartridge 12 and a plunger 13 . The device 10 may contain two components of the dental substance separately stored in chambers (not shown in this Figure) in the cartridge 12 . The components may be merged within a nozzle 14 of the nozzle appliance 11 as the plunger 13 is pushed into the cartridge 12 . The nozzle 14 may contain a static mixer for mixing the two components before they are dispensed from the nozzle 14 . The device 10 may be pre-filled with an amount of substance sufficient for multiple uses, for example already at a manufacturing stage of the device 10 . Further the device 10 is preferably adapted to hermetically encapsulate the components in the cartridge 12 . Therefore the dispensing device 10 preferably allows for storing of the substance over several months or years and for maintaining the desired properties of the substance in essence over such periods of time.
FIG. 2 shows the device 10 with the nozzle appliance 11 detached from the cartridge 12 for the purpose of explanation. The nozzle appliance and the cartridge may in certain embodiments be detachable, but in other embodiments unreleasably interlocked with one another. The cartridge 12 has a front end 15 which accommodates a valve member 16 . The valve member 16 is rotatable about a longitudinal axis A between an open position in which the device 10 can be used for dispensing the substance and a closed position in which the device 10 encapsulates the substance for storage. Preferably the device is adapted such that it can be reopened and reclosed multiple times. The valve member has a channel 17 which in the open position connects outlets (not shown) for the components with the nozzle 14 of the nozzle appliance 11 . Thus in the open position the valve member enables the components to flow from the cartridge 12 through the valve member 16 toward the nozzle 14 . Further the valve member 16 seals the outlets in the closed position. Therefore the valve member seals the front end 15 of the cartridge in the closed position. The cartridge 12 at a rear end 24 receives the plunger 13 . Preferably the plunger 13 is adapted to seal the cartridge 12 at the rear end.
FIG. 3 shows an interior of the nozzle appliance 11 . In particular the nozzle appliance 11 comprises a first engagement member 18 . The first engagement member 18 is adapted to engage the channel 17 ( FIG. 2 ) of the valve member in an assembled stage of the nozzle appliance 11 and the cartridge. However in other examples the valve member may have a second engagement member in addition to the channel 17 , and the first and second engagement members may be adapted for mating and engaging with one another in an assembled stage of the nozzle appliance 11 and the cartridge 12 . The first engagement member 18 preferably provides for an anti-twist connection between the nozzle-appliance 11 and the valve member 16 . Therefore a rotation of the nozzle appliance 11 relative to the cartridge 12 preferably also causes the valve member 16 and the cartridge 12 to rotate relative to each other. Thus the device may be conveniently opened and closed by rotating the nozzle appliance 11 and the cartridge 12 relative to one another.
FIG. 4 shows the valve member 16 in more detail. The channel 17 has a non-circular cross-section. Therefore the channel 17 is adapted for being engaged for rotation of the valve member 16 . In particular the first engagement member 18 of the nozzle appliance 11 and the channel 17 may have similar cross-sectional shapes, for example rectangular, triangular or any other polygonal or non-circular shapes. The valve member 16 further has first and second sealing pads 19 a , 19 b for sealing with outlets of the cartridge 12 as illustrated in FIG. 5 .
FIG. 5 shows a cross-section of the cartridge 12 of the device 10 . The cartridge 12 has a first and a second chamber 20 a , 20 b . Each of the first and second chambers 20 a , 20 b may contain a component of the dental substance. Further the first and second chambers 20 a , 20 b at front ends have first and second outlets 21 a , 21 b , respectively. The first and second outlets 21 a , 21 b are closed by the first and second sealing pads 19 a , 19 b of the valve member 16 . The first and second chambers 20 a , 20 b at rear ends are closed by first and second pistons 22 a , 22 b which are movably and sealingly arranged within the first and second chambers 20 a , 20 b , respectively. The first and second pistons 22 a , 22 b may be part of the plunger 13 , for example may be formed monolithically with the plunger 13 . Further the first and second pistons 22 a , 22 b and the plunger 13 may be separate parts. The situation shown corresponds to the closed position of the valve member and the cartridge relative to each other. The device may be brought in the open position by rotating the valve by about 90 degrees about the longitudinal axis A (not shown). In the open position the channel 17 connects to the first and second outlets 21 a , 21 b (also not shown).
FIG. 6 shows a mold 100 in which a pre-manufactured valve member 16 is placed. The mold 100 is adapted for molding a cartridge around the valve member 16 . Therefore the mold 100 is further adapted to receive a solidifyable material. For example the mold may be suitable for injection molding the cartridge from a molten plastic material and the plastic material may be of a type being generally solid at about room temperature. Possible plastic materials comprise polypropylene, polyoxymethylene, polycarbonate, polyamide, polybutadiene terephthalate, polyethylene terephthalate or rubber for example.
FIG. 7 shows the mold 100 with all mold components and the valve member 16 positioned ready for molding. A mold space 101 , which is the space to be filled by the solidifyable material, is thus formed within the mold 100 . The valve member 16 has a first portion 30 a formed between a first area 31 a and a second area 32 a . The first and second areas 31 a , 32 a are part of an overall outer surface of the valve member 16 . The valve member 16 is placed in the mold space 101 such that the first area 31 a is isolated from the mold space 101 . This is achieved by a first front core 102 a extending in and thus sealing a first blind-hole 23 a of the valve member 16 which is partially formed by the first area 31 a . In particular the first area 31 a is formed by an end wall of the first blind-hole 23 a . Further the first blind-hole 23 a has a stepped cross-section over its depth. The stepped configuration prevents the first front core 102 a to entirely penetrate the first blind-hole 23 a . Accordingly the first area 31 a is spaced from the core 102 a and thus not supported. The second area 32 a is located partially within the mold space 101 and partially covered by a front face of a first rear core 103 a . The covered area of the second area 32 a is therefore also located outside the mold space because material provided in the mold space is prevented from getting into contact with the covered area within the second area 32 a . The valve member 16 in this example further has at least a second portion 30 b formed between a third area 31 b and a fourth area 32 b . Part of the fourth area 32 b is covered by a second rear core 103 b , and a second front core 102 b is placed within a second blind-hole 23 b . The second portion 30 b , the third and the fourth area 31 b , 32 b are preferably configured substantially identical to the first portion 30 a with the first and second areas 31 a , 32 a , respectively. Further the second front and rear cores 102 b , 103 b are configured and arranged generally identical to the configuration and arrangement of the first front and rear cores 102 a , 103 a respectively. The second blind-hole 23 b further generally corresponds in configuration to the first blind-hole 23 a.
FIG. 8 shows the first and second rear cores 103 a , 103 b placed further toward the valve member 16 . As a result the first portion 30 a and the second portion 30 b of the valve member 16 are displaced relative to the remainder of the valve member 16 . Preferably the displacement corresponds to a resilient displacement. This may be provided for example by the valve member 16 being generally elastic. For example the valve member 16 may be made of polyoxymethylene, polycarbonate, polyamide, polybutadiene terephthalate, polyethylene terephthalate or rubber.
In a not shown embodiment the first and second portions 30 a , 30 b may be supported by the front cores 102 a , 102 b in the displaced position, for example fixedly held between the front cores 102 a , 102 b and the rear cores 103 a , 103 b , respectively. In the position shown the mold 100 may be filled with a solidifyable material so that also the valve member 16 is embedded in the material. The solidified material preferably fixes or freezes the displaced first and second portions 30 a , 30 b in place under pre-load as shown in FIG. 9 .
FIG. 9 shows the cartridge 12 as it may be molded using a mold as shown in FIGS. 6-7 . The cartridge has outlets 21 a , 21 b which are sealed by the valve member 16 . In the example the valve member is over-molded by solidified material. In particular the valve member in this example is unreleasably enclosed within the cartridge 12 . The first and second portions 30 a , 30 b exert sealing forces Fa, Fb toward the first and second outlets 21 a , 21 b , respectively. The sealing forces preferably result from reset forces of the first and second portions 30 a , 30 b which are enclosed within the cartridge 12 under pre-load. Such pre-load is preferably generally reestablished or maintained after opening and reclosing the cartridge, for example by rotating the valve member about the longitudinal axis A.
The skilled person will recognize that the invention is not limited to a device for dispensing a substance obtained from two components, but that the invention can likewise be used for a single component device or a device for more than two components.
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This disclosure is directed, inter alia, a method of making a dispensing device for dispensing a substance comprising a step of providing a mold having a mold space for receiving a solidifyable material. The method further comprises steps of providing a valve member having a first portion formed between first and second areas of an outer surface of the valve member; placing the valve member into the mold space such that at the first area is isolated from the mold space and at least part of the second area is within the mold space; displacing the first portion at least partially relative to another portion of the valve member; and solidifying the material in the mold space and thereby fixing the displaced first portion in place. In one embodiment, the method helps minimizing manufacturing costs and maximizing shelf life of a device filled with substance.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application Ser. No. 60/559,349 filed Apr. 2, 2004 entitled “Fastening Tool” and U.S. patent application Ser. No. 11/095,722 filed Mar. 31, 2005, entitled “Method For Operating A Power Driver”.
FIELD OF THE INVENTION
[0002] The present invention generally relates to driving tools, such as fastening tools, and more particularly to a method for operating a driving tool.
BACKGROUND OF THE INVENTION
[0003] Power nailers are relatively common place in the construction trades. Often times, however, the power nailers that are available may not provide the user with a desired degree of flexibility and freedom due to the presence of hoses and such that couple the power nailer to a source of pneumatic power. Accordingly, there remains a need in the art for an improved power nailer.
SUMMARY OF THE INVENTION
[0004] In one form, the teachings of the present invention provide a method that can include: providing a driving tool having a driver, a motor assembly and an electrical power source, the driver being movable along an axis, the motor assembly including a motor and an output member, that is driven by the motor and employed to transmit power to the driver to thereby cause the driver to translate along the axis; transmitting electrical power from the electrical power source to the motor over a first cycle portion to thereby rotate the output member; determining a parameter related to a rotational speed of the output member; and increasing a time interval of the first cycle portion if a magnitude of the parameter is less than a predetermined threshold.
[0005] In another form, form the teachings of the present invention provide a method that can include: providing a driving tool having a driver, a motor assembly and an electrical power source, the driver being movable along an axis, the motor assembly including a motor and an output member, that is driven by the motor and employed to transmit power to the driver to thereby cause the driver to translate along the axis; transmitting electrical power from the electrical power source to the motor over a first cycle portion to thereby rotate the output member; determining a parameter related to a rotational speed of the output member; and decreasing a time interval of the first cycle portion if a magnitude of the parameter is greater than a predetermined threshold.
[0006] In yet another form, the teachings of the present invention provide a method that can include: providing a driving tool having a driver, a motor assembly and an electrical power source, the driver being movable along an axis, the motor assembly including a motor and an output member, that is driven by the motor and employed to transmit power to the driver to thereby cause the driver to translate along the axis; and operating the driving tool over a complete cycle with a first cycle portion and at least one second cycle portion, the complete cycle including: transmitting electrical power from the electrical power source to the motor over the first cycle portion to thereby rotate the output member; determining a first parameter, the first parameter being related to the back electromotive force that is generated by the motor without providing electrical power to the motor; adjusting a time interval of the first cycle portion if a magnitude of the parameter is less than a predetermined first threshold or greater than a predetermined second threshold; transmitting electrical power from the electrical power source to the motor over a first one of the second cycle portions to thereby rotate the output member; re-determining the first parameter after completion of the first one of the second cycle portions; and determining an apparent voltage of a next one of the second cycle portions based on a magnitude of the first parameter.
[0007] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0009] FIG. 1 is a side view of a fastening tool constructed in accordance with the teachings of the present invention;
[0010] FIG. 2 is a schematic view of a portion of the fastening tool of FIG. 1 illustrating various components including the motor assembly and the controller;
[0011] FIG. 3 is a schematic view of a portion of the fastening tool of FIG. 1 , illustrating the controller in greater detail;
[0012] FIG. 4 is a sectional view of a portion of the fastening tool illustrating the mode selector switch;
[0013] FIG. 5 is a schematic illustration of a portion of the controller;
[0014] FIG. 6 is a plot illustrating exemplary duty cycles of a motor of the present invention;
[0015] FIG. 7 is a schematic illustration of a portion of the nailer of FIG. 1 illustrating the controller and the mode selector switch in greater detail; and
[0016] FIG. 8 is a plot illustrating the relationship between actual motor speed and the temperature of the motor when the back-emf of the motor is held constant and when the back-emf based speed of motor is corrected for temperature.
DETAILED DESCRIPTION OF THE INVENTION
[0017] With initial reference to FIG. 1 , an electric fastener delivery device, which may be referred to herein as a nailer, is generally indicated by reference numeral 10 . While the electric fastener delivery device is generally described in terms of a fastening tool 10 that drives nails into a workpiece, the electric fastener delivery device may be configured to deliver different fasteners, such as a staple or screw, or combinations of one or more of the different fasteners. Further, while the fastening tool 10 is generally described as an electric nailer, many of the features of the fastening tool 10 described below may be implemented in a pneumatic nailer or other devices, including rotary hammers, hole forming tools, such as punches, and riveting tools, such as those that are employed to install deformation rivets.
[0018] With continuing reference to FIG. 1 and additional reference to FIGS. 2 and 3 , the fastening tool 10 may include a housing 12 , a motor assembly 14 , a nosepiece 16 , a trigger 18 , a contact trip 20 , a control unit 22 , a magazine 24 , and a battery 26 , which provides electrical power to the various sensors (which are discussed in detail, below) as well as the motor assembly 14 and the control unit 22 . Those skilled in the art will appreciate from this disclosure, however, that in place of, or in addition to the battery 26 , the fastening tool 10 may include an external power cord (not shown) for connection to an external power supply (not shown) and/or an external hose or other hardware (not shown) for connection to a source of fluid pressure.
[0019] The housing 12 may include a body portion 12 a, which may be configured to house the motor assembly 14 and the control unit 22 , and a handle 12 b. The handle 12 b may provide the housing 12 with a conventional pistol-grip appearance and may be unitarily formed with the body portion 12 a or may be a discrete fabrication that is coupled to the body portion 12 a, as by threaded fasteners (not shown). The handle 12 b may be contoured so as to ergonomically fit a user's hand and/or may be equipped with a resilient and/or non-slip covering, such as an overmolded thermoplastic elastomer.
[0020] The motor assembly 14 may include a driver 28 and a power source 30 that is configured to selectively transmit power to the driver 28 to cause the driver 28 to translate along an axis. In the particular example provided, the power source 30 includes an electric motor 32 , a flywheel 34 , which is coupled to an output shaft 32 a of the electric motor 32 , and a pinch roller assembly 36 . The pinch roller assembly 36 may include an activation arm 38 , a cam 40 , a pivot pin 42 , an actuator 44 , a pinch roller 46 and a cam follower 48 .
[0021] A detailed discussion of the motor assembly 14 that is employed in this example is beyond the scope of this disclosure and is discussed in more detail in commonly assigned U.S. Provisional Patent Application Ser. No. 60/559,344 filed Apr. 2, 2004 entitled “Fastening Tool” and commonly assigned co-pending U.S. application Ser. No. 11/095,727 entitled “Structural Backbone/Motor Mount For A Power Tool”, which was filed on Mar. 31 , 2005 , and both of which are hereby incorporated by reference as if fully set forth in their entirety herein. Briefly, the motor 32 may be operable for rotating the flywheel 34 (e.g., via a motor pulley 32 a, a belt 32 b and a flywheel pulley 34 a ). The actuator 44 may be operable for translating the cam 40 (e.g., in the direction of arrow A) so that the cam 40 and the cam follower 48 cooperate to rotate the activation arm 38 about the pivot pin 42 so that the pinch roller 46 may drive the driver 28 into engagement with the rotating flywheel 34 . Engagement of the driver 28 to the flywheel 34 permits the flywheel 34 to transfer energy to the driver 28 which propels the driver 28 toward the nosepiece 16 along the axis.
[0022] A detailed discussion of the nosepiece 16 , contact trip 20 and the magazine 24 that are employed in this example is beyond the scope of this disclosure and are discussed in more detail in U.S. Provisional Patent Application Ser. No. 60/559,343 filed Apr. 2, 2004 entitled “Contact Trip Mechanism For Nailer”, U.S. Provisional Patent Application Ser. No. 60/559,342 filed Apr. 2, 2004 entitled “Magazine Assembly For Nailer”, U.S. Pat. No. 7,213,732 entitled “Contact Trip Mechanism For Nailer” and U.S. patent application Ser. No. 11/050,280 entitled “Magazine Assembly For Nailer” filed on Feb. 3, 2005, all of which are being incorporated by reference as if fully set forth in their entirety herein. The nosepiece 16 may extend from the body portion 12 a proximate the magazine 24 and may be conventionally configured to engage the magazine 24 so as to sequentially receive fasteners F therefrom. The nosepiece 16 may also serve in a conventional manner to guide the driver 28 and fastener F when the fastening tool 10 has been actuated to install the fastener F to a workpiece.
[0023] The trigger 18 may be coupled to the housing 12 and is configured to receive an input from the user, typically by way of the user's finger, which may be employed in conjunction with a trigger switch 18 a to generate a trigger signal that may be employed in whole or in part to initiate the cycling of the fastening tool 10 to install a fastener F to a workpiece (not shown).
[0024] The contact trip 20 may be coupled to the nosepiece 16 for sliding movement thereon. The contact trip 20 is configured to slide rearwardly in response to contact with a workpiece and may interact either with the trigger 18 or a contact trip sensor 50 . In the former case, the contact trip 20 cooperates with the trigger 18 to permit the trigger 18 to actuate the trigger switch 18 a to generate the trigger signal. More specifically, the trigger 18 may include a primary trigger, which is actuated by a finger of the user, and a secondary trigger, which is actuated by sufficient rearward movement of the contact trip 20 . Actuation of either one of the primary and secondary triggers will not, in and of itself, cause the trigger switch 18 a to generate the trigger signal. Rather, both the primary and the secondary trigger must be placed in an actuated condition to cause the trigger 18 to generate the trigger signal.
[0025] In the latter case (i.e., where the contact trip 20 interacts with the contact trip sensor 50 ), which is employed in the example provided, rearward movement of the contact trip 20 by a sufficient amount causes the contact trip sensor 50 to generate a contact trip signal which may be employed in conjunction with the trigger signal to initiate the cycling of the fastening tool 10 to install a fastener F to a workpiece.
[0026] The control unit 22 may include a power source sensor 52 , a controller 54 , an indicator, such as a light 56 and/or a speaker 58 , and a mode selector switch 60 . The power source sensor 52 is configured to sense a condition in the power source 30 that is indicative of a level of kinetic energy of an element in the power source 30 and to generate a sensor signal in response thereto. For example, the power source sensor 52 may be operable for sensing a speed of the output shaft 32 a of the motor 32 or of the flywheel 34 . As one of ordinary skill in the art would appreciate from this disclosure, the power source sensor 52 may sense the characteristic directly or indirectly. For example, the speed of the motor output shaft 32 a or flywheel 34 may be sensed directly, as through encoders, eddy current sensors or Hall effect sensors, or indirectly, as through the back electromotive force of the motor 32 . In the particular example provided, we employed back electromotive force, which is produced when the motor 32 is not powered by the battery 26 but rather driven by the speed and inertia of the components of the motor assembly 14 (especially the flywheel 34 in the example provided).
[0027] The mode selector switch 60 may be a switch that produces a mode selector switch signal that is indicative of a desired mode of operation of the fastening tool 10 . One mode of operation may be, for example, a sequential fire mode wherein the contact trip 20 must first be abutted against a workpiece (so that the contact trip sensor 50 generates the contact trip sensor signal) and thereafter the trigger switch 18 a is actuated to generate the trigger signal. Another mode of operation may be a mandatory bump feed mode wherein the trigger switch 18 a is first actuated to generate the trigger signal and thereafter the contact trip 20 abutted against a workpiece so that the contact trip sensor 50 generates the contact trip sensor signal. Yet another mode of operation may be a combination mode that permits either sequential fire or bump feed wherein no particular sequence is required (i.e., the trigger sensor signal and the contact trip sensor signal may be made in either order or simultaneously). In the particular example provided, the mode selector switch 60 is a two-position switch that permits the user to select either the sequential fire mode or the combination mode that permits the user to operate the fastening tool 10 in either a sequential fire or bump feed manner.
[0028] The controller 54 may be configured such that the fastening tool 10 will be operated in a given mode, such as the bump feed mode, only in response to the receipt of a specific signal from the mode selector switch 60 . With brief additional reference to FIG. 7 , the placement of the mode selector switch 60 in a first position causes a signal of a predetermined first voltage to be applied to the controller 54 , while the placement of the mode selector switch 60 in a second position causes a signal of a predetermined second voltage to be applied to the controller 54 . Limits may be placed on the voltage of one or both of the first and second voltages, such as ±0.2V, so that if the voltage of one or both of the signals is outside the limits the controller 54 may default to a given feed mode (e.g., to the sequential feed mode) or operational condition (e.g., inoperative).
[0029] For example, the mode selector switch 60 and the controller 54 may be configured such that a +5 volt supply is provided to mode selector switch 60 , placement of the mode selector switch 60 in a position that corresponds to mandatory sequential feed causes a +5 volt signal to be returned to the controller 54 , and placement of the mode selector switch 60 in a position that permits bump feed operation causes a +2.5 volt signal to be returned to the controller 54 . The different voltage may be obtained, for example, by routing the +5 volt signal through one or more resistors R when the mode selector switch 60 is positioned in a position that permits bump feed operation. Upon receipt of a signal from the mode selector switch 60 , the controller 54 may determine if the voltage of the signal is within a prescribed limit, such as ±0.2 volts. In this example, if the voltage of the signal is between +5.2 volts to +4.8 volts, the controller 54 will interpret the mode selector switch 60 as requiring sequential feed operation, whereas if the voltage of the signal is between +2.7 volts to +2.3 volts, the controller 54 will interpret the mode selector switch 60 as permitting bump feed operation. If the voltage of the signal is outside these windows (i.e., greater than +5.2 volts, between +4.8 volts and +2.7 volts, or lower than +2.3 volts in the example provided), the controller 54 may cause the fastening tool 10 to operate in a predetermined mode, such as one that requires sequential feed operation. The controller 54 may further provide the user with some indication (e.g., a light or audible alarm) of a fault in the operation of the fastening tool 10 that mandates the operation of the fastening tool 10 in the predetermined mode.
[0030] The lights 56 of the fastening tool may employ any type of lamp, including light emitting diodes (LEDs) may be employed to illuminate portions of the worksite, which may be limited to or extend beyond the workpiece, and/or communicate information to the user or a device (e.g., data terminal). Each light 56 may include one or more lamps, and the lamps may be of any color, such as white, amber or red, so as to illuminate the workpiece or provide a visual signal to the operator. Where the lights 56 are to be employed to illuminate the worksite, the one or more of the lights 56 may be actuated by a discrete switch (not shown) or by the controller 54 upon the occurrence of a predetermined condition, such the actuation of the trigger switch 18 a. The lights 56 may be further deactivated by switching the state of a discrete switch or by the controller 54 upon the occurrence of a predetermined condition, such as the elapsing of a predetermined amount of time.
[0031] Where the lights 56 are to be employed to communicate information, the light(s) 56 may be actuated by the controller 54 in response to the occurrence of a predetermined condition. For example, the lights 56 may flash a predetermined number of times, e.g., four times, or in a predetermined pattern in response to the determination that a charge level of the battery 26 has fallen to a predetermined level or if the controller 54 determines that a fastener has jammed in the nosepiece 16 . This latter condition may be determined, for example, through back-emf sensing of the motor 32 .
[0032] Additionally or alternatively, the light(s) 56 may be employed to transmit information optically or electrically to a reader. In one embodiment, light generated by the light(s) 56 is received by an optical reader 500 to permit tool data, such as the total number of cycles operated, the type and frequency of any faults that may have occurred, the values presently assigned to various adjustable parameters, etc. to be downloaded from the fastening tool 10 . In another embodiment, a sensor 502 is coupled to a circuit 504 in the fastening tool 10 to which the light(s) 56 are coupled. The sensor 502 may be operable for sensing the current that passes through the light(s) 56 and/or the voltage on a leg of the circuit 504 that is coupled to the light(s) 56 . As the illumination of the light(s) 56 entails both a change in the amount of current passing there through and a change in the voltage on the leg of the circuit 504 that is coupled to the light(s) 56 , selective illumination of the light(s) 56 may be employed to cause a change in the current and/or voltage that may be sensed by the sensor 502 . A signal produced by the sensor 502 in response to the changes in the current and/or voltage may be received by a reader that receives the signal that is produced by the sensor 502 . Accordingly, those of ordinary skill in the art will appreciate from this disclosure that the operation light(s) 56 may be employed to affect an electric characteristic, such as current draw or voltage, that may be sensed by the sensor 502 and employed by a reader to transmit data from the tool 10 .
[0033] The controller 54 may be coupled to the mode selector switch 60 , the trigger switch 18 a, the contact trip sensor 50 , the motor 32 , the power source sensor 52 and the actuator 44 . In response to receipt of the trigger sensor signal and the contact trip sensor signal, the controller 54 determines whether the two signals have been generated at an appropriate time relative to the other (based on the mode selector switch 60 and the mode selector switch signal).
[0034] If the order in which the trigger sensor signal and the contact trip sensor signal is not appropriate (i.e., not permitted based on the setting of the mode selector switch 60 ), the controller 54 does not enable electrical power to flow to the motor 32 but rather may activate an appropriate indicator, such as the lights 56 and/or the speaker 58 . The lights 56 may be illuminated in a predetermined manner (e.g., sequence and/or color) and/or the speaker 58 may be employed to generate an audio signal so as to indicate to the user that the trigger switch 18 a and the contact trip sensor 50 have not been activated in the proper sequence. To reset the fastening tool 10 , the user may be required to deactivate one or both of the trigger switch 18 a and the contact trip sensor 50 .
[0035] If the order in which the trigger sensor signal and the contact trip sensor signal is appropriate (i.e., permitted based on the setting of the mode selector switch 60 ), the controller 54 enables electrical power to flow to the motor 32 , which causes the motor 32 to rotate the flywheel 34 . The power source sensor 52 may be employed to permit the controller 54 to determine whether the fastening tool 10 has an energy level that exceeds a predetermined threshold. In the example provided, the power source sensor 52 is employed to sense a level of kinetic energy of an element in the motor assembly 14 . In the example provided, the kinetic energy of the motor assembly 14 is evaluated based on the back electromotive force generated by the motor 32 . Power to the motor 32 is interrupted, for example after the occurrence of a predetermined event, which may be the elapse of a predetermined amount of time, and the voltage of the electrical signal produced by the motor 32 is sensed. As the voltage of the electrical signal produced by the motor 32 is proportional to the speed of the motor output shaft 32 c (and flywheel 34 ), the kinetic energy of the motor assembly 14 may be reliably determined by the controller 54 .
[0036] As those of ordinary skill in the art would appreciate from this disclosure, the kinetic energy of an element in the power source 30 may be determined (e.g., calculated or approximated) either directly through an appropriate relationship (e.g., e=½ l×ω 2 ; e=½ m×v 2 ) or indirectly, through an evaluation of one or more of the variables that are determinative of the kinetic energy of the motor assembly 14 since at least one of the linear mass and inertia of the relevant component is substantially constant. In this regard, the rotational speed of an element, such as the motor output shaft 32 a or the flywheel 34 , or the characteristics of a signal, such as its frequency of a signal or voltage, may be employed by themselves as a means of approximating kinetic energy. For example, the kinetic energy of an element in the power source 30 may be “determined” in accordance with the teachings of the present invention and appended claims by solely determining the rotational speed of the element. As another example, the kinetic energy of an element in the power source 30 may be “determined” in accordance with the teachings of the present invention and appended claims by solely determining a voltage of the back electromotive force generated by the motor 32 .
[0037] If the controller 54 determines that the level of kinetic energy of the element in the motor assembly 14 exceeds a predetermined threshold, a signal may be generated, for example by the controller 54 , so that the actuator 44 may be actuated to drive the cam 40 in the direction of arrow A, which as described above, will initiate a sequence of events that cause the driver 28 to translate to install a fastener F into a workpiece.
[0038] If the controller 54 determines that the level of kinetic energy of the element in the motor assembly 14 does not exceed the predetermined threshold, the lights 56 may be illuminated in a predetermined manner (e.g., sequence and/or color) and/or the speaker 58 may be employed to generate an audio signal so as to indicate to the user that the fastening tool 10 may not have sufficient energy to fully install the fastener F to the workpiece. The controller 54 may be configured such that the actuator 44 will not be actuated to drive the cam 40 in the direction of arrow A if the kinetic energy of the element of the motor assembly 14 does not exceed the predetermined threshold, or the controller 54 may be configured to permit the actuation of the actuator 44 upon the occurrence of a predetermined event, such as releasing and re-actuating the trigger 18 , so that the user acknowledges and expressly overrides the controller 54 .
[0039] While the fastening tool 10 has been described thus far as employing a single kinetic energy threshold, the invention, in its broader aspects, may be practiced somewhat differently. For example, the controller 54 may further employ a secondary threshold that is representative of a different level of kinetic energy than that of the above-described threshold. In situations where the level of kinetic energy in the element of the motor assembly 14 is higher than the above-described threshold (i.e., so that operation of the actuator 44 is permitted by the controller 54 ) but below the secondary threshold, the controller 54 may activate an indicator, such as the lights 56 or speaker 58 to provide a visual and/or audio signal that indicates to the user that the battery 26 may need recharging or that the fastening tool 10 may need servicing.
[0040] Further, the above-described threshold and the secondary threshold, if employed, may be adjusted based on one or more predetermined conditions, such as a setting to which the fastener F is driven into the workpiece, the relative hardness of the workpiece, the length of the fastener F and/or a multi-position or variable switch that permits the user to manually adjust the threshold or thresholds.
[0041] With reference to FIGS. 1 and 4 , the fastening tool 10 may optionally include a boot 62 that removably engages a portion of the fastening tool 10 surrounding the mode selector switch 60 . In the example provided, the boot 62 may be selectively coupled to the housing 12 . The boot 62 may be configured to inhibit the user from changing the state of the mode selector switch 60 by inhibiting a switch actuator 60 a from being moved into a position that would place the mode selector switch 60 into an undesired state. Additionally or alternatively, the boot 62 may protect the mode selector switch 60 (e.g., from impacts, dirt, dust and/or water) when the boot 62 is in an installed condition. Further, the boot 62 may be shaped such that it only mates with the fastening tool 10 in a single orientation and is thus operable to secure the switch 60 in only a single predetermined position, such as either the first position or the second position, but not both. Optionally, the boot 62 may also conceal the presence of the mode selector switch 60 .
[0042] Returning to FIGS. 2 and 3 , the fastening tool 10 may also include a fastener sensor 64 for sensing the presence of one or more fasteners F in the fastening tool 10 and generating a fastener sensor signal in response thereto. The fastener sensor 64 may be a limit switch or proximity switch that is configured to directly sense the presence of a fastener F or of a portion of the magazine 24 , such as a pusher 66 that conventionally urges the fasteners F contained in the magazine 24 upwardly toward the nosepiece 16 . In the particular example provided, the fastener sensor 64 is a limit switch that is coupled to the nosepiece 16 and positioned so as to be contacted by the pusher 66 when a predetermined quantity of fasteners F are disposed in the magazine 24 and/or nosepiece 16 . The predetermined quantity may be any integer that is greater than or equal to zero. The controller 54 may also activate an appropriate indicator, such as the lights 56 and/or speaker 58 , to generate an appropriate visual and/or audio signal in response to receipt of the fastener sensor signal that is generated by the fastener sensor 64 . Additionally or alternatively, the controller 54 may inhibit the cycling of the fastening tool 10 (e.g., by inhibiting the actuation of the actuator 44 so that the cam 40 is not driven in the direction of arrow A) in some situations. For example, the controller 54 may inhibit the cycling of the fastening tool 10 when the fastener sensor 64 generates the fastener sensor signal (i.e., when the quantity of fasteners F in the magazine 24 is less than the predetermined quantity). Alternatively, the controller 54 may be configured to inhibit the cycling of the fastening tool 10 only after the magazine 24 and nosepiece 16 have been emptied. In this regard, the controller 54 may “count down” by subtracting one (1) from the predetermined quantity each time the fastening tool 10 has been actuated to drive a fastener F into the workpiece. Consequently, the controller 54 may count down the number of fasteners F that remain in the magazine 24 and inhibit further cycling of the fastening tool 10 when the controller 54 determines that no fasteners F remain in the magazine 24 or nosepiece 16 .
[0043] The trigger switch 18 a and the contact trip sensor 50 can be conventional power switches. Conventional power switches, however, tend to be relatively bulky and employ a relatively large air gap between the contacts of the power switch. Accordingly, packaging of the switches into the fastening tool 10 , the generation of heat by and rejection of heat from the power switches, and the durability of the power switches due to arcing are issues attendant with the use of power switches. Alternatively, the trigger switch 18 a and the contact trip sensor 50 can be microswitches that are incorporated into a circuit that employs solid-state componentry to activate the motor assembly 14 to thereby reduce or eliminate concerns for packaging, generation and rejection of heat and durability due to arcing.
[0044] With reference to FIG. 5 , the controller 54 may include a control circuit 100 . The control circuit 100 may include the trigger switch 18 a, the contact trip sensor 50 , a logic gate 106 , an integrated circuit 108 , a motor switch 110 , a first actuator switch 112 , and a second actuator switch 114 . The switches 110 , 112 and 114 may be any type of switch, including a MOSFET, a relay and/or a transistor.
[0045] The motor switch 110 may be a power controlled device that may be disposed between the motor 32 and a power source, such as the battery 26 ( FIG. 1 ) or a DC-DC power supply (not shown). The first and second actuator switches 112 and 114 may also be power controlled devised that are disposed between the actuator 44 and the power source. In the particular example provided, the first and second actuator switches 112 and 114 are illustrated as being disposed on opposite sides of the actuator 44 between the actuator 44 and the power source, but in the alternative could be situated in series between the actuator and the power source. The trigger switch 18 a and the contact trip sensor 50 are coupled to both the logic gate 106 and the integrated circuit 108 . The integrated circuit 108 may be responsive to the steady state condition of the trigger switch 18 a and/or the contact trip sensor 50 , or may be responsive to a change in one or both of their states (e.g., a transition from high-to-low or from low-to-high).
[0046] Actuation of the trigger switch 18 a produces a trigger switch signal that is transmitted to both the logic gate 106 and the integrated circuit 108 . As the contact trip sensor 50 has not changed states (yet), the logic condition is not satisfied and as such, the logic gate 106 will not transmit a signal to the first actuator switch 112 that will cause the logic gate 106 to change the state of the first actuator switch 112 . Accordingly, the first actuator switch 112 is maintained in its normal state (i.e., open in the example provided). The integrated circuit 108 , however, transmits a signal to the motor switch 110 in response to receipt of the trigger switch signal which causes the motor switch 110 to change states (i.e., close in the example provided), which completes an electrical circuit that permits the motor 32 to operate.
[0047] Actuation of the contact trip sensor 50 produces a contact trip sensor signal that is transmitted to both the logic gate 106 and the integrated circuit 108 . If the trigger switch 18 a had continued to transmit the trigger switch signal, the logic condition is satisfied and as such, the logic gate 106 will transmit a signal to the first actuator switch 112 that will cause it to change states. Accordingly, the first actuator switch 112 is changed to a closed state in the example provided. Upon receipt of the contact trip sensor signal, the integrated circuit 108 transmits a signal to the second actuator switch 114 which causes the second actuator switch 114 to change states (i.e., close in the example provided), which in conjunction with the changing of the state of the first actuator switch 112 , completes an electrical circuit to permit the actuator 44 to operate.
[0048] Various other switches, such as the mode selector switch 60 and/or the power source sensor 52 , may be coupled to the integrated circuit 108 to further control the operation of the various relays. For example, if the mode selector switch 60 were placed into a position associated with the operation of the fastening tool 10 in either a bump feed or a sequential feed manner, the integrated circuit 108 may be configured to change the state of the motor switch 110 upon receipt of either the trigger switch signal or the contact trip sensor signal and thereafter change the state of the second actuator switch 114 upon receipt of the other one of the trigger switch signal and the contact trip sensor signal.
[0049] As another example, if the power source sensor 52 generated a signal that was indicative of a situation where the level of kinetic energy in the motor assembly 14 is less than a predetermined threshold, the integrated circuit 108 may be configured so as to not generate a signal that would change the state of the second actuator switch 114 to thereby inhibit the operation of the fastening tool 10 .
[0050] From the foregoing, it will be appreciated that actuation of the motor assembly 14 cannot occur as a result of a single point failure (e.g., the failure of one of the trigger switch 18 a or the contact trip sensor 50 ).
[0051] With reference to FIGS. 3 and 6 , the controller 54 may be provided with additional functionality to permit the fastening tool 10 to operate using battery packs of various different voltages, such as 18 , 14 , 14 and/or 9.6 volt battery packs. For example, the controller 54 may employ. pulse width modulation (PWM), DC/DC converters, or precise on-time control to control the operation of the motor 32 and/or the actuator 44 , for example to ensure consistent speed of the flywheel 34 /kinetic energy of the motor assembly 14 regardless of the voltage of the battery. The controller 54 may be configured to sense or otherwise determine the actual or nominal voltage of the battery 26 at start-up (e.g., when the battery 26 is initially installed or electrically coupled to the controller 54 ).
[0052] Power may be supplied to the motor 32 over all or a portion of a cycle using a pulse-width modulation technique, an example of which is illustrated in FIG. 6 . The cycle, which may be initiated by a predetermined event, such as the actuation of the trigger 18 , may include an initial power interval 120 and one or more supplemental power intervals (e.g., 126 a, 126 b, 126 c ). The initial power interval 120 may be an interval over which the full voltage of the battery 26 may be employed to power the motor 32 . The length or duration (ti) of the initial power interval 120 may be determined through an algorithm or a look-up table in the memory of the controller 54 for example, based on the output of the battery 26 or on an operating characteristic, such as rotational speed, of a component in the motor assembly 14 . The length or duration (ts) of each supplemental power interval may equal that of the initial power interval 120 , or may be a predetermined constant, or may be varied based on the output of the battery 26 or on an operating characteristic of the motor assembly 14 .
[0053] A dwell interval 122 may be employed between the initial power interval 120 and a first supplemental power interval 126 a and/or between successive supplemental power intervals. The dwell intervals 122 may be of a varying length or duration (td), but in the particular example provided, the dwell intervals 122 are of a constant duration (td). During a dwell interval 122 , power to the motor 32 may be interrupted so as to permit the motor 32 to “coast”. The output of the power source sensor 52 may be employed during this time to evaluate the level of kinetic energy in the motor assembly 14 (e.g., to permit the controller 54 to determine whether the motor assembly 14 has sufficient energy to drive a fastener) and/or to determine one or more parameters by which the motor 32 may be powered or operated in a subsequent power interval.
[0054] In the example provided, the controller 54 evaluates the back emf of the motor 32 to approximate the speed of the flywheel 34 . The approximate speed of the flywheel 34 (or an equivalent thereof, such as the value of the back emf of the motor 32 ) may be employed in an algorithm or look-up table to determine the duty cycle (e.g., apparent voltage) of the next supplemental power interval. Additionally, if the back emf of the motor 32 is taken in a dwell interval 122 immediately after an initial power interval 120 , an algorithm or look-up table may be employed to calculate changes to the duration (ti) of the initial power interval 120 . In this way, the value (ti) may be constantly updated as the battery 26 is discharged. The value (ti) may be reset (e.g., to a value that may be stored in a look-up table) when a battery 26 is initially coupled to the controller 54 . For example, the controller 54 may set (ti) equal to 180 ms if the battery 26 has a nominal voltage of about 18 volts, or to 200 ms if the battery 26 has a nominal voltage of about 14.4 volts, or to 240 ms if the battery 26 has a nominal voltage of about 12 volts.
[0055] With reference to FIG. 8 , the back-emf of the motor 32 may change with the temperature of the motor as is indicated by the line that is designated by reference numeral 200 ; the line 200 represents the actual rotational speed as a function of temperature when the back-emf of the motor is held constant. With additional reference to FIG. 3 , the control unit 22 may include a temperature sensor 202 for sensing a temperature of the motor 32 or another portion of the fastening tool, such as the controller 54 , to permit the controller 54 to compensate for differences in the back-emf of the motor 32 that occur with changes in temperature. In the particular example provided, the temperature sensor 202 is coupled to the controller 54 and generates a temperature signal in response to a sensed temperature of the controller 54 . As the controller 54 is in relatively close proximity to the motor 32 , the temperature of the controller 54 approximates the temperature of the motor 32 .
[0056] The controller 54 may employ any known technique, such as a look-up table, mathematical relationship or an algorithm, to determine the effect of the sensed temperature on the back-emf of the motor 32 . In the particular example provided, the relationship between the actual rotational speed of the motor 32 indicates linear regression, which permitted the use of an empirically-derived equation to determine a temperature-based speed differential (AST) that may be employed in conjunction with a back-emf-based calculated speed (S BEF ) to more closely approximate the rotational speed (S) of the motor 32 (i.e., S=S BEF −ΔS T ). The line designated by reference numeral 210 in FIG. 8 illustrates the actual speed of the motor 32 as a function of temperature when the approximate rotational speed (S) is held constant.
[0057] Alternatively, the controller 54 may approximate the rotational speed (S) of the motor 32 through the equation S=|S BATV +ΔS BEF −ΔS T | where S BATV can be an estimate of a base speed of the motor 32 based upon a voltage of the battery 26 , ΔS BEF can be a term that is employed to modify the base speed of the motor 32 based upon the back-emf produced by the motor 32 , and ΔS T can be the temperature-based speed differential described above. In the particular example provided, the voltage of the battery can be an actual battery voltage as opposed to a nominal battery voltage and the S BATV term can be derived as a function of the slope of a plot of motor speed versus battery voltage. As determined in this alternative manner, the speed of the motor can be determined in a manner that is highly accurate over a wide temperature range.
[0058] It will be appreciated that while the fastening tool 10 has been described as providing electrical power to the electric motor 32 except for relatively short duration intervals (e.g., between pulses and/or to check the back-emf of the motor 32 ) throughout an operational cycle, the invention, in its broadest aspects, may be carried out somewhat differently. For example, the controller 54 may control the operation of the motor 32 through feedback control wherein electric power is occasionally interrupted so as to allow the motor 32 and flywheel 34 to “coast”. During the interruption of power, the controller 54 can occasionally monitor the kinetic energy of the motor assembly 14 and apply power to the motor if the kinetic energy of the motor assembly 14 falls below a predetermined threshold. Operation of the fastening tool in this manner can improve battery life.
[0059] While the invention has been described in the specification and illustrated in the drawings with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise, above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the foregoing description and the appended claims.
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A power tool for operating on a workpiece, the power tool having a housing and a motor disposed within the housing. A controller is connected to the motor and receives user inputs for turning on the motor and a power tool battery pack is connected to the controller and the motor. At least one light is connected to the controller for illuminating the workpiece. The controller can turn on the light in a predetermined pattern to alert the user to a tool condition, such as the charge level being below a predetermined level.
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[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/285,863, filed Apr. 23, 2001, and U.S. Provisional Application Ser. No. 60/206,751, filed May 24, 2000.
FIELD OF THE INVENTION
[0002] This invention relates to a wood preservative composition comprising a biocidally effective amount of at least one amine oxide and a method of controlling microorganisms in a wood substrate or other cellulosic or fiber material with the wood preservative composition. This invention also relates to a method of removing algae from a substrate with one or more amine oxides.
BACKGROUND OF THE INVENTION
[0003] Wood is an important building and construction material that is used in a variety of applications, such as housing material, utility poles, and railroad ties. Effective wood preservatives and waterproofing compounds that improve dimensional stability are necessary to maintain the integrity of these structures.
[0004] Quaternary alkyl ammonium compounds (QAC's), such as didecyldimethylammonium chloride (DDAC), have been shown to be effective as fungicides. However, QAC's do not readily penetrate and uniformly distribute into wood. Because of the poor penetration and distribution, certain areas of the wood do not receive adequate protection, often resulting in the wood rotting from the inside out. Furthermore, DDAC corrodes steel tanks and other metal components commonly used in wood treatment systems.
[0005] U.S. Pat. No. 4,357,163 discloses a chlorinated phenol wood treating composition containing a chlorophenol, a fatty acid amine oxide, and water. The amine oxide was included to increase penetration of the chelating agents and chlorophenols into the wood and to stabilize the chlorophenol in water.
[0006] U.S. Pat. No. 5,833,741 discloses a waterproofer wood preservative system comprising a waterproofing enhancing amount of waterproofer composition and a biocidally effective amount of a biocide. The waterproofer is an alkyl dimethyl amine oxide, an alkyl acetoacetate, or a waterproofing quaternary ammonium compound. The biocide comprises at least one biocidal quaternary ammonium compound. Generally, the concentration of biocide in the waterproofer wood preservative system is 0.25 to 4% by weight.
[0007] U.S. Pat. Nos. 3,296,145 and 3,484,523 disclose a composition for cleaning, softening, and sanitizing fabrics; cleaning and sanitizing walls and floors; and cleaning and degerming human skin and similar organic tissue. The composition contains a quaternary alkyl ammonium compound and a tertiary amine oxide.
[0008] U.S. Pat. No. 4,179,504 discloses alkyl amine oxides which are effective as ectoparasiticidal and ovicidal toxicants and their use in shampoos.
[0009] Devinsky et al., Chemical Abstracts 103:122986s (1 986), disclose certain N, N′-didecyl-N,N′-dimethyl-α,ω-alkanediamine dioxides which inhibit the growth of bacteria and fungi.
[0010] Societe de Produits Chimiques et de Synthese, Chemical Abstracts 84849c (1966), discloses that dimethyl-laurylamine oxide, bis(β-hydroxyethyl)laurylamine oxide, and dimethylsoyaamine oxide were used for suppressing the growth of some dermal fungi or bacteria, such as C. perfringens, S. anaerobius, and A. niger.
[0011] However, prior to the present invention, there was no indication that amine oxides would be effective as wood preservatives. In fact, their inclusion in wood treating solutions was to either stabilize a preservative ingredient, such as chlorophenol as in U.S. Pat. No. 4,357,163, or act as a waterproofer in conjunction with a preservative ingredient, as in U.S. Pat. No. 5,833,741.
[0012] In light of the foregoing, it is desirable to have a wood preservative that has broad antifungal activity, low toxicity to non-target organisms, high phase stability in water, and low corrosivity.
SUMMARY OF THE INVENTION
[0013] The present inventors have discovered that amine oxides are highly effective as wood preservatives. The present invention provides a wood preservative composition comprising a biocidally effective amount of one or more amine oxides. Preferably, the wood preservative composition is substantially free of halogenated compounds (such as halides and chlorinated compounds) and quaternary ammonium compounds. The wood preservative composition of the present invention exhibits low toxicity, high stability in water, low corrosivity to metal substrates (such as steel substrates), excellent penetration and uniform distribution into wood, low odor, waterproofing properties, and high leaching resistance. The wood preservative composition may be applied to the surface of a wood substrate or be applied by pressure treating the wood substrate with the wood preservative composition. Other cellulosic and fiber materials, such as cotton, burlap, and like materials, may also be preserved with the composition of the present invention.
[0014] Another embodiment is a method of controlling microorganisms, such as fungal decay organisms (generally known as white rot, brown rot, and soft rot fungi) and sapstain organisms (e.g. stains, mold, and fungi) on and/or in a wood substrate, such as fresh cut lumber, comprising applying a biocidally effective amount of the composition of the present invention to the wood substrate.
[0015] Yet another embodiment is a method of controlling sapstain organisms and/or fungi (including mold) on and/or in a wood substrate, such as fresh cut lumber, comprising applying a sapstain and/or fungicidally (mold) inhibiting effective amount of one or more amine oxides and one or more phosphonic iron stain inhibitors.
[0016] Yet another embodiment of the present invention is a wood preservative system comprising a wood substrate and a biocidally effective amount of one or more amine oxides. Preferably, the wood substrate comprises a fungicidally or sapstain inhibiting effective amount of one or more amine oxides. Detailed Description of the Invention The present invention provides a wood preservative composition comprising a biocidally effective amount of one or more amine oxides. The composition of the present invention exhibits high penetration and uniform distribution into wood substrates as well as low corrosivity to metal substrates and high leaching resistance.
[0017] The amine oxide may be a trialkylamine oxide, an alkylcyclicamine oxide, a dialkylpiperazine di-N-oxide, an alkyldi(poly(oxyalkylene))amine oxide, a dialkylbenzylamine oxide, a fatty acylamidopropyldimethylamine oxide, a diamine dioxide; a triamine trioxide, or any combination of any of the foregoing.
[0018] Preferred trialkylamine oxides have the formula R 1 R 2 R 3 N→O, where R 1 is a linear, branched, cyclic or any combination thereof C 8 to C 40 saturated or unsaturated group; and R 2 and R 3 independently are linear, branched, or any combination thereof C 1 to C 40 saturated or unsaturated groups. R 1 , R 2 , and R 3 independently may be alkyl, alkenyl, or alkynyl groups. More preferably, R 1 is a linear, branched, cyclic or any combination thereof C 8 to C 22 saturated or unsaturated group, such as coco, hydrogenated tallow, soya, decyl, and hexadecyl; and R 2 and R 3 independently are linear, branched, or any combination thereof C 1 to C 22 saturated or unsaturated groups, such as coco, hydrogenated tallow (which is typically about 70-75% by weight of C 18 alkyl, about 20-25% by weight of C 16 alkyl, and traces of lower derivatives), soya, decyl, and hexadecyl.
[0019] A preferred trialkylamine oxide is a dialkylmethylamine oxide having the formula R 1 R 2 CH 3 N→O, where R 1 and R 2 are defined as above. Another preferred trialkylamine oxide is an alkyldimethylamine oxide having the formula R 1 (CH 3 ) 2 N→O, where R 1 is defined as above. More preferred alkyldimethylamine oxides have the formula R 19 (CH 3 ) 2 N→O, where R 19 is a linear or branched C 8 —C 18 alkyl. Preferably, R 19 is a linear or branched C 10 —C 16 alkyl. Alkyldimethylamine oxides are non-toxic and non-mutagenic surfactants. Suitable alkyldimethylamine oxides include, but are not limited to, decyldimethylamine oxide, cocodimethylamine oxide, dodecyldimethylamine oxide, a C 10 —C 14 alkyldimethylamine oxide, hexadecyldimethylamine oxide, a C 16 -C 18 alkyldimethylamine oxide, and any combination of any of the foregoing. A more preferred wood preservative composition contains a mixture of dodecyl dimethyl amine oxide and hexadecyl dimethyl amine oxide.
[0020] Preferred alkylcyclicamine oxides have the formula R 4 R 5 R 6 N→O where R 4 is defined as R 1 above and R 5 and R 6 are linked to form a cyclic group. The cyclic group typically contains from 4 to 10 carbon atoms and may optionally contain oxygen, sulfur, nitrogen, or any combination of any of the foregoing. More preferred alkylcyclicamine oxides include, but are not limited to, an alkylmorpholine N-oxide, a dialkylpiperazine di-N-oxide, and any combination of any of the foregoing.
[0021] Preferred alkylmorpholine N-oxides have the formula
[0022] where R 7 is defined as R 1 above. According to a more preferred embodiment, R 7 is a linear or branched C 10 to C 16 alkyl. Examples of preferred alkylmorpholine N-oxides include, but are not limited to, cetyl morpholine N-oxide and lauryl morpholine N-oxide.
[0023] Preferred dialkylpiperazine di-N-oxides have the formula
[0024] where R 8 is defined as R 1 above and R 9 is defined as R 2 above.
[0025] Preferred alkyldi(poly(oxyalkylene))amine oxides have the formula
[0026] where R 10 is defined as R 1 above; R 11 and R 12 independently are H or CH 3 ; and m and n independently are integers from about 0 to about 10 and at least one of m and n is greater than 0.
[0027] Preferred dialkylbenzylamine oxides have the formula R 13 R 14 R 15 N→O, where R 13 is defined as R 1 above; R 14 is defined as R 2 above; and R 15 is benzyl. More preferred dialkylbenzylamine oxides include, but are not limited to, alkylbenzylmethylamine oxides having the formula R 13 R 15 CH 3 N→O where R 13 and R15 are defined as above. According to a more preferred embodiment, R 13 is a linear or branched C 8 —C 12 alkyl.
[0028] Preferred fatty acylamidopropyldimethylamine oxides have the formula
[0029] where R 16 is defined as R 1 above.
[0030] Preferred diamine oxides have the formula
[0031] where R 17 is defined as R 1 above; and m is an integer from about 1 to about 10.
[0032] Preferred triamine oxides have the formula
[0033] where R 18 is defined as R 1 above; and m and n independently are integers from about 1 to about 10.
[0034] Long chain (C 16 or greater) amine oxides, such as hexadecylamine oxides and hydrogenated tallow amine oxides, are particularly preferable for imparting waterproofing properties to the composition. Short chain (C 14 and shorter) amine oxides aide are water soluble and aide in solubilizing long chain amine oxides and are typically better preservatives.
[0035] A blend of long chain and short chain amine oxides is contemplated in one embodiment of the present invention. The long chain amine oxides are generally blended with the short chain amine oxides at a weight ratio of from about 5:1 to about 1:5 and preferably at a weight ratio of from about 2:1 to about 1:1.
[0036] According to a preferred embodiment, the composition contains a mixture of C 16 —C 18 long chain amine oxides to impart waterproofing properties and C 10 C 14 short chain amine oxides to solubilize the long chain amine oxides. A particularly preferable blend is a mixture of hexadecyldimethylamine oxide and dodecyldimethylamine oxide at a weight ratio of about 5:2.
[0037] The wood preservative composition comprises a biocidally effective amount of one or more amine oxides. Preferably, the composition comprises a fungicidally effective amount and more preferably a sapstain inhibiting effective amount of one or more amine oxides.
[0038] The wood preservative composition can be used to prevent the growth of sapstain (e.g. stains, mold, and fungi) on fresh cut timber between the time the timber is cut into board and the time when the board has dried to a low moisture content.
[0039] An aqueous composition of the present invention generally contains from about 0.1 to about 5%, preferably from about 0.25 to about 3%, and more preferably from about 0.5 to about 1.5% by weight of amine oxide, based upon 100% total weight of wood preservative composition. For application to pressure treated wood, the composition preferably contains from about 0.1 to about 5% and more preferably from about 0.25 to about 3% by weight of amine oxide, based upon 100% total weight of wood preservative composition. For controlling sapstain, the wood preservative composition preferably contains from about 0.1 to about 5% and more preferably from about 0.5 to about 1% by weight of amine oxide, based upon 100% total weight of wood preservative composition.
[0040] According to a preferred embodiment, the wood preservative composition comprises a waterproofing and biocidally, fungicidally, or sapstain inhibiting effective amount of one or more amine oxides.
[0041] The wood preservative composition of the present invention may further comprise a solvent, such as water, a water miscible solvent, or a combination thereof. Suitable water miscible solvents include, but are not limited to, alcohols, glycols, esters, ethers, polyethers, amines, ketones, and any combination of any of the foregoing. Preferably, the solvent is water.
[0042] The wood preservative composition may also comprise further auxiliaries, such as corrosion inhibitors, iron stain inhibitors, wetting agents, adhesives, emulsifiers, fillers, carriers, viscosity and pH regulators, binders, tackifiers, other active ingredients (such as other biocidally active ingredients), and any combination of any of the foregoing.
[0043] Suitable iron stain inhibitors include, but are not limited to, phosphonic iron stain inhibitors, such as aminotri(methylenephosphonic acid), 1-hydroxyethylidene-1,1-diphosphonic acid, diethylenetriaminepenta(methylenephosphonic acid), bis-(hexamethylene)triamine phosphonic acid, and any combination of any of the foregoing. The inventors have discovered that the inclusion of a phosphonic iron stain inhibitor, such as 1-hydroxyethylidene-1,1-diphosphonic acid and bis-(hexamethylene)triamine phosphonic acid, improves the biological efficacy of the amine oxide. Furthermore, since many iron stain inhibitors are highly acidic, prior art treating solutions containing them typically have a pH of less than 2. In contrast, wood preservative compositions of the present invention which contain iron stain inhibitors typically have a pH ranging from about 3 to about 7.
[0044] Other adjuvants may be included in the composition as known to one of ordinary skill in the art.
[0045] Generally, the wood preservative composition is neutral, i.e., has a pH of from about 6 to about 8.
[0046] According to a preferred embodiment, the wood preservative composition is substantially free (i.e., contains less than 0.1% by weight) of quaternary ammonium compounds, halogenated compounds (including halides and chlorinated compounds such as chlorophenols), or both. More preferably, the wood preservative composition contains less than 0.01, 0.001, or 0.0001% by weight of quaternary ammonium compounds, halogenated compounds (including chlorine containing compounds such as chlorophenols), or both. Most preferably, the wood preservative composition is free of quaternary ammonium compounds, halogenated compounds (including chlorine containing compounds such as chlorophenols), or both.
[0047] According to another preferred embodiment, the wood preservative composition is substantially free (i.e., contains less than 0.1% by weight) of biocides, bactericides, or fungicides other than amine oxides. More preferably, the wood preservative composition contains less than 0.01, 0.001, or 0.0001% by weight of biocides, bactericides, or fungicides other than amine oxides. Most preferably, the wood preservative composition is free of biocides, bactericides, or fungicides other than amine oxides.
[0048] A particularly preferable sapstain inhibiting composition of the present invention comprises cocodimethylamine oxide and, optionally, an iron stain inhibitor. Also, special mention is made of cocodimethylamine oxide alone or in combination with hexadecyldimethylamine oxide as a preservative for use in pressure treating lumber.
[0049] The wood preservative composition may be applied to any wood substrate, such as any hard wood or soft wood, to present sapstain. Typically, for preventing or controlling sapstain and mold, the wood preservative composition is applied to green wood. The term “green” as used herein is defined as freshly cut, unseasoned, or the like. Examples of suitable wood substrates include, but are not limited to, maple, oak, birch, cherry, fir, and the like. The wood preservative composition may be applied to any wood substrate which is to be pressure treated. Preferably, the wood substrate is a soft wood, such as a pine, fir, or hemlock. Suitable pine wood substrates include, but are not limited to, southern yellow pine and ponderosa pine. More, preferably, the wood substrate is southern yellow pine.
[0050] Methods of applying the wood preservative composition include, but are not limited to, spraying, soaking, immersing, vacuum impregnation, pressure treatment, brushing, and the like. Preferably, the substrate is immersed in the wood preservative composition of the present invention or the substrate is pressure treated with the composition.
[0051] The composition may be prepared by dissolving the amine oxide and adjuvants in water. The mixture may be heated to a temperature of from about 50 to about 60° C. and/or stirred to expedite mixing. For example, a 30% (w/w) mixture of hexadecyl dimethyl amine oxide, available as Barlox® 16S from Lonza Inc. of Fair Lawn, N.J., which is a paste, may be mixed with a 30% (w/w) aqueous solution of coco-dimethylamine oxide and water to form a concentrated solution suitable for producing use dilutions of the wood preservative composition.
[0052] A wood substrate containing the wood preservative composition generally comprises from about 0.1 to about 5% by weight, preferably from about 0.25 to about 3% by weight, and more preferably from about 0.5 to about 2% by weight of amine oxide, based upon 100% total weight of preserved wood substrate.
[0053] Another embodiment is a method ofcontrolling microorganisms, such as fungi and sapstain organisms, on and/or in a wood substrate comprising applying a biocidally effective amount of the wood preservative composition of the present invention to the wood substrate. The term “controlling” as used herein includes, but is not limited to, inhibiting the growth of microorganisms, such as fungi and sapstain organisms. Non-limiting examples of fungi are Trametes versicolor ( T. versicolor ), Gloeophyllum trabeum ( G. trabeum ), Poria placenta ( P. placenta ), Lentinus lepideus ( L. lepideus ), Coniophoraputeana ( C. puteana ), and Chaetomium globsum ( C. globsum ).
[0054] According to apreferred embodiment, the wood preservative composition further comprises one or more iron stain inhibitors, preferably phosphonic iron stain inhibitors, is applied to a wood substrate to control sapstain organisms. Generally, the composition contains from about 0.05 to about 1% by weight of phosphonic iron stain inhibitor, based upon 100% by weight of composition. Preferably, the composition contains from about 0.1 to about 0.5 and more preferably from about 0.15 to about 0.3% by weight of phosphonic iron stain inhibitor, based upon 100% by weight of composition.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0055] The following examples illustrate the invention without limitation. All parts and percentages are given by weight unless otherwise indicated. All Barlox® ingredients are available from Lonza Inc. of Fair Lawn, NJ.
EXAMPLE 1
[0056] A concentrate of a wood preservative composition was prepared as follows. 50 parts of Barlox® 16S, about 20 parts of Barlox® 12, and about 80 parts water were mixed. Barlox® 16S is an aqueous solution containing 30% by weight of hexadecyldimethylamine oxide. Barlox® 12 is an aqueous solution containing 30% by weight of coco-dimethylamine oxide. The mixture was heated and/or allowed to sit until a clear solution was obtained, e.g., by about 40 to 50° C. for about 2 to 4 hours or simply sitting at room temperature overnight. The resulting composition was clear.
EXAMPLE 2
[0057] The wood preserving efficacy of each aqueous test solution in Table 1 below was tested on freshly cut white birch wood as follows. All percentages in Table 1 are by weight. A branch of white birch tree measuring about 3 inches in diameter was cut into pieces about 6 inch in length. Each piece was then split into 4 sections. Each section was dipped into the test solution for about 1 minute and blotted with a paper towel to remove excess liquid. The sections were sealed in a clear plastic bag and stored at ambient conditions. The sections were observed after 1, 3, 7, and 12 weeks for the growth of stains, molds, and fungi. The aqueous test solutions were prepared by mixing the active ingredient with water. The results are shown in Table 1.
TABLE 1 Rating* of treated white birch sections vs. Time Test solution 1 week 3 weeks 7 weeks 12 weeks None 4 1 1 — Water 3 2 1 — 1% Didecyldimethyl ammonium 4 4 3 3 chloride 1% Coco-dimethyl amine oxide 4 4 3 2 1% Tetradecyl dimethylamine 4 3 2 2 oxide 1% Decyl dimethylamine oxide 3 2 2 2 1% Hexadecyl dimethylamine 3 2 2 2 oxide 0.5% Hexadecyl dimethylamine 4 3 3 3 oxide and 0.5% dodecyldimethyl amine oxide
EXAMPLE 3
[0058] The wood preserving efficacy of each aqueous test solution in Table 2 below was tested on freshly cut green chestnut oak as described in Example 2. All percentages in Table 2 are by weight. The sections were observed after 2, 4, 5, and 9 weeks for the growth of stains, molds, and fungi. The results are shown in Table 2. The aqueous test solutions were prepared by mixing the active ingredient with water.
TABLE 2 Rating of treated green chestnut oak sections vs. Time Test solution 2 weeks 4 weeks 5 weeks 9 weeks None 1 1 Water 2 2 1 0.25% 1-Hydroxyethylidene-1,1- 2 2 1 1 diphosphonic acid (HEDP) 1 1% Didecyldimethyl ammonium 3 2 2 1 chloride 1% Dodecyl dimethylamine oxide 3 2 2 1 1% Dodecyl dimethylamine oxide 4 4 3 1 and 0.25% HEDP 1% Dodecyl dimethylamine oxide 4 4 3 2 and 0.2% bis-(hexamethylene)triamine phosphonic acid 2 1% Didecyldimethyl ammonium 3 2 1 1 chloride and 0.25% HEDP
[0059] The pH of the 1% didecyldimethyl ammonium chloride and 0.25% HEDP solution was about 1.9 while the pH of the 1% dodecyl amine oxide and 0.25% HEDP solution was about 4.8.
EXAMPLE 4
[0060] The efficacy of aqueous solutions of amine oxides and didecyldimethyl ammonium chloride to inhibit fungus growth was evaluated by the agar plate method known in the art. The concentration (IC 50 ) of each aqueous solution at which 50% retardation of the growth of the fungi is observed was determined. The fungi tested were Trametes versicolor ( T. versicolor ), a white rot fungus; Gloeophyllum trabeum ( G. trabeum ), a brown rot fungus which is tolerant of arsenic and phenolic type wood preservatives; Poria placenta ( P. placenta ), a brown rot fungus which is tolerant to copper in wood preservatives; Lentinus lepideus ( L. lepideus ), a brown rot fungus which is tolerant to creosote; Coniophora puteana ( C. puteana ), a brown rot fungus; and Chaetomium globsum ( C. globsum ), a soft rot fungus. The results are shown in Tables 3A and 3B below.
TABLE 3A IC 50 (ppm) T. Aqueous Test Solution versicolor G. trabeum P. placenta Octyldimethylamine oxide 800 250-400 300 Decyldimethylamine oxide 300-500 20-40 15-25 Coco-dimethylamine oxide 40-50 10-15 3-7 Tetradecyl dimethylamine oxide 70 15-25 2-5 Hexadecyl dimethylamine oxide 30 25-30 5-25 Octadecyl dimethylamine oxide 800 250 20-50 Mixture of hexadecyl dimethyl- 10 4 3 amine oxide and coco-dimethyl- amine oxide at a 5:2 weight ratio Didecyldimethyl ammonium 30-50 10-40 5-25 chloride
[0061] [0061] TABLE 3B IC 50 (ppm) L. Aqueous Test Solution lepideus C. puteana C. globsum Octyldimethylamine oxide — — 400 Decyldimethylamine oxide — — 50-100 Coco-dimethylamine oxide 15 80 50-70 Tetradecyl dimethylamine oxide — — 80-100 Hexadecyl dimethylamine oxide 3 80 20-50 Octadecyl dimethylamine oxide — — 600 Mixture of hexadecyl dimethyl- 10 3 10 amine oxide and coco-dimethyl- amine oxide at a 5:2 weight ratio Didecyldimethyl ammonium — — 10-20 chloride
EXAMPLE 5
[0062] The aqueous test solutions in Table 4 below were prepared and tested as follows.
[0063] Wafers about ¼ inch thick were cut from southern yellow pine board and placed in a vacuum desiccator. The vacuum pressure was maintained at about −80 kPa for about 15 minutes. Test solutions listed in Table 4 were injected into the vacuum. Vacuum was broken by the addition of air and the board was allowed to stand for about 10 minutes. Excess solution was blotted from the wafers. The wafers were returned to the desiccator and another vacuum was drawn to about −80 kPa pressure for about 15 minutes to remove any kickback solution.
Leaching in Water
[0064] About 10 g of the test solution treated wafers were vacuum impregnated with about 200g of water and soaked in water for about 5 days with occasional shaking. After the 5 days, the concentration of preservative in the water and in the wafers was determined. The concentration of preservative in the water was determined by American Wood-Preserver's Association Standard No. A18-99. The concentration of preservative in the wood was determined by the high performance liquid chromatography method described in American Wood-Preserver's Association Standard No. A16-93.
Leaching in Water and Soil
[0065] About 10 g of the test solution treated wafers and about 10 g of air dry organic forest soil were vacuum impregnated with about 150g water, slowly agitated for about 5 days, and separated. After the 5 days, the concentration of preservative in the soil and in the wafers was determined as described above.
[0066] The results are shown in Table 4.
TABLE 4 Wafer treated with Wafer treated with Water Water and Soil Concentration Concentration Concentration Concentration of of of of Preservative in Preservative in Preservative in Preservative Aqueous Test Wafer after 5 Water after 5 Wafer after 5 in Soil after 5 Solution days (% w/w) days (ppm) days (% w/w) days (% w/w) 1.5% Didecyldimethyl 1.5 40 1.1 0.4 ammonium chloride 1.5% Octadecylbenzyl 2.0 50 1.3 0.1 dimethyl ammonium chloride 1.5% 1.5 90 0.7 05 Dodecyldimethyl- amine oxide 1% Dodecyldimethyl 1.5 140 0.7 05 amine oxide and 0.5% decyldimethyl amine oxide
EXAMPLE 6
[0067] Southern yellow pine (SYP) lumber pieces were pressure treated to assess penetration of amine oxides. An aqueous test solution containing 1.7% by weight of hexadecyl dimethylamine oxide (hexadecyl DMAO) and 0.6% by weight of dodecyl dimethylamine oxide (dodecyl DMAO) was prepared. Two 2′ pieces of kiln dried #1 grade SYP 2×4's were end coated with an epoxy paint. The wood pieces were placed in a pressure treating cylinder for about 30 minutes at about −90 kPa, injected with the aqueous test solution, and pressurized to about 950 kPa for about 30 minutes. The pressure was released by the addition of air, the solution was drained, and the wood pieces were exposed to a vacuum of about −90 kPa for about 30 minutes. After air drying, the pieces were cut in the middle and several ¼″ wafers were removed from the outer 0.3″, second 0.3″, and inner 0.3″. The wafers were analyzed by HPLC to determine the concentration of amine oxide in the wafers.
[0068] The results are shown in Table 5.
TABLE 5 Amine Oxide found in zones (%) Retention (%) Outer Second Piece Preservative Target Actual 3″ 3″ Inner 3″ #1 Hexadecyl DMAO 1.9 2.3 2.9 2.0 1.7 Dodecyl DMAO 0.7 1.1 2.4 1.4 0.8 #2 Hexadecyl DMAO 1.7 2.0 2.5 2.1 2.1 Dodecyl DMAO 0.6 0.8 2.0 1.2 1.1
[0069] The target retention is the desired amount of the ingredient to be retained in the wood substrate.
EXAMPLE 7
[0070] Wafers were prepared as described in Example 5 with the aqueous treatment solution described in Example 6 and with an aqueous solution containing 1% (w/w) of didecyldimethyl ammonium chloride (DDAC). The samples were shaken for 7 days instead of the 5 days described in Example 5. The results are shown in Table 6.
TABLE 6 Concentration Concentration of Concentration Concentration of Concentration Preservative of of Preservative of in Unleached Preservative Preservative in Wafer after Preservative Wood after 7 in after 7 days in Water after 7 days in Soil after 7 Sample days (% w/w) (% w/w) 7 days (ppm) (% w/w) days (% w/w) Hexadecyl- 2.3 2.6 <10 1.5 0.33 DMAO Dodecyl- 1.1 1.7 <10 0.5 0.15 DMAO DDAC 1.25 1.24 <10 0.95 0.5
EXAMPLE 8
[0071] Southern yellow pine lumber pieces were pressure treated with an aqueous solution containing hexadecyldimethylamine oxide and dodecyldimethylamine oxide by the procedure described in Example 6. Two pieces were treated with an aqueous solution containing 1.65% by weight of hexadecyldimethylarnine oxide and 0.6% by weight of dodecyldimethylamine oxide and two pieces were treated with an aqueous solution containing 0.8% by weight of hexadecyldimethylamine oxide and 0.3% by weight of dodecyldimethylamine oxide. The treated pieces were placed outside on a rack and the effect of natural weathering was observed after 2, 6, and 10 months.
[0072] This procedure was repeated with aqueous solutions containing 0.5% or 1% by weight of copper chromium arsenate or 0.5% or 1% by weight of didecyldimethyl ammonium chloride.
[0073] Four pieces were treated with water (untreated lumber pieces) and tested as described above.
[0074] The results are shown in Table 7.
TABLE 7 Observations Test Solution After 2 Months After 6 Months After 10 Months Untreated Generally darker The pieces were The pieces were dark surface with sections darker overall, had black with numerous quite dark. A new many cracks, and a cracks. crack developed on wet appearance. one piece. Hexadecyldimethyl- All four pieces Two of the four All four pieces were amine oxide (1.65 clean, clear, and pieces were clean a uniform light gray and 0.8%) and unchanged from the and clear. The other color and had some dodecyldimethyl- start. two pieces had cracks. amine oxide (0.6 darker sections and and 0.3%) fine cracks. Copper chromium General covering of Small mildew spots The pieces were arsenate (0.5 and small dark spots. and many small brownish with 1%) Surface integrity is cracks were present brown and black unchanged. in all four pieces spots and many cracks Didecyldimethyl Few spots and Three of the four The pieces were a ammonium chloride darker black sections pieces had dark gray black color with (0.5 and 1%) covering two of the sections and many many cracks. four pieces. A crack cracks. developed in one of the pieces
EXAMPLE 9
[0075] The corrosivity of each aqueous amine oxide solution and each aqueous didecyldimethyl ammonium chloride solution in Table 8 and water on steel substrates was determined as follows. A carbon steel coupon was submerged into the aqueous solution so that the coupon was about ¾ covered and stored for two weeks. The coupon was shaken occasionally so that the top of the coupon was wetted periodically. After two weeks, the coupon was weighed to determine the amount of steel corroded and the surface of the coupon was observed. The results are shown in Table 8.
TABLE 8 Test Solution Weight Lost (%) Observations Water 0.28 Solution is rust colored. Coupon is rusted. 0.3% didecyldimethyl 0.44 Black corrosion ammonium chloride 1% didecyldimethyl 0.40 Black corrosion ammonium chloride 1% hexadecyl −0.02 1 Coupon and solution dimethylamine oxide both clear 1% decyl dimethylamine −0.02 Coupon and solution oxide both clear 1% decyl dimethylamine −0.01 Coupon and solution oxide and 0.1% ammonia both clear 1% decyl dimethylamine 0.4 Orange rust oxide and 0.1% acetic acid (the pH of the solution was 5.1) 1% decyl dimethylamine 0.01 Coupon and solution oxide and 0.01% acetic acid both clear (the pH of the solution was 6.7) 1% decyl dimethylamine 0.01 Coupon and solution oxide and 0.1% lauric acid both clear (the pH of the solution was 6.7)
EXAMPLE 10
[0076] Ponderosa pine wafers and southern yellow pine sticks were treated with the aqueous test solutions shown in Tables 9-12 by the procedures described above to determine their waterproofing efficacy. The treated wafers and sticks were air dried and weathered for up to 700 days. A water uptake test was performed to determine the water resisting efficacy of each wafer or stick. The water uptake was determined by air drying the wafer or stick to a constant weight, immersing the wafer or stick in water for 30 minutes, weighing the wafer or stick, and calculating the water uptake. The percentage water resisting efficiency (% WRE) was determined by the following formula:
[0077] % WRE=100*(Weight of Immersed Treated Wood−Weight of Immersed Untreated Wood)/(Weight of Immersed Untreated Wood)
[0078] The weight of the immersed untreated wood was measured after 30 minutes and used as the control. The results are shown in Tables 9-12 below.
TABLE 9 Water Uptake (%) of Weathered Ponderosa Pine Wafers % WRE Start Day Day Day Test solution Day 0 (Day 0) 170 330 690 Control (Untreated) 58 — 104 154 161 Thompson's Waterseal ™* 11 87 13 43 119 1% Didecyldimethyl 58 33 73 87 107 ammonium chloride 1%hexadecyl 35 60 51 77 89 dimethylamineoxide
[0079] [0079] TABLE 10 Water Uptake (%) of Weathered Ponderosa Pine Wafers Test solution* Day 0 Day 105 Day 430 Untreated 47 64 124 48 63 123 1% Didecyldimethyl ammonium 35 56 71 chloride 38 58 80 1.5% hexadecyl dimethylamine 16 23 38 oxide and 0.6% dodecyl 17 25 38 dimethylamine oxide 0.4% Didecyldimethyl 16 29 53 ammonium chloride and 0.6% 18 41 60 HT-AO 1
[0080] [0080] TABLE 11 Water Uptake (%) of Weathered SYP Treated Sticks Test solution Day 0 Day 220 Day 610 Untreated 23 27 77 1% decyl dimethylamine oxide 22 39 71 1% didecyldimethyl ammonium 17 22 36 chloride 1% hexadecyl 12 14 17 dimethylamine oxide
[0081] [0081] TABLE 12 Water Uptake (%) of Weathered SYP Treated Sticks % WRE start Test solution Day 0 (Day 0) Day 90 Day 310 Day 480 Untreated 36 — 35 65 74 1% didecyldimethyl 17 53 24 36 29 ammonium chloride 1% hexadecyl di- 10 72 13 18 14 methylamine oxide 1% dodecyl di- 14 61 15 20 24 methylamine oxide 1% hexadecyl 7 81 14 17 23 dimethylamine oxide and 0.5% didecyldimethyl ammonium chloride
EXAMPLE 11
[0082] The procedure for determining waterproofing efficacy was repeated with southern yellow pine sticks, southern yellow pine end grain wafers, and ponderosa pine wafers and the aqueous solutions in Table 13 below by the procedure described in Example 10.
[0083] The results are shown in Table 13.
TABLE 13 Water Uptake % of Weathered Wood Test solution Day 0 Day 100 Day 225 SYP sticks ¼ × ¾ × 10″ Untreated 37 45 55 1% didecyldimethyl ammonium 27 34 26 chloride 1.5% HT-AO and 0.75% dodecyl 9 11 8 dimethylamine oxide SYP end grain wafers Untreated 40 71 77 Thompson's Waterseal ™ 2 13 24 1% didecyldimethyl ammonium 41 41 56 chloride 1.5% HT-AO 1 and 0.75% dodecyl 22 29 15 dimethylamine oxide Ponderosa Pine wafers Untreated 75 89 Thompson's Waterseal ™ 2 11 12 1% didecyldimethyl ammonium 62 73 chloride 1.5% HT-AO 1 and 0.75% dodecyl 24 33 dimethylamine oxide
EXAMPLE 12
[0084] The efficacy of the aqueous amine oxide solutions in Table 14 at various concentrations against the wood rot fungi T. versicolor (white rot fungi), G. trabeum (brown rot fungi), P. placenta (brown rot fungi), and C. globosum (soft rot decay fungi) were determined using the agar dilution plate method well known in the art. The minimum concentration of each amine oxide required to achieve 100% growth retardation of each specific organism, i.e., the minimum inhibitory concentration (MIC), was determined. The percent retardation of the fungi was determined by the percentage change in the diameter of the fungi on the agar plate (i.e. Percent Retardation=((Diameter of Control)−(Diameter of Treated Fungi))/(Diameter of Control)*100%).
[0085] The results are shown in Table 14 below.
TABLE 14 MIC (ppm of amine oxides) T. G. P. C. versicolor trabeum placenta globosum Amine Oxide (ppm) (ppm) (ppm) (ppm) Octyldimethylamine 750 1000 1000 >1000 oxide Decyl-DMAO 750 250 500 >1000 Coco-DMAO 750 500 500-1000 >1000 Branched alkyl (C 10 - 500 250 500 >1000 C 14 ) DMAO Dodecyl-DMAO 250 250 250 >1000 Tetradecyl-DMAO >1000 >1000 >1000 >1000 Hexadecyl-DMAO >1000 >1000 >1000 >1000 Oleyl-DMAO >1000 >1000 >1000 >1000 Octadecyl-DMAO >1000 >1000 >1000 >1000 Coco- 500 500 500 >1000 di(hydroxyethyl)- amine oxide Tallow >1000 >1000 >1000 >1000 di(hydroxyethyl)- amine oxide Dodecyl-BMAO >1000 1000 >1000 >1000 Lauryl morpholine N- 750 1000 500 >1000 oxide
[0086] The minimum concentration of the aqueous amine oxide solutions in Table 15 required to achieve 50% growth retardation of each specific organism, i.e., IC 50 , was estimated from the data obtained using Table2D curve fitting. The results are shown in Table 15.
TABLE 15 Barlox ® 12 Barlox ® 12i Bardac ® 2280 IC 50 MIC IC 50 MIC IC 50 MIC Fungi (ppm) (ppm) (ppm) (ppm) (ppm) (ppm) T. versicolor 51 750 84 500 28 >1000 G. trabeum 9 250 44 250 8 >1000 P. placenta 5 1000 89 500 <5 <1000 C. globosum 47 >1000 153 >1000 28 >1000
EXAMPLE 13
[0087] 40″ by ¾″ by ¾″ pieces of southern yellow pine lumber were treated with the aqueous solution prepared in Example 1 according to the procedure described in the American Wood Preservers' Association test method E7, which is hereby incorporated by reference. The procedure is generally as follows. The southern yellow pine lumber pieces were placed in a pressure treating cylinder for about 30 minutes at about −90 kPa, injected with the aqueous solution, and pressurized to about 800 kPa for about 30 minutes. The pressure was released by the addition of air and the solution was drained.
[0088] This procedure was repeated with aqueous solutions containing 0.5 or 1.0% by weight of copper chromium arsenate (CCA) and aqueous solutions containing 0.5, 1.0, or 1.5% by weight of didecyl dimethyl ammonium chloride (DDAC).
[0089] From each treated piece, two matched 18″ stakes and one 4″ center piece were obtained. The 18″ stakes were placed in the ground at different field sites, field sites A and B. A total of 10 test stakes treated with each aqueous solution were placed in each field site. After 11 months, the stakes were observed. The results are shown in Table 16 below.
TABLE 16 Rating* after 11 Months Target Field Site A Field Site B Aqueous Treatment Retention Termite Termite Solution (kg/m 3 ) Decay Attack Decay Attack Untreated — 6.2 ± 2.4 4.4 ± 4.2 7.2 ± 4.2 8.5 ± 3.1 0.5% (w/w) CCA 3 10 10 10 10 1.0% (w/w) CCA 6 10 10 10 10 0.5% (w/w) DDAC 3 9.9 ± 0.3 9.3 ± 0.9 10 10 1.0% (w/w) DDAC 6 10 9.9 ± 0.3 10 10 1.5% (w/w) DDAC 9 10 8.9 ± 1.3 10 10 0.82% (w/w) of 5 (Coco) + 9.5 ± 0. 9.0 ± 1.2 9.9 ± 0.3 10 coco-DMAO and 2 (C 16 ) 0.33% (w/w) of hexadecyl-DMAO at a 5:2 weight ratio 1.65% (w/w) of 10 (coco) + 10 9.8 ± 0.4 10 10 coco-DMAO and 4 (C 16 ) 0.67% (w/w) of hexadecyl-DMAO at a 5:2 weight ratio 2.5% (w/w) of 15 (coco) + 9.8 ± 0.4 9.9 ± 0.3 10 10 hexadecyl-DMAO 6 (C 16 ) and 1.0% (w/w) of coco-DMAO at a 5:2 weight ratio
EXAMPLE 14
[0090] The wood preserving efficacy of each aqueous test solution in Table 17 below was tested on freshly cut tulip wood (also known as Tulip-Popular, Yellow Popular, and Liriodendron tulipfera L.) as follows. All percentages in Table 17 are by weight. Pieces of tulip wood cut from a 4″ debarked branch were cut into pieces. Each piece was then split into 4 sections. Each section was dipped into the test solution for about 1 minute and blotted with a paper towel to remove excess liquid. The sections were sealed in a clear plastic bag and stored at ambient conditions. The sections were observed after 1, 3, 7, and 11 weeks for the growth of stains, molds, and fungi. The aqueous test solutions were prepared by mixing the active ingredient with water. The results are shown in Table 17.
TABLE 17 Rating* of treated tulip sections vs. Time 1 3 7 11 Aqueous test solution week weeks weeks weeks None 3 2.5 2 1 Water 4 2 1 1 0.65% Didecyldimethyl ammonium 4 4 4 4 chloride 0.32% Didecyldimethyl ammonium 4 4 3.5 3.5 chloride 1.0% Hexadecyl DMAO and 4 3 2 1 0.4% Dodecyl DMAO 0.5% Hexadecyl DMAO and 5 5 3 2 0.2% Dodecyl DMAO 1.0% Hexadecyl DMAO, 4 4 3.5 3 0.4% Dodecyl DMAO, and 0.15% 1-Hydroxyethylidene-1,1- diphosphonic acid (HEDP) 0.5% Hexadecyl DMAO, 4 4 2 1 0.2% Dodecyl DMAO, and 0.08% HEDP 1.0% Hexadecyl DMAO, 4 4 3.5 3 0.4% Dodecyl DMAO, and 0.045% Ammonia 1.0% Hexadecyl DMAO, 4 4 3 2 0.4% Dodecyl DMAO, 0.15% HEDP, and 0.045% Ammonia 1.0% Dodecyl DMAO 4 4 4 4 0.5% Dodecyl DMAO 4 3 2 1 1.0% Dodecyl DMAO and 3 3 2 1 0.045% Ammonia 1.0% Dodecyl DMAO and 3.5 3.5 3 2 0.15% HEDP, and 0.045% Ammonia None 3 3 2 — 1.0% Dodecyl DMAO 4 4 3 — 1.0% Dodecyl DMAO and 4 4 3.5 — 1.0% Coco-dimethyl amine 1 1.0% Dodecyl DMAO and 4 4 4 — 0.5% Coco-dimethyl amine 1.0% Dodecyl DMAO and 4 4 4 — 0.25% Coco-dimethyl amine 0.5% Hexadecyl dimethylamine 4 3 3 3 oxide and 0.5% dodecyldimethyl amine oxide
EXAMPLE 15
[0091] The wood preserving efficacy of each aqueous test solution in Table 18 below was tested on freshly cut beech wood (Fagus grandifolia Ehrh.) as follows. All percentages in Table 18 are by weight. A 1″ branch of a beech tree was split into two pieces. The bark was left on the pieces. Each piece was dipped into the test solution for about 1 minute and blotted with a paper towel to remove excess liquid. The pieces were sealed in a clear plastic bag and stored at ambient conditions. The pieces were observed after 1, 3, 7, and 11 weeks for the growth of stains, molds, and fungi. The aqueous test solutions were prepared by mixing the active ingredient with water. The results are shown in Table 18.
TABLE 18 Rating* of treated tulip sections vs. Time 1 3 7 11 Aqueous test solution week weeks weeks weeks None 3 3 2 1 Water 4 3 2 1 0.65% Didecyldimethyl ammonium 4 3.5 2 2 chloride 0.32% Didecyldimethyl ammonium 4 2 2 2 chloride 1.0% Hexadecyl DMAO and 4 2 1 1 0.4% Dodecyl DMAO 0.5% Hexadecyl DMAO and 4 3 2 1 0.2% Dodecyl DMAO 1.0% Hexadecyl DMAO, 4 3.5 2.5 2 0.4% Dodecyl DMAO, and 0.15% 1-Hydroxyethylidene-1,1- diphosphonic acid (HEDP) 0.5% Hexadecyl DMAO, 4 3 2 1 0.2% Dodecyl DMAO, and 0.08% HEDP 1.0% Hexadecyl DMAO, 4 2 2 1 0.4% Dodecyl DMAO, and 0.045% Ammonia 1.0% Hexadecyl DMAO, 4 3 2.5 2 0.4% Dodecyl DMAO, 0.15% HEDP, and 0.045% Ammonia 1.0% Dodecyl DMAO 4 2 2 2 0.5% Dodecyl DMAO 4 4 2.5 2.5 1.0% Dodecyl DMAO and 4 3 2.5 2 0.045% Ammonia 1.0% Dodecyl DMAO and 4 2.5 2 2 0.15% HEDP, and 0.045% Ammonia None 3.5 3 2.5 — 1.0% Dodecyl DMAO 3.5 3 2 1 1.0% Dodecyl DMAO and 4 3.5 3.5 — 1.0% Coco-dimethyl amine 1 1.0% Dodecyl DMAO and 3.5 2 2 1 0.5% Coco-dimethyl amine 1.0% Dodecyl DMAO and 4 3 2 — 0.25% Coco-dimethyl amine
[0092] All patents, applications, articles, publications, and test methods mentioned above are hereby incorporated by reference.
[0093] Many variations of the present invention will suggest themselves to those skilled in the art in light of the above detailed description. Such obvious variations are within the full intended scope of the appended claims.
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The present inventors have discovered that amine oxides are highly effective as wood preservatives. The present invention provides a wood preservative composition comprising a biocidally effective amount of one or more amine oxides. Preferably, the wood preservative composition is substantially free of halogenated compounds (such as halides and chlorinated compounds) and quaternary ammonium compounds. The wood preservative composition of the present invention exhibits low toxicity, high stability in water, low corrosivity to metal substrates (such as steel substrates), excellent penetration and uniform distribution into wood, low odor, waterproofing properties, and high leaching resistance. The wood preservative composition may be applied to the surface of a wood substrate or be applied by pressure treating the wood substrate with the wood preservative composition. Other cellulosic and fiber materials, such as cotton, burlap, and like materials, may be preserved with the composition of the present invention. Another embodiment is a method of controlling microorganisms, such as fungal decay organisms (generally known as white rot, brown rot, and soft rot fungi) and sapstain organisms, on and/or in a wood substrate, such as fresh cut lumber, comprising applying a biocidally effective amount of the composition of the present invention to the wood substrate.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation of U.S. patent application Ser. No. 10/706,537 filed on Nov. 12, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The field of invention relates generally to imprint lithography. More particularly, the present invention is directed to reducing the time required to fill the features of a template with imprinting material during imprint lithography processes.
[0003] Micro-fabrication involves the fabrication of very small structures, e.g., having features on the order of micro-meters or smaller. One area in which micro-fabrication has had a sizeable impact is in the processing of integrated circuits. As the semiconductor processing industry continues to strive for larger production yields while increasing the circuits per unit area formed on a substrate, micro-fabrication becomes increasingly important. Micro-fabrication provides greater process control while allowing increased reduction of the minimum feature dimension of the structures formed. Other areas of development in which micro-fabrication has been employed include biotechnology, optical technology, mechanical systems and the like.
[0004] An exemplary micro-fabrication technique is shown in U.S. Pat. No. 6,334,960 to Willson et al. Willson et al. disclose a method of forming a relief image in a structure. The method includes providing a substrate having a transfer layer. The transfer layer is covered with a polymerizable fluid composition. A mold makes mechanical contact with the polymerizable fluid. The mold includes a relief structure, and the polymerizable fluid composition fills the relief structure. The polymerizable fluid composition is then subjected to conditions to solidify and to polymerize the same, forming a solidified polymeric material on the transfer layer that contains a relief structure complimentary to that of the mold. The mold is then separated from the solid polymeric material such that a replica of the relief structure in the mold is formed in the solidified polymeric material. The transfer layer and the solidified polymeric material are subjected to an environment to selectively etch the transfer layer relative to the solidified polymeric material such that a relief image is formed in the transfer layer. The time required and the minimum feature dimension provided by this technique are dependent upon, inter alia, the composition of the polymerizable material.
[0005] It is desired, therefore, to provide a technique that decreases the time required to fill a feature of an imprint lithography template.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a conductive template and of a method forming conductive templates that includes providing a substrate; forming a mesa on the substrate; and forming a plurality of recessions and projections on the mesa with a nadir of the recessions comprising electrically conductive material and the projections comprising electrically insulative material. It is desired that the mesa be substantially transparent to a predetermined wavelength of radiation, for example ultraviolet radiation. As a result, it is desired to form the electrically conductive material from a material that allows ultraviolet radiation to propagate therethrough. In the present invention indium tin oxide is a suitable material from which to form the electrical conductive material. However, indium tin oxide is difficult to pattern due to its resistance to etch. Nonetheless, the present method provides a manner in which to form a conductive template with indium oxide suitable for use in imprint lithography. These other embodiments are discussed more fully below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a lithographic system in accordance with the present invention;
[0008] FIG. 2 is a simplified elevation view of a lithographic system shown in FIG. 1 ;
[0009] FIG. 3 is a simplified representation of material from which an imprinting layer, shown in FIG. 2 , is comprised before being polymerized and cross-linked;
[0010] FIG. 4 is a simplified representation of cross-linked polymer material into which the material shown in FIG. 3 is transformed after being subjected to radiation;
[0011] FIG. 5 is a simplified elevation view of a mold spaced-apart from the imprinting layer, shown in FIG. 1 , after patterning of the imprinting layer;
[0012] FIG. 6 is a top down view showing an array of droplets of imprinting material deposited upon a region of the substrate shown above in FIG. 2 in accordance with a first embodiment of the present invention;
[0013] FIG. 7 is a simplified schematic view of cantilevering impingement of a mold, shown in FIG. 2 , impinging upon the array of droplets, shown in FIG. 6 , in accordance with one embodiment of the present invention;
[0014] FIGS. 8-11 are top down views showing the compression of droplets, shown above in FIG. 6 , employing cantilevering impingement of mold, shown in FIG. 7 ;
[0015] FIG. 12 is a bottom up view of a mold having individually addressable electrical conductors in accordance with an alternate embodiment of the present invention;
[0016] FIG. 13 is a side cross-sectional view of the template shown in FIG. 12 ;
[0017] FIG. 14 is a top down view of a substrate employed to fabricate the template shown in accordance with yet another embodiment of the present invention;
[0018] FIG. 15 is a side cross-sectional view of a region of the substrate, shown in FIG. 14 , taken across lines 15 - 15 ;
[0019] FIGS. 16-23 are side cross-sectional views of the region shown in FIG. 15 demonstrating the various processes employed to fabricate the template shown in FIG. 13 ;
[0020] FIG. 24 is a top down view of the region shown in FIG. 6 , with the droplets of imprinting material disposed in an array according to yet a fourth embodiment of the present invention;
[0021] FIG. 25 is a top down view showing the compression of droplets, shown above in FIG. 24 , employing mold, shown in FIG. 2 , in accordance with a fifth embodiment of the present invention;
[0022] FIG. 26 is a cross-sectional view of a template in accordance with a sixth embodiment of the present invention;
[0023] FIG. 27 is a top down view of a substrate employed to fabricate the template, shown in FIG. 26 , in accordance with a seventh embodiment of the present invention;
[0024] FIG. 28 is a cross-sectional view of a region of the substrate shown in FIG. 27 taken along lines 28 - 28 ; and
[0025] FIGS. 29-30 are cross-sectional views of the region shown in FIG. 28 demonstrating the various processes employed to fabricate the template shown in FIG. 26 .
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 depicts a lithographic system 10 in accordance with one embodiment of the present invention that includes a pair of spaced-apart bridge supports 12 having a bridge 14 and a stage support 16 extending therebetween. Bridge 14 and stage support 16 are spaced-apart. Coupled to bridge 14 is an imprint head 18 , which extends from bridge 14 toward stage support 16 and provides movement along the Z-axis. Disposed upon stage support 16 to face imprint head 18 is a motion stage 20 . Motion stage 20 is configured to move with respect to stage support 16 along X- and Y-axes. It should be understood that imprint head 18 may provide movement along the X- and Y-axes, as well as the Z-axis, and motion stage 20 may provide movement in the Z-axis, as well as the X- and Y-axes. An exemplary motion stage device is disclosed in U.S. Pat. No. 6,900,881, which is assigned to the assignee of the present invention, and which is incorporated by reference herein in its entirety. A radiation source 22 is coupled to system 10 to impinge actinic radiation upon motion stage 20 . As shown, radiation source 22 is coupled to bridge 14 and includes a power generator 23 connected to radiation source 22 . Operation of system is typically controlled by a processor 25 that is in data communication therewith.
[0027] Referring to both FIGS. 1 and 2 , connected to imprint head 18 is a template 26 having a mold 28 thereon. Mold 28 includes a plurality of features defined by a plurality of spaced-apart recessions 28 a and protrusions 28 b. The plurality of features defines an original pattern that is to be transferred into a substrate 30 positioned on motion stage 20 . To that end, imprint head 18 and/or motion stage 20 may vary a distance “d” between mold 28 and substrate 30 . In this manner, the features on mold 28 may be imprinted into a flowable region of substrate 30 , discussed more fully below. Radiation source 22 is located so that mold 28 is positioned between radiation source 22 and substrate 30 . As a result, mold 28 is fabricated from material that allows it to be substantially transparent to the radiation produced by radiation source 22 . To that end, mold 28 may be formed from materials that includes quartz, fused-silica, silicon, sapphire, organic polymers, siloxane polymers, borosilicate glass, fluorocarbon polymers or a combination thereof. Further template 26 may be formed from the aforementioned materials, as well as metal.
[0028] Referring to both FIGS. 2 and 3 , a flowable region, such as an imprinting layer 34 , is disposed on a portion of surface 32 that presents a substantially planar profile. An exemplary flowable region consists of imprinting layer 34 being deposited as a plurality of spaced-apart discrete droplets 36 of material 36 a on substrate 30 , discussed more fully below. An exemplary system for depositing droplets 36 is disclosed in U.S. Pat. No. 6,926,929, which is assigned to the assignee of the present invention, and which is incorporated by reference herein in its entirety. Imprinting layer 34 is formed from a material 36 a that may be selectively polymerized and cross-linked to record the original pattern therein, defining a recorded pattern. An exemplary composition for material 36 a is disclosed in U.S. Pat. No. 7,157,036, which is incorporated by reference in its entirety herein. Material 36 a is shown in FIG. 4 as being cross-linked at points 36 b, forming cross-linked polymer material 36 c.
[0029] Referring to FIGS. 2 , 3 and 5 , the pattern recorded in imprinting layer 34 is produced, in part, by mechanical contact with mold 28 . To that end, distance “d” is reduced to allow imprinting droplets 36 to come into mechanical contact with mold 28 , spreading droplets 36 so as to form imprinting layer 34 with a contiguous formation of material 36 a over surface 32 . In one embodiment, distance “d” is reduced to allow sub-portions 34 a of imprinting layer 34 to ingress into and to fill recessions 28 a.
[0030] To facilitate filling of recessions 28 a, material 36 a is provided with the requisite properties to completely fill recessions 28 a while covering surface 32 with a contiguous formation of material 36 a. In the present embodiment, sub-portions 34 b of imprinting layer 34 in superimposition with protrusions 28 b remain after the desired, usually minimum, distance “d”, has been reached, leaving sub-portions 34 a with a thickness t 1 and sub-portions 34 b with a thickness t 2 . Thicknesses “t 1 ” and “t 2 ” may be any thickness desired, dependent upon the application. Typically, t 1 is selected so as to be no greater than twice the width u of sub-portions 34 a, i.e., t 1 ≦2u, shown more clearly in FIG. 5 .
[0031] Referring to FIGS. 2 , 3 and 4 , after a desired distance “d” has been reached, radiation source 22 produces actinic radiation that polymerizes and cross-links material 36 a, forming cross-linked polymer material 36 c. As a result, the composition of imprinting layer 34 transforms from material 36 a to cross-linked polymer material 36 c, which is a solid. Specifically, cross-linked polymer material 36 c is solidified to provide side 34 c of imprinting layer 34 with a shape conforming to a shape of a surface 28 c of mold 28 , shown more clearly in FIG. 5 . After imprinting layer 34 is transformed to consist of cross-linked polymer material 36 c, shown in FIG. 4 , imprint head 18 , shown in FIG. 2 , is moved to increase distance “d” so that mold 28 and imprinting layer 34 are spaced-apart.
[0032] Referring to FIG. 5 , additional processing may be employed to complete the patterning of substrate 30 . For example, substrate 30 and imprinting layer 34 may be etched to transfer the pattern of imprinting layer 34 into substrate 30 , providing a patterned surface 34 c. To facilitate etching, the material from which imprinting layer 34 is formed may be varied to define a relative etch rate with respect to substrate 30 , as desired.
[0033] Referring to FIGS. 2 , 3 and 6 , for molds having very dense features, e.g., recessions 28 a on the order of nanometers, spreading droplets 36 over a region 40 of substrate 30 in superimposition with mold 28 to fill the recessions 28 a can require long periods of time, thereby slowing throughput of the imprinting process. To facilitate an increase in the throughput of the imprinting process droplets 36 are dispensed to minimize the time required to spread over substrate 30 and to fill recessions 28 a. This is achieved by dispensing droplets 36 as a two-dimensional matrix array 42 so that a spacing, shown as S 1 and S 2 , between adjacent droplets 36 is minimized. As shown, droplets 36 of matrix array 42 area arranged in six columns n 1 -n 6 and six rows m 1 -m 6 . However, droplets 36 may be arranged in virtually any two-dimensional arrangement on substrate 30 . What is desired is maximizing the number of droplets 36 in matrix array 42 , for a given total volume, V t , of imprinting material 36 necessary to form a desired patterned layer. This minimizes the spacing S 1 and S 2 between adjacent droplets. Further, it is desired that each of droplets 36 in the subset have substantially identical quantities of imprinting material 36 a associated therewith, defined as a unit volume, V u Based upon these criteria, it can be determined that the total number, n, of droplets 36 in matrix array 42 may be determined as follows:
[0000] n=V t /V u (1)
[0000] where V t l and V u are defined above. Assume a square array of droplets 36 where the total number, n, of droplets 36 is defined as follows:
[0000] n=n 1 ×n 2 (2)
[0000] where n 1 is that number of droplets along a first direction and n 2 is the number of droplets along a second direction A spacing S 1 between adjacent droplets 36 along a first direction, i.e., in one dimension, may be determined as follows:
[0000] S 1 =L 1 /n 1 (3)
[0000] where L 1 is the length of region 40 along the first direction. In a similar fashion, a spacing S 2 between adjacent droplets 36 along a second direction extending transversely to the first direction may be determined as follows:
[0000] S 2 =L 2 /n 2 (4)
[0000] where L 2 is the length of region 40 along the second direction.
[0034] Considering that the unit volume of imprinting material 36 a associated with each of droplets 36 is dependent upon the dispensing apparatus, it becomes clear that spacings S 1 and S 2 are dependent upon the resolution, i.e., operational control of the droplet dispensing apparatus (not shown) employed to form droplets 36 . Specifically, it is desired that the dispensing apparatus (not shown) be provided with a minimum quantity of imprinting material 36 a in each of droplets 36 so that the same may be precisely controlled. In this fashion, the area of region 40 over which imprinting material 36 a in each droplet 36 must travel is minimized. This reduces the time required to fill recessions 28 and cover substrate with a contiguous layer of imprinting material 36 a.
[0035] Another problem that the present invention seeks to avoid is the trapping of gases in imprinting layer 34 once patterned surface 34 c is formed. Specifically, in the volume 44 between spaced-apart droplets 36 of matrix array 42 , there are gases present, and droplets 36 in matrix array 42 are spread over region 40 so as to avoid, if not prevent, trapping of gases therein. To that end, in accordance with one embodiment of the present invention, a subset of droplets 36 in matrix array 42 that are compressed along a first direction by mold 28 along a first direction and subsequently compressing the remaining droplets 36 of matrix array 42 along a second direction, extending transversely to the first direction. This is achieved by cantilevering impingement of mold 28 onto droplets 36 , shown in FIG. 8 .
[0036] Referring to FIGS. 6 , 7 and 8 , template 26 is positioned so that surface 28 c of mold 28 forms an oblique angle θ with respect to substrate surface 30 a of substrate 30 , referred to as cantilevering impingement. An exemplary apparatus that facilitates formation of angle θ is disclosed in U.S. Pat. No. 6,873,087, which is incorporated by reference in its entirety herein. As a result of the cantilevering impingement of mold 28 , as a distance between mold 28 and substrate 30 decreases, a sub-portion of mold 28 will come into contact with a sub-set of droplets 36 in matrix array 42 before the remaining portions of mold 28 contact the one edge of mold 28 contact the remaining droplets 36 of matrix array 42 . As shown, mold 28 contacts all of droplets 36 associated with column n 6 , substantially concurrently. This causes droplets 36 to spread and to produce a contiguous liquid sheet 46 of imprinting material 36 a extending from edge 40 a of region 40 toward droplets in columns n 1 -n 5 . One edge of liquid sheet 46 defines a liquid-gas interface 46 a that functions to push gases in volumes 44 away from edge 40 a and toward edges 40 b, 40 c and 40 d. Volumes 44 between droplets 36 in columns n 1 -n 5 define gas passages through which gas may be pushed to the portion of perimeter of region 40 . In this manner, interface 46 a in conjunction with the gas passages reduces, if not prevents, trapping of gases in liquid sheet 46 .
[0037] Referring to FIGS. 7 and 9 , as template 26 is moved toward substrate 30 , rotation of mold 28 occurs to allow imprinting material 36 a associated with subsequent subsets of droplets 36 in columns n 4 and n 5 to spread and to become included in contiguous fluid sheet 46 . Template 26 continues to rotate so that mold 28 subsequently comes into contact with droplets 36 associated with columns n 2 and n 3 so that the imprinting material 36 a associated therewith spreads to become included in contiguous sheet 46 , shown in FIG. 10 . The process continues until all droplets 36 are included in contiguous sheet 46 , shown in FIG. 11 . As can be seen, interface 46 a has moved toward edge 40 c so that there is an unimpeded path for the gases (not shown) in the remaining volume 44 a of region 40 to travel thereto. This allows gases in volume 44 a to egress from region 40 vis-à-vis edge 40 c. In this manner, the trapping of gases in imprinting layer 34 , shown in FIG. 5 , having surface 34 c is reduced, if not avoided.
[0038] Referring to FIGS. 3 , 12 and 13 , in another embodiment of the present invention, sequential spreading of droplets 36 in matrix array 42 column-by-column, as described with respect to FIGS. 7-11 may be achieved without requiring cantilevering impingement of mold 28 . This may be achieved by employing electromagnetic forces to move imprinting material 36 a across region 40 and/or toward mold 128 . To that end, mold 128 includes a plurality of individually addressable conductive elements, shown as q 1 -q 6 forming nadirs 118 a of recessions 128 a of mold 128 . Sub-portions 118 b of body 150 flanking sub-portions 118 b are in superimposition with protrusions 128 b and do not include any conductive material there. Formation of mold 128 is discussed more fully below.
[0039] Referring to FIG. 14 , one manner in which to form a template includes obtaining a body 150 and identifying four regions 150 a, 150 b, 150 c and 150 d on which to form a template. Specifically, body 150 consists of a standard 6025 fused silica. Four templates, shown as templates 126 , 226 , 326 and 426 , are formed, concurrently, in four separate areas of body 150 . For simplicity of the present disclosure, fabrication of template 126 is discussed with the understanding that the discussion with respect to template 126 applies with equal weight to templates 226 , 326 and 426 .
[0040] Referring to FIGS. 15 and 16 , body 150 , typically measures 152.4 mm on a side. Body 150 has a chrome layer 130 present on an entire side 112 thereof. A photoresist 132 layer covers chrome layer 130 . Photoresist layer 132 is patterned and developed away to expose a region 134 surrounding a central portion 136 of side 112 . Central portion 136 typically has dimensions measuring 25 mm on a side. Typically, photoresist layer 132 is patterned employing a laser writer. After photoresist layer 132 has been developed away, chrome layer 130 in superimposition with region 134 is etched away using any suitable etching techniques, e.g., ammonium nitrate or plasma etch. In this manner, a portion of body 150 in superimposition with region 134 is exposed. Thereafter, suitable post etching processes may occur, e.g., an oven bake or other cleaning processes.
[0041] Assuming body 150 is formed from fused-silica, a suitable etching technique would involve a buffered oxide etch (BOE). This occurs for a sufficient amount of time to provide a desired height, h, for mesa 133 , as measured from surface 112 of body 150 , shown in FIG. 18 . An exemplary height is 15 microns. Thereafter, the remaining portion of photoresist layer 132 is removed and any remaining portions of chrome layer 130 on central portion 136 are removed. A layer of photoresist material 134 is deposited over template 126 , shown in FIG. 19 . Regions of photoresist material 134 in superimposition with mesa 133 are patterned and developed away to expose regions 136 of body 150 , using standard techniques, leaving patterned photoresist layer 138 , shown in FIG. 20 . Thereafter, a layer of indium tin oxide (ITO) 140 is deposited on template 126 to cover patterned photoresist layer 138 , shown in FIG. 21 . ITO is a suitable material for use with mold 128 , because it is electrically conductive and substantially transparent to the wavelength of radiation produced by radiation source 22 , shown in FIG. 2 . A lift-off process is employed to remove patterned photoresist layer 138 , shown in FIG. 20 , with all of the portions of ITO layer not in superimposition with regions 136 being removed during the lift-off process. In this fashion, a patterned ITO layer 142 , with regions 144 of body 150 being exposed, is formed, shown in FIG. 22 . Following formation of patterned ITO layer 142 , a layer 146 of silicon oxide SiO 2 146 is deposited, shown in FIG. 23 . This forms mold 128 , with silicon oxide layer 146 being patterned so that silicon oxide is not in superimposition with ITO material in ITO layer 142 that is in superimposition with regions 144 , shown in FIG. 13 . In this manner, the nadir of recessions 128 a are formed from ITO, and protrusions 128 b are formed from SiO 2 .
[0042] Referring to FIGS. 3 , 12 and 13 , understanding that protrusions 128 a are formed from an electrically insulative material, it is realized that the electromagnetic field, EM 1 , proximate to recess 128 a is greater than the electromagnetic field, EM 2 , that is proximate to protrusions 128 b. To this end, voltage source 120 is in electrical communication with conductive elements q 1 -q 2 using any suitable coupling technique known, shown in FIG. 12 . In the present example, conductive elements q 1 -q 6 are formed to extend beyond mold 128 and voltage source 120 is connected thereto. Furthermore, by selectively addressing the conducting elements q 1 -q 6 , selected droplets 36 may be selectively spread in virtually any manner desired, including the spread pattern discussed above with respect to FIGS. 7-11 .
[0043] Referring to FIGS. 3 , 24 and 25 , as discussed above, droplets 136 and 236 may be arranged in virtually any matrix array. As shown, droplets 136 and 236 are arranged in two sets. The quantity of imprinting material 36 a in each of droplets 136 is substantially identical, and the quantity of imprinting material 36 a in each of droplets 236 is substantially identical. The quantity of imprinting material in each of droplets 236 is substantially greater than the quantity of imprinting material 36 a in each of droplets 136 . By arranging droplets 136 and 236 with differing quantities of imprinting material 36 a in this fashion, it is believed that the time required to fill recessions 128 a of mold 28 may be minimized while avoiding trapping of gases in imprinting layer 36 a, without employing cantilevering impingement of mold 128 onto substrate 30 . Specifically, by providing droplets 136 with a minimum volume, the advantages discussed above with respect to reduced filling time of recessions 128 a is achieved. The relatively large quantity of imprinting material 36 a, shown in FIG. 3 , in droplets 236 , shown in FIG. 24 , and the location of the same increases the probability that the flow of imprinting material-gas interface 146 a created by droplets 236 will be sufficiently forceful to drive gas toward perimeter of region 140 without trapping gas in imprinting material 36 a.
[0044] Referring to FIGS. 3 , 12 and 24 , to further decrease the time required to spread and to pattern imprinting material 36 a in droplets 136 and 236 , template 128 may be employed and conductive elements q 1 -q 6 may be activated sequentially, as discussed above, or concurrently.
[0045] Referring to FIGS. 3 , 26 and 27 , were it desired to concurrently apply an electromagnetic field across the mold, template 526 may be employed. Template 526 is formed from a body 550 of a suitable material, such as fused silica. An exemplary material is standard 6025 fused silica having measurements, on a side, of approximately 152.4 mm. Four templates 526 , 626 , 726 , and 826 are formed, concurrently, in four separate regions 550 a, 550 b, 550 c and 550 d, respectively. For simplicity of the present disclosure, fabrication of template 526 is discussed with the understanding that the discussion with respect to template 526 applies with equal weight to templates 626 , 726 and 826 .
[0046] Referring to FIGS. 28 and 29 , body 550 has a chrome layer 530 present on an entire side 512 thereof. A mesa 533 is formed on body 550 in the manner discussed above with respect to FIGS. 16-18 . A layer of indium tin oxide (ITO) 534 is then deposited over the entire side 512 of body 550 using standard techniques, shown in FIG. 30 . Deposited atop of the ITO layer 534 is a silicon oxide layer SiO 2 that is patterned and etched employing standard techniques to form recessions 528 a and protrusions 528 b, shown in FIG. 26 . In this manner, the nadir of recessions 128 a are formed from ITO and protrusions 528 b are formed from ITO. Understanding that protrusions 528 a are formed from an electrically insulative material, it is realized that the electromagnetic field, EM 1 , proximate to recess 528 a is greater than the electromagnetic field, EM 2 , which is proximate to protrusions 528 b. As a result, imprinting material 36 a proximate to mold 528 is more likely to be drawn into recessions 528 a, thereby reducing the time required to conform material 36 a to mold 528 .
[0047] The embodiments of the present invention described above are exemplary. Many changes and modifications may be made to the disclosure recited above, while remaining within the scope of the invention. For example, the use of electromagnetic filed may prove beneficial in ensuring that imprint material fully fill the features on the mold, thereby avoiding discontinuities in the imprinting layer. Such discontinuities occur when imprinting material fails to fill the recessions of the mold. This may be due to various environment and material based parameters, such as capillary attraction between a protrusion and a surface in superimposition therewith. Applying an electromagnetic field to attract imprinting material to the mold will overcome these properties. Therefore, the scope of the invention should not be limited by the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents.
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The present invention is directed to a method forming conductive templates that includes providing a substrate; forming a mesa on the substrate; and forming a plurality of recessions and projections on the mesa with a nadir of the recessions comprising electrically conductive material and the projections comprising electrically insulative material. It is desired that the mesa be substantially transparent to a predetermined wavelength of radiation, for example ultraviolet radiation. As a result, it is desired to form the electrically conductive material from a material that allows ultraviolet radiation to propagate therethrough. In the present invention indium tin oxide is a suitable material from which to form the electrical conductive material.
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BACKGROUND
Integrated circuits currently are manufactured in compact packages including thousands, and even millions, of transistors and other components fabricated on semi-conductor wafers, connected to lead frames and potted in packages from which a large number of leads extend. Large scale integrated circuits and very large scale integrated circuits (LSI and VLSI circuits) result in complete electronic systems or major parts of complex electronic systems, all packaged in relatively small-sized integrated circuit packages. These circuit packages sometimes are used alone as the electronic "heart" of a system or device, or are interconnected together as part of a larger system in which more than one LSI or VLSI integrated circuits are used.
It is very important for integrated circuits to operate properly for their intended purposes once they are shipped from the manufacturing facility, since, if such circuits are incorporated into other devices, failure of the circuit to properly function could result in the failure of a much more expensive device or system into which the circuits are incorporated. It has been found, that if an LSI circuit or VLSI circuit is defective in some way which may cause it to fail, the failure usually occurs within the initial hours of operation. Once some pre-established minimum number of hours of proper operation takes place, the circuit typically does not fail; unless of course it is subjected to some type of catastrophic surge voltage, or the like.
In order to ensure that integrated circuit packages, which are shipped to customers for incorporation into finished products, will operate properly in those finished products, it is a common practice to operate the finished, packaged integrated circuits for a period of time under power. This is done to cause any failures which are likely to occur to occur before the integrated circuit packages are shipped. To do this, several integrated circuit packages are interconnected into receptacles on relatively large "burn-in" printed circuit boards, which have printed circuit interconnections going to each of the receptacles for each of the integrated circuits to be operated on the board. The circuit leads for each of the different receptacles extend to one edge of the board, where they terminate in a connector block having a large number of pin connectors extending from it. The different pin connectors each are connected to different ones of the printed circuit leads, connected to the sockets for the different integrated circuits to undergo test.
Burn-in boards can have hundreds of connector pins on the connector block. These pins are physically aligned with a corresponding group of pin receptacles on the front of a tester, which then provides the operating power and signals to the pins in accordance with the devices undergoing test. Thus, to effect a "burn-in" of a number of LSI or VLSI circuits, the circuits are mounted in the receptacles on an appropriate burn-in board designed to operate those particular circuits. That burn-in board is plugged into the tester, which is programmed to operate the desired burn-in test for the integrated circuit packages which are to undergo test.
The printed circuit burn-in board typically is mounted on a frame; and the board is moved toward the test fixture with the pin connectors aligned with the corresponding pin receptacles on the test fixture. Usually, the board is manually inserted into the test fixture; so that all of the pin connectors are seated firmly into the receptacles on the test fixture. Each pin makes a friction fit engagement into the receptacle into which it is placed, to cause good electrical interconnection to take place between the tester receptacles and the pins connected to the printed circuit wiring on the printed circuit burn-in board.
In the past, when a different burn-in board is to be used with the test fixture, it is necessary to remove whichever burn-in board is in place by withdrawing it from the test fixture prior to insertion or interconnection of a new board. Because each of the pin connectors makes a friction fit with the receptacle into which it is inserted, some force is required to withdraw each pin from the receptacle. When only a small number of pins and a correspondingly small number of receptacles are involved, the force is not great; and pin separation readily, manually, can be accomplished. For the testing of a large number of LSI of VLSI integrated circuit packages, however, the number of pins inserted into the corresponding number of receptacles may extend into the hundreds. A typical commercial tester or test bench may include as many as four hundred sixteen pins and receptacles for interconnection. The result is a significant amount of withdrawal force is encountered when the burn-in test board is to be withdrawn or removed from the tester or test fixture.
In the past, it has been common for test engineers to carefully insert a screwdriver between the edge of the printed circuit burn-in board and the front of the tester to pry the burn-in board away from the tester. Usually, the screwdriver is inserted first on one side to move that side out a short distance, and then is moved to the opposite side of the test board to pry that side outwardly. This operation is alternated until the board is loose enough to be withdrawn by hand from the test fixture. A problem with the use of a screwdriver or similar tool to pry the burn-in board or other test board away from the test fixture is that the pressure of the screwdriver between the edge of the board and the front of the tester may cause damage to one or the other or both of these components. In addition, the prying, first of one side and then the other, causes a strain on the pin connectors, tending to bend them first in one direction or the other. A similar strain, which may result in misalignment of pin connectors, occurs when the test board is grasped on opposite sides and wiggled back-and-forth while at the same time applying withdrawing pressure to it.
If a pin connector is bent or misaligned, the next time the burn-in board is used, the misaligned pin may prevent insertion of the board into the test fixture; or the pin may require repair or replacement. The pin connectors have a relatively small diameter, and are somewhat fragile; so that bending or misalignment of the pins can occur when withdrawal of the burn-in board or other test board is effected using these techniques.
It is desirable to provide a device for extracting burn-in boards and other test boards, having large numbers of pin connectors in them, from a test fixture in a simple and effective manner, and which overcomes the disadvantages noted above.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved board extractor for removing printed circuit test boards from a test fixture.
It is another object of this invention to provide an improved manually operated board extractor for removing a printed circuit board from a test fixture.
It is a further object of this invention to provide a board extractor for removing a printed circuit board from a test fixture with reduced stress on the pin connectors attached to the edge of the printed circuit board.
In accordance with a preferred embodiment of the invention, a board extractor is designed for use with an integrated circuit test fixture. The extractor is designed to facilitate removal of printed circuit boards from the test fixture, where the test fixture has a number of pin receptacles on the front and the circuit board has a corresponding number of pin connectors attached to one edge for insertion into the pin receptacles on the front of the test fixture. The extractor includes a movable member, which is mounted adjacent the front of the test fixture for engaging a circuit board to move the board from a first position, where the pin connectors of the circuit board are inserted into the pin receptacles of the test fixture, to a second position pushing the circuit board away from the test fixture to remove the pin connectors on the edge of the circuit board from the pin receptacles on the front of the test fixture. An operating member is coupled with the movable member to move it from the first position to the second position.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top perspective view of a preferred embodiment of the invention;
FIG. 2A is a partially cut-away side view of the embodiment shown in FIG. 1 in a first position of operation;
FIG. 2B is a partially cut-away side view of the same portion of the embodiment shown in FIG. 2A, but in a different position of operation; and
FIGS. 3A and 3B are cross-sectional views taken along the lines 3A--3A and 3B--3B, respectively, of FIGS. 2A and 2B.
DETAILED DESCRIPTION
Reference now should be made to the drawing, in which the same reference numbers are used throughout the different figures to designate the same components. FIG. 1 illustrates a perspective view of a test bench or tester system 9, which is broken away to show the bottom 16 and the front 10 only. The tester 9 includes circuit interconnections for effecting burn-in or other tests of integrated circuits, which are coupled to the tester 9 through a large number of pin receptacles 15 located in rows and columns in a rectangular recess 11 located near the upper side of the front 10 of the tester or test fixture 9.
As is illustrated in FIG. 1, the pin receptacles 15 in the recess 11 are centered in the front 10 of the test fixture 9; but the receptacles could be located to one or the other sides of the center of the front of the test fixture 9, if desired. The test fixture 9 is placed on a base 16 and is oriented to receive a corresponding number of aligned pin connectors 25 in a connector block 21 attached to the leading edge of a printed circuit test board 20. The test board 20 typically is mounted on a frame, with guide rails 26 attached to each side of the printed circuit board 20. The rails 26 extend over the left-hand and right-hand edges of the board 20 and typically are made of metal, while the printed circuit board is made of a non-metal, non-conductive material.
The balance of the tester 9, including the assembly for aligning connector block 21 of the printed circuit board 20 with the recess 11, so that the pins 25 properly enter into and are aligned with the corresponding pin receptacles 15, is not shown in FIG. 1, since these components are standard and are well known. Testers which are made by different manufacturers incorporate the general features which are illustrated. The printed circuit board 20 may be a "burn-in" board, which is to be connected with the test fixture 9 for a length of time suitable to provide an accurate burn-in test of individual integrated circuits, connected at designated areas on the burn-in board. These areas are indicated diagrammatically in FIG. 1 as areas 28. The particular details are not important for an understanding of this invention.
The portion of FIG. 1, which has been described thus far, is conventional and is well known. To facilitate the removal of a burn-in board 20 once the connector pins 25 are fully inserted into the pin receptacles 15 on the test fixture 9, however, a pair of left-hand and right-hand board extractor mechanisms 30 and 40 are provided. In a preferred embodiment of the invention, these mechanisms are attached to the front of the tester 9, and are located on opposite sides of the printed circuit burn-in board 20, as shown most clearly in FIG. 1. The extractors 30 and 40 are attached by means of screws or other suitable fasteners, such as the screws 34, to the base plate 16 of the tester, as illustrated in FIGS. 2A and 2B.
The extractors 30 and 40 are identical in construction. For that reason, only the details of the extractor 30 are shown in FIGS. 2A through 3B. It is to be understood, however, that the structure of the extractor 40 is identical to the one shown in FIGS. 2A to 3B; so that the description of FIGS. 2A through 3B applies equally as well to the structure of the components in the extractor 40.
As illustrated in FIGS. 2A through 3B, the interior of the extractor 30 has a pair of rectangular chambers 31 and 33 in it. The chamber 31 is located toward the rear of the extractor 30 (adjacent the front face 10 of the test fixture 9), and accommodates a bearing 35 and a short internal lever 37. The lever 37 is rigidly attached to a shaft 50, which passes through the bearing 35 and extends across the front 10 of the test fixture 9 above the base 16 and below the recess 11. The shaft 50 also passes through a corresponding bearing 45 on the extractor 40. The shaft 50 causes the components located within both of the extractors 30 and 40 to operate in conjunction with one another. The shaft 50 extends completely through the extractors 30 and 40, and terminates on the outside of both where it is secured to an operating lever 36 for the extractor 30, and a lever 46 for the extractor 40.
The structure which has been described functions so that the operating levers or handles 36 and 46 may be rotated clockwise and counterclockwise to rotate the shaft 50 correspondingly. When this is done, the projection 37 (and a corresponding projection 47 in the block 40) are rotated clockwise and counterclockwise, along with the operating levers 36 and 46, since the levers 36 and 46, as well as the projections 37 and 47 are secured to the shaft 50 for rotation with it.
The rectangular elongated chamber 33 extends from the chamber 31 toward the front of the extractor assembly 30, and opens at the front of the assembly, as shown clearly in FIGS. 1, 2A and 2B. An elongated rectangular bar or slide member 38 is placed in the chamber 33 for reciprocating movement in the chamber 33.
When a printed circuit board, such as a burn-in board 20, is moved to insert the pin connectors 25 into the receptacles 15, guide rails 26 on the opposite edges of the board are seated in front of the slide members 38 and 48 in the position shown in FIGS. 2A and 3A. The front edge of the printed circuit board 20 and the connector block 21 attach to that front edge, pass over the shaft 50; and the connector block 21 is seated in the recess 11 on the front 10 of the test fixture 9.
The depth of the block 21 and the extension or notched edge of the printed circuit board 20 are selected to equal the front-to-back dimension of the extractors 30 and 40, causing the relative locations of the parts to be as illustrated in FIGS. 2A and 3A when the burn-in board 20 is connected to the test fixture 9 for operation. It should be noted that if the slide members 38 and 48 (or either of them) is extended outward (to the right, as viewed in FIGS. 2A through 3B) from the slots or chambers 33, when the board 20 is inserted as described above, the guide rail 26 on each side of the board 20 engages the extended ends of the slide members 38 and 48 and pushes them toward the left (as viewed in all figures), which, in turn, causes the left-hand ends of these members 38 and 48 to push on the lever 37 (for the member 38), rotating the lever 37 (and a corresponding lever 47, not shown, for the member 48) counterclockwise, as viewed in FIGS. 2A and 2B. This raises the operating levers 36 and 46 to the position shown in FIGS. 1, 2A and 3A. Also, as is most apparent in an examination of FIGS. 2A and 3A, the guide rail 26 engages the end of the slide member 38 and no contact between the printed circuit board 20 and the slide member 38 takes place. Also, as shown most clearly in FIGS. 3A and 3B, the inset or notched portions of the printed circuit board 20 are dimensioned to slide past the facing edges of the extractors 30 and 40.
When the test operation is complete and the burn-in board 20 is to be removed, the levers 36 and 46 are pressed downwardly or rotated clockwise (as shown most clearly in FIG. 2B). This causes the lever 37 to rotate clockwise, pushing the left-hand end of the slide member 38 toward the right, as illustrated in FIG. 2B. This causes the slide member 38 to project out of the end of the slot 33, pushing the guide rail 26 of the burn-in board 20 toward the right, as viewed in all figures, to a distance selected to disengage all of the pins 25 from the receptacles 15. The burn-in board 20 then readily may be lifted out of the test fixture 9 and replaced with another test board for subsequent operation with the tester.
It should be noted that since the shaft 50 interconnects the components in both of the extractors 30 and 40, the pressure applied to the guide rails 26 on the edges of the burn-in board 20 is divided, or is substantially equal; so that the board 20 is pushed straight out of the test fixture 9 without any side-to-side movement or wiggling. As a consequence, the likelihood of bending any of the connector pins 25, extending from the connector block 21, is significantly reduced. At the same time, the force multiplication which is effected by the utilization of the relatively long operating levers 36 and 46 permits the extraction of the board 20 to be accomplished with relatively little effort, in contrast to manual prior art techniques.
The foregoing description of the preferred embodiment of the invention should be considered as illustrative, and not as limiting. For example, the relative locations of the connector pins 25 and receptacles 15 could be reversed; so that connector pins extend outward from the front of the test fixture, and receptacles are provided in the block 21. The operation of the extractor mechanism would be the same. In addition, reconfiguration of the mechanisms in the blocks 30 and 40 could be made; so that the lever 37, for example, could be rotated directly to engage the guide rail 26 without requiring the intermediate slide member 38. Various other changes and modifications will occur to those skilled in the art to provide a device which performs substantially the same function, in substantially the same way, to achieve substantially the same result, without departing from the true scope of the invention as defined in the appended claims.
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A circuit board extractor particularly suitable for extracting "burn-in" boards from a test fixture is attached to the front of the test fixture between the tester connector assembly and the burn-in board, or burn-in board frame rails, for movement of a movable member between first and second positions. The first position of the movable member occurs when the pin connectors on the edge of the burn-in board are inserted into corresponding pin receptacles on the front of the test fixture. Movement of the movable member from the first position thereof to its second position pushes the burn-in board away from the front of the test fixture to cause withdrawal of the pin connectors on the edge of the burn-in board from the pin receptacles on the edge of the test fixture without damaging the burn-in board or the test fixture.
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FIELD OF THE INVENTION
This invention pertains to cutting tools. This invention particularly pertains to cutting tools for pipes surrounded by jacketing material.
BACKGROUND OF THE INVENTION
Pipes, electrical wires, and the like often comprise an inner core covered by jacketing or insulating material. In the case of pipes it may be desirable to jacket the pipe with such material so as to insulate the pipe, to protect the pipe from damage from external sources, or to provide a secondary containment system for the pipe. Electrical wires, including coaxial cable, require jacketing insulation so as to avoid the possibility of short circuits.
The use of a jacketing material for pipes is of great use in providing a secondary containment system for the materials transported via the pipe, as well as in providing for a means to determine whether a failure or leakage of the primary pipe has occurred. This is accomplished by providing a jacketing material with an inner diameter greater than the outer diameter of the pipe so as to allow fluids which leak from the primary pipe to be contained within the void between the pipe and the jacketing material. Allowing such fluids to drain to a sump, and periodically inspecting the sump for fluid, provides a convenient method of determining if a pipe has failed or is otherwise leaking.
Although referred to as pipe, the conduit may be flexible and be considered a hose.
It is often necessary to couple together sections or links of such pipes, wires, or other jacketed material. To do so generally requires cutting through both the jacketing material and the pipe or wire to provide a mating surface perpendicular to the axis of the pipe or wire, and then to strip or remove portions of the jacketing material near an end so as to expose a portion of the pipe or wire to allow for the coupling of sections of the pipe or wire. In the case of pipes, it is of great importance not to puncture or otherwise damage the pipe when removing the jacketing material so as to avoid pipe failures and leaks. Similarly, it is undesirable to damage wires when removing insulation material from the wires as a loss of conductivity may occur.
One simple tool which may be used to perfume the described operation is a knife. A simple knife, however, provides no means to ensure that the primary pipe or wire is not cut or damaged while removing a portion of the jacketing material. Moreover, the user of the knife may be injured due to the exposed blade of the knife.
Cutting tools in which a cutting blade may be set at various distances via the use of set screws and the like are also known in the art. Such tools, however, require the operator to accurately set the blade location so as to avoid damaging the primary pipe. If the user is unaware of the specific dimensions of the pipe and the jacketing material, such an operation may be difficult. Additionally, the jacketing material may be such that multiple cuts through the jacketing material must be performed. In such a situation, the operator must adjust the position of the cutting blade multiple times.
Additionally, for ease of removal of the jacketing material, it is often desirable to longitudinally cut through the jacketing material in addition to making a circumferential cut. A longitudinal cut allows the jacketing material to be more easily removed. A cutting tool which provides the capability to cut both latitudinally and longitudinally through the use of separate blades set via set screws is known in the art. Such a tool, however, suffers from disadvantages associated with the use of set screws and requires a plurality of blades.
Thus, a cutting tool which allows an operator to safely cut a pipe and easily remove jacketing material from the pipe while not risking damage to the pipe is desirable.
SUMMARY OF THE INVENTION
The present invention provides a cutting tool for safely and easily cutting through pipes and the like and removing jacketing material therefrom. In accordance with the present invention, a cutting tool is provided wherein a blade is mounted to a blade mounting assembly contained in a handle extending laterally from a side of a semicylindrical hollow pipe guide. A spring biases the blade mounting assembly towards the guide. An arm extends from a portion of the blade mounting assembly protruding from the handle, and the arm is selectively fittable into each of a plurality of slots in the end of the handle. Differing depths of the radial slots allow the blade to be extended from the handle predetermined distances and at predetermined orientations.
The present invention thereby provides a tool for safely and easily cutting jacketed materials such as pipes and removing the jackets therefrom to allow for coupling or connecting sections of such pipes. The attendant features of this invention will be more readily appreciated as the same becomes better understood by reference to the following detailed description and considered in connection with the accompanying drawings in which like reference symbols designate like parts throughout.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an embodiment of the cutting tool of the present invention;
FIG. 2 is a side view of the housing of the cutting tool of FIG. 1;
FIG. 3 is a perspective view of the blade holder and transverse pin of the cutting tool of FIG. 1; and
FIG. 4 is a sectional side view of the cutting tool of FIG. 1 taken along the plane 4--4 identified in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A cutting tool embodying the present invention is shown in FIG. 1. The cutting tool has a handle 13 mounted to a semicylindrical hollow guide 11. The guide has a substantially C-shaped cross-section with an inner surface 27 adapted for engaging pipes and the like. An aperture 39 is formed in the guide approximately midway along the length of the guide. The handle 13 extends laterally from the guide and is mounted over the aperture, the handle and the guide thus together forming a T. The handle has a cavity 37 (shown in FIG. 2) in a blade end 24 of the handle, which is the end of the handle attached to the guide. A bore 38 (shown in FIG. 2), of a smaller diameter than the cavity, extends from the cavity to a free end 25 of the handle, which is the end of the handle opposite the end attached to the guide. A blade mounting assembly 16 is placed within the cavity and the bore. A base 43 of the blade mounting assembly is placed in the cavity. A pin 41 projects from the base and through the bore such that a portion of the pin protrudes from the free end of the handle. A blade 17 is mounted to the base 43 so that the blade extends from the base on a side opposite the pin. An engagement arm 19 laterally extends from the portion of the pin protruding from the free end of the handle. The arm is placed in a slot 21d, which is one of several slots 21a-d formed in the free end of the handle. The slots radiate from the bore.
The handle 13 is shown in FIG. 2 attached to the guide 11. The cavity and the bore together form a passage from the blade end of the handle to the free end of the handle. The change in diameter from the cavity to the bore forms an internal shoulder 33 in the handle.
The blade mounting assembly is shown in FIG. 3 and is comprised of the base 43 and the pin 41. The base is substantially a right circular cylinder with approximately one-quarter of the cylinder removed. The removed volume provides a flat blade mounting surface 47. The blade mounting surface allows a conventional blade 17 (shown in FIG. 4) with a diagonal cutting surface 49 to be mounted such that the tip of the blade is located along the center axis of the base and the cutting edge of the blade extends axially and radially therefrom. A threaded hole 49 extends into the base from the blade mounting surface. The threaded hole provides a means for securing the blade to the blade mounting surface.
The pin 41 is a cylinder extending coaxial from the base. As the pin is of a smaller diameter than the base, the interface between the pin and the base forms a shoulder 45 on the blade mounting assembly. A hole 51 extends radially through the free end of the pin. The hole is adapted to receive the engagement arm. The engagement arm therefore extends radially from the pin when placed in the hole.
FIG. 4 shows further detail of this embodiment of the invention. The blade mounting assembly is substantially contained within the handle. The blade is secured to the blade mounting surface by a thin rectangular shim 61 attached to the base. The shim is attached to the base by passing a screw 63 through the shim and into the threaded hole. The cavity has an axial depth greater than the axial length of the base of the blade mounting assembly. Therefore, a portion of the pin is within the cavity. A spring 23 is coiled around the portion of the pin within the cavity. The spring abuts both the internal shoulder of the handle and the shoulder on the blade mounting assembly, the shoulders compressing the spring. The compressed spring biases the blade mounting assembly, and therefore the blade, in the direction of the guide. The blade mounting assembly's motion in the direction of the guide is limited by the engagement arm contacting the free end of the handle, specifically the slots in the free end of the handle. The blade extends from the handle different distances and at different angles when the engagement arm is placed in the different slots because the slots adapted to receive the engagement arm are at differing depths and angles.
In practice, therefore, the engagement arm can be placed in a first slot 21a which is of insufficient depth to allow the blade to extend from the handle. The engagement arm is held securely in the first slot as the spring tends to force the mounting assembly towards the guide. Thus, with the engagement arm in the first slot, the blade is safely housed within the handle and cannot accidentally damage material or personnel.
Placing the engagement arm in the second slot 21b permits the blade to circumferentially cut the pipe and its jacketing material. With the engagement arm in the second slot the blade extends from the handle a sufficient distance to cut both a pipe and the pipe's jacketing material. The guide is placed over the pipe and the cutting tool rotated circumferentially around the pipe. Such a cut provides a mating surface for the connection of additional pipe segments.
When the engagement arm is placed in the fourth slot 21d, the blade also extends circumferentially with respect to the guide. The depth of the fourth slot, however, is only sufficient to allow the blade to extend a sufficient distance from the handle to cut the pipe's jacketing material, but not the pipe. Placing the guide over the pipe and circumferentially rotating the cutting tool around the pipe cuts a section of the jacketing material only. The third radial slot is also a depth sufficient to allow the blade to extend a sufficient distance to cut only the pipe's jacketing material. The third slot, however, radiates at 90° to the second and fourth slots. Thus, with the engagement arm in the third slot the blade extends longitudinally with respect to the guide. Placing the guide over the pipe and moving the cutting tool longitudinally along the pipe cuts the jacketing material lengthwise between the mating surface and the circumferential cut in the jacketing material. This lengthwise cut allows the jacketing material to be more easily removed.
Thus, the cutting tool of the present invention provides an easy and safe tool for cutting a pipe and removing jacketing material therefrom. Although this invention has been described in a certain specific embodiment, many additional modifications and variations will be apparent to those skilled in the art. It is therefore to be understood that this invention may be practiced otherwise than is specifically described. For example, modifications could be made to the shape of the blade holder, the handle, or the semicylindrical guide. Thus, the present embodiment of the invention should be considered in all respects as illustrative and not restrictive, the scope of the invention to be indicated by the appended claims rather than the foregoing description.
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A cutting tool for cutting jacketed pipes and other cylindrical objects comprising a handle attached to a guide and a blade translatably and rotatably secured within the handle. The blade is mounted to a blade mounting assembly. The blade mounting assembly is biased towards the guide by a spring. Extension of the blade in the direction of the guide is limited by an engagement arm of the blade mounting assembly which may be placed in slots radiating in different directions in the free end of the handle. Thus, the blade may be securely positioned at differing amounts of extension and at differing angles with respect to the handle.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates in general to the knowledge management and innovative services fields and, in particular, but not exclusively, to an innovation engine portal method and system for collecting, supporting, accessing, and leveraging the value of ideas.
BACKGROUND AND STATE OF THE ART
[0002] Many organizations have not institutionalized innovation, or found a way to embed innovation into their cultures and activities. Frequently, in these organizations, new ideas are submitted to managers who have no incentive to develop them. Worse yet, some of these ideas are never brought to the attention of others, so the ideas often wither and die like fruit on the vine. Unfortunately, the loss of such an idea is not recognized by the organization, and as a result, opportunities to develop new strategies, cultures, services, markets, and operating models can be missed without note or comment.
[0003] Even when innovators are motivated enough to develop their ideas with little support, it is inherently difficult for them to work within organizations that lack an effective and efficient innovation process. The infrastructure needed to connect innovators both to the demand for innovation and the supporting resources usually does not exist in such organizations. For example, innovators looking for documented expertise on a particular topic have to resort to the use of inefficient search engines which yield average hit counts of thousands per search. In these organizations, those individuals who need innovation can only resort to the use of personal networks and canvassing in order to identify potential sources of new ideas. Those individuals who have ideas are forced to canvass their own personal networks, which often do not overlap with each other in an organization of significant size.
[0004] In such an environment, whenever an organization provides an array of services to a wide variety of clients, it is rare that every employee is able to match services with clients effectively. This problem is compounded whenever the services are highly technological and complex in nature. As such, it is very difficult for every employee to keep up to date with the large list of services offered, because the list changes often in response to the rapid pace of change in the technological environment of today's “Digital Economy”. Even with some understanding of the services involved, it is usually not obvious to most employees just what type of client would utilize what service.
[0005] In this environment, employees find that they can no longer be self-contained at providing the expertise required to serve their clients properly. There is a significant need for a wide range of expertise to be leveraged into each client's project. The traditional approach of telephoning other employees worked with in the past is no longer viable. A natural first reaction is to telephone a known expert. Consequently, the experts within an organization typically receive numerous telephone calls and emails, which ask for the names of persons who can provide expertise on particular topics. However, a more scalable and efficient mechanism for finding expertise is required.
[0006] In order to leverage an organization's accumulated expertise into each client project that needs it, the mechanism for accessing people and documents needs to be enhanced. The particular areas of expertise, training, and experience of each employee need to be made available. The successes and lessons learned from each project need to be documented and stored. The latest technologies, trends, and innovations need to be folded into such a knowledge base.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention, an enterprise-wide knowledge management system is provided, which includes an innovation engine portal method and system that can link each user to any needed expertise, throughout an enterprise, in a consistent manner. As a result, enterprise experts are free to pursue more higher-value-added activities such as, for example, the formation of additional strategic alliances and pursuit of additional mega-deals. As such, in today's “Digital Economy,” a successful organization needs to be able to eliminate boundaries, collaborate in new ways, establish trust, and continuously seek improvements. The entire innovation life cycle is made accessible to all employees, consisting of the initial demand for innovation, searches for innovation, spark of innovation creation, innovation collaboration and investment, and innovation reporting and communications. The enterprise-wide knowledge management system provides a system of business processes and tools, which are designed to collect, enhance, and leverage the organization's intellectual capital. The individual efforts made to deliver innovative solutions to clients benefit from their coordination into an efficient and effective organization-wide mechanism.
[0008] In accordance with one example embodiment of the present invention, the innovation engine portal can provide employees of the organization access to a set of knowledge management tools. These tools are designed to support the delivery of innovative offerings to an organization's clients. A common login to the system can provide access to all of the component tools. The business processes of the innovation life cycle are embedded within these tools. Experts can be brought together who have symbiotic expertise at solving the various problems of, and meeting the various requests made by, the organization and its clients.
[0009] For this example embodiment, an innovation engine portal includes four component tools: 1) Idea Workflow Tool; 2) Requests for Innovation; 3) Internal Innovation Index; and 4) External Innovation Index. Essentially, for an organization, there are three primary points of view for users playing the various roles in the business processes involved: innovator; administrator; and manager. Innovators' primary purpose for using a component tool is to promote their own innovative ideas and/or to seek others' innovative ideas with which the innovators can collaborate. Administrators' primary purpose for using a component tool is to facilitate use of a system by others, which can include specifying the system's configuration, making the system available, and ensuring that progress is being made within the processes to develop the ideas involved. Managers' primary purpose for using a component tool is to support their oversight responsibilities. If an organization's innovation initiative includes target metrics for a certain number of ideas of certain types being implemented for clients within a specified period of time, in accordance with this example embodiment, the system can provide suitable reports to serve such needs.
[0010] An important technical advantage of the present invention is that organizations can foster innovation and enhance their brands by revealing the nature and scope of innovation that occurs within the organizations to key external audiences. This feature delivers value directly, and also fosters an organizational culture of innovation that leads to additional innovations that, in turn, deliver additional value. To be effective at fostering innovation, the business process can provide an entrepreneurial environment that nurtures and rewards speed, teamwork, and prudent risk-taking.
[0011] Another important technical advantage of the present invention is that an innovation engine portal is provided, which includes a set of tools that can implement and support a set of business processes to foster innovation at both the individual and organizational levels. The rewards associated with a successful idea for the idea's originator are significant, both in organization-wide recognition for the innovative effort and monetarily. Because the amount of effort and expertise required for launching a new commercial offering is so large, a successful idea typically has many persons nurturing and developing the idea along the way. As such, the Innovation Engine Portal is a process and system designed primarily to provide access, in a convenient and quick manner, to the people and expertise needed by the idea originator. The process provides a series of funding-related steps that gives idea originators the opportunity to prove their ideas (e.g., even unconventional ideas that have no other chance to be attempted). Such strong encouragement of innovative ideas can involve a higher risk than that for expanding existing capabilities incrementally. However, innovative ideas also have higher differentiation benefits, and disadvantages can be cropped as soon in the process as it is recognized that the ideas are infeasible or do not have the originally intended value. Each of the Innovation Engine Portal's tools has its own value, which can vary according to the tool's alignment with the goals of the organization using the system.
[0012] Still another important technical advantage of the present invention is that an idea workflow tool is provided, which ensures that all new ideas and innovations are captured enterprise-wide, and given a fair hearing through a standard process. These new ideas and innovations represent new technologies and business concepts that can maintain an organization in a leadership position into the future. Each idea carries with it the potential for creating new value and differentiation. Also, the existence of an idea workflow tool as an implementation of and idea development process in an organization is visible evidence to all employees that the organization values (and is willing to invest in) innovation.
[0013] Yet another important technical advantage of the present invention is that an idea workflow tool can be made available to users on a standard platform such as a web-based intranet or the Internet, at any location around the world and any time of the day. The workflow nature of such an activity enables users to communicate effectively without having to be available to each other at literally the same moment.
[0014] Still another important technical advantage of the present invention is that an idea workflow tool can send notification of events within a process to suitable users in the form of configurable communications. For example, such communications can be delivered via a standard email messaging system. Whenever a user logs into the system, the tasks required for that user to perform can be indicated on a local screen to facilitate convenient and prompt actions on the ideas flowing through the workflow process. Administration of an idea workflow tool can be performed with screens associated with that tool, by users assigned privileges based on the role or roles to which they are assigned.
[0015] Still another important technical advantage of the present invention is that a request for innovation tool component is included, which provides a convenient, efficient mechanism for connecting the developers of innovative ideas with clients that desire services resulting from those ideas.
[0016] Another important technical advantage of the present invention is that an internal innovation index tool is provided, which is designed to provide innovators within an organization ready access to key expertise in a simple and expeditious manner. This feature raises the level of awareness of innovative ideas among the organization's employees. Furthermore, the internal innovation index tool supports the development of nascent ideas while helping to identify opportunities for collaboration. As such, innovators have easy access to previously reviewed high quality information in much less time than previous techniques.
[0017] Another important technical advantage of the present invention is that an external innovation index tool is provided, which is designed to provide users outside an organization with ready access to key expertise within the organization in a simple and expeditious manner. This feature raises the level of awareness of an organization's innovative ideas among clients, prospects, partners, investors, analysts, and other parties interested in the organization. The external innovation index tool provides key external audiences with hard evidence of thought leadership and innovation.
[0018] Other technical advantages of the present invention will be readily apparent to one skilled in the art from the following figures, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a more complete understanding of the present invention and its advantages, reference is now made to the following descriptions, taken in conjunction with the accompanying drawings, in which:
[0020] [0020]FIG. 1 illustrates an example system, which can be used to implement an innovation engine portal in hardware and/or software, in accordance with one example embodiment of the present invention;
[0021] [0021]FIG. 2 illustrates an innovation engine portal process, which may be used to implement an example embodiment of the present invention;
[0022] [0022]FIGS. 3A and 3B are related diagrams that illustrate an example method for collecting, enhancing, and leveraging innovative ideas, in accordance with one example embodiment of the present invention;
[0023] [0023]FIG. 4 illustrates an example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0024] [0024]FIG. 5 illustrates a second example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0025] [0025]FIG. 6 illustrates a third example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0026] [0026]FIG. 7 illustrates a fourth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0027] [0027]FIG. 8 illustrates a fifth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0028] [0028]FIG. 9 illustrates a sixth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0029] [0029]FIG. 10 illustrates a seventh example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention;
[0030] [0030]FIG. 11 illustrates an eighth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention; and
[0031] [0031]FIG. 12 illustrates a ninth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0032] The preferred embodiment of the present invention and its advantages are best understood by referring to FIGS. 1 - 12 of the drawings, like numerals being used for like and corresponding parts of the various drawings.
[0033] [0033]FIG. 1 illustrates an example system 100 , which can be used to implement an innovation engine portal in hardware and/or software, in accordance with one example embodiment of the present invention. For this example embodiment, system 100 can include a web server 102 . Alternatively, for increased performance, system 100 can include a pool of multiple web servers. A primary function of web server 102 (or pool of web servers) is to allow a user 106 to send or receive content over or from the Internet using a standard user interface language such as, for example, the HyperText Markup Language (HTML). Web server 102 can accept a request for content from user 106 via a web browser (e.g., Microsoft Internet Explorer or Netscape Navigator) and return the appropriate HTML documents from an external database 104 or internal database 112 (e.g., through a secure firewall 108 used by the organization involved). For this embodiment, web server 102 can be implemented using a Microsoft Internet Information Server (IIS), which is a high-end, enterprise-level server for Windows NT platforms. Also, for this embodiment, Microsoft's Structured Query Language (SQL) Server can be used as a database server associated with external database 104 or internal database 112 . Alternatively, for increased performance, a pool of multiple database servers can be used with external database 104 and/or internal database 112 . The Secured HyperText Transfer Protocol (HTTPS) can be used as a secure client-server communications protocol. Certain programming languages and technologies can be used to increase the performance of web server 102 , such as for example, Active Server Pages (ASP) and Visual Basic Script (VBScript). The Practical Extraction and Reporting Language (Perl) can be used for batch programs to connect some or all of the above-described components together. The Microsoft Indexing Service (IS) can be used for indexing documents.
[0034] Also for this example embodiment, system 100 can include a web server 110 . A primary function of web server 110 is to allow a user 112 internal to an organization involved (e.g., enterprise employee) to send or receive content over or from an intranet using a standard user interface language such as, for example, HTML. Web server 110 can accept a request for content from user 114 via a web browser, and return the appropriate documents from internal database 112 . Web server 110 can be implemented and function similar to web server 102 , as described above. Notably, the above-described technologies can be used to implement at least one example embodiment of the present invention, but the scope of the present invention is not limited by the technologies shown. As such, any suitable technologies can be used to implement an innovation engine portal as a system, method and/or process in hardware and/or software, in accordance with the teachings of the present invention.
[0035] As described earlier, for this example embodiment, the innovation engine portal can include the following four components or tools: idea workflow tool; requests for innovation; internal innovation index; and external innovation index. The idea workflow tool, requests for innovation component, and internal innovation index component can reside on web server 110 and a database server (not shown) associated with internal database 112 , on the organization's network (e.g., intranet) on the internal side of firewall 108 . All internal users (e.g., 114 ), which can include an organization's employees and other persons authorized to use the organization's network, can access the idea workflow tool, requests for innovation, and internal innovation index components directly. Firewall 108 functions primarily for security purposes to limit network access from one side of the firewall to the other. The external innovation index component can reside on web server 102 and a database server (not shown) associated with external database 104 on the Internet side or external side of firewall 108 . An external user 106 (e.g., presumably not an employee or authorized user of the organization's network) can access the external innovation index component directly via the Internet. For implementation, standard technologies can be used where feasible, in order to minimize costs and provide the most flexible and responsive implementation possible within a dynamic business environment. As such, software used for implementing the components of the innovation engine portal can be designed to support a variety of particular idea development processes. However, if a particular set of desired phases, roles, notifications, statuses, etc. differ from the example embodiments described herein, the system administration functionality can be used to reconfigure a particular tool to meet those needs. Also, even within the operating lifecycle of a single process, some reconfiguration of a tool may be performed to reflect the dynamically changing business environment.
[0036] In accordance with the present invention, the idea workflow tool component of an innovation engine portal system and method is an execution in technology of one or more workflow-style business processes that can collect, support, and leverage ideas. As described in detail below, an example embodiment of such a process is the Idea2Reality workflow process, which has been developed by Electronic Data Systems, Inc (EDS). The idea workflow tool can support the submission of an idea by an employee anywhere in an organization worldwide, and ensure that the idea is managed appropriately throughout its life cycle. The submission of an idea can be accomplished using a form accessible, for example, through a user's web browser (e.g., assuming that the tool's interface is web-based).
[0037] There is a significant amount of effort expended in developing an idea into a well-formed technical and business state that can warrant a new internal service or commercial offering. Normally, an organization cannot afford to allow employees to “play around” with all ideas when there is no assurance that such activities can deliver some value. The ideas that have the most pilot success and effective designs, sufficient scalability, and most efficient delivery of value are adopted as organization-wide solutions and/or are delivered as solutions to the organization's clients. The process inherently prioritizes the ideas on merit, so that those ideas having the highest priority receive the most attention and funding.
[0038] If multiple workflow-style business processes are implemented by the same system, the idea workflow tool can track each idea into each process into which the idea has been submitted. As a result, the appropriate administrators and other users can be informed about an idea's progress at the appropriate times. Each separate process may be configured with different users, roles, phases, and so forth. The idea workflow tool can support multiple, collocated processes.
[0039] Users who submit ideas can review such information displayed on their home screens in a section entitled “My Ideas”. As such, users can track the status of their ideas within a process, at any time from anywhere in the world. Communications to idea originators, their managers, and others involved in an idea development process can be triggered by changes in a process phase or status. Furthermore, the idea workflow tool can support the administration of an idea, and the management of the idea workflow process. Reports can be provided to reviewers who are assigned by an organization to evaluate the ideas. Each reviewer can have a worklist specific to that user, which shows the actions that user needs to perform. Summary reports and aging reports can also be provided, which can identify those ideas that exceed configured thresholds for aging on a phase-by-phase and status-by-status basis.
[0040] The idea workflow tool also provides a tool administrator which can manage communications to users of the tool, assign roles to those users, and control rights to those users through a special selection screen. The system can store user profiles, which enable users to identify and contact each other and thereby foster collaboration. The idea workflow tool can be implemented with standard technologies in a manner that makes it relatively inexpensive for an organization to own and maintain, and is highly configurable to implement quickly any requested changes in the business process(es) being supported.
[0041] The requests for innovation tool enables client relationship managers and other client-interfacing employees to enter requests for innovative solutions directly into the innovation engine portal. Any authorized user logged into the system can browse these requests, or locate these requests by keyword lookup searches, by using the internal innovation index tool (as described below). When a user finds a request for an innovative solution that piques that user's interest, suits that user's skills, or matches an innovation that user has developed or envisioned, the requests for innovation tool can be used to list that user as a collaborator on the request. As a result, the requests for innovation tool can make that user's contact information available to the request originator. As a collaborator, that user can also contact the request originator directly. Users who have submitted requests for innovation or listed themselves as collaborators on other requests can view such information listed on their home screen in a section entitled “My Requests”.
[0042] The requests for innovation tool can also enable a user who is not an employee of the organization to submit a particular form, in order to make a request for innovation to that organization. For example, such a user can be a current or potential client. This (external) form can be submitted to an employee of the organization. The employee can then submit the external request for innovation into the idea, workflow component of the development process, where the request can be processed in the same manner as internal requests, except that the external user is not allowed to log into the system to view and act on the request directly. In this case, an employee of the organization (e.g., the client relationship manager) who can represent the external user can view and act on this particular request.
[0043] The internal innovation index tool is designed to provide innovators within an organization with ready access to key expertise in both a simple and expedited manner. This expertise may reside in documentation, be available through an alliance with an academic institution or strategic partner, or be available from another employee of the organization involved. The internal innovation index may be characterized as being similar to a set of library card catalogs. A user can select a given catalog and search for the needed information within that catalog, or in all of the catalogs.
[0044] The internal innovation index tool can maintain information catalogs both manually and automatically. This feature permits the index administrators to ensure that the stored content is of the highest quality and also that it is approved. An example internal innovation index contains one catalog including approximately 450 white papers. A group of organizational leaders referred to as a “Community of Thought Leaders” can approve all new white papers before they are added to the internal innovation index. The internal innovation index can automatically update and fully integrate a first catalog that links to the requests for innovation and another catalog that links to ideas in the organization's overall system. As such, certain indexed content can be hosted and stored within the organization's system, while other indexed content can be hosted and stored elsewhere.
[0045] The scope of the internal innovation index is inherently internal to an organization. In other words, any information that is acceptable to show to an internal audience can be included in the internal innovation index, so that search results can span that scope. The scope of the internal innovation index can include information generated within or outside of the organization involved. An administration screen is provided for maintaining an index for all catalogs included in the internal innovation index. For example, the following types of catalogs can be included in an organization's internal innovation index: ideas; requests for innovation; U.S. patents granted to the organization; academic alliances and strategic partnerships; white papers; organization-authored journal articles and conference presentations; and organization-authored books.
[0046] The external innovation index can be functionally similar to the internal innovation index. However, the scope of the external innovation index is inherently external to an organization. In other words, any information that is acceptable to show to an external audience can be included in the external innovation index, so that search results can span that scope. The scope of the external innovation index can include information generated within or outside of the organization involved. Notably, it is highly likely that much of the internally generated information within the scope of the internal innovation index does not also reside within the scope of the external innovation index, because an organization's intellectual property is typically safeguarded. Consequently, the administrator of the external innovation index (e.g., an employee of the organization involved) can decide whether none, some, or all of the information in the internal innovation index can be migrated to the external innovation index (e.g., on a document-by-document basis).
[0047] [0047]FIG. 2 illustrates an innovation engine portal process 200 , which may be used to implement an example embodiment of the present invention. For example, process 200 can be implemented using system 100 shown in FIG. 1. Referring to FIGS. 1 and 2, it can be assumed that an employee of an organization has become aware that the innovation engine portal can be used to request a solution from the organization's innovators. Also, the employee knows that a particular client has a problem, and it is likely that the employee's organization can sell that client a solution to that problem if such a solution is available. The employee can login to the organization's network (e.g., intranet) and thereby become a user (e.g., user 114 or 202 ). The user can perform an innovation search for ideas using an innovation index tool ( 206 ), which can form part of the innovation repository (of ideas) 204 . The innovation repository 204 , which can be stored in the internal database 112 , can contain all of the system's ( 100 ) innovation-related data that is neither in an idea workflow 208 nor the innovation index 206 . As a result of the innovation search, the user may find that a suitable solution exists in the repository 204 , and a cross-selling opportunity may arise.
[0048] On the other hand, as a result of the search, the user may not find a suitable solution in the repository 204 . In that case, the user can become an innovation requester 210 and submit a request for innovation to the repository 204 in database 112 (e.g., via web server 110 ). As a result of this request for innovation, the user (innovation requester) may receive information and determine that other users have submitted similar requests for solutions to similar problems for other clients. Also, while browsing the results of the innovation search, the user may realize that another known set of documents stored in the internal network may be useful to other users who perform similar searches. The user can recommend to the system administrator that the location of this set of documents be included in the internal innovation index 206 .
[0049] After considering the innovation search results in more detail, the employee may recognize that a solution can be developed to solve this client's problem, as well as other problems reported in other requests for innovation. Furthermore, this solution may also be valuable to other clients. As such, by returning to use the innovation engine portal ( 200 ), the employee can become a user in the role of an idea originator 210 . The idea originator 210 can present the idea by answering certain questions on a draft idea submission form 212 (e.g., displayed on a computer monitor). The idea originator can complete the draft form 212 over a period of time (e.g., during research time, breaks, or in between attending to other duties). The draft submission form 212 containing the idea can be updated as needed by the idea originator 210 . Once the idea is initially documented (e.g., by completion of the draft idea submission form 212 ), the idea originator can promote the idea ( 214 ) into one of the idea development processes that are available in the organization involved.
[0050] An example of such an idea development process is an incubator, which is a process whereby ideas that have not yet matured to the point of demonstrable value can be nurtured. For example, an incubation process may be used if the potential business value or technical value of an idea has not yet been fully developed. Typically, all of the ideas in an incubator are visible to all internal users, so it is likely that someone who can (and is willing to) help develop an idea will do so. Also, in an incubator, multiple partially-formed ideas can be combined into a single complete idea via the collaboration that can occur within such an incubation process.
[0051] As mentioned earlier, another example of an idea development process is an EDS Idea2Reality workflow process, which has been developed by EDS and can be used to implement an example embodiment of the present invention. Essentially, an idea workflow development process can begin by having the originator of an idea submit the idea into the organization's idea development workflow. An idea support team can review the idea for completeness, and assign a set of subject matter experts who can assist the originator with refining the idea. Once the idea is completely defined and properly formed, it can be presented to a seed-funding committee for evaluation and prioritization. If the seed-funding committee determines that the idea has merit and a high enough priority, seed funding can be provided. The seed funding can provide the time, money, and other required resources to prove the business opportunity presented by the idea. The results of this “proof-of-concept” effort, which can include, for example, a fully developed business plan, can be presented to a build funding committee. The build funding committee can determine if the idea has ongoing, large-scale merit, and a high enough priority. If so, the build funding committee can provide build funding for the idea. The build funding can provide the time, money, and other required resources needed to build the solution presented by the idea, into its final form. The finalized solution can be integrated into the organization's overall business systems and/or delivered to clients as a commercial offering.
[0052] The idea workflow development process can specify that certain employees be involved in meetings to review, discuss, and determine the disposition of ideas currently at their relevant steps of the process. This meeting activity can be supported by the tool involved. Whenever such a meeting is to occur, a user authorized to do so by an assigned role (e.g., an idea administrator), can call up an automated meeting agenda maker feature of the idea workflow development process. This feature can display (e.g., on a screen for the authorized user) all ideas that are in the pre-configured phases and statuses qualifying for a meeting of this type, allow the user to select which items are to be placed on the meeting's agenda, and trigger a notification (e.g., via email) of the agenda to the participants of the meeting. The meeting participants can be determined based on the pre-configured invitee roles for meetings of this type. The user has a link back to a screen (e.g., on a web-based system) which displays the details of the ideas on the agenda for that meeting. Multiple distinct meeting types, with each having its own such phases, statuses, and roles specified by the business process involved, can be configured by an authorized user (e.g., an idea administrator).
[0053] [0053]FIGS. 3A and 3B are related diagrams that illustrate an example method 300 for collecting, enhancing, and leveraging innovative ideas, in accordance with one example embodiment of the present invention. For this example embodiment, method 300 can represent the EDS Idea2Reality workflow process mentioned earlier. Also, for this example, method 300 can be implemented by an organization using the example technologies described above with respect to system 100 of FIG. 1. At step 310 in FIG. 3A (e.g., idea submission phase), an originator of an idea (e.g., internal user 114 in FIG. 1) can submit the idea for consideration by an organization, by completing an idea submission form. For example, a pre-defined idea submission form can be displayed on a computer screen, completed by the idea originator, and entered on-line via web server 110 . Before the idea is allowed to be submitted to the workf low process, the system can ensure that each field of the form includes some text, and an option has been selected for each multiple-option question.
[0054] For example, at step 312 , the idea submission form can be reviewed to determine whether or not all of the fields are filled in. Suitable application software running on web server 110 can be used to determine whether or not each field of the idea submission form contains text. If all of the form's fields are not filled in, then returning to step 310 , system 100 (e.g., via the application software) can send a suitable message to prompt the idea originator to fill in the missing field(s). The idea originator can save a partially completed version (draft) of the form, and retrieve the form at a later time for further completion.
[0055] The idea submission form can be configurable. Standard web form type questions can be included, which can be added, edited, or deleted by a system administrator in order to reflect suitable information to describe an idea for a desired business process involved. As such, system 100 can construct the idea submission form dynamically whenever a user displays a particular screen, in accordance with the configuration desired.
[0056] Returning to step 312 , if all of the idea submission form's fields are filled in, at step 320 (e.g., idea review phase), one or more persons of an idea development support team can work with the idea originator to ensure that the information in the idea submission form is complete and meaningful, from the standpoint of the organization involved. For example, at step 322 , the idea support team can review the idea submission form, and determine whether or not the information contained in each of the form's fields is both accurate and valid (e.g., does not contain random text). If the information in any field of the idea submission form is neither accurate nor valid, then returning to step 310 , the idea support team can prompt the idea originator to revise the idea submission form and resubmit it with accurate and valid information.
[0057] Otherwise, if at step 322 , the idea support team determines that the information in each field of the idea submission form is both accurate and valid, then at step 324 , the idea support team can determine whether or not the idea presented in the idea submission form is worth pursuing (e.g., idea describes a capability that falls within the scope of idea development workflow process, or has merit from the supporting organization's point of view). If the idea support team determines that the idea presented in the idea submission form is not worth pursuing, then at step 390 , the process of reviewing this particular idea can be terminated. However, if at step 324 , the idea support team determines that the idea presented in the idea submission form has merit within the scope of the idea development workflow process involved and is worth pursuing, then the method can proceed to step 330 (e.g., idea refinement phase).
[0058] Essentially, some members of the idea development support team can be deemed to be idea administrators. The remaining team members can be deemed to be idea facilitators. The idea administrators can perform step 322 and then assign each completely submitted form to one or more of the idea facilitators to perform step 324 (e.g., working with the idea originator). For example, the idea facilitators can function as process coaches up until the build funding step in the workflow process.
[0059] Preferably, the idea administrators and idea facilitators have the ability to transition an idea from one phase or status to the next phase or another status. The system administrator can configure notifications of these events to be triggered in accordance with predetermined definitions of the particular business process involved. A correspondence template can be configured with “smart tags” for any desired phase or state transitions, with the smart tags representing data fields associated with each idea (e.g., idea originator's name, idea facilitator's name, idea identification number, idea submission date, etc.). The roles of the individuals to which each of the notifications are to be sent can also be configured. Whenever a phase or status transition is initiated for an idea, any correspondence that is triggered as a notification message is presented to the user for editing and approval. After the user indicates acceptance of the pending transition, system 100 can initiate the transition for that idea and send out the resulting correspondence (e.g., via email) to the intended recipients.
[0060] The idea administrators can have the ability to administer the roles of the various users of system 100 . If a new role is added to the workflow process (e.g., idea facilitator, subject matter expert, seed funding committee member, or other suitable role), the idea administrators can assign the proper role to the new user, so that the new user can access the needed functionality (e.g., using a browser on a suitable screen) for the particular role involved. Notably, the roles assigned to users may be altered by the idea administrators as desired to support the different business processes involved. Also, the functionality associated with each role can be reconfigured by the idea administrators as desired.
[0061] The idea administrators and idea facilitators can have the ability to associate particular users with particular ideas. For example, the idea originator and idea administrators can be automatically assigned as contacts for a particular idea. Thereafter, an idea administrator can assign idea facilitators as contacts for the idea, and the idea facilitators can assign subject matter experts, seed funding committee members, and so on, as contacts for that idea. As such, in order for a user to be able to access the specific functionality for an idea, the user can be required to have the proper role and also be specified as a contact for that idea. For example, a user having the role of a subject matter expert can be allowed to view all ideas and add comments to each subject matter expert folder associated with each idea. Notably, a “folder” is a labeled unit of storage on a database system that can store comments made by users and documents uploaded by users. On the other hand, an idea facilitator can be allowed only to transition an idea from one status to another (e.g., after being specified by an idea administrator as a contact for that idea). For increased flexibility, a user can specify that a particular piece of correspondence not be sent out for a particular phase change or status change (e.g., if the system is being updated off-line), or that a particular piece of correspondence be sent out at any time (e.g., to send out another copy of the correspondence). Each user designated as a contact for an idea can have the ability to review all details of that idea, which can include, for example, the submission date, responses to the questions on the idea submission form, and the contents of any folders associated with that idea.
[0062] As such, each idea being processed (e.g., through the example EDS Idea2Reality workflow described herein) can have a configured set of process folders associated with that idea. The contents of each such folder can be manually or automatically created. For example, a suitable comment can be added to the process folder for an idea, whenever a notification message is triggered by a phase change or status change. Whenever correspondence is sent out for a particular idea, a copy of that correspondence can be stored in a process folder for that idea. Any user who is identified as a contact for an idea can add comments to and upload documents into a process folder for that idea (e.g., to which that user is authorized access). All public folders and process folders associated with an idea can be made available to all users who are designated as contacts for that idea. A user designated as an idea contact and assigned the role of a subject matter expert for that idea can access any subject matter expert folder associated with that idea. Notably, for added flexibility, other folders and access roles can be configured to meet the various requirements for collaboration on the development of an idea across an organization (e.g., with or without tighter role-based restrictions imposed on the folders' contents).
[0063] Returning to the idea refinement phase at step 330 , the submitted idea can be assessed by a team of subject matter experts to determine whether or not that idea has technical merit. If the submitted idea is deemed by the subject matter experts to have technical merit, then at step 334 , the experts can determine whether or not the idea is feasible from a basic business standpoint for the organization involved. Otherwise, if the subject matter experts determine that the submitted idea neither has technical merit nor is feasible (steps 332 , 334 ), then at step 390 , the process of refining this particular idea can be terminated.
[0064] Returning to step 334 , if the subject matter experts determine that the submitted idea is feasible, then the method can proceed to step 340 (e.g., seed funding phase) in FIG. 3B. At step 340 , the details of the idea can be presented to a review committee. At step 342 , the review committee can determine whether or not to fund the submitted idea for “proof-of-concept” development. The “proof-of-concept” development effort can be large enough to be difficult for the idea originator to perform in addition to normally assigned day-to-day duties, but small enough to minimize the resources expended to prove that the idea works and can do so in a manner that is efficient enough to be worthwhile on a large scale. Part of the benefit derived from using this centralized funding is that it can avoid having the idea originator impose the cost, time, and other resources needed solely on the idea originator's own department. Such impositions often stifle ideas for reasons not related to their true value to the organization involved.
[0065] At step 342 , if the review committee determines that the submitted idea should be funded, then the method can proceed to step 350 (e.g., prove phase). Otherwise, if the review panel determines that the idea should not be given seed funding, then at step 390 , the concept development process for the submitted idea can be terminated.
[0066] At step 350 , using the seed funding provided, the originator of the idea can develop the idea into a proof-of-concept. At step 352 , the review committee can determine whether or not the proof-of-concept provides sufficient evidence that the idea warrants further development. If (e.g., after learning about the idea's characteristics in the proof-of-concept development) the review committee determines that the idea should be developed further, then the method can proceed to step 360 (e.g., build funding phase). Otherwise, at step 390 , the process of proving the concept for the submitted idea can be terminated.
[0067] At step 360 , the developed idea can be presented to a review panel for consideration of build funding. Typically, build, funding provides significantly greater resources than that provided by seed funding. However, the build funding allows the development of a significantly greater process, functionality, and planning for the idea involved (e.g., up to the point where the idea can be delivered in a production-ready mode to the organization and/or as a commercial offering to the organization's clients. At step 362 , the review panel can determine whether or not the idea has enough merit to provide build funding. If the review panel decides to continue funding the idea, then the method proceeds to step 370 (e.g., idea build phase). Otherwise, at step 390 , the process of funding the submitted idea can be terminated.
[0068] At step 370 , in the idea build phase, the idea originator can attempt to fully develop the submitted idea into a commercial offering or other production service or product useful to the organization. At step 372 , the review panel can determine whether or not the idea has successfully developed into a viable commercial offering. If the review panel determines that the idea has been successfully developed into a viable commercial offering or other useful production service or product, then the method can proceed to step 380 (e.g., idea apply phase). Otherwise, at step 390 , the process of building the idea into a commercial offering can be terminated. During the idea apply phase, the development can be managed long-term by individuals who may or may not have been involved with the idea's development up to that point.
[0069] Notably, throughout the idea development workflow process (e.g., the EDS Idea2Reality workflow process described above), the process participants and managers of the organization involved are typically interested in the details of the activities occurring in the process. System 100 can provide suitable reports with pertinent information, such as for example, the number of ideas currently in each phase and/or status, the number of ideas that have reached each phase, the number of ideas submitted per month on a historical basis, the number of active ideas per geographical region, etc. An Idea Aging Report can be useful for judging the overall health of the idea development workflow process. For example, each idea that is in a particular phase or status for which an acceptable time delay has been configured, can be shown in an aging report as a line item in a summary format, along with a colored icon (e.g., red, yellow, or green). A red icon can indicate that the acceptable time delay for a particular phase or status has been exceeded. A yellow icon can indicate that a red icon's condition has occurred, but an idea administrator has over-ridden the acceptable time delay, and the new time delay has not yet been exceeded. A green icon can indicate that the original acceptable time delay has not been exceeded. The portion of each colored icon appearing on the Idea Aging Report can indicate whether the participants in the idea development process are acting promptly (e.g., relative to configured standards).
[0070] [0070]FIG. 4 illustrates an example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent a “myHome” screen for a typical idea originator. As such, the topmost menu bar is a common menu bar for all of the tools associated with the innovation engine portal. The second menu bar can provide quick access to each component of the innovation engine portal other than the external innovation index. The external innovation index is not needed on the organization's internal network because it is redundant to the internal innovation index. The user's EDS Idea2Reality menu appears in the upper left section of the screen below the menu bars. Any idea that has an action pending by this user is displayed in the “myWorklist” section. Such an idea has a link to the action that is required next by the process. These ideas may include the originator's own idea (e.g., as in this case when it needs reworking), or they may be other originators' ideas at a step in the process that requires the attention of an idea administrator, idea facilitator, subject matter expert, or other role that this user plays in the process. The ideas that this user originated, which are in the process in someone else's worklist, appear in the “myIdeas” section of the screen, so that the idea originator user can monitor them.
[0071] The EDS Idea2Reality workflow tool functions as a portal, so this initial “myHome” screen can also include quick access to the most significant feature of each of the requests for innovation tool and the internal innovation index tool. As such, the internal innovation index lookup box is at the left side of this screen, and this box functions just as it does when the user explicitly visits the internal innovation index component. The “myInnovationRequests” section of the screen provides a quick summary of all requests for innovation that this user either has initiated or is collaborating on.
[0072] [0072]FIG. 5 illustrates a second example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent an “Idea Details” screen. For example, whenever the user follows the link for a particular idea on the “myHome” screen (FIG. 4), the “Idea Details” screen is displayed, which can provide access to the idea's submission form, its folders, the history of the idea submission form's phase and status transitions, and any data attributes that are associated with a phase or status, such as Seed Funding Priority for the Seed Funding phase. Also, this screen can be used to add comments and upload files to the idea's folders. The idea administrator and idea facilitator users have additional features available whenever they view this screen. Also, the idea administrator and facilitator have access to more folders and additional features via this screen, such as for example, the “Change Phase” or “Change Status”, “Update Idea Contacts”, etc.
[0073] [0073]FIG. 6 illustrates a third example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent an “Update Idea” screen. For example, the action that was required next for the idea on this user's “myHome” screen (FIG. 4) was to rework the idea via the “Update Idea” screen. The responses that had been provided to the questions presented when the idea was submitted can be recalled and displayed, with the option available to update all or any of the responses. The “Image Cut Here” bar represents a shortening of the actual screen image, for clarity purposes. Each question on the idea submission form can be configurable, so the additional questions not shown on the shortened screen image are not significant. Once the user has completed making updates to the form (using this screen), the “Update Form and Re-submit” button can be pressed to re-submit the form back to the phase and status in the process from which the form came.
[0074] [0074]FIG. 7 illustrates a fourth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent a “myHome” screen for use by a system administrator. For example, the “myHome” screen for a system administrator can indicate additional functionality of the example tool in the EDS Idea2Reality menu. This screen can also indicate that several ideas with pending actions are in the process in various phases and statuses. The remainder of this screen (not shown) is analogous to the “myHome” screen for an idea originator (FIG. 4).
[0075] [0075]FIG. 8 illustrates a fifth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent a “Change Phase or Status” screen for use by an idea facilitator. For example, the idea facilitator assigned to an idea can have this additional functionality available when viewing an “Idea Details” screen (FIG. 5). The system administrator typically has access to all system functionality in order to verify that the system is operating properly whenever needed, and this screen image represents such a user, the EDS Idea2Reality menu on the left side of the screen displays more options than provided for a typical idea facilitator. This screen can be displayed when the “Update Phase or Status” link is followed from any of the “Idea Details” screens (FIG. 5). The comment provided here by the idea facilitator via this screen is placed in a Process folder. The phase attribute value provided here is required because the “Sub-IOT” committee meeting date attribute is associated with the next phase (e.g., “3-SubIOT”). The user can then click on the “Increment Phase” button to proceed to edit any triggered correspondences that serve as email message notifications to users associated as contacts for this idea. Similarly, if the user selects a new status and clicks on the “Update Status” button, the triggered correspondences can be presented. After the user reviews and edits any correspondences, the user can then finalize the change, which can include the system sending the related correspondences to the configured user via any available mail system.
[0076] [0076]FIG. 9 illustrates a sixth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent an “Idea Aging Dashboard” report screen. For example, this report can show which ideas are overdue for a pending action (as described earlier).
[0077] [0077]FIG. 10 illustrates a seventh example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent a “System Configuration” screen for a system administrator. For example, this screen is one of the screens that can be used by a system administrator user to configure the behavior of the system according to the desired idea development workflow and associated rules. Each system configuration screen shows the categories of system configuration that are supported. This particular screen shows the set of roles to which this correspondence (e.g., “C12-Cancel”) can be sent via email, and in which addressee category, “To”, “Cc”, or “Bcc”. Contacts of the idea who are playing these roles can be sent this correspondence whenever it is triggered as a notification due to a change in the idea's phase or status.
[0078] [0078]FIG. 11 illustrates an eighth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent an “Innovation Index” tool screen. For example, this component of the system can be available to all users. The Innovation Index lookup form is displayed on the left side of the screen. The drop-down menu of catalogs that were available at that time is shown expanded. The user may select a particular catalog, or all catalogs at once. The user provides a search string in the text box, and then clicks on the “Lookup” button. Hidden (temporarily) by the expanded catalogs menu is a link to the “Lookup Tips” screen, which explains how to use the advanced lookup capabilities such as, for example, wildcards and Boolean logic. The “Document Administration” menu item is available to the index administrator, and it is where documents can be added to, updated, and removed from catalogs. A typical idea originator user does not have access to this screen. When the user selects the “Innovation Index” component in the second menu bar, as opposed to using the “Innovation Index” lookup form displayed directly on the EDS Idea2Reality screens, the system displays a summary of the various defined catalogs. The update intervals are configurable on the “Document Administration” screen. The batch program that actually prepares the documents for indexing can be implemented with the Perl language. The Microsoft IS technology requires that a copy of a remote web-based document be cached locally. As a result, such a batch program is required to support this requirement. If an alternative indexing service is utilized, then this batch program is likely not needed. The Microsoft IS makes the status of each of its catalogs available to the system, which status is displayed on this screen to ease index administration.
[0079] [0079]FIG. 12 illustrates a ninth example screen image that can be used to demonstrate key functionality of an innovation engine portal, in accordance with one example embodiment of the present invention. This example screen image can represent a “Requests for Innovation” tool screen. For example, the “Requests for Innovation” tool allows any user to submit requests for innovation. Each request includes a customer name and associated expiration time delay. The request initiator can update or deactivate the request as needed via buttons that appear on the “View Request” page whenever they are appropriate, according to this particular request and user and to the processing rule. The summary of active requests is available via the “Browse Innovation Requests” menu item, and it appears the same as the “myInnovationRequests” section of the user's “myHome” page, though with all users' active requests displayed instead of just those of this user. Clicking on any particular request takes the user to the “View Request” page, where a button is available to add the user to the request in the role of collaborator. All other users can see which users have added themselves as collaborators.
[0080] Although a preferred embodiment of the method and apparatus of the present invention has been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiment disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.
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An enterprise-wide knowledge management system is disclosed, which includes an innovation engine portal that can link each user to any needed expertise, throughout an enterprise, in a consistent manner. As a result, enterprise experts are free to pursue more higher-value-added activities such as, for example, the formation of additional strategic alliances and pursuit of additional mega-deals. As such, in today's “Digital Economy,” a successful organization is enabled to eliminate boundaries, collaborate in new ways, establish trust, and continuously seek improvements. The entire innovation life cycle is made accessible to all employees, from the initial demand for innovation, through the searches for innovation, sparking of innovation creations, innovation collaborations and investments, and innovation reporting and communications. The enterprise-wide knowledge management system provides a system of business processes and tools, which are designed to collect, enhance, and leverage the organization's intellectual capital. The individual efforts to deliver innovative solutions to clients are coordinated into an efficient and effective organization-wide mechanism.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of application Ser. No. 10/230,169, filed Aug. 29, 2002, now U.S. Pat. No. 6,691,708, which is a divisional of U.S. application Ser. No. 09/608,440, filed Jun. 30, 2000, now U.S. Pat. No. 6,463,931, which is a continuation of U.S. application Ser. No. 09/008,708, filed Jan. 16, 1998, now U.S. Pat. No. 6,119,693, the specifications and drawings of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention generally relates to an improved comfort device to be used with a nasal mask. In particular, the device is useful in combination with masks which are used for the treatment of respiratory conditions and assisted respiration. The invention assists in fitting the mask to the face as well.
BACKGROUND OF THE INVENTION
Nasal masks are commonly used in the treatment of respiratory conditions and sleep disorders by delivering a flow of breathable gas to a patient to either assist the patient in respiration or to provide a therapeutic form of gas to the patient to prevent sleep disorders such as obstructive sleep apnea. These nasal masks typically receive a gas through a supply line which delivers gas into a chamber formed by walls of the mask. The mask is generally a semi-rigid mask which has a face portion which encompasses at least the wearer's nostrils. Additionally, the mask may be a full face mask. The mask is normally secured to the wearer's head by straps. The straps are adjusted to pull the mask against the face with sufficient force to achieve a gas tight seal between the mask and the wearer's face. Gas is thus delivered to the mask through the aperture to the wearer's nasal passages and/or mouth.
One of the problems that arises with the use of the mask is that in order for the straps to be tight, the mask is compressed against the wearer's face and may push unduly hard on the wearer's nose. Additionally, the mask may move around vis-à-vis the wearer's face. Thus, there has been provided a forehead support, which provides a support mechanism between the mask and the forehead. This forehead support prevents both the mask from pushing too strongly against the wearer's nose and/or facial region as well as minimize movement of the mask with the addition of a contact point between the mask and the wearer's head as well as minimize uncomfortable pressure points of the mask. Additionally, the forehead support may prevent the air flow tube from contacting the wearer's forehead or face.
Prior to the present invention, the forehead supports were generally a single cushion with a single contact point which may be adjustable by rotation of a screw, with the single cushion pushing on the forehead at a single point. This is oftentimes uncomfortable for the patient, and the adjustability of the distance of the pad for different forehead protuberances oftentimes was difficult if not impossible to be performed. Additionally, a single contact point does not provide necessary lateral support to the mask. Finally, a single contact point may apply too much pressure at the single point.
Examples of prior art nasal masks are shown in U.S. Pat. Nos. 4,782,832 and 5,243,971.
There is a need for an improved forehead support for nasal and facial masks which adjusts to different angles on the face.
There is a need for a forehead support for nasal masks which may be adjusted to different forehead shapes.
There is a need for a multi-point forehead support for nasal masks.
These and other advantages will be described in more detail below.
SUMMARY OF THE INVENTION
The present invention is directed to an improved forehead support for nasal and facial masks. In particular, the present invention utilizes a dual cantilevered forehead support which preferably utilizes dual contacts which are arranged at an obtuse angle with respect to one another and which may be easily adjusted for different forehead protuberances. Preferably, the forehead support has two arms extending from the mask or gas supply line, with the two arms engagable into a bridge system wherein the arms may be adjusted to different positions on the bridge allowing optimal positioning of the mask on the face. This achieves even pressure of the mask on the face. The mask also provides an excellent fit which limits movement of the mask during sleep. The forehead support is adjustable such that the support is closer or further away from the front plane of the facial mask. The bridge supports the pad or pads which contact the wearer's forehead. The support also may allow the mask to be secured such that more pressure is applied to one area of the mask, to seal a leak for example.
The present invention allows the mask user to adjust the angle of the mask to the face. This is possible due to the two point contact of the forehead support to the forehead working in combination with the point of contact of the mask to the face. The system thus has three points of contact, wherein the forehead pads provide two contact points and the mask to the face is a third point of contact. Adjusting the angle of the forehead pads or the distance of the legs to the forehead pads adjusts the angle of the mask vis-à-vis the face of the user. This unique system provides a mask system which can be adjusted to fit the different face angles or profiles required by users.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the forehead support of the present invention attached to a mask, headgear and a gas supply tube.
FIG. 2 is a perspective view of the forehead support of the present invention removed from the mask and gas line.
FIG. 3 is an exploded view of the forehead support of the present invention.
FIG. 4 is a side view of the present invention secured to a mask.
FIG. 5 is a top view of the forehead support of the present invention in a first position.
FIG. 6 is a top view of the forehead support of the present invention in a second position.
FIG. 7 is a top view of the forehead support of the present invention in a third position.
FIG. 8 is a top view of the forehead support of the present invention in a fourth position.
FIG. 9 is a front view of the bridge of the present invention.
FIG. 10 is a single pad of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a general perspective view of the forehead support 10 of the present invention. The forehead rest or support 10 is attached to an extending airflow tube 12 from the mask 14 . The mask 14 and forehead support 10 are shown with headgear 16 which secures the mask 14 to the head of a patient. The headgear 16 may take a variety of forms, with one example being shown as 16 . As can be seen in FIG. 1 , preferably the headgear 16 loops through the forehead support 10 at 18 and 20 . This pulls the forehead support 10 against the forehead, thus creating a snugly fitted mask 14 and also provides a stabilizing member for the mask 14 .
The mask 14 , shown in FIG. 1 is merely one example of a mask which can be used with a forehead support, but any respiratory mask could be used. A full face mask which may cover the entire face or just both the nose and mouth could be used, for example. Additionally, the airflow tube 12 could be extending from the bottom of the mask 14 , thus the tube 12 supporting the forehead support 10 would terminate above forehead support 10 . If the airflow tube 12 extended in a downward or other direction from the mask 14 , then preferably a post would extend up from the mask 14 (this post position is referenced as 22 ). This post 22 would terminate slightly above where forehead support 10 is shown secured to tube 12 . Thus the forehead support 10 would be secured to the post in this alternative embodiment.
FIG. 2 discloses the preferred construction of the forehead support 10 of the present invention. The forehead support 10 has pads 24 and 26 . These pads 24 and 26 are the actual contact points of the forehead support 10 to the forehead. Pads 24 and 26 are preferably made of a deformable elastomeric material which retains its original shape upon release of pressure and provides the wearer with increased comfort and stability. As can be seen in the preferred embodiment, the forehead pads 24 and 26 have an annular interior construction with two retaining walls 28 and 30 . The retaining walls 28 and 30 provide structural integrity to the forehead contact support pads yet allow the pads to be deformed. The deformation preferably occurs by deflection of the pad walls. The pads also may be solid pads. The support pads 24 and 26 are mounted to the bridge 32 . The bridge 32 provides basically three purposes to the forehead support 10 . First off, it acts as a securing means for forehead pads or cushions 24 and 26 . Second of all, it has annular spaces 18 and 20 which receive the optional headgear 16 shown in FIG. 1 . Finally, it receives arms 34 and 36 , which may be adjusted, as described below. The bridge 32 and arms 34 and 36 operate in a cantilever fashion and are preferably made of a polymeric material, which may be easily molded, preferably injection molded. Arms 34 and 36 are secured to bridge 32 by an adjustable locking mechanism which is better illustrated in the figures below. Additionally, arms 34 and 36 join together to create an annular space 38 which may receive airflow tube 12 which is preferably connected to a flow generator to generate breathable air or some type of therapeutic gas. Arms 34 and 36 preferably create an operational hinge. The tube 12 may be an axis of this hinge. The hinge could also be a flexible membrane and not a rotational or axial hinge. Alternatively, the tube may extend through annular space 38 and terminate as described above (in the “post” embodiment) if the air flow tube is connected to another port on the mask.
FIG. 3 is an exploded view of FIG. 2 and shows the forehead support 10 in greater detail. FIG. 3 discloses how bridge 32 is configured such that forehead pads 24 and 26 may be secured thereto. In particular, tongues 40 , 42 , 44 and 46 all engage forehead pads 24 and 26 by entering the interior space of the pads. This is shown in FIG. 2 wherein tongues 42 and 46 are shown securing pads 24 and 26 respectively by entering the annular space of the pads 24 and 26 . Additionally, there may be engaging surfaces such as 48 , 50 , 52 and 54 , as shown in FIG. 3 , which engage an inner side wall of forehead pads 24 and 26 . The means by which the forehead pads are secured to the bridge 32 can be done in many manners, and one skilled in the art can come up with numerous methods of achieving this securement. Two sided tape may be used, protruding pegs and apertures on the forehead pad may be used or many other methods. What is desirable is that the forehead pad(s) may be replaced after extended use or, in a clinical setting, with each new patient. The method of securement of the pad(s) to the support is not a limiting feature of the present invention.
The type of forehead pad may also vary, it may include a solid foam sponge, a stuffed pad, a dual durometer foam which may be a single pad or multiple pads attached together, or many other known pads which would impart comfort when placed directly on the forehead. Finally, a single pad which extends all the way across bridge 32 may be used or more than two pads may be used.
Bridge engaging pins 56 , 58 , 60 and 62 are shown in FIG. 3 . As will be more apparent in the figures below, these engaging pins provide for the adjustability of the forehead support 10 of the present invention. There are pin receiving means located on the bridge 32 which receive pins 56 , 58 , 60 and 62 . The pins 56 , 58 , 60 and 62 are merely one example of how the arms 34 and 36 may be secured to bridge 32 . There are other designs which would work just as well as the pin designs. Such designs are known to those skilled in the art. Additionally, there is a space or recess at arms 34 and 36 shown clearly on arm 34 as 64 . The purpose of this space 64 is so that the user may compress arm 34 and thus press 56 and 58 together by pressing on surfaces 66 and 68 . The purpose of the compression is such that the distance between prongs 56 and 58 is decreased and thereby they may be inserted and locked into bridge 32 . The structure and method of this insertion will be described in further detail below.
FIG. 4 is a side view of the mask 14 and forehead support 10 of the present invention. The mask is shown as 14 with a dotted line showing the nose of a wearer 70 and the dotted line showing the forehead 72 of the wearer. Pad 26 is shown compressed by the forehead of the individual wearing the mask.
FIG. 5 is a top view of the forehead support 10 of the present invention taken along lines 5 of FIG. 4 . Also, the mask 14 is not shown in FIG. 5 . This figure illustrates the forehead support 10 in a position wherein the forehead support is the closest to the tube 12 (shown as merely a space in FIGS. 5 - 8 ). The bridge 32 is shown essentially in contact with tube 12 . The pins 56 , 58 , 60 and 62 are shown in their furthest position from the center of the bridge 32 . This position may be utilized by someone with a large, protruding or bulbous forehead, or a high nasal bridge, or someone who prefers the airflow tube to be snug against their forehead.
FIG. 6 shows the same forehead support in the next position, wherein the bridge 32 is moved away from tube 12 such that there is a gap 74 between bridge 32 and tube 12 . As is visible from the figure, the forehead support 10 is now moved further away from tube 12 , and is positioned differently than in FIG. 5 . This may be configured to fit someone with a less protruding forehead, or someone who wants the flexible tube further from their head than is possible in FIG. 5 .
FIGS. 7 and 8 show the third and fourth position for the forehead support of the present invention. Although the present embodiment shows a four-positioned forehead support, the number of slots, shown as 76 , 78 , 80 , 82 , 84 86 , 88 and 90 may be varied. There may be more or fewer slots, or there may just be one single slot wherein pins 56 and 58 slides transversely across bridge 32 and has locking recesses located along the slide. Additionally, the adjustments do not have to be uniform. In other words, the right side may be adjusted to slot 88 where the left side may be adjusted to slot 84 for some particular patient. There may also be more slots or adjustments on one side of the bridge as compared to the other side of the bridge. Finally, the arms may be coupled such that movement of just one arm moves the other arm in a likewise manner.
FIG. 9 shows an isolated view of bridge 32 . The slots 76 , 78 , 82 , 84 , 86 , 88 and 90 are visible from this view. The slots are configured such that prongs 56 , 58 , 60 and 62 may be inserted therein. There is a mirror set of slots on the upper portion of bridge 12 which are not visible in FIG. 9 . Again, there can be additional slots, fewer slots, or different methods of locking the arms 34 and 36 to various positions along the bridge 32 . What is important to the present invention is that the bridge 32 with the accompanying pads 24 and 26 may be positioned to a variety of distances between the tube 12 and the pads 24 and 26 . Additionally, the pad may be one continuous pad, three pads, five pads, four pads, etc. There also may a double bridge used, wherein there could be a total of two or more pads with two bridges.
FIG. 10 is a perspective view of the preferred forehead pad of the present invention. As indicated above, there could be many shapes or variations of a forehead pad and type of forehead pad or the shape of forehead pad is not limited in the present invention.
It is to be understood that while the invention has been described above in conjunction with preferred specific embodiments, the description and examples are intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims.
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An adjustable forehead support for a nasal mask. The present invention discloses an adjustable forehead support for a nasal or full-face mask wherein the forehead support may be adjusted for the different shapes and sizes of a facial profile. The forehead support utilizes a dual-arm system which adjusts the position of the forehead support vis-à-vis the mask and/or air flow tube. The angle of the mask to the face may be adjusted with the present invention.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. provisional patent application No. 60/271,891, filed Feb. 27, 2001, incorporated herein by reference, including the color figures filed therein. This application is related to commonly-assigned U.S. patent application Ser. No. 10/084,551, filed Feb. 26, 2002, and entitled “Visualizing The Mission Impact Arising From Security Incidents In A Computer Network.”
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material that 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 files or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
The present invention is directed to increasing a user's situation awareness in the field of information assurance. Specifically, the present invention is directed to increasing the ability of an information analyst, responsible for preventing security breaches, to analyze large quantities of data describing previous security events and to assess the organizational impact of potential security breaches.
BACKGROUND OF THE INVENTION
Effective cyber defense (i.e., the defense of an organization's information technology infrastructure against a variety of security breaches) is aided by the following kinds of information: i) information that permits accurate perception of the overall security state of the organization's information infrastructure; ii) comprehension of current and past security incidents and of their impact on the organization's overall mission or goals; and iii) projection of the effects on the organization's overall mission or goals of both unmitigated security incidents and of the courses of action that may be taken to counteract those incidents. Comprehension of these and other types of information provides an organization's information analyst with what may be referred to as “situational awareness.”
Situational awareness does not come easily, especially in an area of expertise as new as information assurance. Currently available security tools are good at providing data, but they do not provide an integrated picture to the user. For example, published PCT application, with international publication number WO 00/05852 and a publication date of Feb. 3, 2000, discloses software programs designed for active or passive LAN/WAN monitoring and visual displays, but does not show an integrated visual display which allows the user to see the “big picture” of the infrastructure's security state. Likewise, U.S. Pat. No. 5,361,385 discloses software for displaying images in 3-D but does not show a visual display that would be useful to an information analyst.
Since visual representations are known to be generally useful in assisting in the comprehension of information, particularly if the information is complex or voluminous, there exists a need to apply visual representational techniques to facilitate situational awareness in cyber defense.
SUMMARY OF THE INVENTION
Visual representations can be useful in helping an analyst to form a mental model of past and current security incidents and also in projecting the impact of those incidents on the ability to achieve a final objective or mission goal. In order to facilitate an analyst's situational awareness, visual displays should provide the analyst with the ability to integrate data from many sources, correlate that data and to otherwise see the overall security state of the organization's information technology infrastructure.
Analysts often find that knowledge of previous security incidents helps them to assess the nature and sophistication of a current or future threat, the timing of an attack, and the next likely steps in the attack sequence. To achieve situational awareness an information analyst must form a mental model or picture of the information such that he or she can assess new information and project its effect, if any, on the organization's information technology infrastructure. This often requires the analyst to visualize and correlate a myriad number of data points from a multitude of information sources.
According to one aspect of the invention, a method of visualizing information about the security of a network is provided. The method includes providing a 3-D visualization tool for simulating 3-D space on a two dimensional display device. The tool accesses a database which relationally associates security events with network elements, wherein each said security event is associated with at least one of a plurality of categories of security events. At least some of the categories of security events are visually depicted in a first section of simulated 3-D space, and at least some of the network elements are visually depicted in a second section of simulated 3-D space. Association lines are displayed in the 3-D simulated space between one or more displayed categories of security events and one or more displayed network elements, to thereby facilitate human perception of patterns in the security events/information.
The database preferably includes temporal information reflecting a time at which each security event occurred. In addition, the database may also store a variety of additional properties or characteristics of the network elements.
In preferred embodiments, the aforesaid first section of simulated 3-D space displays a first graph having a security event category axis and a temporal axis. Each displayed security event is visually indicated at a position on the graph corresponding to the category and time of the security event. The second section of simulated 3-D space displays a second graph having an axis pertaining to a first property of the network element and an axis pertaining to a second property of the network element. For example, one property may be information for correlating the network element with a role in, or department of, the organization. Another property may be location information for indicating the physical location of the network element. The graphical objects representing network elements are displayed on the second graph at axes positions corresponding to the first and second properties thereof. The association lines are drawn between the first graph and the second graph.
As used herein, the term “security event” refers to any vulnerability, suspicious activity or actual breach that constituted a real or potential threat to the computerized information resources of an organization. Also, as used herein, the term “mission impact”refers to an actual or perceived impact of a security event on tasks that are critical to the performance of an organization's objective or mission. Definitions of other terms used herein are provided below, in context. The term “organization” as used herein refers to an individual, collection of individuals, company, corporation or any other joint or separate effort the objective of which is the fulfillment of a mutually beneficial task.
The visual representations according to the present invention are designed in 3D space and utilize numerous visual attributes of geometric objects to carry meaning in the visualization. Some of the visual attributes according to the present invention include shape, position, motion, size, dynamic size changes that express growth or shrinking, orientation, color, transparency, texture and blinking. The invention is not limited to these visual attributes and other attributes, as known generally in the field of data visualization, can be used. These visualization attributes are used, according to the present invention, to symbolize a given aspect of the monitored computer operations and the dynamic changes thereto. For example, a cube can indicate a router and a blinking cube can indicate a router under attack. Various colors, e.g., red, yellow, green, blue, black, etc., or a combination of two or more colors, can be used to show how many times the same router previously had been under attack or to show any other visual attribute. One of the most compelling attributes of a 3-D visualization, as provided by the present invention, is its ability to render a perspective that can be viewed from a virtually unlimited number of observation points. More specifically, the objects in a 3-D representation can be viewed from the front, back, left, right, top, and bottom as well as any other position in 3-D space. In contrast, 2-D representations cannot provide a perspective view and the number of 2-D views is severely limited in comparison to 3-D.
Temporal Displays
According to one embodiment of the present invention, a temporally-oriented visualization has some or all of the following capabilities with respect to analyzing past or present security breaches:
User-selectable time gradations (such as, for example, seconds, minutes, hours, days, months) User-selectable time range (such as, for example, from May 1 through Jun. 15) User ability to annotate time grid (such as, for example, with milestones such as “June 13 —Checkpoint firewall vulnerability becomes public”) Ability to relate specific security events to time (such as, for example, showing specific times that various probes occurred) Ability to relate the characteristics of security events to time (such as, for example, showing the times at which certain types of attacks are most prevalent) Ability to relate target characteristics to time (such as, for example, showing time periods during which specific operating systems or locations were attacked) Ability to relate attack sources to time (such as, for example, showing period of time when certain attacker IP addresses are active) Ability to simultaneously relate types of security incidents, targeted resources and attack sources to specific time periods (such as, for example, depict the exact time and the order that specific workstations were probed, show both the operating system and location of the targeted workstations, and highlight any known information about the attack source) Depict frequencies of specific classes of incidents View sequence of incidents irrespective of absolute time (such as, for example, at Hanscom site #125, these events occurred in sequence from May 1-7) Depict duration of events (such as, for example, length of Denial of Service [DOS]attacks on Feb. 6-12) Simultaneously compare patterns of events over multiple user-specified time ranges (such as, for example, compare number of probes during April 1-7, May 1-7, June 1-7) Show time lapse between exposure or vulnerability and a related security event Show differences between two user-selected times (such as, for example, show differences in vulnerabilities on a specific network on Apr. 1 and June 1).
Mission Impact Displays
According to a further embodiment of the present invention, an alternative way of assessing computer security events is to view information about the impact of a potential security event on a specific goal or objective, referred to herein as a “mission impact.”
According to one aspect of the invention, a method of visualizing mission impact(s) is provided. The method includes: mapping computer system resources to one or more business functions of the organization; representing each computer system resource and each business function with a graphical object; displaying the graphical objects on a display device; and displaying relationship lines between the graphical objects in accordance with the dependencies between the computer system resources and the business functions.
In accordance with another aspect of the invention, each computer system resource and each business function is represented with a graphical object selected from one of two classes of visually distinct objects, one class for each of the computer system resources and business functions. Each class of graphical objects is displayed in a separate layer of a simulated 3-D space on a display device. In response to a user selecting one of the displayed objects, relationship lines are displayed between the selected graphical object and any other displayed object associated therewith in accordance with the mapping relationship between the computer system resources and the business functions.
In order to further refine and present visual representations of mission impacts, terminology is herein introduced to distinguish between various types of computer system resources, such as, for example, hardware devices, software applications, databases, network services and connectivity. Such resources are categorized into three major categories:
i) A “network device” as used herein refers to a hardware platform used for information technology. A device can be a workstation, printer, router, etc.
ii) A “simple resource” as used herein refers to a single application, database, service or file provided by a single device. A simple resource typically resides on one network device. However, a single network device can support one simple resource (such as, for example, hosting personnel files for the entire organization) or it can support many simple resources (such as, for example, hosting word processing applications, accounting applications, and budget data for a specific department).
iii) A “compound resource” is more complex and represents a service to an organization (such as, for example, e-mail service or web access). A compound resource requires one or more network devices and simple resources and/or other compound resources, to provide its service.
According to a preferred embodiment of the present invention, a mission impact visualization has some or all of the following capabilities:
Illustrate dependencies between types of computer system resources and mission-critical tasks; Highlight dependence of a specific mission-critical task on computer system resources (such as, for example, show all the specific resources that are required for a specific mission-critical task); Highlight resource to missions dependencies (such as, for example, show all the mission-critical tasks that depend on a single specific resource); Provide user with ability to select the level of granularity he or she wishes to see regarding the dependencies between mission-critical tasks and resources (such as, for example, collapse and expand across devices, simple resources, compound resources and mission-critical tasks); Show strength of dependencies (low, medium, high) between resources and mission-critical tasks; Show “and/or” dependencies between resources and mission-critical tasks (such as, for example, to generate a military Air Tasking Order informing military pilots of their destination(s) and itinerary, one needs the Joint mapping application for showing pilots images of their destination(s) in order to facilitate their recognition thereof, and either (1) access to the imagery database or (2) a printer and access to a secure fax machine); Show redundancies and substitutability of resources needed to support mission-critical tasks; Depict how the strength of a mission-critical task's dependence on specific resources varies based on the phase of a mission (such as, for example, the mapping application is only needed in the first phase of planning, whereas access to situation reports is needed throughout the entire planning process); Depict the sequential order in which specific resources are needed for mission-critical tasks (such as, for example, imagery files must be accessed by users before mission planning packages are put together).
The embodiments of the present invention are further discussed below. Although the present invention is directed toward visual aids for the presentation and correlation of data in the information assurance field, it will be apparent to one skilled in the art that the visual aids of the present invention can be applied to any field where the visual presentation and correlation of data will enhance the user's situational awareness.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the figures of the accompanying drawings which are meant to be exemplary and not limiting, in which like references are intended to refer to like or corresponding parts, and in which:
FIG. 1 shows the front view of a temporal display according to an embodiment of the present invention showing time that specific security events occurred and the targets of their attacks;
FIG. 2 shows the rear view of a temporal display according to an embodiment of the present invention showing times that specific attackers are active;
FIG. 3 shows the top down view of a temporal display according to an embodiment of the present invention showing how the attackers, targeted hosts and events are related in time;
FIG. 4 shows a temporal display according to an embodiment of the present invention showing frequencies of security events displayed by the time of detection and intended target;
FIG. 5 shows a mission impact display according to an embodiment of the present invention showing dependencies between missions, the mission-critical tasks that support the missions, and the cyber resources needed for the mission-critical tasks; and
FIG. 6 shows a mission impact display according to an embodiment of the present invention showing what cyber resources and mission-critical tasks will be affected by a breach of a specific device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Collection of Information
The present invention is based upon a study of how military and commercial information security analysts currently use information and known tools to achieve situational awareness and to assess mission impact of potential security events.
The embodiments of the present invention have been illustrated using the Virtual Reality Modeling Language (VRML), which easily permits the creation of displays in three dimensions; however, one can use any other suitable modeling language known in the art. VRML can be viewed using a viewer such as, for example, the Intervista WorldView, by Intervista, now owned by Computer Associates of Islandia, N.Y. Visualizations also may be rendered in the Intervista WorldView VRML viewer, or using any other tool known to one skilled in the art. An application program was developed in C++ on a Pentium platform to convert the temporal and mission impact data of a test database into the VRML visualizations presented herein.
Temporal Displays
FIG. 1 shows a sample of a temporal event scene, comprised of the following elements. The two main elements are a vertical “wall ” 2 and a horizontal host grid 4 . The vertical wall 2 displays temporal information in accordance with a time axis 6 and information about event type in accordance with an event axis 8 . The time axis 6 is horizontal, while the event type axis 8 is vertical. Preferably, the time is defined by a range and granularity, which are specified by the user. For example, some users are interested in trends in time measured in hours, others are interested in trends over months and yet others over one or more specific periods of time. Therefore, the time range can be days, months, years, time segments, etc., and the granularity can be expressed in days, hours, seconds, or any other convenient measurement for the passage of time in regular intervals. For example, a user can specify the time range of Jan. 1-10, 2000 and the granularity of 1-hour periods. FIG. 1 focuses on a particular day in 1-hour intervals. The event type axis 8 shows classes (or categories) of vulnerability, types of attacks or types of probes. FIG. 1 shows several possible categories of events, but it will be apparent to one skilled in the art to modify the example shown in FIG. 1 to accommodate other categories.
Referring to FIG. 1 , the host grid 4 provides information about the characteristics and interrelation of the computer systems (or hosts) of an organization that has been the target of security attacks or breaches. Each host's organizational role is shown by its placement relative to an organization axis 10 and each host's location in the organization is shown by its placement relative to a location axis 12 . In particular, FIG. 1 designates each location in a fictional version of Hanscom military base, as Hanscom Loc. 07 , Hanscom Loc. 24 , etc. Of course, each location also may be labeled as Floor 1 , or Red Room, or Cubicle 5 or any other designation that would be convenient given a particular layout. For example, a host 14 is shown as being in Logistics and at location Hanscom Loc. 26 . The operating system of each host is represented by various attributes, such as geometric shape, color, etc. For example, FIG. 1 shows cubes that may have different colors.
Referring to FIG. 1 , the host grid 4 preferably also shows a relationship between various hosts. Lines 15 , referred to as trusted relationship lines, show that the host(s) connected to each end of each line 15 have access to or share each other's files and databases, in effect forming a “trusted relationship” with each other. If one host in a trusted relationship is affected, its partners also may be affected. By following the trusted relationship lines 15 , an information analyst can better assess the effect that an attack on one host can have on an organization's overall information infrastructure.
It will be understood by one skilled in the art that the axes of FIG. 1 can be changed in orientation in a variety of ways while staying within the scope and spirit of the present invention. For example, the relative positions of the time and event axis on the vertical wall 2 can be swapped, as can the relative positions of the axis of host grid 4 . Furthermore, the relative positioning of the vertical wall 2 and host grid 4 can be changed such that the vertical wall 2 is horizontal, while the host grid 4 is vertical.
Referring to FIG. 1 , association lines 16 show, for all security-related events that occur at a specific time (on axis 6 ) and are of a specific event type (on axis 8 ), the specific hosts affected (on host grid 4 ). Specifically, a cluster of association lines 16 emanate from security events located at 16 b on the vertical wall 2 . As can be seen, security events at 16 b occurred between 8:00 and 9:00 PM and are of event type Network Access. A particular association line 16 a goes from location 16 b on vertical wall 2 to host 17 of host grid 4 . From host grid 4 , a user can see that host 17 is part of the Command and Control system located at Hanscom Loc. 07 . As will be discussed further with respect to FIG. 2 , the association lines 16 shown in phantom and projecting behind the vertical wall 2 are used to trace the source of the event or attack.
While FIG. 1 shows events as occurring in discrete points in time, it is also possible to use the vertical wall 2 to show duration of events. For example, this could be shown by having point 16 b on wall 2 have a horizontal extent along time axis 6 .
FIG. 2 shows the rear portion of the vertical wall 2 of FIG. 1 , as well as an attack source grid 20 . As discussed in reference to FIG. 1 , association lines 16 are used to trace an event occurring at a certain point, such as each event at 16 b, to a representation 22 of its source or sources on the attack source grid 20 .
The attack source grid 20 provides information about the characteristics of the attack sources, such as IP address, number of hops used to reach the target, and/or any other factor relevant to one skilled in the art. For example, a user can click on the geometric representations 22 of attack sources shown on the attack source grid 20 to obtain information about a particular attack source. The attack source grid 20 also can be used to show information about which specific sensors detected a given event or events, and the times that those sensors detected the event(s). The information can be displayed in any desired way or format, such as, for example, in a chart or box appearing on the screen after the user clicks on a given attack source representation 22 .
FIG. 2 shows attack sources as cubes with black and white shadings, however, the present invention encompasses any desired geometric shape, any desired color and/or the use of any other visual attributes. For example, a blinking geometric shape may be used to represent an active attack source or a given color may be used to represent an attack source that previously attacked the same target host. The characteristics and other information pertaining to the attack sources likewise can be color-coded to facilitate visualization of the situation.
FIG. 3 shows a top-down view of the embodiments shown in FIGS. 1 and 2 . The user can simultaneously view and see the association between the attack source grid 20 , the timeline 6 , and the host grid 4 via the association lines 16 . Since this top down view does not show the vertical event axis 8 , peak periods of attacker activity and the sequence of events against targeted hosts are emphasized.
FIG. 4 shows an alternative embodiment of the visualization shown in FIG. 1 . According to this embodiment, frequency distributions are shown on the vertical wall 2 . Referring to FIG. 4 , the horizontal axis of the vertical wall 2 is divided into columns of time slots. In FIG. 4 the time slots denote minutes, but the time slots can denote any other desirable time measurement specified by the user, such as, for example, days, minutes, seconds, months, years or time ranges (such as, for example, the first ten days of every month). The vertical axis 2 is divided into rows of event types 8 as has been discussed previously with respect to FIG. 1 . As a specific event type 8 is recorded in each time slot, a frequency bar 24 is formed. As the same event type 8 recurs in the same time slot, the frequency bar 24 increases in height. The user can click on the frequency bar 24 to get more information. Upon clicking on the frequency bar 24 , association lines 26 connect the frequency bar 24 to the target host or hosts that experienced the security events. Also, upon clicking on a specific target host, all association lines of that target host are shown and therefore display the various security events that this particular host has experienced at various points in time. For each of these points in time the user then can see the frequency with which the specific target host came under attack or threat of attack. This frequency information also allows the user to determine the event type or types 8 that is/are most often directed against the clicked-on target host.
As discussed in connection with FIG. 1 , preferably the host grid 4 also shows a relationship between various hosts. Trusted relationship lines 15 indicate which hosts are in a “trusted relationship” with each other, thereby allowing an information analyst to better access the effect that an attack on one host can have on an organization's overall information infrastructure. The visualization shown in FIG. 4 can aid a user to make a number of data correlations, such as, for example, determining which target host is most susceptible to a particular event type during a particular time. For example, it may be determined that certain operating systems are most susceptible to a Services Access event during the early hours of the morning.
Mission Impact Displays
In order to implement the mission impact display visualizations, it is necessary first to collect and store information about the interdependencies between several levels of representations of both computer (or host) system resources and organizational mission objectives. For example, a five level representation hierarchy may be used, with each level being defined (from bottom to top level) as follows: i) network devices of computer system resources (as defined above); ii) simple resources of computer system resources (as defined above); iii) compound resources of computer system resources (as defined above); iv) mission-critical tasks and v) missions (or goals). Missions (or goals) are the overall objectives that an organization is working towards accomplishing through utilization of its information technology infrastructure. Mission-critical tasks are sub-missions (or sub-goals) that are a necessary part of an organization's accomplishment of particular missions.
FIG. 5 shows an embodiment of 3-D mission impact visualization. FIG. 5 shows the five layers discussed: network devices 52 (referred to in FIG. 5 as “network devices”), simple resources 56 , 58 , 60 , compound resources 64 , 68 , mission critical tasks 70 and missions 72 . Each layer is preferably represented in a different color for clarity of perception. It will be apparent to one skilled in the art that all of the geometric and other visual attributes shown in FIG. 5 to represent various interdependencies, network devices, etc., are used by way of example only and can be substituted by any other visual attributes.
Referring to FIG. 5 , the network devices 52 are represented as darkly shaded cubes and occupy a single layer. As shown in FIG. 5 , each device 52 is labeled with its name. Optionally, the mission display visualization may have drill down capabilities to allow a user to click on a network device 52 and obtain additional information about it, such as, for example, its IP address, administrator, or any other network device information desired by the user. The additional information can be displayed in any desired way or format, such as, for example, in a chart or box appearing on the screen after the user clicks on a given network device 52 .
A simple resources layer is logically located one level above the network devices layer and comprises simple resources supported by network devices 52 . As discussed above, a single network device 52 can support one simple resource or a plurality of simple resources. Referring to FIG. 5 , three different geometrical object shapes are used to represent three types of simple resources: a light shaded cube 56 represents an application program, a cylinder 58 represents a data store and a sphere 60 represents peripheral devices that are not directly network-addressable (i.e. peripheral devices that do not have their own IP address).
A compound resources layer is logically located one level above the simple resources layer and comprises resources that are more complex and represent a service to an organization, such as, for example, an e-mail service or web access. Compound resources combine one or more network devices 52 and simple resources 56 , 58 , 60 and even other compound resources 64 , 68 , to provide their service. Referring to FIG. 5 , compound resources are arranged in one or more rings above the level of the simple resources layer.
Referring to FIG. 5 , compound resources are represented as either a diamond shape 64 or a cone shape 68 . A diamond shape 64 indicates the resource is an AND type which requires all of the compound and/or simple resources upon which it is dependent. For example, FIG. 5 shows that one of the diamond-shaped compound resources 64 a, labeled “Network,” has an AND relationship with two simple resources 56 , as shown by association lines 74 a. This means that for compound resource 64 a to function properly, both of the simple resources with which it has an AND relationship must be fully operational. In addition, of course, for compound resource 64 a to function properly it also requires its third AND dependency, compound resource 68 .
Referring to FIG. 5 , a cone shape 68 indicates the resource is an OR type which requires only one of the compound and/or simple resources upon which it is dependent. For example, the cone-shaped compound resource 68 in FIG. 5 has an OR relationship with two simple resources below it. This means that one of those two simple resources can be substituted for another, i.e., only one of the two has to be fully operational for the compound resource 68 to function properly.
A compound resource can have either an AND or an OR relationship with other compound resources or with simple resources. For example, one compound resource, such as, for example, an e-mail system can have an OR relationship with another compound resource, such as, for example, another e-mail system, as well as with two simple resources, such as, for example, a printer and a fax machine. To carry this example further, in the event that one e-mail system experiences a security breach which renders it unreliable, the user can either switch over to using the other e-mail system or the user can choose to print out his/her messages and fax them to the recipient.
When a compound resource depends on simple resources, the simple resources preferably appear in the layer below that compound resource. The simple resources are placed below the compound resource because the simple resources may have relationships with many compound resources; the hierarchical layer structure makes it easier to clearly depict these multiple relationships.
A mission critical tasks layer is located above the compound resources layer and comprises objects each of which represents specific tasks that must be achieved by the organization, such as, for example, Air Tasking Order generation, production of mission situation reports, shipping of supplies, or any other tasks to be achieved by an organization as part of achieving its missions. Referring to FIG. 5 , the mission critical tasks 70 are represented by lightly shaded spheres.
A missions layer is the top-most layer and comprises objects that represent the major goals or missions that an organization is striving to achieve. Each mission requires multiple mission-critical tasks to be accomplished for the mission to be achieved, utilizing each of the lower layers. Referring to FIG. 5 , the missions 72 are represented by darkly shaded spheres.
Referring to FIG. 5 , the association lines 74 that connect objects in each layer represent dependencies. Specifically, the association lines represent how objects at the higher layers depend upon the successful functioning of objects at lower layers. A user of FIG. 5 to assess mission impact may utilize the following procedure. First the user assumes that one or more objects are not functioning successfully (presumably due to a security threat) and then via the association lines determines which other objects are affected by that lack of functionality. For example, a user may click on a selected network device to see the association lines 74 between the selected network device and the associated resource(s), sub-mission(s) and mission(s). The user may see the entire display shown in FIG. 5 , with the association lines highlighted or, alternatively, see a limited display, showing only the resource(s), sub-mission(s) and mission(s) associated with the selected network device. The user may select any network device, resource, sub-mission or mission in order to see the association lines emanating from the selection both up and down the five layers shown in FIG. 5 .
The association lines 74 can vary in thickness or color, such that stronger dependencies can be shown using thicker association lines 74 and/or brighter colors, while weaker dependencies can be shown using thinner association lines 74 and/or lighter colors. Many other variations in dependency representations will be apparent to one skilled in the art.
FIG. 5 shows an embodiment where a user selected to see all the dependencies within and between the hardware devices, simple resources, compound resources, mission critical tasks and missions layers. Alternatively, a user can select to view only one or several layers at a time.
FIG. 6 shows an embodiment of the present invention which combines the mission impact display with a host grid 76 , the host grid 76 being similar to the host grid 4 shown in the temporal display embodiments discussed above. The lower portion of the display shows a host grid 76 , which displays the network devices 52 that are on a given network (hence the referral to such hardware devices as also being “network devices”). Note that in FIG. 1 , such network devices 52 of FIG. 6 were discussed as being only host computer systems (such as hosts 14 and 17 ). The upper portion of the display shows resources (simple or compound), mission-critical tasks and missions that require those devices. In order to see which resources, tasks and missions are associated with a given network device 52 , a user clicks on the network device of interest. Referring to the embodiment shown in FIG. 6 , the user had clicked on a specific device 52 on the network that may have sustained an attack or that is believed to be under threat of an attack. As can be seen, the user then sees the following layers supported by device 52 : simple resource 56 ; compound resources 64 , 68 ; mission-critical tasks 70 ; and missions 72 . The display allows the user to see the interconnections between the layers and the potential impact on the organization's missions that may result if the selected network device 52 is compromised. The display also allows the user to see any available redundancies as seen through, for example, differences in object shape and/or color. For example, network devices 52 that offer redundant support for simple resources 56 can be shown in a different color and/or shape than other simple resources; alternatively, the association lines between redundant and supported elements can be draw in a distinguishing color, width, etc.
With regard to complete physical realization of the present invention, it can be implemented on known computer systems using any one of a variety of known software engineering techniques.
It will be understood that the specification and figures are illustrative of the present invention and that other embodiments within the spirit and scope of the invention will suggest themselves to those skilled in the art.
All references cited herein are incorporated by reference.
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A method of visualizing the impact of security flaws or breaches in a network. A 3-D visualization tool that simulates 3-D space on a monitor interfaces with a security database which relationally associates security events with the network elements affected thereby. The security events are visually depicted in a first section of simulated 3-D space and the network elements are depicted in a second section of simulated 3-D space. Relationship lines are drawn between displayed categories of security events and the displayed network elements in order to aid an analyst to visualize the impact of security breaches on the organization. Various other properties of the network elements may also be displayed such as the role of the network device within the organization, and the business functions of the organization.
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BACKGROUND OF INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to video content detection, and more particularly, to a highlight detecting circuit and related method for video highlight detection utilizing an audio signal to determine a highlight segment within a video signal.
[0003] 2. Description of the Prior Art
[0004] Consider a video program containing large segments of content that are uninteresting to a viewer but the same video program also contains individual events interspersed within that contact that the viewer finds very interesting. Extracting the interesting events while discarding the boring and uninteresting content allows the viewer to less thoroughly watch the video program. The viewer can spend more time viewing only the video segments that are considered exciting. For example, during a baseball game, most of the time the audience is waiting. It takes some time for a next hitter to walk up to the plate after a previous hitter is called out. It takes some time for a pitcher to exchange signals with a catcher before they reach a consensus on what kind of ball is going to be delivered. It also takes some time for a change of inning when both teams switch the roles as offense and defense sides. Exciting events, such as home runs, scoring, and double plays exist sparsely in long baseball games. For baseball fans or regular viewers, it is difficult for them to always have plenty of time to be sitting in front of a TV and watching the whole game thoroughly. Baseball highlight detection could help extract those exciting moments and skip those waiting times.
[0005] Some prior art methods have been proposed to deal with these kinds of highlight detection problems. These methods utilize a probabilistic framework to deal with this problem and need training data to estimate the parameters of probability models. In this way, the computational complexity is very high, and the execution speed is slow, resulting in difficulty in implementing the prior art method on an embedded system.
SUMMARY OF THE INVENTION
[0006] It is therefore one of the objectives of the claimed invention to provide an apparatus and related method for video highlight detection utilizing an audio signal to determine a highlight segment to solve the above-mentioned problem.
[0007] According to an exemplary embodiment of the present invention, a highlight detecting circuit for detecting a highlight segment within a video signal is disclosed. The highlight detecting circuit includes a pitch-tracking module for estimating a plurality of pitch values for an audio signal; a pitch difference detecting module coupled to the pitch-tracking module for computing a plurality of pitch difference values according to the pitch values; and a highlight detecting module coupled to the pitch difference detecting module for determining a starting point and a stopping point of the highlight segment according to the pitch difference values.
[0008] According to an exemplary embodiment of the present invention, a method for detecting a highlight segment within a video signal is disclosed. The method includes estimating a plurality of pitch values for an audio signal; computing a plurality of pitch difference values according to the pitch values; and determining a starting point and a stopping point of the highlight segment according to the pitch difference values.
[0009] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 is a block diagram of a highlight detecting circuit according to an embodiment of the present invention.
[0011] FIG. 2 is a diagram illustrating the operation of a pitch smoother shown in FIG. 1 .
DETAILED DESCRIPTION
[0012] Please refer to FIG. 1 . FIG. 1 is a block diagram of a highlight detecting circuit 100 according to an embodiment of the present invention. As shown in FIG. 1 , the highlight detecting circuit 100 comprises a sampling circuit 110 , a pitch-tracking module 120 , a pitch smoother 130 , a pitch difference detecting module 140 , a modulator 150 , a highlight detecting module 160 , and a highlight fine-tuning module 170 . The sampling circuit 110 down-samples an audio signal with an appropriate sampling rate, for example, 8000 Hz, and outputs a down-sampled audio signal to the pitch-tracking module 120 for generating a plurality of pitch values. The audio signal in this embodiment is an audio part of a baseball game broadcasted via a digital TV (DTV) signal. A video signal in this embodiment represents an image part of the baseball game broadcasted via the DTV signal. The pitch values outputted from the pitch-tracking module 120 are utilized to represent a commentator's voice during the baseball game. The commentator's voice is the basis for the following signal processing to detect a highlight segment within the video signal.
[0013] The pitch values are then fed into the pitch smoother 130 . The pitch smoother 130 reduces the affect of sudden noise generated from the crowd and outputs a plurality of resulting pitch values to the pitch difference detecting module 140 and the modulator 150 . The pitch difference detecting module 140 computes a plurality of pitch difference values according to the resulting pitch values and then outputs these pitch difference values to the modulator 150 . The modulator 150 receives the pitch difference values and the resulting pitch values and modulates them by multiplication to output a plurality of modulated pitch difference values. The highlight detecting module 160 then determines a starting point and a stopping point of a highlight segment within the video signal coarsely according to the modulated pitch difference values. Finally, the highlight fine-tuning module 170 advances the starting point to generate an updated starting point and delays the stopping point to generate an updated stopping point according to the shot detection performed on the video signal.
[0014] The operation of the pitch-tracking module 120 is detailed as follows. Given the sampling rate of 8000 Hz, for each frame of 1024 samples (128 ms) with a sliding size of 400 samples (50 ms), prior art Fourier Transform is applied to each frame to generate a frequency-domain signal. Next, the prior art Harmonic Product Spectrum (HPS) algorithm is utilized to estimate the above-mentioned pitch values. Thus, the pitch-tracking module 120 generates 20 pitch values per second. One ordinary person skilled in the art will be familiar with the operation of the Fourier Transform and the HPS algorithm and further description is omitted here for brevity. The outputted pitch values are the estimated commentator's voice (hereinafter, the commentator's voice is also called real pitch). However, a harmonic having a frequency twice that of the real pitch is sometimes erroneously taken as the real pitch by the HPS algorithm. The pitch-tracking module 120 will check if there is a pitch value located at half frequency of an estimated real pitch with a magnitude comparable to, for example, 50%, of a magnitude of the estimated real pitch. If true, the pitch-tracking module 120 replaces the estimated real pitch with the half pitch. In addition, an output value of the pitch-tracking module 120 will be set to zero if the output value is too small. Please note, that utilizing the HPS algorithm is only one example of a pitch tracking method. Any other operation capable of tracking a pitch, such as an autocorrelation operation, can be utilized.
[0015] Please refer to FIG. 2 . FIG. 2 is a diagram illustrating operation of the pitch smoother 130 shown in FIG. 1 . The pitch values received in this stage include a large amount of noise from the crowd. Besides, the commentator voice is filled with many silence periods between every two words. These silence periods do not have any pitch. Therefore, the pitch smoother 130 first determines whether a plurality of pitch values in a specific window, for example, a 1-sec window, is larger than a first threshold value, for example, 10 Hz, or not macroscopically. In this embodiment, if the percentage of the pitch values larger than the first threshold value within the specific window is greater than a second threshold value, for example, 50%, the pitch smoother 130 outputs an averaged pitch value by averaging these pitch values above the first threshold value; otherwise, the pitch smoother 130 sets a predetermined value (e.g., zero) to the averaged pitch value directly. Then, this 1-sec window slides forward a sample and the pitch smoother 130 repeats the procedure detailed above.
[0016] In order to exaggerate a dramatic pitch change of the pitch values, the pitch difference detecting module 140 first determines a specific pitch difference value corresponding to a specific averaged pitch value by summing a plurality of averaged pitch values, for example, 100 averaged pitch values (corresponds to a 5-sec window), prior to the specific averaged pitch value to generate a first sum value, summing a plurality of averaged pitch values, for example, 100 averaged pitch values (corresponds to a 5-sec window), following the specific averaged pitch value to generate a second sum value, and setting the specific pitch difference value to a result obtained by subtracting the first sum value from the second sum value. The pitch difference value is then fed into the modulator 150 . The modulator 150 then generates a modulated pitch difference value by multiplying a specific pitch difference value corresponding to a specific averaged pitch value by the specific averaged pitch value. Until now, a contour of a plurality of dramatic pitch changes of the commentator's voice is tracked and is represented as a plurality of peaks and valleys in the modulated pitch difference values.
[0017] The highlight detecting module 160 determines peaks from the modulated pitch difference values. Each peak represents a starting point of a highlight segment having a large pitch change. In this embodiment, if an exciting event happens, a commentator will change the voice style to express emotion, resulting in a higher pitch as well as a denser pitch without silence. Both will contribute to the modulated pitch difference values. The highlight detecting module 160 first picks a peak from the modulated pitch difference values as a starting point SP′ of a highlight segment. During a period of time (say, 5-20 seconds) after the peak, the highlight detecting module 160 picks a valley on the modulated pitch difference values as a stopping point PP′ of the highlight segment. Please note that selecting a peak or a valley as a starting point of a highlight segment is subjected to how the pitch difference values are defined. As mentioned above, a pitch difference value is defined as a difference of subtracting a first sum value from a second sum value and therefore, a peak should be selected as a starting point and a valley should be selected as a stopping point. On the contrary, if a pitch difference value is defined as a difference of subtracting a second sum value from a first sum value, a valley should be selected as a starting point and a peak should be selected as a stopping point.
[0018] The highlight segment detected by the starting point SP′ and the stopping point PP′ is coarsely determined by the highlight detecting module 160 . However, the highlight segment is not a complete event because the coarsely determined starting point SP′ might lag behind the actual starting time of the wanted event. Further, the highlight segment might not end smoothly due to the coarsely determined stopping point PP′. Therefore, the highlight fine-tuning module 170 fine-tunes the starting point SP′ and the stopping point PP′ by performing a well known shot detection operation to the video signal according to the starting point SP′ and the stopping point PP′ determined by the highlight detecting module 160 . The shot detection is used during a period of time (say, 3-20 seconds) before the starting point SP′ of the highlight segment. A time having a largest shot change in this period will be a new starting point SP for the highlight segment. Similarly, the shot detection is also utilized during a period of time (say, 1-10 seconds) after the stopping point PP′ of the highlight segment. A time having a largest shot change in this period will be a new stopping point PP for the highlight segment. Thus, a fine-tuned highlight segment is determined. Please note, that utilizing the shot detection in the highlight fine-tuning module 170 is only one example of this embodiment. Any other operation or algorithm capable of fine-tuning the starting point SP′ and the stopping point PP′ can be utilized. Besides, since the present invention extracts highlight segments of a video program, it is especially suitable for a video program having at least one commentator to commentate the content but it should not be limited to these kinds of programs only. Then, according to the starting point SP and the stopping point PP generated by the highlight detecting circuit 100 , a successive circuit can extract the highlight segment from the video signal to acquire only the image part of the DTV signal. On the other hand, the successive circuit can also extract the highlight segment from both the video signal and the audio signal to acquire the image part as well as the audio part of the DTV signal according to the starting point SP and the stopping point PP generated by the highlight detecting circuit 100 .
[0019] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
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A highlight detecting circuit for detecting a highlight segment within a video signal includes a pitch-tracking module for estimating a plurality of pitch values for an audio signal; a pitch difference detecting module coupled to the pitch-tracking module for computing a plurality of pitch difference values according to the pitch values; and a highlight detecting module coupled to the pitch difference detecting module for determining a starting point and a stopping point of the highlight segment according to the pitch difference values.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 12/950,140 filed on Nov. 19, 2010, the contents of which are incorporated herein by reference in its entirety, and which claims the benefit of U.S. Provisional Application Ser. No. 61/262,938 filed on Nov. 20, 2009, the contents of which are incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a catalyst system for preparing carboxylic acids and/or carboxylic anhydrides, which system comprises a plurality of superposed catalyst layers arranged in a reaction tube, where vanadium antimonate is introduced into the active catalyst material in at least one of the catalyst layers. The present invention further relates to a process for gas-phase oxidation, in which a gaseous stream comprising at least one hydrocarbon and molecular oxygen is passed through a plurality of catalyst layers and the maximum hot spot temperature is below 425° C.
BACKGROUND OF THE INVENTION
[0003] Many carboxylic acids and/or carboxylic anhydrides are prepared industrially by catalytic gas-phase oxidation of hydrocarbons such as benzene, xylenes, naphthalene, toluene or durene in fixed-bed reactors. It is in this way possible to obtain, for example, benzoic acid, maleic anhydride, phthalic anhydride, isophthalic acid, terephthalic acid or pyromellitic anhydride. In general, a mixture of an oxygen-comprising gas and the starting material to be oxidized is passed through tubes in which a bed of a catalyst is present. To regulate the temperature, the tubes are surrounded by a heat transfer medium, for example a salt melt.
[0004] The catalysts used in the process of the invention are generally coated catalysts in which the catalytically active material has been applied in the form of a shell to an inert support. The shell thickness of the catalytically active material is generally from 0.02 to 0.25 mm, preferably from 0.05 to 0.15 mm. The proportion of active composition in the catalyst is usually from 5 to 25% by weight, mostly from 7 to 15% by weight. In general, the catalysts have a shell of active material having an essentially homogeneous chemical composition. Furthermore, two or more different shells of active material can also be applied in succession to a support. This is then referred to as a two-shell or multishell catalyst (see, for example, DE 19839001 A1).
[0005] As inert support material, it is possible to use virtually all support materials of the prior art which are advantageously employed in the production of coated catalysts for the oxidation of aromatic hydrocarbons to aldehydes, carboxylic acids and/or carboxylic anhydrides, as described, for example, in WO 2004/103561. Preference is given to using steatite in the form of spheres having a diameter of from 3 to 6 mm or of rings having an external diameter of from 5 to 9 mm, a length of from 4 to 7 mm and an internal diameter of from 3 to 7 mm.
[0006] Titanium dioxide is usually used in the anatase form for the catalytically active composition. The titanium dioxide preferably has a BET surface area of from 15 to 60 m 2 /g, in particular from 15 to 45 m 2 /g, particularly preferably from 13 to 28 m 2 /g. The titanium dioxide used can comprise a single titanium dioxide or a mixture of titanium dioxides. In the latter case, the value of the BET surface area is the weight average of the contributions of the individual titanium dioxides. The titanium dioxide used advantageously comprises, for example, a mixture of a TiO 2 having a BET surface area of from 5 to 15 m 2 /g and a TiO 2 having a BET surface area of from 15 to 50 m 2 /g.
[0007] A suitable vanadium source is, in particular, vanadium pentoxide or ammonium metavanadate. Suitable antimony sources are various antimony oxides. Possible phosphorus sources are, in particular, phosphoric acid, phosphorous acid, hypophosphorous acid, ammonium phosphate or phosphoric esters and especially ammonium dihydrogenphosphate. Possible sources of cesium are the oxide or hydroxide or the salts which can be thermally converted into the oxide, for example carboxylates, in particular the acetate, malonate or oxalate, carbonate, hydrogencarbonate, sulfate or nitrate.
[0008] Apart from the optional additions of cesium and phosphorus, small amounts of many other oxidic compounds which act as promoters to influence the activity and selectivity of the catalyst, for example by decreasing or increasing its activity, can be comprised in the catalytically active composition. As promoters, mention may be made by way of example of the alkali metals, in particular the abovementioned cesium and also lithium, potassium and rubidium, which are usually used in the form of their oxides or hydroxides, thallium(I) oxide, aluminum oxide, zirconium oxide, iron oxide, nickel oxide, cobalt oxide, manganese oxide, tin oxide, silver oxide, copper oxide, chromium oxide, molybdenum oxide, tungsten oxide, iridium oxide, tantalum oxide, niobium oxide, arsenic oxide, antimony tetroxide, antimony pentoxide and cerium oxide.
[0009] Among the promoters mentioned, preferred additives are the oxides of niobium and tungsten in amounts of from 0.01 to 0.50% by weight, based on the catalytically active composition.
[0010] The application of the individual shells of the coated catalyst can be carried out by any methods known per se, e.g. by spraying of solutions or suspensions onto the support in a coating drum or coating with a solution or suspension in a fluidized bed, as described, for example, in WO 2005/030388, DE 4006935 A1, DE 19824532 A1, EP 0966324 B1. Organic binders, preferably copolymers, advantageously in the form of an aqueous dispersion, of acrylic acid-maleic acid, vinyl acetate-vinyl laurate, vinyl acetate-acrylate, styrene-acrylate and vinyl acetate-ethylene, are generally added to the suspensions used. The binders are commercially available as aqueous dispersions having a solids content of, for example, from 35 to 65% by weight. The amount of such binder dispersions used is generally from 2 to 45% by weight, preferably from 5 to 35% by weight, particularly preferably from 7 to 20% by weight, based on the weight of the suspension.
[0011] The support is fluidized in, for example, a fluidized-bed or moving-bed apparatus in an ascending gas stream, in particular air. The apparatuses usually comprise a conical or spherical vessel into which the fluidizing gas is introduced from below or from the top via an immersed tube. The suspension is sprayed via nozzles from the top, from the side or from below into the fluidized bed. The use of a riser tube arranged centrally within or concentrically around the immersed tube is advantageous. A higher gas velocity which transports the support particles upward prevails within the riser tube. In the outer ring, the gas velocity is only a little above the loosening velocity. In this way, the particles are moved circularly and vertically. A suitable fluidized-bed apparatus is described, for example, in DE-A 4006935.
[0012] When coating the catalyst support with the catalytically active composition, coating temperatures of from 20 to 500° C. are generally employed, with coating being able to be carried out under atmospheric pressure or under reduced pressure. In general, coating is carried out at from 0° C. to 200° C., preferably from 20 to 150° C., in particular from 60 to 120° C.
[0013] As a result of the thermal treatment of the resulting precatalyst at temperatures of from >200 to 500° C., the binder is driven off from the applied layer by thermal decomposition and/or combustion. The thermal treatment is preferably carried out in situ in the gas-phase oxidation reactor.
[0014] The Japanese published specification No. 180430/82 discloses two-layer catalysts comprising titanium dioxide and vanadium antimonate as catalytically active components for the oxidation of o-xylene to phthalic anhydride. However, the possible o-xylene loadings and the space velocities are limited in the case of these catalysts.
[0015] The hot spot temperatures in, for example, the oxidation of o-xylene to phthalic anhydride (PA) at loadings in the range from 80 to 100 g of o-xylene/standard m 3 are usually above 440° C. High hot spot temperatures reflect an excessive increase in the total oxidation of o-xylene to CO, CO 2 and water and are associated with increased damage to the catalyst. The lowest possible hot spot temperatures are therefore desirable.
BRIEF SUMMARY OF THE INVENTION
[0016] It was an object of the present invention to provide an improved catalyst for preparing carboxylic acids and/or carboxylic anhydrides, in particular an improved catalyst for the partial oxidation of o-xylene to PA for o-xylene loadings of at least 80 g/standard m 3 .
[0017] The object is achieved by a multilayer catalyst for preparing carboxylic acids and/or carboxylic anhydrides which has at least 3 layers and in the production of which a vanadium antimonate is added to at least one catalyst layer. The hot spot temperature of such a catalyst is overall significantly lower than in the case of a comparable catalyst which was produced without addition of vanadium antimonate, and the carboxylic acid or carboxylic anhydride yields are significantly higher.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The vanadium antimonate introduced into at least one layer in the active material can be prepared by reaction of any vanadium and antimony compounds. Direct reaction of the oxides to give a mixed oxide or vanadium antimonate is preferred. The vanadium antimonate can have various molar ratios of V/Sb and can also, if appropriate, comprise further vanadium or antimony compounds and can be used in admixture with further vanadium or antimony compounds. The preparation of the vanadium antimonate can, for example, involve reaction of the oxides in aqueous solution or the use of hydrogen peroxide. In the latter case, for example, vanadium pentoxide can be dissolved in an aqueous hydrogen peroxide solution and subsequently reacted with antimony trioxide to form vanadium antimonate.
[0019] In a preferred embodiment, the catalysts of the invention comprise three, four or five layers and can, for example to avoid high hot spot temperatures, also be used in combination with suitable upstream and/or downstream beds or together with intermediate layers, with the upstream and/or downstream beds and the intermediate layers generally being able to comprise catalytically inactive or less active material.
[0020] The invention further provides a process for producing a multilayer catalyst for preparing carboxylic acids and/or carboxylic anhydrides which has at least 3 layers, wherein a vanadium antimonate is added to at least one catalyst layer.
[0021] The invention further provides a process for the gas-phase oxidation of hydrocarbons over a multilayer catalyst which has at least 3 layers and in the production of which a vanadium antimonate is added to at least one catalyst layer. The process of the invention is preferred for the gas-phase oxidation of aromatic C6-C10-hydrocarbons such as benzene, xylenes, toluene, naphthalene or durene (1,2,4,5-tetramethyl-benzene) to carboxylic acids and/or carboxylic anhydrides such as maleic anhydride, phthalic anhydride, benzoic acid and/or pyromellitic dianhydride. The process is particularly suitable for the preparation of phthalic anhydride from o-xylene and/or naphthalene. Gas-phase reactions for preparing phthalic anhydride are generally known and are described, for example, in WO 2004/103561.
[0022] In a preferred embodiment of the process of the invention, the hot spot temperature is not above 425° C. in any of the catalyst layers.
[0023] The invention further provides for the use of a multilayer catalyst which has at least 3 layers and in the production of which a vanadium antimonate is added to at least one catalyst layer for preparing carboxylic acids and/or carboxylic anhydrides.
EXAMPLES
Example 1
According to the Invention
Catalyst Layer 1 (CL1) (Vanadium Antimonate as V and Sb Source):
Preparation of the Vanadium Antimonate:
[0024] 6 l of demineralized water were placed in a thermostated double-walled glass vessel. 2855.1 g of vanadium pentoxide and 1827.5 g of antimony trioxide were suspended therein. Further rinsing-in with a further liter of demineralized water was subsequently carried out, the suspension was heated to 100° C. while stirring and after 100° C. had been reached was stirred at this temperature for 16 hours. The suspension was subsequently cooled to 80° C. and dried by spray drying. The inlet temperature was 340° C., and the outlet temperature was 110° C. The spray-dried power obtained in this way had a vanadium content of 32% by weight and an antimony content of 30% by weight. The vanadium antimonate prepared in this way had a vanadium oxidation state of 4.24 and a BET surface area of 95 m 2 /g.
Preparation of the Suspension and Coating:
[0025] 4.44 g of cesium carbonate, 413.7 g of titanium dioxide (Fuji TA 100CT type, anatase, BET surface area: 27 m 2 /g), 222.1 g of titanium dioxide (Fuji TA 100 type, anatase, BET surface area: 7 m 2 /g) and 91.6 g of vanadium antimonate were suspended in 1869 g of demineralized water and stirred for 18 hours to achieve a homogeneous distribution. 78.4 g of organic binders comprising a copolymer of vinyl acetate and vinyl laurate were added in the form of a 50 wt.-% aqueous dispersion to this suspension. In a fluidized-bed apparatus, 768 g of this suspension were sprayed onto 2 kg of steatite (magnesium silicate) in the form of rings having dimensions of 7 mm×7 mm×4 mm and dried.
[0026] After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite ring was 8.4%. The analyzed contents of the active material were 7.1% of V 2 O 5 , 4.5% of Sb2O 3 , 0.50% of Cs, balance TiO 2 .
[0027] In contrast to CL1, vanadium pentoxide and antimony trioxide were used instead of vanadium antimonate as V and Sb source for making up the suspension in the production of CL2, CL3, CL4 and CL5.
[0028] Catalyst layer 2 (CL2) (vanadium pentoxide and antimony trioxide as V and Sb source): Production analogous to CL1 with variation of the composition of the suspension. After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 9.1%. The analyzed contents of the active material were 7.1% of V 2 O 5 , 1.8% of Sb 2 O 3 , 0.38% of Cs, balance TiO 2 having an average BET surface area of 16 m 2 /g.
[0029] Catalyst layer 3 (CL3) (vanadium pentoxide and antimony trioxide as V and Sb source): Production analogous to CL1 with variation of the composition of the suspension. After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 8.5%. The analyzed contents of the active material were 7.95% of V2O 5 , 2.7% of Sb 2 O 3 , 0.31% of Cs, balance TiO 2 having an average BET surface area of 18 m 2 /g.
[0030] Catalyst layer 4 (CL4) (vanadium pentoxide and antimony trioxide as V and Sb source): Production analogous to CL1 with variation of the composition of the suspension. After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 8.5%. The analyzed contents of the active material were 7.1% of V 2 O 5 , 2.4% of Sb 2 O 3 , 0.10% of Cs, balance TiO 2 having an average BET surface area of 17 m 2 /g.
Catalyst Layer 5 (CL5):
[0031] Production analogous to CL1 with variation of the composition of the suspension. After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 9.1%. The analyzed contents of the active material were 20% of V 2 O 5 , 0.38% of P, balance TiO 2 having an average BET surface area of 23 m 2 /g.
[0000] Oxidation of o-xylene to phthalic anhydride:
[0032] The catalytic oxidation of o-xylene to phthalic anhydride was carried out in a tube reactor which was cooled by means of a salt bath and had an internal diameter of the tubes of 25 mm. From the reactor inlet to the reactor outlet, 80 cm of CL1, 60 cm of CL2, 70 cm of CL3, 50 cm of CL4 and 60 cm of CL5 were introduced into a 3.5 m long iron tube having an internal diameter of 25 mm. The iron tube was surrounded by a salt melt to regulate the temperature, and a thermocouple tube having an external diameter of 4 mm and an installed withdrawable thermocouple served for measuring the catalyst temperature.
[0033] 4.0 standard m 3 /h of air having loadings of 99.2 wt.-% o-xylene of from 30 to 100 g/standard m 3 were passed through the tube from the top downward. At 80 g of o-xylene/standard m 3 , the results summarized in table 1 were obtained (“PA yield” is the amount of phthalic anhydride obtained in percent by weight, based on 100% pure o-xylene).
Example 2
Not According to the Invention
[0034] From the reactor inlet to the reactor outlet, 130 cm of CL2, 70 cm of CL3, 60 cm of CL4, 60 cm of CL5 were introduced into a 3.5 m long iron tube having an internal diameter of 25 mm. In contrast to Example 1, vanadium antimonate was not added to any of the catalyst layers.
[0000]
TABLE 1
Example 1
Example 2 (not
(according to
according to
Pilot tube results
the invention)
the invention)
Amount of air [standard m 3 /h]
4.0
4.0
Loading [g/standard m 3 ]
80
80
Period of operation [days]
29
37
Salt bath temperature [° C.]
349
359
Hot spot temperature [° C.]
421
450
PA yield [% by weight]
114.7
113.5
[0035] In both examples, the content of xylene and phthalide in the reactor outlet gas was below 0.10 or below 0.15% by weight. The PA yield in Example 1 is significantly higher than that in Example 2, and the hot spot temperature in Example 1 is significantly lower than in Example 2.
Example 3
According to the Invention
[0036] Catalyst layer 6 (CL6) (vanadium pentoxide and antimony trioxide as V and Sb source): Production analogous to CL1 with variation of the composition of the suspension. After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 8.5%. The analyzed contents of the active material were 11.0% of V2O 5 , 2.4% of Sb 2 O 3 , 0.22% of Cs, balance TiO 2 having an average BET surface area of 21 m 2 /g.
[0000] Oxidation of o-xylene to Phthalic Anhydride:
[0037] From the reactor inlet to the reactor outlet, 80 cm of CL1, 60 cm of CL2, 70 cm of CL3, 50 cm of CL6 and 60 cm of CL5 were installed. 4.0 standard m 3 /h of air having loadings of 99.2 wt.-% o-xylene of from 30 to 100 g/standard m 3 were passed through the tube from the top downward. At 80 and 100 g of o-xylene/standard m 3 , the results summarized in table 2 were obtained (“PA yield” is the amount of phthalic anhydride obtained in percent by weight, based on 100% pure o-xylene).
[0000]
TABLE 2
Example 3
Example 3
(according to
(according to
Pilot tube results
the invention)
the invention)
Amount of air [standard m 3 /h]
4.0
4.0
Loading [g/standard m 3 ]
80
100
Period of operation [days]
61
138
Salt bath temperature [° C.]
350.5
347.0
Hot spot temperature [° C.]
406
414
PA yield [% by weight]
114.6
114.6
Example 4
According to the Invention
[0038] Catalyst layer 7 (CL7) (Vanadium Antimonate as V and Sb Source):
[0039] The vanadium antimonate was prepared by a method analogous to example 1 with variation of the V/Sb ratio. The spray-dried powder obtained in this way had a vanadium content of 28.5% by weight and an antimony content of 36% by weight.
Preparation of the Suspension and Coating:
[0040] See example 1 with variation of the composition of the suspension using the vanadium antimonate from example 4.
[0041] After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 8.3%. The analyzed contents of the active material were 7.1% of V 2 O 5 , 6.0% of Sb 2 O 3 , 0.50% of Cs, balance TiO 2 having an average BET surface area of 20 m 2 /g.
[0000] Oxidation of o-xylene to Phthalic Anhydride:
[0042] From the reactor inlet to the reactor outlet, 80 cm of CL7, 60 cm of CL2, 70 cm of CL3, 50 cm of CL6 and 60 cm of CL5 were installed. 4.0 standard m 3 /h of air having loadings of 99.2 wt.-% o-xylene of from 30 to 100 g/standard m 3 were passed through the tube from the top downward. This gave the results summarized in table 3 (“PA yield” is the amount of phthalic anhydride obtained in percent by weight, based on 100% pure o-xylene).
Example 5
According to the Invention
[0043] Catalyst layer 8 (CL8) (vanadium antimonate as V and Sb source): The vanadium antimonate was prepared by a method analogous to example 1 with variation of the V/Sb ratio. The spray-dried powder obtained in this way had a vanadium content of 35% by weight and an antimony content of 25.5% by weight.
Preparation of the Suspension and Coating:
[0044] See example 1 with variation of the composition of the suspension using the vanadium antimonate from example 5.
[0045] After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 8.3%. The analyzed contents of the active material were 7.1% of V 2 O 5 , 3.5% of Sb 2 O 3 , 0.55% of Cs, balance TiO 2 having an average BET surface area of 20 m 2 /g.
[0000] Oxidation of o-xylene to Phthalic Anhydride:
[0046] From the reactor inlet to the reactor outlet, 80 cm of CL8, 60 cm of CL2, 70 cm of CL3, 50 cm of CL6 and 60 cm of CL5 were installed. 4.0 standard m 3 /h of air having loadings of 99.2 wt.-% o-xylene of from 30 to 100 g/standard m 3 were passed through the tube from the top downward. This gave the results summarized in table 3 (“PA yield” is the amount of phthalic anhydride obtained in percent by weight, based on 100% pure o-xylene).
[0000]
TABLE 3
Example 4
Example 5
(according to
(according to
Pilot tube results
the invention)
the invention)
Amount of air [standard m 3 /h]
4.0
4.0
Loading [g/standard m 3 ]
100
100
Period of operation [days]
27
78
Salt bath temperature [° C.]
352.5
344.0
Hot spot temperature [° C.]
407
423
PA yield [% by weight]
113.9
114.1
Example 6
Not According to the Invention
[0047] Catalyst layer 9 (CL9) (vanadium pentoxide and antimony trioxide as V and Sb source): Production analogous to CL1 with variation of the composition of the suspension. After calcination of the catalyst at 450° C. for one hour, the amount of active material applied to the steatite rings was 8.5%. The analyzed contents of the active material were 7.1% of V 2 O 5 , 6.0% of Sb 2 O 3 , 0.38% of Cs, balance TiO 2 having an average BET surface area of 20 m 2 /g.
[0000] Oxidation of o-xylene to Phthalic Anhydride:
[0048] From the reactor inlet to the reactor outet, 80 cm of CL9, 60 cm of CL2, 60 cm of CL3, 60 cm of CL6 and 60 cm of CL5 were installed. 4.0 standard m 3 /h of air having loadings of 99.2 wt.-% o-xylene of from 30 to 100 g/standard m 3 were passed through the tube from the top downward. This gave the results summarized in table 4 (“PA yield” is the amount of phthalic anhydride obtained in percent by weight, based on 100% pure o-xylene).
[0000]
TABLE 4
Example 6 (not
according to
Pilot tube results
the invention)
Amount of air [standard m 3 /h]
4.0
Loading [g/standard m 3 ]
75
Period of operation [days]
29
Salt bath temperature [° C.]
361
Hot spot temperature [° C.]
448
PA yield [% by weight]
112.4
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The present invention relates to a catalyst system for preparing carboxylic acids and/or carboxylic anhydrides, which system comprises a plurality of superposed catalyst layers arranged in a reaction tube, where vanadium antimonate is introduced into the active material in at least one of the catalyst layers. The present invention further relates to a process for gas-phase oxidation, in which a gaseous stream comprising at least one hydrocarbon and molecular oxygen is passed through a plurality of catalyst layers and the maximum hot spot temperature is below 425° C.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 60/269,872, which was filed with the U.S. Patent and Trademark Office on Feb. 16, 2001.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the isolation of a nucleic acid sequences that encode an enzyme that catalyzes the transfer of electrons to protons for the production of molecular hydrogen, and more particularly to iron hydrogenase and genes encoding for the iron hydrogenase in microscopic organisms known as unicellular green algae.
2. Prior Art
Molecular hydrogen is currently being considered as a candidate for replacing or supplementing fossil fuels and as a source of clean energy. A potential method for producing hydrogen on a commercial scale is the photobiological production of hydrogen by eukaryotic organisms. Green algae respond to anaerobic stress by switching the oxidative pathway to a fermentative metabolism. The fermentation of organic compounds and residual photosynthetic electron trasport in the green algae are associated with hydrogen evolution. The key enzyme hydrogenase, which is synthesized only after an anaerobic adaptation, catalyzes the reversible reduction of protons to molecular hydrogen. This method is capable of generating renewable hydrogen fuel from light and water, which are among nature's most plentiful resources.
The ability of green algae, such as Chlamydomonas reinhardtii , to produce hydrogen from water has been recognized for over 55 years. This reaction is catalyzed by a reversible hydrogenase, an enzyme that is induced in the cells after exposure to a short period of anaerobiosis. However, the activity of the hydrogenase is rapidly lost when cells are illuminated because of the immediate inactivation of the reversible hydrogenase by photosynthetically generated O 2 .
Methods have been devised to circumvent the hydrogenase inactivation problem. U.S. Pat. No. 4,532,210 discloses the biological production of hydrogen in an algal culture using an alternating light and dark cycle. The process comprises alternating a step for cultivating the alga in water under aerobic conditions in the presence of light to accumulate photosynthetic products (starch) in the alga, and a step for cultivating the alga in water under microaerobic conditions in the dark to decompose the accumulated material by photosynthesis to evolve hydrogen. This method uses a nitrogen gas purge technique to remove oxygen from the culture.
U.S. Pat. No. 4,442,211 discloses that the efficiency of a process for producing hydrogen, by subjecting algae in an aqueous phase to light irradiation, is increased by culturing algae which has been bleached during a first period of irradiation in a culture medium in an aerobic atmosphere until it has regained color and then subjecting this algae to a second period of irradiation wherein hydrogen is produced at an enhanced rate. A reaction cell is used wherein light irradiates the culture in an environment which is substantially free of CO 2 and atmospheric O 2 . This environment is maintained by passing an inert gas (e.g. helium) through the cell to remove all hydrogen and oxygen generated by the splitting of water molecules in the aqueous medium. Although continuous purging of H 2 -producing cultures with inert gases has allowed for the sustained production of H 2 , such purging is expensive and impractical for large-scale mass cultures of algae. In view of the foregoing, there remains a need for a microorganism that produces a hydrogenase enzyme suitable for use in a sustainable process of photosynthetic hydrogen production.
SUMMARY
Accordingly, it is an object of the present invention to provide a gene encoding for hydrogenase and a method for using the gene product for the microbial production of molecular hydrogen. Specifically, the invention provides isolated nucleic acid sequences encoding a stable hydrogenase enzyme (HydA) that will catalyze the reduction of protons to form molecular hydrogen.
Another object of the present invention is to provide isolated nucleic acid sequences encoding a protein that catalyzes the reduction of protons to form molecular hydrogen comprising SEQ. ID. NO. 1. SEQ. ID. NO. 1 comprises a nucleic acid sequence that encodes Scenedesmus obliquus HydA.
It is yet a further object of the present invention to provide isolated nucleic acid sequences encoding a protein that catalyzes the reduction of protons to form molecular hydrogen comprising SEQ. ID. NO. 2. SEQ. ID. NO. 2 comprises a nucleic acid sequence that encodes Chlamydomonas reinhardtii HydA.
A further object of the present invention is to provide fragments of the nucleic acid sequence comprising SEQ. ID. NO.1 or SEQ. ID. NO.2, encoding iron hydrogenase, that code for products that maintain the biological activity necessary to catalyze the transfer of electrons to protons in a process for producing molecular hydrogen. Such fragments can be either recombinant or synthetic or a combination thereof.
The features of the invention believed to be novel are set forth with particularity in the appended claims. However the invention itself, both as to organization and method of operation, together with further objects and advantages thereof may be best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of S. obliquus HydA genomic and cDNA structures.
FIG. 2 is a comparison of the S. obliquus - derived iron hydrogenase amino acid sequence with HydA sequences derived from other organisms.
FIG. 3 is a schematic diagram showing the conserved cysteine residues and other important amino acids of the H cluster
FIG. 4 (A) is a schematic view of the structure of S. obliquus HydA.
FIG. 4 (B) is a schematic view of the S. obliquus electron donor ferredoxin.
FIG. 5 (A) is a schematic map of the cDNA and the genomic DNA region of HydA from C. reinhardtii .showing the structural features of the HydA cDNA. Coding regions are marked as large arrows with the transit peptide shown in black.lines indicate 5′ and 3′ URTs.
FIG. 5 (B) is a schematic map of the cDNA and the genomic DNA region of HydA from C.reinhardtii .showing the structural features of the HydA cDNA. In FIG. 3 (B), the mosaic structure of hydA is illustrated by gray (exons) and white (introns) boxes. The RNA and DNA probes that were used for the blotting experiments are noted on the Figure.
FIG. 6 shown the nucleotide sequence of the hydA cDNA and the deduced amino acid sequence of the hydrogenase from C. reinhardtii.
FIG. 7 is a schematic diagram showing the light-dependent photoevolution of hydrogen in green algae.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The isolation, purification and biochemical and genetic characterization of a novel iron hydrogenase from S. obliquus and C. reinhardtii and C. fuscus is disclosed.
I. Scenedesmus obliquus
S. obliquus Algal Strains and Growth Conditions
Wild-type S. obliquus Kützing 276-6 was obtained originally from the culture collection of algae at the University of Göttingen Cells were cultured photoheterotrophically in batch cultures at 25° C. under continuous irradiance of 150 μmol photons per square meter per second. For anaerobic adaptation, 4-liter cultures were bubbled with air supplemented with 5% CO 2 . After harvesting the cells in the mid-exponential exponential stage of growth, the pellet was resuspended in fresh Tris acetate phosphate (TAP) medium. The algae were anaerobically adapted by flushing the culture with argon in the dark.
Hydrogen Evolution Assay
The in vitro hydrogenase activity was measured by using a Hewlett Packard (HP 5890, Series II) gas chromatograph, equipped with a thermal conductivity detector and a molecular sieve column. Methyl viologen reduced by sodium dithionite was used as an electron donor. 1 unit is defined as the amount of hydrogenase evolving 1 mmol of molecular hydrogen (H 2 ) per minute at 25° C.
The in vivo activity in the presence of different inhibitors of the photosynthetic electron flow was determined as described by Happe et al., in: European Journal of Biochemistry, 214, 475-481 (1993). After anaerobic adaptation, algal cells were harvested, diluted in fresh Tris acetate phosphate medium, and transferred to sealed tubes. Inhibitors were added 1 hour before H 2 evolving activity was measured. Cells were broken by sonification. Thylakoid membranes and photosynthetic transport chain remained intact as demonstrated by oxygen polarography. Ferrodoxin of both C. reinhardtii and S. obliquus was isolated according to the method of Schmitter et al. ( Eur. J.l of Biochem., 172, pages 405-412 (1988)).
Rapid Amplification of cDNA Ends-Polymerase Chain Reaction (RACE-PCR)
RACE-PCR was performed with the Clontech SMART™RACE cDNA Amplification Kit (Clontech Laboratories, Palo Alto, Calif.) according to the manufacturer's recommendations, except for modification of the PCR and hybridization conditions. Starting material consisted of 1 μg of mRNA from anaerobically adapted cells. The reverse transcription reaction was carried out with a Moloney murine leukemia virus reverse transcriptase in two separate reaction tubes containing either the 5′ or the 3′ RACE-PCR specific primer from the kit. The cDNA of each sample served as template for the following PCR. For the 5′-RACE-PCR, a Universal Primer Mix (UPM) and the antisense primer, Sc7, were used. The amplification of the 3′-cDNA end was performed with a UPM and the sense primer Sc6. To obtain more distinct PCR signals, the PCR was repeated for both reactions with nested universal primers and designed primers (inverse Sc6 and inverse Sc7, respectively) using a dilution of the products of the first PCR as template.
Primer Extension
RACE-PCR was also implemented to map the transcription initiation site of the hydA mRNA. A gene-specific primer (Sc17) was used to carry out the first strand cDNA synthesis with the Superscript II reverse transcriptase (Life Technologies, Rockville, Md., USA) and 200 ng of mRNA as template. PCR was performed using either Sc12 or Sc27 and the SMART™ specific adapter primer UPM. Two different DNA fragments of 234 bp and 183 bp were amplified under standard PCR conditions. Both fragments were cloned into the pGEM™T-Easy vector (Promega, Madison, Wis., USA) and sequenced using primers from the polylinker of the vector.
Genome Walking with Genomic DNA
Applying the Clontech Walker Kit (Clontech Laboratories), genomic libraries from S. obliquus were generated by digestion with different blunt-end cutting endonucleases (NaeI DraI, PvuIIm, HincII and EcORV) and by adapter ligation at the ends of the resulting DNA fragments. These libraries were utilized as independent templates in five different PCR reactions. Two gene-specific primers (Sc27, Sc35) derived from the hydA cDNA sequence of S. Obliquus were used in combination with a kit adapter primer (AP1) in a first PCR reaction. Subsequently, 1 μl of the first PCR served as a template in a secondary PCR, applying two nested gene-specific primers (i-Sc10, Sc32) along with a nested kit adapter primer (AP2). The resulting products were cloned into pGEM™T-Easy and sequenced. Sequencing was performed by the dideoxy termination method (see, for example: Sanger et al., Proc. Natl. Acad. Sci ., U.S,A., 74, 5463-5467 (1977)).
Purification of the Fe-Hydrogenase
40-liter cultures of Scenedesmus obliquus were grown heterotrophically. After centrifugation (10 min, 5000×g) the pellet we re-suspended in 200 ml TAP medium. The cells were anaerobically adapted by flushing the solution with argon for 1 hour in the dark. All further purification steps were performed in an anaerobic chamber (Coylab, Ann Arbor, Mich., USA). The cells were disrupted in a 50 mM Tris/HCl, buffer pH 8.0, 10 mM sodium dithionite by vortexing 3 min with glass beads. The further purification steps were made as described hereinbelow for the isolation of the Fe-hydrogenase of Chlamydomonas reinhardti . Automated Edman degradation of the N-terminal site of the protein was performed with an Applied Biosystem model 477A sequencer with online analysator model 120 A.
RNA Blot Hybridization
Total RNA of S. Obliquus was isolated according to the method described by Johanningmeier et al. ( J. Biol. Chem. 259, 13541-13549 (1984)). Equal amounts (20 μg) were separated electrophoretically on 1.2% agarose gels containing formaldehyde. The RNA was transferred onto nylon membranes (Hybond + , Amersham) and hybridized with RNA probes labeled DIG-dUPT using in vitro transcription methodology. A 1.3 kb EcOR1 cDNA fragment was used to detect transcripts with a hydA gene, while a DIG-dUPT-labeled cDNA encoding constitutively expressed plastocyanin, was used as a control. Hybridization reactions were carried out using protocols supplied by the manufacturer (Roche Diagnostics, Mannheim, Germany).
Sequence Analysis Software
Nucleic acid and protein sequences were analyzed with the programs Sci Ed Central (Scientific Educational Software) and ClustalW. The Blast server of the National Center for Biotechnology Information (Bethesda, Md.) was used for database searches.
Recombinant Expression in E. coli
The hydA open reading frame was amplified by PCR using the primer pair Sc29 and Ac30 containing flanking NdeI-BamHI sites. The PCR product was cloned into the pGEM™T-Easy vector. After digestion with NdeI-BamHI, the hydA gene was cloned into the corresponding site of the pET9a expression vector (Promega), producing pLF29.2. The insert of pLF29.2 was sequenced confirming that the fragment contained the exact full coding region of the hydrogenase without transit peptide. E. coli strain BL21(DE3)pLysS was transformed with pLF29.2. Expression was induced with 1 mM isopropyl-thio-β-D-galactoside at an OD 600 of 0.3. Pelleted cells were re-suspended in lysis buffer (100 mM Tris/HCl; 4 mM EDTA; 16% Glycine; 2% SDS; 2% Mercaptoethanol; 0.05% Bromophenolblue; 8 M Urea). After heating, the protein extract was separated by 10% SDS-PAGE and blotted onto a PVDF membrane. Western blot analyses were performed using antisera against the Fe-hydrogenase of Chlamydomonas reinhardtii at 1:1000 dilution.
Results for Scenedesmus obliquus
Induction of Hydrogenase Activity and Purification of the Fe-hydrogenase Protein
Anaerobic adaptation is the most efficient way to induce hydrogenase activity in Scenedesmus obliquus . Bubbling the alga culture in the dark with argon led to a dramatic increase (10-fold) of hydrogenase activity during the first 2 hours. The enzyme of S. obliquus was purified to homogeneity by successive column chromatography. Since the enzyme is irreversibly inactivated by very low levels of oxygen, all purification steps were performed under strictly anaerobic conditions and in the presence of reducing agents (dithionite). The purification scheme resulted in a 5200-fold purification of HydA with 5% recovery (data not shown). The most powerful step for purifying the protein was a Q-Sepharose high performance column chromatography with pH gradient elution. Gel infiltration chromatography of hydrogenase on a calibrated Superdex-75 column resulted in a single activity peak corresponding to a molecular mass of 45 kDa. The monomeric structure of the enzyme could also be shown on a SDS polyacrylamide gel after Coomassie-blue staining (data not shown). The N-terminal sequence of HydA was determined by Edman degradation. The protein sequence (AGPTAECDRPPAPAPKAXHWQ) is, except for two amino acids, identical to the amino acid sequence deduced from the DNA data (AGPTAECDCPPAPAPKAPHWQ). In the course of the purification procedure there was no indication of a second hydrogenase in S. obliquus because the hydrogenase activity was never separated into distinct fractions. Biochemical data show a high similarity of HydA to the Fe-hydrogenase from C. reinhardtii (Table 1). The enzymes have a high temperature optimum of about 60° C., are strongly inhibited by O 2 and CO, and catalyze the H 2 -evolution with a typical high specific activity. Experiments with inhibitors of translators on ribosomes (data not shown) and analysis of the gene structure show that HydA from S. obliquus is translated in the cytoplasm and transported to the chloroplast.
TABLE I Biochemical data comparison of purified iron hydrogenases from C. reinhardtii and S. obliquus C. Reinhardtii S. obliquus Size 49 kDa 44.5 kDa Specific activity 935 U/mg protein 700 U/mg protein Temperature optimum 60° C. 60° C. pH optimum 6.9 7.3 Localization chloroplast stroma chloroplast Coding site nuclear nuclear pI value 5.3 5.17 K M value (MV) 830 μM 800 μM K M value (ferredoxin) 35 μM Not determined
Ferredoxin is the Natural Electron Donor of the Fe-Hydrogenase
Hydrogenase activity was determined in intact and broken cells after anaerobic adaptation. The integrity of the photosynthetic electron transport in the sonified cell preparation was demonstrated by the rate of oxygen evolution (154 μmole O 2 /mg Chl×h). This rate corresponds to 85% of the oxygen evolution measure with intact Scenedesmus cells.
In S. obliquus , the hydrogen evolution is linked to the photosynthetic electron transport chain through PSI. As shown in Table II, the cells were still able to photoproduce hydrogen when electron flow on the PSII was blocked by DCMU. In contrast, addition of DCMIB resulted in inhibition of the H 2 -production, thus giving evidence of the involvement of PSI in the supply of electrons to hydrogenase. With reference to Table II, after anaerobic adaptation, cells were harvested, diluted in fresh, TAP medium, and incubated with inhibitors as described herein. α-PetF-antibody was raised against spinach ferredoxin. In Table II, DCMU=3-(3,4-dichlorophenyl)-1,1-dimethylurea; DBMIB=2,5-dibromo-3-methyl-6 isopropyl-p-benzochinone; Sulfo-DSPD=sulfodisalicylidinepropanediamin; DCPIP=2,6-dichlorophenolindophenol. The electron transport from PSI to ferredoxin was inhibited using the artificial electron acceptor DCPIP. In this reaction, DCPIP is reduced instead of ferredoxin and electron transfer to hydrogenase is interrupted.
TABLE II
Effects of different photosynthetic inhibitors on hydrogenase activity
Hydrogenase activity
Units/mg chlorophyll
Intact cells (control)
0.11
+ DCMU (10 −5 M)
0.10
+ DBMIB (10 −5 M)
0.005
Broken cells
0.1
+ DCMU (10 −5 M)
0.11
+ DBMIB (10 −5 M)
0.006
+ DCPIP (10 −4 M)
0.003
+ sulfo-DSPD (10 −4 M)
0.003
+ α-PetF-antibody (1:1000)
0.008
Hydrogenase activity was dramatically reduced (up to 30-fold) by the ferredoxin antagonist sulfo-DSPD (Table II). Similar results were achieved with α-PetF-antibodies that specifically recognize the ferredoxin protein. In both cases, the hydrogenase enzyme cannot evolve hydrogen, thus demonstrating the role of ferredoxin as the obligatory donor for the hydrogenase reaction.
The electron transfer properties of different plant-type ferredoxins were measured in vitro with dithionite as a reducing reagent. The ferredoxin proteins of spinach, C. reinhardtii and S. obliquus were comparable regarding their capability to reduce purified S. obliquus hydrogenase. In this assay, H 2 -evolving activities of 420, 390 and 350 U/mg protein with S. obliquus, C. reinhardtii and spinach ferredoxin, respectively, were observed. No hydrogen production could be measured with other possible electron donors like cytochrome and NADPH. In D. desulfuricans , the Fe-hydrogenase has been reported to catalyze both hydrogen production and uptake with low potential multiheme cytochromes such as cytochrome c 3 .
Molecular Characterization of hdyA Encoding a Fe-Hydrogenase
In order to isolate the gene encoding a Fe-hydrogenase in S. obliquus , polyA + RNA was isolated from cell cultures after one hour of anaerobic adaptation. Isolated RNA was transcribed and amplified by RT-PCR using oligonucleotides derived from conserved regions within the C. reinhardtii HydA gene (Happe, unpublished results). The complete cDNA clone of 2609 bp was obtained by 5′- and 3′-RACE PCR. It contains an open reading frame of 1344 bp encoding a polypetide of 448 amino acids ( FIG. 1 ) followed by an extensive 3′ UTR of about 1100 bp. The coding region of S. obliquus hydA exhibits features common to other green algae such as high GC content (64.2%) and a characteristic putative polyadenylation signal, TGTAA, 15 bp: upstream of the polyA + sequence.
In order to examine the exon-intron structure and the promoter region of the hydA gene, about 5 kb of the genomic DNA from S. obliquus were sequenced. The gene comprises 5 introns with a total size of 1310 bp ( FIG. 1 ) whose 5′- and 3′-end contain typical plant splice donor and acceptor sites that follow the GT/AG rule. In FIG. 1 , which is a schematic representation of S. obliquus hydA genomic and cDNA structures, the coding region of the hydA cDNA is illustrated as a large arrow with the transit peptide shown in black. The untranslated 59 and 39 sequences are marked as lines. The arrows below indicate the sequencing strategy; each arrow represents an independent sequence determination. TSP, transcription start point; ATG, start codon. The mosaic structure of hydA is indicated by gray (exons) and white (introns) boxes. The S2 probe and different restriction enzymes that were used in the Southern blot experiments are indicated on the figure.
A genomic southern blot was probed with a 750 bp PCR fragment to determine the copy number of the hydA gene. Single bands were observed in lanes with samples digested with HincII, EcORV and NdeI and a double band in the lane containing genomic DNA digested with SacI. The band migration positions matched the sizes predicted from the sequence of the hydA gene, indicating that HydA is encoded by a single copy gene. The same hybridization pattern was observed even under low stringency conditions (hybridization temperature 50° C.; data not shown). The transcription start position was determined by primer extension using RACE-PCR and was found 139 bp upstream of the ATG start codon. Several primers within 100 bp of the 5′-end of the known hydA cDNA were designed to confirm the accuracy of the transcription initiation site. All of the sequenced PCR clones had the same 5′-ends at position +1. As described for other green algae genes, a highly conserved TATA box element upstream of the transcription start point is absent (see, for example: C. D. Siflow in: The Molecular Biology of Chloroplasts and Mitochondria in Chlamydomonas , pp 25-40, (J. D. Goldschmidt-Clermont et al., eds.) Kluwer Academic Publishers, Dorecht, The Netherlands (1998)). However, the TACATAT motive at position −25 in a GC rich region shows similarities to other TATA motives in C. reinhardtii and therefore might be involved in gene expression.
HydA is a Novel Type of Fe-Hydrogenase
The polypeptide derived from the cDNA sequence has a length of 448 amino acids and a predicted molecular mass of 48.5 kDa (44.5 kDa excluding the transit peptide); consequently HydA is the smallest hydrogenase protein known so far. The N-terminus of HydA is basic and contains numerous hydroxylated amino acids and a Val-X-Ala motive at position 35, a characteristic feature of chloroplast transit peptides. The processed HydA protein is compared with four bacterial and two eukaryotic Fe-hydrogenases as shown in FIG. 2 . FIG. 2 is a comparison of the S. obliquus -derived iron hydrogenase amino acid sequence with HydA sequences derived from other organisms. In FIG. 2 , the protein alignment was done by using the Vector NTI program (InforMax). White letters with black background indicate amino acids identical to the HydA protein. Black letters with gray background indicate conserved changes of the amino acids. S. o., S. obliquus (this work); M. e., Megasphaera elsdenii ; D. d., D. desulricans ; T. v., Trichomonas vaginalis ; C. p., C. pasteurianum ; T. m., T. maritima ; N. o., N. ovalis.
The homology in the carboxy-terminal region of all proteins is quite striking. For example, the S. obliquus HydA protein shows 44% identity and 57% similarity to the C. pasteurianum Fe-hydrogenase. The H-cluster in S. obliquus might be coordinated by four cysteine residues at positions 120, 175, 335, and 340. Other strictly conserved amino acid structures such as FTSCCPGW (334-350), TGGVMEAALR (474-483) and MACPGGCXXGGGQP (586-589) probably define a pocket surrounding the active center as shown by the structural data of C. pasteurianum and D. desulfuricans . On the other hand, the N-terminal region is completely different from all other Fe-hydrogenases. The protein sequences of the other enzymes comprise at least two [4Fe-4S] ferredoxin-like domains (called “f-cluster”) which are necessary for the electron transport from the electron donor to the catalytic center. The Fe-hydrogenases of C. pasteurianum, Thermotoga maritima and Nyctotherus ovalis contain an extra [4fe-4S] cluster and one [2Fe-2S] center. This N-terminal domain with the F-cluster or other [Fe-S] centers is completely lacking in HydA of S. obliquus . This indicates that there is a direct electron transport pathway from the exogenous donor to the H-cluster.
To verify that the isolated cDNA encodes a Fe-hydrogenase, the hydA clone was expressed in the heterologous system E. coli . One band of recombinant HydA was observed on SDS-PAGE at approximately 44 kDa, in agreement with the molecular mass of the polypetide predicted from the cDNA sequence. Antibodies raised against the HydA protein of the C. reinhardtii , which cross-react with other Fe-hydrogenases but not with NiFe-hydrogenases (data not shown), were applied in Western blot analysis. One distinct signal with the over-expressed HydA protein of S. obliquus was obtained. The lysate of induced E. coli cells exhibited no hydrogenase activity. This result corresponds to observations by Voordouw et al. ( Eur. J. Biochem., 162, 31-36 (1987)) and Stokkermans et al. ( FEMS Microbiol. Lett., 49, 217-222 (1989)) who also detected no H 2 -production of recombinant Fe-hydrogenases in E. coli cells. The reason for that might be that the bacterial cells do not have the ability to assemble the special H-cluster of the Fe-hydrogenases.
Rapid Induction of hydA mRNA During Anaerobic Adaptation
The regulation of the hydA gene expression was examined by Northern blot analysis and reverse transcription-PCR (RT-PCR). Aerobically grown cells of S. obliquus did not show a hydrogenase activity. Total RNA and mRNA were isolated from cells which were induced by argon bubbling for 0, 1 and 4 hours. Northern blot analysis and RT-PCR demonstrated that the hydA gene is expressed after anaerobic adaptation. There is a very weak signal without adaptation (t=0), but strong signals of the transcript could be detected after anaerobic induction. The full length of the hydA cDNA clone was confirmed by the transcript signal (2.6 kb) on the Northern blot.
Discussion
In green algae, the occurrence of a hydrogen metabolism induced by anaerobic conditions is well established. Despite the great interest in hydrogen evolution for practical applications (“biophotolysis”), the hydrogenase genes from green algae have heretofore not been isolated. The hydA gene and the HydA protein of Scenedemus obliquus presented herein belong to the class of Fe-hydrogenases.
Fe-hydrogenases have been isolated only from certain anaerobic bacteria and some anaerobic eukaryotes as well as from the anaerobically adapted green alga C. reinhardtii (T. Happe et al., Eur. J. Biochem. 214, 475-481 (1993)). The enzymes are found to exist in monomeric, dimeric and multimeric forms; however, in eukaryotes, only monomeric proteins have been isolated.
The HydA protein of S. obliquus is synthesized in the cytoplasm. The first 35 residues M 1 to A 35 ) of the amino acid sequence derived from the cDNA sequence are supposed to function as a short transit peptide which routes the nuclear encoded protein to the chloroplast. Several positively charged amino acids which describe a typical feature for algal transit peptides are found in HydA. The three terminal residues of the signal sequence, Val-X-Ala, constitute the consensus for stromal peptidases.
The hydrogenase of S. obliquus represents a novel type of Fe-hydrogenase. The monomeric enzyme of 448 amino acids and a calculated molecular mass of 44.5 kDA for the processed protein is the smallest Fe-hydrogenase isolate so far. The protein sequence consists of an unusual N-terminal domain and a large carboxyterminal domain containing the catalytic site. The structurally important C-terminus of the S. obliquus HydA sequence is very similar to that of other Fe-hydrogenases. Four cysteine residues at positions C 120 , C 175 , C 336 and C 340 coordinate the special [6Fe] cluster (H-cluster) of the active site. A number of addition residues define the environment of the catalytic center. Peters et al. postulated twelve amino acids in C. pasteurianum to form a hydrophobic pocket around the cofactor (Science, 282, 1853-1858 (1998)). Ten residues are strictly conserved while two amino acids vary within the Fe-hydrogenase family (S 232 , I 268 , in C. pasteurianum , A 119 , T 155 in T. vaginalis and A 44 , T 80 in S. obliquus ). A small insertion of 16 amino acids is noted in S. obliquus but this addition occurs in an external loop of the protein and probably has no special function.
Until now, all Fe-hydrogenases possess a ferredoxin-like domain in the N-terminus coordinating two [4Fe4S] clusters (FS4A, FS4B, as shown in FIG. 3 . FIG. 3 is a schematic diagram showing the conserved cysteine residues and other important amino acids of the H cluster. In FIG. 3 , the protein is illustrated as a large gray arrow. Small arrows indicate parallelograms which demonstrate conserved amino acids in the protein. Cysteines participating at the coordination of the [Fe-S] clusters are gray, whereas identical amino acids are black. An insertion of 16 amino acids in the S. obliquus protein is illustrated as a spotted bar. FS4 indicates the [4Fe-4S] cluster; and FS2 indicates the [2Fe-2S] cluster.
The iron sulfur cluster facilitates the transfer of electrons between external electron donors or acceptors and the H-cluster. The N-terminus of the S. obliquus protein is strongly reduced compared to other Fe-hydrogenases and no conserved cysteines are found. Therefore it is postulated that all accessory Fe-S clusters (FS2, FS4A, FS4B, FS4C) are missing. No indication of a second subunit has been observed during purification of the protein.
In contrast to earlier observations in S. obliquus , the present inventor could neither detect the postulated two subunits of a potential NiFe-hydrogenase, nor could he find a Ni-dependency related to the hydrogenase activity. Francis reported about two forms of hydrogenases in S. obliquus ( Photosynthetica, 23, 43-48 (1989)), but although the present inventor used the same alga strain and identical adaptation conditions, a second hydrogenase activity was not detected during the purification steps.
Physiological studies by others have shown that the hydrogen evolution is coupled to the light reaction of the photosynthesis. In contrast to earlier observations in S. obliquus , the measurment of PSII independent H 2 -production was not influenced by DCMU. The electrons required for H 2 -evolution come from redox equivalents of the fermentative metabolism and are supplied into the photosynthetic electron transport chain via the plastochinone pool.
For the first time, it is demonstrated that the ferredoxin PetF functions as the in vivo electron donor of the Fe-hydrogenase from S. obliquus . Hydrogenase activity can be specifically blocked by addition of the ferredoxin antagonist sulfo-DSPD (A. Trebst, J Methods Enzymol., 69, 675-715 (1980)) and antibodies raised against the PetF protein. In vitro, a hydrogen evolution by HydA was only measured with plant-type [2Fw-2S] ferredoxins like PetF of S. obliquus, C. reinhardtii and spinach as electron mediators. Bacterial Fe-hydrogenases are known to be reduced by [4Fe4S] ferredoxins and do not accept electrons from plant-type proteins (J. M. Moulis et al., Biochemistry, 34, 16781-16788 (1995)).
The analysis of the 3D-structure of the Fe-hydrogenase from C. pasteurianum (CpI) gave evidence that the interaction with external electron donors might occur at the accessory [Fe-S] clusters in the N-terminal domain (J. W. Peters, Curr. Opin. Struct. Biol., 9, 670-676 (1999)). Based on the X-ray structure of CpI (N. Guex et al., Trends Biochem. Sci., 24, 364-367 (1999), the Fe-hydrogenase of S. obliquus was modeled. FIG. 4 is a Schematic view of the structures of S. obliquus HydA (A), and the electron donor ferredoxin (B). The figure shows the α carbons and the side chains of charged residues that might be important for the electron transfer reaction or the interaction between HydA and the ferredoxin from S. vacuolatus . The 16-amino acid insertion of the hydrogenase appears as external loop and is distinguished as a dotted line. The amino acid sequence of the mature HydA protein (His 19-Tyr 404) was submitted to the SWISS-MODEL server. The present inventor generated a model of HydA with the known three-dimensional structure of the iron hydrogenase from C. pasteurianum as template, sharing 57% sequence identity with the submitted sequence. The Protein Data Bank file was visualized by the Swiss-PDB viewer !(J. M. Moulis, Biochemistry, 34, 16781-16788 (1995)). As shown in FIG. 4 , a region of positive surface potential is observed within HydA based on a local concentration of basic residues. In contrast to the docking position of ferredoxin in CpI, these charged amino acids in the S. obliquus Fe-hydrogenase are located within the C-terminal domain, forming a niche for electron donor fixation.
The known alga ferredoxin proteins exhibit high degrees of sequence identity (over 85%) and the charged amino acids are strictly conserved. The petF sequence of S. obliquus is unknown, but very recently the X-ray model of the ferredoxin from another Scenedesmus species ( Scenedesmus vacuolatus ) was published (M. T. Bes et al., Structure, 7, 1201-1213 (1999)). The structure revealed negatively charged amino acids like aspartate and glutamate near the [2Fe-2S] cluster. The [Fe-S] center and the H-cluster of the hydrogenase probably come into close proximity through electrostatic interactions. This geometry is consistent with efficient electron transfer among these prosthetic groups.
As already shown in various studies, a correlation exists between the duration of time of the anaerobic adaptation and increase of hydrogen production. RT-PCR and Northern blot analyses with mRNA of aerobic and anaerobically adapted cells from S. obliquus showed an increased level of hydA transcript after one hour of induction. Correspondingly, hydrogen evolution was only measured after a short time anaerobic adaptation. These results suggest that the expression of the hydA gene is regulated at the transcriptional level. The small amount of transcript that was detected at t=0 may be due to transcript analysis induced by micro-anaerobic conditions during the RNA isolation procedure. Alternatively, a low level of hydA transcript might be constitutively present in the cell and is only drastically increased after anaerobic adaptation.
The foregoing discloses a monomeric enzyme, iron hydrogenase (HydA), having a molecular mass of 44.5 kDa. (exclusive of the transit peptide associated therewith) derived from Scenedesmus obliquus . The polypeptide derived from the cDNA sequence, set forth herein as SEQ. ID. NO. 4, has a length of 448 amino acids and is the smallest hydrogenase described to date. The nucleic acid sequence coding HydA in Scenedesmus obliquus is set forth in SEQ. ID. NO. 1 appended hereto, and the cDNA sequence is set forth as SEQ. ID. NO. 7.
In addition to the unicellular green algae Scenedesmus obliquus , discussed above, other algae within the order of Chlorophyta (e.g. Chlamydomonas reinhardtii and Chlorella fusca ) contain a gene (hydA) coding for a novel iron-hydrogenase enzyme (HydA) as will be discussed below. This gene, through its encoded enzyme, catalyzes the synthesis of molecular hydrogen from protons and high potential energy electrons, and releases significant amounts of hydrogen gas, which is a valuable and clean source of energy. As with Scenedesmus obliquus , the process of H 2 -production entails the utilization of sunlight and the oxidation of water or organic substrate in photosynthesis to generate reduced ferredoxin, which is the carrier of the high potential energy electrons. The isolation, sequencing and characterization of the hydA genomic DNA, cDNA, precursor and mature iron-hydrogenase of two additional photosynthetic eukaryotes which may be used for hydrogen gas production is disclosed below.
II. Chlamydomonas reinhardtii
C. reinhardtii Algal Strains and Growth Conditions
Wild-type C. reinhardtii 137c(mt+) strain was originally obtained from the Chlamydomonas Culture Collection at Duke University. The stain was cultured photoheterotrophically in batch cultures at 25° C. under continuous irradiance of 150 μmol photons per square meter per second. Cultures containing TAP (Tris acetate phosphate) medium were flushed vigorously with air supplemented with 5% CO 2 . Cells were collected by centrifugation (8 minutes @ 5000 g) in the mid-exponential growth stage (1−2×10 6 cells per ml). After harvesting the cells in the id-exponential stage of growth, the pellet was resuspended in 0.02 vol. of fresh TAP medium. The algae were anaerobically adapted by flushing the culture with argon in the dark.
Hydrogen Evolution Assay
Hydrogenase activity of C. reinhardtii was determined in vitro with reduced methyl viologen using a gas chromatograph (Hewlett Packard 5890 {acute over (Å)} Series II, column: molecular Sieve 5 {acute over (Å)}, Mesh 60/80). The assay, containing in a final volume of 2 mL Pipes pH 6.8 (20 mM), Na 2 S 2 O 4 (20 mM), MV (5 mM), was incubated anaerobically at 25° C. for 20 min. One unit is defined as he amount of hydrogenase evolving 1 μmol H2 per minute.
Purification of the Fe-hydrogenase and Amino Acid Sequence
Cells from a 40-L culture of C. reinhardtii were harvested by ultra filtration through an Amicon Ultrafiltration System DC 10 LA, with a hollow-fiber filter. The pellet was resuspended in 200 mL TAP medium. After anaerobic adaptation by flushing the solution with argon for 1 h in the dark, all steps were performed under strictly anaerobic conditions. The isolated Fe-hyrogenase was chemically cleaved by cyanogen brormide (CNBr). After separation of he CNBr fragments on an SDS polyacrylamide gel, four peptides were blotted onto a poly(vinylidene difluoride) membrane and were sequenced. Automated Edman degradation was performed with an Applied Biosystem model 477 A sequencer with online analysator model 120 A.
RNA Blot Hybridization
Total nucleic acids were isolated from algae grown under aerobic conditions and after anaerobic adaptation. Poly(A)+ RNA was isolated using the RNA Kit (Qiagen); 10 μg total RNA or 0.5 μg poly(A)+ RNA were separated on each lane of 1.2% agarose gels in formaldehyde. The RNA was transferred to n ion membranes (Hybond+, Amersham) and hybridized with RNA probes, which were labeled with digoxygenin (DIG)-dUTP by in vitro transcription. Transcripts of the hydA gene were detected using a 1.0-kb Sma I cDNA fragment. A DIG-dUTP labeled cDNA, which encodes the malate dehydrogenase, was used as a control for a constitutive express gene. FIG. 5 (A) shows the structural features of the HydA cDNA. Coding regions are marked as large arrows with the transit peptide shown in black. Lines indicate 5′ and 3 URT's. In FIG. 5 (B), the mosaic structure of HydA is illustrated by gray (exons) and white (introns) boxes. The RNA and DNA probes that were used for blotting are as noted on the figure.
Suppression Subtractive Hybridization (SSH)
SSH was performed with the Clontech P WR-select4 cDNA Subtraction Kit (Clontech Laboratories Inc., Palo Alto, Calif., USA.) according to the manufacturer's recommendations, except for modifications of th PCR and hybridization conditions. The mRNA was isolated from aerobically grown cells (driver) and from anaerobically adapted algae (tester). The driver and tester cDNAs were denatured separately for the first hybridization at 100° C. for 30 s and then incubated for 10 h a 68° C. For the second hybridization, driver cDNA was denatured at 100° C. for 30 s, then directly added to the pooled mix of the previous hybridization, and incubated at 68° C. for 20 h. Primary and secondary PCR conditions were altered to increase the specificity of the amplification. The PCR conditions with subtracted cDNA were as follows: 25 cycles each 94° C. for 30 s, 68° C. for 30 s, and 72° C. for 1 min. The subtracted cDNA was subjected to a second round of nested PCR, using the same PCR conditions with a decreased number of 15 cycles. Specific primers were used for the identification of the amplified HydA cDNA fragment. From the N-terminal amino-acid sequence, a degenerate oligonucleotide Hyd5 [5′-GCCGCCCC(GC)GC(GCT)GC(GCT)GA(AG)GC-3′] was synthesized, thing into account known C.reinhardtii amino-acid sequences. The second primer, Hyd2 (5′-CCAACCAGGGCAGCAGCTGGTGAA-3′), was deduced from the conservative amino acid sequence motif of Fe-hydrogenases FTSCCP.
PCR was performed using either Hyd5 or Hyd2 and the nested PCR primer 2R from the Clontech Subtraction Kit. The PCR conditions were as follows: 20 pmol per ml of each primer were used; 35 cycles (denaturing at 95° C. for 40s, annealing at 54° C. for 1 min, and extension at 72° C. for 1 min). The amplified cDNA fragments were cloned into the T overhang vector pGEM®-T Easy (Promega).
Screening of the cDNA Library, Cloning and Sequencing
A cDNA library was constructed using the Stratagene ZAP Express cDNA synthesis Kit (Stratagene, La Jolla, Calif., USA) with 5 μg mRNA of anaerobically adapted cells of C. reinhardtii . Double-stranded cDNA was ligated into the ZAP Express vector, packaged with the Gigapack Gold Kit, and transfected into Escherichia coli XL Blue MRF cells. The primary recombinant library contained 5× 10 6 recombinant phages and was amplified according to the manufacturer's instructions.
A 366-bp PCR fragment was radiolabeled with [α-32P]dCTP using he random-primer method. Approximately 5×10 5 plaques were analyzed under stringent hybridization conditions, resulting in 20 positive signals. The pBK-CMV phagemid vector with the different cDNAs was excised and used as a template for PCR, which was performed by using Hyd2 and Hyd5 primers at an annealing temperature of 56° C. for 1 min. Four plasmids contained cDNA fragments that showed similarities to the 366-bp fragment. All cDNA fragments were partially sequenced, and the largest clone, pAK60, was completely sequenced. Sequencing was carried out by the dideoxy nucleotide triphosphate chain-termination method using the T 7 sequencing Kit (Pharmacia Biotech). Both strands of genomic and cDNA of hydA were completely sequenced using a nested set of unidirectional deletions or hydA specific synthetic oligonucleotides. The sequences of the Fe-hydrogenase are available under accession number CREO 12098.
Primer extension experiments were performed as described previously by the present inventor ( J. Biol. Chem., 276, 6125-6132 (2001)) using a 22-mer oligonucleotide (5′-AATAGGTGGTGCGATGAAGGAG-3′), which is complementary to the 5′ end of the hydA transcript.
Expression Studies in E. coli and Western Blot Analysis
The coding region of hydA was amplified by PCR The primers were identical to the cDNA sequences coding for he N-and the C-terminus of the mature protein plus several additional bases including NdeI and BamI restriction sites, respectively (underlined). The oligonucleotide sequences were: HydNde (5′-CATATGGCCGCACCCGCTGCGGAGGCGCCT-3′), HydBam (5′-CCGGATCC TCAAGCCTCTGGCGCTCCTCA-3′).
The hydA gene, corresponding to amino acids 57-497, was amplified, confirmed by sequences analysis and cloned into corresponding sites of he pET9a expression vector (Promega). The constructed plasmid was then ransformed into E. coli strain BL21(DE3). After induction with 1 mM isopropyl-thio-β-D-galactoside, the cells were resuspended in lysis buffer. Crude extracts from C. reinhardtii were isolated by harvesting cells after indicated anaerobic adaptation times. The pellet was resuspended in solubilization buffer and incubated with vigorous vortexing at RT for 30 min. The protein extracts from C. reinhardtii and E. coli were separated by 12% SDS/PAGE and blotted onto a poly(vinylidenedifluoride) membrane. Affinity-purified antibodies were diluted 1:200 and used for Western blot analyses.
Sequence Analysis and Protein Modeling
Nucleic acid and protein sequences were analyzed with the programs SCI ED CENTRAL (Scientific Educational Software) and CLUSTALW. The BLAST server (Altschul et al., Nucleic Acid Res., 25, 3389-3402 (1985)) of the National Center for Biotechnology Information (Bethseda, Md., USA) was used for database searches.
Isolation of cDNA Clones, which are Differentially Expressed During Anaerobic Adaptation
In order to amplify a part of the hydrogenase gene in a PCR reaction, degenerate oligonucleotides corresponding to conserved regions of known Fe-hydrogenases were used. All products of expected sizes were cloned and sequenced, but they showed no homologies to other hydrogenases (data not shown). Examinations were then focused on the process of anaerobic adaptation in C. reinhardtii , because the Fe-hydrogenase was only detected under these conditions. The present inventor isolated two different populations of mRNA and advantageously employed the SSH technique. Poly(A)+ RNA was isolated from aerobically grown C. reinhardtii cells and from a cell suspension flushed 15 min with argon. After cDNA synthesis, subtractive hybridization, and PCR experiments, the amplified PCR fragments were cloned and sequenced. Twenty different clones containing inserts of 184-438 bp were analyzed. In transcription analyses, 15 of them showed an increased signal under anaerobic conditions (data not shown). Database comparisons (using GenBank/EBI DataBank) confirmed that eight of these cDNA fragments are similar to genes encoding proteins of the cytoplasmic ribosome complex. The sequences of six clones did not correspond to any entries in the databases. Four of these novel clones showed differences in expression between aerobically grown and anaerobically adapted cultures. Another cDNA fragment indicated similarity to the 5′ region of the Fe-hydrogenase from bacteria.
Analysis of the hydA cDNA and Genomic Sequences
A cDNA expression library was constructed using poly(A)+ RNA from anaerobically adapted cells (15 min). Two oligonucleotides were generated on he basis of the cDNA fragment isolated by SSH and the N-terminal sequences of the purified hydrogenase. They were used to amplify a 366-bp cDNA fragment that showed 41% identity to the corresponding part of the Fe-hydrogenase of C. pasteurianum . The fiagment was labeled with [α- 32 P]dCTP and used to screen the cDNA library. Four independent cDNA clones with different sizes of 2.4-,1,9-, 1.7- and 1.6-kb were identified and sequenced. The nucleotide sequence of the largest clone, 2399-bp, revealed an ORF encoding a polypeptide of 497 amino acids. The cDNA also contained a 5′UTR (158-bp) and a longer 3′UTR (747-bp excluding the polyadenylated tail). Characteristic features of other C. renhardtii cDNA clones, e.g. a high average G/C content (62.1%)and a putative polyadenylation signal (TGTAA) 727-bp downstream of the stop codon were found. The transcription start position was confirmed by primer extension 158-bp upstream of the ATG start codon.
FIG. 5 (A) is a schematic map of the cDNA and the genomic DNA region of HydA from C. reinhardtii .showing the structural features of the HydA cDNA. Coding regions are marked as large arrows with the transit peptide shown in black.lines indicate 5′ and 3′ URTs. FIG. 5 (B) is a schematic map of the cDNA and the genomic DNA region of HydA from C. reinhardtii .showing the structural features of the HydA cDNA. In FIG. 5 (B), the mosaic structure of hydA is illustrated by gray (exons) and white (introns) boxes. The RNA and DNA probes that were used for the blotting experiments are noted on the Figure.
Approximately 5-kb of the hydA genomic region was determined. The coding sequence is interrupted by seven introns with sequences at their 5′ and 3′ ends, corresponding to the typical splicing sequences from eukaryotes as shown in FIG. 5 B. The promoter region does not contain a putative TATA box or any other known transcription motifs. The sequence data were submitted to the GenBank/EBI DataBank under accession number CRE012098. In subsequent studies, parts of the cDNA sequence were determined by another group and deposited under accession number AF289201.
Southern hybridization experiments were performed at high stringency using a PCR fragment as probe. They showed the presence of one hybridizing signal of similar intensity in different digestions, suggesting that HydA is encoded by a single copy gene in the C. reinhardtii genome. The same hybridization pattern was observed even under low stringency conditions (hybridization temperature 50° C.; data not shown).
Characterization of the Fe-Hydrogenase HydA from C. reinhardtii
The mature polypeptide consists of 441 amino acids with a calculated molecular mass of 47.5 kDa and a predicted isoelectric point of 5.6. The N-terminal 56 amino acids probably function as a transit peptide, because they show characteristics of polypeptides that route proteins into the chloroplast stroma. The stromal targeting domain is most likely cleaved by a stromal peptidase at the conserved cleavage motive Val-Ala-Cys-Ala. In addition to the detection of the protein using antibodies raised against the Fe-hydrogenase, the localization of the mature protein in the chloroplast stroma is indicated by a high content of hydroxylated and basic amino acids in the transit peptide sequence.
The deduced amino-acid sequence of he mature HydA polypeptide from C. reinhardtii shows 60% identity and 71% similarity to the Fe-hydrogenase of S.obliquus , Comparisons with NiFe-hydrogenases of bacteria (including the photosynthetic cyanobacteria) had obviously lower scores, e.g. 25% similarity with the NiFe-hydrogenase (HoxH) of Ralstonia eutropha . A conserved domain of about 300 amino acids is found in the C-terminal part of all Fe-hydrogenases. The sequences are highly conserved, especially in the region that is involved in the catalytic mechanism (H-cluster), indicating structural similarity between Fe-hydrogenases. Four cysteine residues at positions 114, 169, 361 and 365 might coordinate the H-cluster in C. reinhardtii . Twelve strictly conserved amino acids of HydA proteins probably define a binding pocket surrounding the active center as shown by structural data reported by others for C. pasteurianum and D. desulficans iron hydrogenase. All of them are present in the C. reinhardtii protein (Pro37, Ala38, Thr74, Ala78, Cys113, Pro138, Met167, Lys172, Glu175, Phe234, Val240 and Met359). An interesting insertion of 45 amino acids was only identified at the C-terminus of the C.reinhardtii polypeptide (position 285.329).
The N-terminal region of the green algae protein is much shorter and completely different than all known Fe-hydrogenases. Amino-acid sequence analyses have indicated that Fe-hydrogenases, in general, contain two [4Fe)4S ] clusters (F-cluster) in a ferredoxin-like domain. They might be involved in the transfer of electrons from the donor to the catalytic center. This N-terminal domain with the F-cluster or other conserved cysteines is completely missing in HydA of C. reinhardtii . A novel electron transport pathway is postulated from the exogenous donor (ferredoxin) directly to the H-cluster.
Protein Sequencing of the Enzyme and Recombinant Expression of HydA in E. coli
To verify that the hydA ORF encodes the Fe-hydrogenase of C. reinhardtii , the enzyme was purified according to Happe and Naber ( Eur. J. Biochem. 214,475-481 (1993)). The purified protein was able to evolve hydrogen, when incubated with reduced methyl viologen. After proteolytic digestion with cyanogen bromide, four bands of 4, 8, 9 and 11 kDa were detected after SDSIPAGE separation (data not shown). Two fragments (9 and 11 kDa) were sequenced by Edman degradation. FIG. 6 shows the nucleotide sequence of the hydA cDNA and the deduced amino acid sequence of the hydrogenase from C. reinhardtii . The two fragment sequences are identical with he deduced amino-acid sequence of hydA (sequences are shadowed in gray in FIG. 6 ). The fragment corresponding to the cDNA region between 158 and 1636 bp of hydA was NdeI-BamHI cloned into the expression vector pET9a. The heterologous expressed protein was detected using antibodies raised against the Fe-hydrogenase. Both the purified Fe-hydrogenase of C. reinhardtii and the overexpressed enzyme had the same size (47.5 kDa). No hydrogenase activity could be measured within the lysate of the induced E. coli cells. This result is in agreement with Stokkermans et al. and Voordouw et at. (ibid) who also detected no H 2 -production of the recombinant expressed Fe-hydrogenase from Desulfovibrio vulgaris in E. coli cells. An explanation might be the inability of E. coli to assemble the unique active site of the Fe-hydrogenases. It is known that E. coli has only three NiFe-hydrogenases with a different maturation system for the catalytic center.
FIG. 6 shows the nucleotide sequence of the hydA cDNA and the deduced amino acid sequence of the hydrogenase from C. reinhardtii . The sequence was submitted to the GenBank/EBI Data Bank under accession number CRE012098. A curved arrow marks the transcription start point. The ATG start codon and the TGA stop codon are drawn in boxes. Boldface letters indicate the cDNA sequence. Gray shadows mark amino acids corresponding to polypeptide sequences that were determined by sequencing the N-terminus of the protein. Black shadows mark the putative transit peptide, and the underlined amino acids indicate the putative cleavage site for the endopeptidase. Boldface double underlined letters indicate a signal for polyadenylation.
Induction of Gene Expression During Anaerobic Adaptation
In aerobically grown cells, neither hydrogenase activity nor protein can be identified by immunoblot analysis. However, HydA can be detected only 15 min after anaerobic adaptation. The expression of the hydA gene is probably regulated at the transcriptional level. Total RNA was isolated from cells that had been anaerobically adapted by flushing with argon for 0,15, and 30 min. Northern blot hybridization demonstrated that the hydA gene is expressed very rapidly after the beginning of anaerobic adaptation. No transcript could be detected before adaptation (t=0), but a significant signal occurred after just 15 min of anaerobiosis. The size of the transcripts (2.4 kb) confirmed the full-length of the isolated hydA cDNA fragment.
Differentially Expressed Genes During Anaerobic Adaptation
In the light, algae degrade cellular starch via glycolysis and hydrogen gas is evolved. It has been suggested that reducing equivalents from the glycolysis or the citric acid cycle can transfer their electrons to the photosynthetic electron transport chain (M. Gibbs et al., Plant Physiol. 82, 160166 (1986)). However, the molecular principles of the gene induction under anaerobic conditions in C. reinhardtii are poorly understood.
The present inventor has investigated the patterns of gene expression in aerobically grown and anaerobically adapted cells by isolating differentially expressed genes. The SSH method combines subtractive hybridization with PCR to generate a population of PCR fragments enriched with gene sequences that are only expressed under anaerobic conditions. Compared to other PCR-based cloning strategies, such as differential display, the great advantage of SSH is that fewer false positives are generated; 70% of the cloned fragments represented differentially expressed genes.
Among the 20 sequenced cDNA clones, three DNA fragments encoding the ribosomal S8 protein were found. Most of the other sequences (eight of 20) also corresponded to ribosomal protein sequences. This might indicate that the transcripts of the ribosomal protein genes (rps, rpl) accumulate under stress conditions. This is in good agreement.with Dumont et al. ( Plant Sci., 89, 55-67 (1993)) who found that an accumulation of ribosomal proteins takes place under phosphate starvation. Moreover, two of the identified cDNAs encode for proteins, (aldolase, enolase), which are induced in other organisms by anaerobic stress. Anaerobic treatment of maize seedlings alters he profile of total protein synthesis. It is known that the induction of the anaerobic proteins is the result of an increased mRNA level. Maize ( Zea mays L.) responds to anaerobic stress by redirecting the synthetic machinery towards the synthesis of some enzymes involved in glycolysis or sugar-phosphate metabolism.
C. reinhardtii HydA Belongs to a New Class of Fehydrogenases
HydA of C. reinhardtii , the first isolated gene encoding a hydrogenase of a photosynthetic eukaryotic cell, represents a novel type of Fe-hydrogenases. Parts of the deduced amino-acid sequence of the cDNA correspond to the polypeptide sequence of the tryptic fragment (VPAPGSKFEELLKHRAAARA), and the N-terminus (AAPAAAEAPLSHVQQALAELAKPKD) from the purified native enzyme. Further evidence that the isolated cDNA encodes an Fe-hydrogenase is the fact that the recombinant HydA specifically reacts with the antibodies raised against the active enzyme. The amino-acid sequence of HydA shows only considerable similarity to Fe-hydrogenases but not to NiFe-hydrogenases. The Fe-hydrogenase family is one class of hydrogenases defined by Vignais et al. ( FEMS Microbiol. Rev. 25, 455-501 (2001)). The enzymes have been identified in a small group of anaerobic microbes, where they often catalyze the reduction of protons with a high specific activity to yield hydrogen. Interestingly, Fe-hydrogenases were not found in cyanobacteria, the free-living ancestor of plastids, suggesting a noncyanobacterial origin for the algal hydrogenases.
The important structural features found among the amino-acid sequences of Fe-hydrogenases are also present in the C. reinhardtii hydrogenase sequence. A highly conserved domain of about 130 amino acids was detected in the C-terminal part of the protein. The designated active site domain consists of an atypical [Fe-S] cluster (H-cluster). In C. pasteurianum , the H-cluster contains six Fe atoms arranged as a [4Fe-4S] subcluster bridged to a [2Fe] subdluster by a single cysteinyl sulfur. The [4Fe-4S] subcluster is coordinated to the protein by four cysteine ligands, which have also been found in the amino acid sequence of C. reinhardiii . A number of mostly hydrophobic amino acid residues define the environment of the active site and might have a function in protecting the H-cluster from solvent access. In contrast to all Fe-hydrogenases, including HydA of S. obliquus , the enzyme of C. reinhardtii has an interesting additional 18 protein domain. A small insertion of 45 amino acids between residue Ser284 and Val330builds an external loop of the protein that might be involved in electrostatic binding of the natural electron donor ferredoxin (Happe et al., unpublished results)
In the N-terminus of other Fe-hydrogenases, further cysteine residues were found that bind accessory iron sulfur clusters. Others have shown that a ferredoxin homologous domain (F-cluster) coordinates two [4FeAS] clusters in all non-algal Fe-hydrogenases. An additional [4Fe-4S] cluster and one [2Fe-2S] center were detected within the Fe-hydrogenases of C. pasteurianum (Peters et al., Science, 282, 1853-1858 (1998)). Based on similarities of the primary sequences, the same cofactors are proposed for Thermotoga maritime (A. Akhmanova et al., Nature, 396,527-528 (1998)) and Nyctotherus ovalis (J. Meyer et al., Biochim. Biophys. Acta, 1412, 212-229 (1999)). The F-cluster is responsible for the electron transfer from the electron donor (mostly ferredoxin) to the active center. It has been suggested by Vignais et al. ( FEMS Microbiol. Rev., 25, 455-501 (2001)) that the proteins containing two F-clusters are ancestors of the Fe-hydrogenases.
The N-terminus of the C. reinhardtii and S. obliquus proteins is strongly reduced, and conserved cysteines were also not found. Therefore it is suggested that all accessory [Fe-S] clusters are missing in the algal hydrogenases. The native protein of C. reinhardtii is located in the chloroplast stroma. The first 56 amino acids of the unprocessed enzyme probably function as a transit peptide, because they were not characterized in the purified hydrogenase and a putative peptidase cleavage site (Val-Ala-Cys-Ala) could be detected at the end of this fragment.
The natural electron donor of the hydrogenase in C. reinhardtii is the ferredoxin (PetF) of the photosynthetic electron ransport pathway. Measuring the H 2 -evolution, it has been found that the hydrogenase activity is directly linked to the 47.5 kDa subunit. As a second subunit necessary for hydrogenase activity has not been found, it is suggested that a direct electron transfer from PetF to HydA takes place. In vitro, a hydrogen evolution by HydA was only measured with plant-type [2Fe-2S] ferredoxins such as PetF of C. reinhardtii, S. obliquus and spinach as electron mediators (data not shown).
FIG. 7 is a schematic diagram illustrating the light-dependent photoevolution of hydrogen in green algae. The electrons for hydrogen evolution are fed into the photosynthetic electron transport chain either via PS II or via the plastoquinone pool after oxidation of reducing equivalents. The natural electron donor, PetF, transfers the electrons from PS I to the hydrogenase.
The most likely explanation for photosynthetic green algae retaining the anaerobically induced hydrogenases is that the enzymes ensure the survival of the ceus under anaerobic conditions. Melis et al. have shown that H 2 -evolution is the only mechanism available to the algae for generating sufficient amounts of ATP under S-depleted anaerobic conditions. It is known that C. reinhardtii is still able to photoproduce hydrogen when photosystem II is inhibited by DCMU, but no H 2 -evolution occurs after an addition of 2,5-dibromo-3-methyl-6-isopropyl-p-benzochinon (DBMIB; FIG. 7 ). Under anaerobic conditions, accumulated reducing equivalents from the fermentative metabolism cannot be oxidized via respiration, as the electron acceptor oxygen is missing. The NAD(P)H reductase protein complex has recently been isolated from plants, and inhibitor experiments have shown evidence of a membrane-bound, chloroplast-located reductase in C. reinhardtii (D. Godde et al., Arch Microbiol. 127, 245-252 (1980)). The light-dependent electron transport of the H 2 -evolution is driven by plastoquinone and photosystem I. The donor ferredoxin transfers electrons to the hydrogenase in a final step and molecular hydrogen is released (FIG. 7 ).
Regulation of hydA at the Transcriptional Level
Studies indicate that there is a correlation between the increase of hydrogen production and the anaerobic adaptation, which was documented by activity measurements (T. Happe et al., Eur. J. Biochem. 222, 769-775 (1994)), and immunoblots. It is likely that the induction of hydA is regulated on the level of transcription. It is observed that the amount of mRNA increased directly with the measured H 2 -evolution. In C. reinhardtii , a dramatic change in the hydrogenase transcript level occurs during the shift from an aerobic to an anaerobic atmosphere, which means that the transcription is regulated by the oxygen status of the cells. A very rapid increase of the hyd transcript was detected in the first 30 min of anaerobiosis. This quick increase of gene transcription is only reported for the cyc6 gene in C. reinhardtii (K. L. Hill et al., J. Biol. Chem. 266, 15060-15067 (1991)) and for the SAUR (Small Auxin-Up RNA) genes in plants (Y. Li et al., Plant Physiol. 106, 37-43 (1994)). Interestingly, the hyd, gene of S. obliquus is constitutively transcribed under aerobic conditions indicating another regulation system for the expression of the hydrogenase. At the moment, it is not clear if his effect rests upon a new synthesis or a higher stability of the hydA mRNA.
As with other nuclear genes, the promoter region of the hydA from C. reinhardtii contains no conserved TATA box or other motif similarities. As no defined motif structures in the promoter region of hydA have been found, further genetic analyses are necessary to investigate the rapid induction of hydA in C. reinhardtii.
III. Chlorella fusca
The isolation and molecular characterization of the Fe-hydrogenase from the unicellular green alga Chlorella fusca was also performed. Hydrogenase activity was observed in a culture of the unicellular green alga Chlorella fucsa after anaerobic incubation, but not in the related species Chlorella vulgaris . Specific PCR techniques lead to the isolation of the cDNA and the genomic DNA of a special type of [Fe]-hydrogenase in C. fusca . The functional Fe-hydrogenase was purified to homogeneity as described above, and its N-terminus was sequenced. The polypeptide sequence shows a high degree of identity with the amino acid sequence deduced from the respective cDNA region. Structural and biochemical analyses indicate that ferredoxin is the main physiological electron donor to this [Fe]-hydrogenase. The nucleotide sequence reported herein has been submitted to the GenBank/EBI Data Bank with accession number AJ 298227. The nucleic acid sequence of the genomic DNA (3,290 bp) of C. fusca is set forth in SEQ. ID. NO. 3, and the amino acid sequence of the precursor protein (436 amino acids) is set forth in SEQ. ID. NO. 6. The cDNA sequence is presented in SEQ. ID. NO. 9.
The transcription of the iron-hydrogenase is very rapidly induced during anaerobic adaptation of the green algae. Hydrogen photoproduction by the cells can be observed soon following this induction. The genomic, cDNA and polypeptide sequences of three representative green algae are offered as examples of the properties of the HydA gene and of the enzyme that it encodes. These genomic, cDNA and polypeptide sequences from three representative green algae are also offered as examples of the potential application of the hydA gene from Chlorophyta in the process of commercial hydrogen production:
Scenedesmus obliquus
Genomic DNA: 5,001 bp, SEQ. ID NO. 1 (attached hereto)
cDNA: 2,636 bp SEQ. ID NO. 7 (attached)
Precursor protein: 448 amino acids, 44.5 kD, SEQ. ID NO. 4 (attached hereto)
Chlamydomonas reinhardtii
Genomic DNA: 5,208 bp, SEQ. ID. NO. 2 (attached)
cDNA: 2,399 bp, SEQ. ID. NO. 8 (attached)
Precursor protein: 497 amino acids, 53.1 kD, SEQ. ID. NO. 5 (attached)
Chlorella fusca
Genomic DNA: 3,265 bp, SEQ. ID. NO. 3 (attached)
cDNA: 2,421 bp, SEQ. ID NO. 9 (attached)
Precursor protein: 436 amino acids, SEQ. ID. NO. 6 (attached)
This new class of iron-hydrogenases has a C-terminal portion and active site region (H-cluster) similar to that reported in non-photosynthetic prokaryotes (e.g. Clostridium pasteurianum ). Cysteine residues and distinct other amino acids which are strictly conserved in the active site (H-cluster) of such non-photosynthetic prokaryotes are also conserved in the iron-hydrogenase of green algae. However, the N-terminal region of the green alga iron-hydrogenase is substantially different from that of HydA in non-photosynthetic prokaryotes, revealing novel and unobvious pathways of electron transport for photosynthetic hydrogen production in green algae.
Distinct iron-sulfur [Fe-S] centers, referred to as FS2, FS4C, FS4B and FS4A, are encountered in the N-terminal region of the iron-hydrogenase in non-photosynthetic prokaryotes, and are thought to be instrumental in the transport of high potential energy electrons from bacterial ferredoxins to the catalytic site of the H-cluster of the hydrogenase. These distinct FS2, FS4C, FS4B and FS4A [Fe-S] centers are missing from the HydA of green algae. A mature-protein folding-model of the green alga iron-hydrogenase and analysis of its structure revealed a protein region of positive surface potential, evidenced by the presence of basic amino acids, which are uniquely localized within the C-terminal domain and, therefore, near the catalytic site of the H-cluster. On the other hand, a model of the structure of green alga ferredoxin, which is different from prokaryotic ferredoxins, revealed negatively charged amino acids near the [2Fe-2S] electron donor site of this molecule. Structural analysis revealed that the [2Fe-2S] center of green algal ferredoxin and the H-cluster of the hydrogenase probably come into close proximity through electrostatic interactions. This molecular geometry is consistent with a direct and efficient electron transfer between these two prosthetic groups. Thus, the hydA gene of green algae encodes an iron-hydrogenase polypeptide with a novel structure, one that uniquely permits a direct coupling and efficient electron-transfer from a [2Fe-2S] photosynthetic ferredoxin to the active site of the H-cluster. In support of this conclusion, inhibitor experiments revealed that the PetF ferredoxin functions as a natural electron donor in green algae, linking the iron-hydrogenase with the photosynthetic electron transport chain in the chloroplast of these unicellular organisms.
In summary, a process, operable in a culture comprising unicellular green algae, is described whereby transcription of algal HydA genomic DNA, followed by translation of the resulting HRNA, followed by targeting of the precursor protein and import of the polypeptide into the chloroplast, followed by the mature iron-hydrogenase folding and catalysis, leads to hydrogen (H 2 ) gas production.
Levels of HydA protein in the cells are very low, even under hydrogen production conditions, and this is a primary reason for the currently low yield of hydrogen production in green algae. It is suggested that genetic engineering of the green algae in order to overexpress the hydA gene would result in strains with far greater yields of hydrogen production, which is of obvious practical importance. Moreover, another use of the hydA genes is that they can be transformed then transferred into other photosynthetic and non-photosynthetic organisms that lack the ability to produce hydrogen. Such genetic transformation with the hydA gene(s) of green algae, will confer to a variety of organisms commercial utility for the production of hydrogen.
There are many species of unicellular green algae that may have variants of the HydA gene described herein for Scenedesmus obliquus, Chlamydomonas reinhardiii and Chlorella fusca . It is the intended to encompass within the scope of the present invention all green alga HydA genes and gene products that are similar to the unique HydA genes and HydA described herein. A HydA that is “similar” is meant to mean that the HydA has a 75% or greater homology in the amino acid sequence between an isolated HydA and a polypeptide selected from the group consisting of SEQ ID NO. 4, SEQ ID NO. 5, or SEQ ID NO. 6.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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The enzyme, iron hydrogenase (HydA), has industrial applications for the production of hydrogen, specifically, for catalyzing the reversible reduction of protons to molecular hydrogen. The present invention relates to the isolation of a nucleic acid sequence from the algae Scenedesmus obliquus, Chlamydomonas reinhardtii , and Chlorella fusca that encodes iron hydrogenase. The invention further discloses the genomic nucleic acid, c-DNA and the protein sequences for HydA. The genes and gene products may be used in a photosynthetic process for hydrogen production which includes growing a microorganism containing the gene coding for HydA in a culture medium under illuminated conditions sufficient to accumulate an endogenous substrate; depleting a nutrient selected from the group consisting of sulfur, iron, and manganese from the medium; then allowing the culture to become anaerobic by consumption of an endogenous or exogenous substrate in the light.
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FIELD OF THE INVENTION
The present invention relates to the use of Tagetes minuta oil and its components as antiviral agent. More particularly this invention relates to identification of antiviral activity of Tagetes minuta oil. This invention also relates to the use of the compounds Z-β-ocimene and dihydrotagetone present in Tagetes minuta oil which are now found to inhibit Carnation Ring Spot (CaRSV) and Carnation Vein Mottle Viruses (CaVMV).
BACKGROUND OF THE INVENTION
Carnation Ring Spot (CaRSV) and Carnation Vein Mottle Viruses (CaVMV) are widespread in carnations and cause appreciable amount of damage. Production of disease free plants and chemical control of vectors are the methods employed for reducing disease incidence in the field (Matthews R. E. F. 1991, Plant Virology, Academic Press, San Diego, pp. 835).
Carnation Vein Mottle virus (CaVMV) is a member of potyvirus group, first reported from U.S.A. and is found all over the world (Kissanis B., 1954, Nature 173:1097). On natural hosts chlorotic and darker green spots, flecks and mottling, flower breaking and malformation symptoms are developed after infection. Virus is transmitted mechanically, and also by aphid vectors.
Chenopodium amranticolor, Chenopodium quinoa and Silene pendule are diagnostically susceptible hosts. On Chenopodium amaranticolor chlorotic and necrotic local lesions appear whereas, in Chenopodium quinoa , chlorotic lesions with systemic develop after inoculation. Chenopodium quinoa and Dianthus barbatus are the maintenance and propagation host. It has RNA genone, which is single stranded and virions found in all parts of the host plant. (Morgan J. R., Verhoyen M. and Caneghem, G. V., 1996, Carnation Vein Mottle Potyvirus, In-Viruses of plants, Description and lists from VIDE database ed. Brunt A. A., Crabtree K., Dallwitz M. J., Gibbs A. J. and Watson L. CAB International pp 309-312).
Carnation Ring Spot Virus (CaRSV) first isolated from Dianthus species from U.K. by Kassanis belongs to dianthovirus group (Kassanis B., 1995, Ann. Appl. Biol. 43:103). CaRSV is found all over the world wherever carnations are grown. Virus is transmitted mechanically, and by grafting. Vector transmission is by nematodes. The virus causes leaf mottling, ring spotting, plant stunting, distortion, and flower distortion in host plants whereas, in experimentally infected plants chlorotic and necrotic local lesions, rings and flecks and occasional systemic symptom also appear.
Chenopodium amaranticolor, Chenopodium quinoa and Vigna unguiculata are local lesion assay hosts. Virus can be maintained on Dianthus barbatus, Nicotiana clevelandii and Phaseolus vulgaris . Virions are isometric, non-enveloped 34 nm in diameter. Gonome of virus consists of RNA, linear, single stranded. Virions are found in all part of the host plant. (Termaine J. H. and Moran J. R., 1996, Carnation Ring spot virus. In-Viruses of plants, Description and lists for VIDE database ed. Brunt A. A., Crabtree K., Dallwitz M. J., Gibbs A. J., and Watson L. CAB International pp 309-312).
The plant volatile oils have been recognised since antiquity to possess biological activity and a number of plant extracts and pure isolates have been mentioned as containing substances which interfere with or inhibit infection of viruses. Some of the compounds like galangin when used in concentrations ranging form 12-47 μg/ml showed significant antiviral activity against HSV- 1 and Cox B 1 (Meger J. J. M., Afoloyan A. J., a Taylor M. B., Erasmus D., 1997, Antiviral activity of galangin isolated from the aerial parts of Helichrysum aureonitens, J. Ethnopharma , 56:165). Plant Hyptianthera stricta L. is used against Encephalitis causing viruses pronounced inhibiting activity 75% and 50% CPE inhibition at 62.5 μg/ml and 15.6 μg/ml against these two viruses (Saxena G., Gupta P., Chandra K., Lakshmi V., 1997, Antiviral activity of Hyptianthera shivta L. against encephalitis causing viruses, Indian Drugs, 34:694). The essential oil of Melaleuca alternifolia in concentration of 100, 250, 500 ppm was found to be effective in decreasing local lesions of TMV on host plant Nicotiana glutinosa (Bishop C. D., 1995, Antiviral activity of the essential oil of Melaleuca alternifolia (Maiden & Betche) cheel (Teatree) against Tobacco Mosaic Virus,. J. Essen. Oil Res 7:641). The chemical composition of essential oil for Senecio graveleopeus was analysed by GLC-MS and different components like isovaleraldehyde, α-pinene, sabinene, p-cymene, terpinen-4-ol, α and β-eudesmone were identified and found to have antimicrobial activity against Microccus letus, staphylococus aureus and antifungal activity against canidida albicans . The MIC (Minimum Inhibitory Concentration) was 8.73, 10.91 and 2.13×10 −2 mg/ml respectively against all the three organisms. A number of compounds from different plant extracts have antiviral activity (Perez C., Agnese A. M. Cabrere J. L., 1999, The essential oil of Senecio graveoleus (Compositae): chemical composition and antimicrobial activity test 66:91). A new acelycated flavonol glycoside, quercetin exhibited IC 50 values of 18.1±1.3 μg/ml against HIV integrase (Kim J. H., Woo E. R., Shin C. G., Park 1998 , Acer okamotoanum and its inhibitory activity against HIV-1 integrase. J. Natural Products 61:145). Three new triterpene lactones lancilactones A, B, C together with the known Kadsulactone A were isolated from stems and roots of Kadsura lancilimba . Their structure with sterochemistries was determined- from mass and NMR. Compound 3 inhibited HIV replication with an EC 50 value of 1.4 mg/ml and a therapeutic index of greater than 71.4 (Chen F. D., Zhang X. S., Wang K. H., Zhang Y. S., Sun Q. Z., Cosentine L. M., and Lee K. H. 1999, Novel Anti-HIV Lancilactone C and related Triterpense from Kadsura lancilimba J. Natural Products 62:94). Salvia fructiosa essential oil extracted form aerial parts was analysed by GC-MS. It contained 1,8 cineole (eucalyptol) (47.48%) α+β thujone (11.93%) and camphor (9.04%). The essential oil of S. fuctiosa and its isolated components; thujone and 1,8 cineole, exhibited activity against 8 bacterial strains. Camphor was almost inactive against 8 bacterial strain. Camphor was almost inactive against all the bacteria tested. The essential oil was almost inactive against all the bacteria tested. The essential oil was bactericidal at 1/4000 dilution; dilutions of upto /1/0000 decreased bacterial growth rates. The essential oil of S. fructicosa and its three main components exhibited cytotoxic activity against African Green Monkey Kidney (vero) cells and high levels of virucidal activity against Herpes Simplex Virus 1 (Sivropou A., Nikolaou K. E., Kokkini S. L. and Arsenalics M., 1997, Antimicrobial, cytotoxic and antiviral activities of Saliva fructicosa essential oil. Journal of Agriculture and Food chemistry, 45: 3197.) The essential oils and their components exhibited inhibiting properties against viruses (Deans S. G. and Waterman P. G., 1993, Biological activity of volatile oils, in: Volatile oil crops, Hay R. K. M. and Waterman P. G. Longman Scientific and Technical pp. 97) fungi (Baruah P., Sharma R. K. Singh, R. S. and Ghosh A. C. 1996, Fungicides activity. of some naturally occurring essential oils against Fusarium monitiform , Journal of Essen. Oil Res 8:411) bacteria (Chalchal J. C., Garry R. P., Menut C., Lamaty Li., Malhuret R. and Chopineau, J., 1997, correlation between chemical composition and antimicrobial activity VI, Activity of some African essential oils, Journal of Essen. Oil Res. 9:67) malaria (Milnau G., Valentin A., Benoit R., Mallie M., Bastide J. M., 1997, in vitro antimalarial activity of eight essential oils, Journal of Essen. Oil Res. 9:329). These are very few reports on effects of essential oils on viruses or viral infection in either animals or plants.
Tagetes minuta L. (Asteraceae) grows wild and yields essential oil having commercial value in perfumery and flavour industry (Handa K. L., Chopra M. M., Nigam M. C., 1963, The Essential Oil Res. 54:372). The essential oil produced from plants has been chemically investigated (Chopra I. C., Nigam M. C., Kapoor C. D. and Handa K. L., 1963, Indian Tagetes Oils, Soap Perfumes Cosmetics , 36, 686; Razden T. K., Wanchoo R. K. and Dhar K. L., 1986, Chemical composition and antimicrobial activity of the oil of Tagetes minuta L. Perfum. Kosmet . 67:52: Villeirs F. J., Garbes C. F. and Lasnvie R. N. 1971, synthesis of tagetones and their occurrence in oil of Tagetes minuta , Phytochemistry, 10:1359; Lawrence B. M., Powell R. H., Swith T. M. and Kranes S. W. chemical composition of Tagetes minuta , Perf & Flav., Singh B., Sood R. P. and Singh V. 1992, chemical composition of Tagetes minuta L. from Himachal Pradesh (India), Jour Essent. Oil Res. 4:525; Thapa R. K., Agrawal S. G., Kalia N. K. and Kapoor R., 1993, Changes in chemical composition of Tagetes minuta at various stages of flowering and fruiting, Jour, Essen. Oil Res; 5:375). The oil produced from Tagetes minuta was reported to have hypotensive, branchodilatory, spasmolytic, anti-inflammatory and tranquilizing properties (Chandhoke N. and Ghatak B. J. R., 1969 , Tagetes minuta ; Pharmacological action of the essential oil, Indian J. Med Res, 5:864); juvenile hormone mimicking activity (Saxena B. P. and Srivastava J. B., 1973, juvenile hormone mimicking substances, Indian J. Exp. Biol, 11:56) 5-E Ocimenone was reported to exhibit mosquito larvaecideal activity (Maradufu A., Lubega R. and Dorn F., 1978, Isolation of 5-E-ocimenone, A mosquito larvicides from Tagetes minuta . J. Natu.Prod.41:183).
So far only synthetic compounds have been used against plant viruses. Ribavirin (Virazole) (Lozoya-Saldana H., Dawson O. and Murashige T., 1984, Effect or ribavirin and adenine arabinoside on tobacco mosaic virus in Nicotiana tabacum L. var. xanthim tissue cultures. Plant Cell Tissue Org. Cult., 3:41). Tiazofurin (Caner J., Amelia V. and Vicente M., 1984, Effect of tiazofurin on tomato plants infected with tomato spotted wilt virus. Antiviral Res., 4:325) and Pyrazofurin (Lerch B., 1987, on inhibition of plant virus multiplication by ribavirin, Antiviral Res., 7:257). Synthetic compounds which inhibit virus replication are found to be effective against at least 16 plant viruses (Hansen A. J. 1989, Antiviral chemicals for plant disease control, Critical Review in Plant Sciences, 8: (1) 45). Approximately 1000 ppm ribavirin are needed to inhibit local lesion development and to prevent infection with susceptible viruses such as PVX. In callus culture, PVX was not inhibited by 100 ppm ribavirin in the medium. However, when these calli started to differentiate, 10 ppm were enough to prevent virus spread into 90% of developing shoots.
PNRSV seems to be resistant to ribavirin (Hansen A. J. 1984, Effect of ribavirin on green ring mottle saucan agent and necrotic rings spot virus in Prumus species, Plant Dis. Rep. 68:216) and TMV is much less susceptible than other viruses, except during the very early replicative steps directly following inoculation (Dawson O. and Lozoya—Saldana H., 1984, Examination of niode of action of ribavirin against tobacco mosaic virus. Intervirology, 22:77) Ribavirin is relatively or completely ineffective against BGMV, SSV and CaMV (Kluge S. and Ortel C., Arch 1976, Priufung von virazol auf vermehrung des gurkenmosaik-virus (cucumber mosaic virus) und des nelken scheckungs-virus (carnation mottle virus) Phytopathoi. Pflanzenschutz , 14:219; Caner J., Amelia V., and Vicente M. 1984, Effect of tiazofurin on tomato plants infected with tomato sported wilt virus. Antiviral Res., 4:325). In some reports, tiazofurin (Lerch B., 1987, on the inhibition of plant virus multiplication by ribavirin Antiviral Res., 7:257) and Pyrazofurin are tested to see antiviral effect on a range of plant viruses. Other synthetic antivirals are purine-based analogs 8′-azaguanine (Matthews R. E. F., 1954 Effects of some purine analogues on tobacco mosaic virus. J. Gen Microbiol 10:521), adenine arabinoside. (Lozoya—Saldana H. and Dawson W. O. Rev. Mex. 1986, Effect de ribavirin adenina arabinosida sorbre el virus mosaico del tabac el virus moteado clorotico del chicaro de vace in vivo. Fitopatrol . 3:38, 1985, Rev. Plant Pathol 65:306) Uracils (Commoner B. and Mercer F. L. 1951, Inhibition of biosynthesis of tobacco mosaic virus by thiouracil, Nature (London), 168:113) 5-Azauracil (Cassells A. C. and Long R. D. 1982, The elimination of potato viruses X, Y. S and M in meristen and explant cultures of potato in presence of virazole, Potato Res., 25:165) and other large number of cyclic compounds and non-cyclic azyne compounds (Schuster G., Heinisch L., Schulze W., Ulbright H. and Willitzer H., 1984, Antiphytovirole verbindungen mit nich and zyklischer Azin-struktur Phytopathol. Z 111:97).
Some plant extracts have also been screened for their antiviral activity but these extracts have not been exploited commercially. Only a few reports are available in which essential oils were used as antiviral agent. Most of this work done on Tobacco mosaic virus (Bishop C. D, 1995. Antiviral activity of essential oil of Melaleuca alternifolia (Maidan & Betche) cheel (Tea tree) against tobacco mosaic virus. J. of Essen Oil Res., 1995 7:6,641).
The essential oil of Melaleuca alternifolia (100, 250 or 500 ppm) was sprayed on plants of Nicotiana glutinosa inoculated before plants were inoculated with tobacco mosaic virus isolated form infected tomato leaves. The essential oil treatment reduced lesion number for at least 10 days post inoculation. (Rao G. P., Pandey A. K., Shukla K., 1986, Essential oils of some higher plants vis-a-vis some legume viruses. Indian perfumer 30:4, 483-486). Essential oils of Ageratum conyzoides, Callistemon lanceolatus (C.citrinus), Carum copticum (Trachyspermum ammi) Ocimum sanctum and Peperomia pellucida were evaluated for inhibitory activity against cowpea mosaic virus (CPMV), mung bean mosaic virus (MBMV), bean commonil mosaic virus (BCMV) and southern bean mosaic virus (SBMV). Ocimum sanctum at 3000 ppm gave the best inhibition of 89.6, 90, 92.7, 88.2% against CMV, MBMV, BCMV, and SBMV respectively. The other oils also showed inhibitory activity against other viruses.
Another report showed 62% inhibition against tobacco mosaic virus. The fresh hydrodistilled carrot leaves yielded 0.07% essential oil, analysed by GLC and TLC. Constituents were identified by IR, NMR and mass spectra. Antifungal activity was tested against Colletotrichum capsici and Sclerotium rolfsii , antibacterial activity tested against E. Coli and Aeromonas sp. and antiviral activity against tobacco mosaic tobamovirus. Twenty nine compounds were identified and the major constituents were Sabinene (10.93%) linalool (14.90%), linalyl acetate (8.35%), Carvone (8.77%) of C. caprici and S. folfric by 3-6% and 80% respectively. Aeromonas sp. and E. coli were inhibited at 20% and 16% respectively (Khanna R. K., Sharma O. S., Singh A., Battacharya S. C., Sen N., Sethi K. L. 1989, The essential oil from leaves of Dacus carota Linn. Var Sativa . Proceedings of 11th International Congress of essential oils, fragrances and flavours. New Delhi India, Nov. 12-16, 1989 Vol 4 Chemistry analysis and structure 1990, 173-176).
Tagetes minuta oil was found to be active against carnation ring spot (CaRSV) and carnation vein mottle viruses (CaVMV). The ingredients present in the oil namely dihydrotagetone and ocimene when tested individually in pure form, were found to have enhanced antiviral activity against two carnation viruses. The oil as such and the bioactive consitituent present in oil can be commercially used as an natural and eco-friendly antiviral products.
After application of whole oil of Tagetes minuta and its compounds (ocimene and dihydrotagetone) individually for antiviral activity for two carnation viruses i.e. CaVMV and CaRSV following results were observed. In case of whole oil which is applied on the half leaf of the host plant Chenopodium amaranticolor in comparison to control (Virus+Buffer only) applied on other half of leaf, number of lesions were observed. Each concentration of whole Tagetes minuta oil and its pure isolated components were applied on 10 leaves so that the average could be taken.
Objects of the invention
The main object of the present investigation is to evaluate the antiviral activity of Tagetes minuta oil.
Another object of the present invention is to isolate and characterize antiviral components from Tagetes minuta oil.
Still another object of the present invention is to provide easy and convenient method to enrich Z-β-ocimene and dihydrotagetone from the tagetes oil by solvent-solvent partitioning.
Yet another object of the present investigation is to provide control measure for carnation and for other plant viruses using natural products.
Yet another object of the present investigation is to provide quick and efficient natural products to control Poty and Diantho group viral infection.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1 is a gas chromatogram of Tagetes minuta oil.
FIG. 2 is a gas chromatogram of the acetonitrile fraction.
FIG. 3 is a gas chromatogram of Z-β-ocimene.
FIG. 4 is a mass spectrum representation of Z-β-ocimene.
FIG. 5 is the 1 H NMR of Z-β-ocimene.
FIG. 6 is the 13 C NMR of Z-β-ocimene.
FIG. 7 is the gas chromatogram of dihydrotagetone.
FIG. 8 is the mass spectrum representation of dihydrotagetone.
FIG. 9 is the 1 H NMR of dihydrotagetone.
FIG. 10 is the 13 C NMR of dihydrotagetone.
SUMMARY OF THE INVENTION
Accordingly the present investigation provides identification of antiviral activity of Tagetes minuta oil and its components which comprises of (a) Hydrodistillation of Tagetes oil (b) drying and storage of oil (c) fractionating the oil into the hydrocarbon rich fraction and ketone rich fraction by solvent—solvent partitioning (d) Isolation of dihydrotagetone and ocimene by chromatographic techniques (e) Raising of host plant (f) Application of whole oil and pure isolates in ppm concentration on leaves of Chenopodium amaranticolor.
In an embodiment of the present invention Tagetes minuta oil was obtained by hydro/steam distillation in laboratory/pilot scale.
In another embodiment of the present invention the two major constituents ocimene and dihydrotagetone were enriched in the oil by solvent—solvent partitioning.
In yet another embodiment of the present invention, Tagetes minuta oil was tested against two carnation viruses.
In yet another embodiment of the present invention, dihydrotagetone was tested against two carnation viruses.
In yet another embodiments of the present invention, ocimene was tested against two carnation viruses.
DETAILED DESCRIPTION OF THE INVENTION
The essential oil of Tagetes minuta was produced by steam distillation in pilot plant or by hydrodistillation on Clevenger type apparatus (Clevenger J. F. 1928, J. Amer Pharm Assoc. 17:346) when the crop is matured generally during the month of Sept-Dec (India). Drying of the oil is generally done in anhydrous sodium sulphate or sodium chloride. The oil may be stored in aluminium containers or in amber coloured glass bottles, without leaving any gap of foreign particles. The freshly distilled Tagetes minuta oil contains ocimene 54.97%, and dihydrotegetone 32.58% 9Singh B., Sood R. P. and Singh V., 1992, chemical composition of Tagetes minuta oil from Himachal Pradesh (India) J; Essent. Oil Res. 4:1992).
For enrichment of two major constituents present in tagetes oil, primary fractionation of hydrocarbons and ketones (ocimene and dihydrtotagetone), it is subject to solvent—solvent partitioning using n-pentane n-hexane may also be used and acetonitrile. Final purification of these components is achieved by chromatographic separation using Silica gel (60-120 mesh). The purity of the compounds was checked with the help of TCL and GC. Other components, tagetones and ocimenones could not be isolated in pure form because these components get polymerise at faster rate.
The whole oil of Tagetes minuta and its pure components i.e. ocimene and dihydrotagetone were tested individually with virus cultures of CaVMV and CaRSV and applied on the leaves of Chenopodium amaranticolor . In all the experiments each concentration of three testing mixtures were applied on ten leaves of Chenopodium amaranticolor plant. The isolated compounds were stored at 0° C. for two months and the experiments were repeated.
EXAMPLE 1
In 350 ml of Tagetes minuta oil, 250 ml of acetonitrile and 250 ml of n-pentane (may be replaced by n-hexane or n-heptane) were added and mixture was shaken slowly in separating funnel. This was allowed to stand for half an hour. After separating two layers, the acetonitrile layer was washed three times with n-pentane (250 ml each), the pentane fractions were combined and the solvent evaporated i.e. n-pentane from pentane fraction and acetonitrile form acetonitrile fraction. After analysing both the fractions by Gas Chromatographic technique, following percentage of ocimene (hydrocarbon) and dihydrotagetone (ketone) were observed. The freshly distilled Tagetes minuta oil contained ocimene 54.97% and dihydrotagetone 32.58%.
1. Pentane fraction : Ocimene 62.5% Dihydrotagetone 24.62%
2. Acetonitrile Fraction Ocimene 26.96% Dihydrotagetone 69.87%
The enrichment of dihydrotagetone was achieved form 32.5%, present in freshly distilled oil to nearly 70% after partitioning.
The acetonitrile fraction was subjected to the column chromatography on Silica gel (60-120 mesh), run initially with n-hexane and then with an increasing polarity with ethyl acetate upto 2% to get pure dihydrotagetone. Confirmation of dihydrotagetone was made by various analytical techniques like IR, GC, GC-MS, 1 H & 13 C NMR spectroscopy and the odour profile was checked by the internal faculty members.
Identification
The identification and structure confirmation was done with the help of MS, IR, 1 H-NMR and 13 C-NMR
Dihydrotagetone
Molecular Formula
C 10 H 18 O
m/e (%)
154 (10), 97 (30), 85 (100), 69 (50)
57 (65), 55 (35), 53 (18), 44 (15), 41 (60)
1 H-NMR (ppm, CDCl 3 )
4.89-5.02 (2H, m, H-1), 5.64-5.78 (1H, m,
H-2) 2.68-2.75 (1H, m H-3), 2.09-2.47
(4H, m, H-4, 6) 1.11-1.26 (3H, d J=
6 Hz, H-8), 1.02-0.89 (6H, d, J=
6 Hz, H-9, 10)
13 C-NMR(ppm, CDCl 3 )
112.49, (C-1), 142.64 (C-2), 23.97 (C-3), 207.9
(C-4), 51.94 (C-5), 49.4 (C-6) 32.75 (C-7),
32.75 (C-7), 22.23 (C-8) 19.8 (C-9), 22.23
(C-10).
Ocimene
Molecular Formula
C 10 H 16
m/e (%)
136 (5), 121 (15), 1.5 (19), 93 (100), 91 (52),
79 (45), 65 (15), 53 (20), 41 (27)
1 H-NMR (ppm, CDCI 3 )
1.55, (3H, s, H-8), 1.63 (3H,s, H-10),
1.81 (3H, s, H-9), 2.85 (2H, t, J=7.5 Hz,
H-5), 5.06-5.38 (4H, m, H-1, 4, 6), 6.73-6.87
(1H, m, H-2).
13 C-NMR(ppm, CDCl 3 )
113.83 (C-1), 134.04 (C-2), 132.34 (C-3)
130.0 (C-4), 26.85 (C-5, 122.92 (C-6)
132.34 (C-7), 18.07 (C-8) 26.03 (C-9)
20.09 (C-10)
EXAMPLE 2
Virus Culture
The Cultures of Carnation ring spot and Carnation vein motto viruses were maintained both in natural host and on Phaseolus vulgaris and Chenopodium quinoa which are maintenance and propagation host of these viruses respectively. For virus culture, leaves of fifteen days old individual virus inoculated host plants with CaVMV and CaRSV were ground in phosphate buffer pH 7.5 and the viruses were extracted separately in crude sap.
Screening of Antiviral Activity
Activity of the above volatile oils were tested against Carnation ring spot and Carnation vein mottle virus in different dilutions. Most of the tests were performed by using 0.5% and 2.5% concentration of essential oils as the phytotoxic effect appeared on Chenopodium amaranticolor leaves, at higher concentrations. The 0.5% and 2.5% concentration of essential oils were mixed with crude sap containing each virus and incubated at room temperature for 24 hrs. After incubation, sap containing virus were inoculated individually on bioassay host Chenopodium amaranticolor after adding Cellite (as abrasive) to monitor the inhibitory effect. Following results were obtained in different concentrations.
TABLE 1a
Treatment of CaVMV with 0.5% Tagetes minuta oil
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
39
713
3.9
71.1
94.5
2.
46
657
4.6
65.7
92.2
3.
42
702
4.2
70.2
94.2
TABLE 1b
Treatment of CaRSV with 0.5% Tagetes minuta oil
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
67
761
6.7
76.1
91.3
2.
55
769
5.5
76.9
92.8
3.
65
770
6.5
77
91.5
TABLE 2a
Treatment of CaVMV with 2.5% Tagetes minuta oil
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
82
699
8.2
69.9
88.2
2.
76
648
7.6
64.8
88.2
3.
70
655
7.0
65.5
89.3
TABLE 2b
Treatment of CaRSV with 2.5% Tagetes minuta oil
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
73
582
7.3
58.2
87.45
2.
77
624
7.7
62.4
87.6
3.
75
612
7.5
61.2
87.7
TABLE 3a
Treatment of CaVMV with 0.5% Dihydrotagetone
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
38
141
4.22
15.66
73.04
2.
40
150
4.44
15.66
73.3
3.
45
152
5.00
15.70
70.3
TABLE 3b
Treatment of CaRSV with 0.5% Dihydrotagetone
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
32
115
4.22
15.66
72.1
2.
41
141
4.44
15.66
70.9
3.
42
150
5.00
15.70
72.0
TABLE 4a
Treatment of CaVMV with 2.5% Dihydrotagetone
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
31
183
3.44
20.33
83.0
2.
25
192
2.77
21.33
87.0
3.
38
200
4.20
22.22
81.0
TABLE 4b
Treatment or CaRSV with 2.5% Dihydrotagetone
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
82
155
2.8
15.5
81.8
2.
25
140
2.5
14.0
82.0
3.
40
195
4.0
19.5
79.4
TABLE 5a
Treatment of CaVMV with 0.5% Ocimene
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
66
228
6.6
22.8
71.05
2.
70
215
7.0
21.5
63.50
3.
65
233
6.5
23.3
72.1
TABLE 5b
Treatment of CaRSV with 0.5% Ocimene
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
60
198
6.0
19.8
69.6
2.
65
195
6.5
19.5
66.6
3.
58
180
5.8
18.0
67.7
TABLE 6a
Treatment of CaVMV with 2.5% Ocimene
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
43
262
4.3
26.8
83.58
2.
40
250
4.0
25.0
84.00
3.
38
265
3.8
26.5
85.66
TABLE 6b
Treatment of CaRSV with 2.5% Ocimene
No. of Lesions on
Average No. of lesions
S.No.
Test
Control
Test
Control
% inhibition
1
40
205
4.0
20.5
80.4
2.
25
135
2.5
13.5
81.4
3.
35
185
3.5
18.5
81.0
When these pure isolated compounds were stored at 0° C. for two months, following results were obtained.
TABLE 7a
Treatment of CaVMV with DHT (stored at 0° C. for two months)
0.5% concentration
2.5% concentration
S. No.
Test
Control
Test
Control
1
0
158
0
200
2.
0
170
0
185
3.
0
165
0
189
TABLE 7b
Treatment of CaRSV with DHT (stored at 0° C. for two months)
0.5% concentration
2.5% concentration
S. No.
Test
Control
Test
Control
1
0
141
0
195
2.
0
168
0
188
3.
0
166
0
190
TABLE 8a
Treatment of CaVMV with Ocimene
(stored at 0° C. for two months)
0.5% concentration
2.5% concentration
S. No.
Test
Control
Test
Control
1
0
200
0
262
2.
0
250
0
285
3.
0
260
0
203
TABLE 8b
Treatment of CaRSV with Ocimene
(stored at 0° C. for two months)
0.5% concentration
2.5% concentration
S. No.
Test
Control
Test
Control
1
0
210
0
267
2.
0
235
0
282
3.
0
216
0
213
TABLE 9a
Percentage Inhibition of CaVMV with Three Treatments
1st Treatment
IInd Treatment
IIIrd Treatment
Component
0.5%
2.5%
Component
0.5%
2.5%
0.5%
2.5%
Whole oil
93.8
88.5
Ocimene
70.2
84.3
100
100
Dihydrotegetone
72.2
83.6
100
100
I Treatment: With Whole oil
II Treatment: With Both the compounds after Extraction
III Treatment: With both the compounds after storing at 0° C.
TABLE 9b
Percentage Inhibition of CaRSV with Three Treatments
1st Treatment
IInd Treatment
IIIrd Treatment
Component
0.5%
2.5%
Component
0.5%
2.5%
0.5%
2.5%
Whole oil
91.5
87.5
Ocimene
67.9
80.9
100
100
Dihydrotegetone
71.6
81.06
100
100
I Treatment: With Whole oil
II Treatment: With Both the compounds after Extraction
III Treatment: With both the compounds after storing at 0° C.
The main advantages of the present invention are:
1 . Tagetes minuta plant grows wild in the hilly areas like Himachal Pradesh, Jammu and Kashmir, Uttar Pradesh, North Eastern States of India, and cultivated as commercial Tagetes oil crop hence easily available in bulk quality.
2. The oil and pure isolates are natural products and hence no threat to environment.
3. Application of oil and pure isolates ensure quick and efficient recovery from viral infections.
4. It also helps in the plant virus management.
5. Tagetes crop grows wild and can be distilled in rich pockets/places with prototype distillation unit.
6. A cheap, eco-friendly and easily available anti-viral natural product.
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This invention relates to an antiviral composition for the treatment of plant viruses comprising an effective amount of Tagetes minuta oil, its active constituents, Z-β-ocimene and dihydrotagetone, or any mixture thereof. The invention also relates to the use of Tagetes minuta oil, its active constituents Z-β-ocimene and dihydrotagetone, or any mixture thereof for the treatment of plant viruses.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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, convex or concave as long as the fluid from the tank may flow into the area above the filter.
[0011] 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.
[0012] 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.
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] 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.
[0023] 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.
[0024] 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.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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
[0029] FIG. 1 illustrates a front elevational view of a skimmer system attached to a tank and a cover/access assembly;
[0030] FIG. 2 is a cross sectional view of the skimmer system illustrated in FIG. 1 ;
[0031] FIG. 3 is a top view of a fabricated surface and a first embodiment of a cover/access assembly shown in FIG. 2 ;
[0032] FIG. 4 is a side elevational view of an inlet illustrated in FIG. 2 ;
[0033] FIG. 5 is an exploded view of the first embodiment of the cover/access assembly shown in FIG. 2 ;
[0034] FIG. 6 is a top view of a cap member illustrated in FIG. 5 ;
[0035] FIG. 7 is a front cross sectional view of the cover illustrated in FIGS. 5 and 6 ;
[0036] FIG. 8 is an exploded view of a second embodiment of a cover/access assembly;
[0037] FIG. 9 is a top view of a cap member illustrated in FIG. 8 ;
[0038] FIG. 10 is a front cross sectional view of the cover illustrated in FIGS. 8 and 9 ;
[0039] FIG. 11 is an exploded view of a third embodiment of a cover/access assembly;
[0040] FIG. 12 is a top view of a cap member and a frame illustrated in FIG. 11 ; and
[0041] FIG. 13 is a front cross sectional view of the cover illustrated in FIGS. 11 and 12 .
DETAILED DESCRIPTION OF THE INVENTION
[0042] 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.
[0043] 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.
[0044] 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 .
[0045] 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 .
[0046] 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.
[0047] 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.
[0048] 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 .
[0049] 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.
[0050] 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 .
[0051] 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 twenty degrees. 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.) 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 .
[0052] 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 .
[0053] 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 .
[0054] 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 .
[0055] 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 .
[0056] 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.
[0057] 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.
[0058] 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 .
[0059] 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 .
[0060] 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 .
[0061] 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 tank fluid surface 16 . If the level of the tank 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 .
[0062] 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 . 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 .
[0063] 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 .
[0064] 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.
[0065] 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.
[0066] 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 .
[0067] 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.
[0068] 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.
[0069] 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.
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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.
[0074] 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.
[0075] 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.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] 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.
[0080] 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 .
[0081] 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.
[0082] 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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BACKGROUND OF THE INVENTION
The present invention relates to the manufacture of artificial branch assemblies and more particularly to a machine for making artificial pine limbs used for the manufacture of artificial Christmas trees.
In prior art methods and machines for manufacturing artificial limbs the limbs must usually involve additional steps and handling to cut them and, in some cases, shape them with separate steps of assembling and attaching needles and attaching together to form the artificial branch. Each step used adds to the time and expense of manufacture.
SUMMARY OF THE INVENTION
It is an object of the present invention to assemble artificial limbs such as may be used to manufacture artificial pine trees in a speedy and inexpensive manner.
It is a further object of the present invention to do this assembly in a single machine which performs the work in a continuous manner.
Basically the present invention is a machine which makes a simulated pine tree limb from a continuous wire, having the needles already attached thereon, which wire is cut and formed into a branch in this machine.
In the present invention the machine disclosed uses a continuous wire having simulated pine needles attached thereto, cutting this wire to form twigs and immediately twists each of the twigs into a pair of continually twisting wires, both the pair of twisting wires and the twigs being fed as a continuous wire or wires to the machine with continuous non-stop operation of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages will be apparent from the description of the present invention and the accompanying drawings in which:
FIG. 1 is a side elevational view of the overall machine of the present invention;
FIG. 2 is a perspective view of the folding-cutting twig forming end of the machine viewing from the left side of the machine of the present invention;
FIG. 3 is an end view of the limb cutter portion of the machine;
FIG. 4 is a top view in section of the limb bending and forming portion of the machine with the cams controlling the operation.
FIGS. 5 through 9 illustrate the machine cutting and bending operation; and
FIG. 10 illustrates graphically the cam movement of the cam in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIGS. 1 and 2, there is shown a pair of twisted wires 10 with simulated pine or fir needles 11, for example, a monofilament cut in short lengths, which are fed through tube 12 which is swivel-mounted in holder 13 which is mounted on support arm 14 connected to carrier or distributor 15 which is mounted for transverse movement relative to the limb maker machine.
Carrier 15 is moved transversely through the pivotal movements of arms 16, 17 and 18 and rotating shaft 19, rotated from gear box 21 through motor 22 and belt 23 arrangement.
At the same time that twisted wires 10 with needles 11 are moving through tube 12 into the machine, wires 26 and 27, with a strand 28 of decorative material to add to the look of the wires to give a better appearance as a branch of a tree, are fed into the peripheral grooves of pulleys 31 and 32. The twisted wires 10 with needles 11 are fed as shown in FIG. 2, positioned perendicular to and in between wires 26 and 27 so as to be disposed between wires 26 and 27 when they emerge from between pulleys 31 and 32 as twisted strands 33 with cut lengths 10' therebetween.
Carriage 34 riding in track 35 carries rotating chuck 36 which is rotated through gearing and belts connected to motor 37. Carriage 34 and attached motor 37 are moved along track 35 by motor driven belt 38. Rotating chuck 36 grasps strands 33, twisting and maintaining tension on strands 33 throughout the process of manufacturing the artificial tree limbs.
The speed of movement of carriage 34 is variable and is varied to determine the spacing of cut lengths 10' along strands 33. This speed is also set so as to vary between groups of cut lengths 10' and introduce an enlarged spacing 39 between such groups, as illustrated between a group of six cut lengths 10'. Each branch will consist of two such groups and will be cut by limb cutter 40 further illustrated in more detail in the enlarged illustration of FIG. 3.
As shown in FIG. 3, cutters 41 and 42 are mounted for reciprocating movement on rails 43,44. Cutters 41, 42 are moved respectively by air cylinders 45 and 46.
In order to form cut lengths 10' and attach them to strands 33 the mechanism illustrated in FIGS. 2 and 4 is used with the steps in its use illustrated in FIGS. 5-9.
Wires 10 with simulated needles 11 held therein are fed continuously through tube 12 to cutters 50 alternately on opposite sides of pulleys 31, 32 by transverse movement of tube 12 in holder 13. At each of cutters 50 (only one shown on FIG. 2) wires 10 are cut at the end of each cross movement of tube 12 with the end of wires 10 (or cut length 10') held until the next transverse movement.
This cutting of wires 10 along with bending of the ends of cut lengths 10' is accomplished by the mechanism shown in FIG. 4. A shaft 51 with power through rod 52 rotates three cams 53, 54 and 55 which operate cutting slide element 56 and bending side elements 57 and 58 respectively.
Their operation as illustrated in FIGS. 5-9 are as follows. The slide elements 56, 57 and 58 start in the positions shown in FIG. 5. A clear path is shown between the elements as they move together with twisted wires 10 between them. Cam 53 moves cutting slide elements 56 inward past each other to perform the initial cutting of wires 10 into cut lengths 10' and the start of the bending of cut lengths 10' as shown in FIG. 6. When cutting slide elements 56 are fully extended through the horizontal axis of lengths 10' as shown in FIG. 7, the ends of lengths 10' are bent at an angle of 90° to those lengths. This is performed by the elongated notches 59 which bring the wire ends to their 90° position. Note that bending slide elements 57 in opposite positions to slide elements 56 have withdrawn from the horizontal axis of lengths 10' to allow room for the bending operation of FIGS. 5 and 7. By the motion of cams 53 and 54, slide elements 56 now withdraw and slide elements 57 go forward toward the horizontal axis. As shown in FIG. 8, the bent ends of lengths 10' are further bent to approximately 45° by notches 60 in slide elements 57. In the last step as illustrated in FIG. 9, cam 55 moves bending slide elements 58 toward the horizontal axis of lengths 10' to complete the bend to a 180° bend. At this point, the slide elements 56, 57 and 58 are back to their original position of FIG. 5, ready to separate and then receive the next portion of wires 10. The surfaces of the cams 53, 54 and 55 relative to each other during a complete 360° rotation is illustrated graphically in FIG. 10. The column on the left side has legends wherein C refers to the cam operating cutting slide elements 56, 1° B. refers to first bending slide elements 57, and 2° B. refers to second bending slide elements 58.
Therefore, not only is a branch for an artificial tree formed by a continuous and back and forth action combined for continuous operation, but included in the action is the bending of the ends to prevent sharp ends which would add to the possibility of accident.
It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification.
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A machine for making artificial limbs as for a Christmas tree where twisted wires having simulated needles attached are fed by a reciprocating transverse action to a pair of cutters which cut the wires to predetermined lengths while at the same time a pair of wires and a strand of decorative material are fed between a pair of pulleys where the cut lengths are attached perpendicularly to the pair of wires and decorative strand being twisted.
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FIELD OF THE INVENTION
[0001] This invention relates to a two-port capacity control valve for a variable capacity refrigerant compressor, and more particularly to a pneumatic regulating control valve that is electrically biased to adjust the pneumatic regulation setpoint.
BACKGROUND OF THE INVENTION
[0002] Variable capacity refrigerant compressors have been utilized in automotive air conditioning systems, with the compressor capacity being controlled by a control valve that is either pneumatically-operated or electrically-operated. In either case, the control valve typically varies the pressure in a crankcase of the compressor to control the compressor capacity. In a particularly economical arrangement, the compressor includes an internal bleed passage coupling the crankcase to suction (low-side) refrigerant pressure, and the control valve controls refrigerant flow though a control passage coupling the crankcase to discharge (high-side) refrigerant pressure by controlling the position of a plunger relative to the control passage. In pneumatically-operated control valves, the plunger is positioned by a bellows or diaphragm that is responsive to suction pressure, whereas in electrically-operated control valves, the plunger is positioned by the armature of a solenoid that is energized by a system controller. In general, pneumatically-operated control valves offer superior stability, while electrically-operated control valves offer superior flexibility. Accordingly, it has been proposed to integrate both pneumatic and electric control elements into a single control valve to obtain inherently stable and flexible suction pressure control. In such integrated control valves, the pneumatic control element establishes a predefined regulation setpoint for the suction pressure, and the electric control element is variably energized to bias the pneumatic element, effectively adjusting the regulation setpoint. See, for example, the U.S. Pat. Nos. 6,439,858 and 6,126,405, which are incorporated herein by reference.
SUMMARY OF THE PRESENT INVENTION
[0003] The present invention is directed to an improved integrated capacity control valve for a variable capacity refrigerant compressor, wherein the valve includes an integral pressure sensor that is continuously coupled to a discharge chamber of the valve for measuring the compressor discharge pressure. A plunger of the control valve is disposed within a passage coupling the compressor crankcase to the discharge chamber, and is positioned by pneumatic and electric control elements to regulate the suction pressure of the compressor. The plunger has intersecting axial and lateral bores that define a continuous passage between the discharge chamber and a cavity in which the pressure sensor is retained so that the sensor is continuously exposed to the discharge pressure regardless of the plunger position, and discharge pressure in the lateral bore produces a bias force on the plunger that compensates the pneumatic suction pressure setpoint for a pressure drop between the evaporator and the suction port of the compressor. The solenoid armature is pressure balanced and includes a movable coil that interacts with a stationary pole piece including one or more permanent magnets.
BRIEF DESCRIPTION OF THE DRAWING
[0004] FIG. 1 is a cross-sectional view of an integrated capacity control valve according to this invention.
[0005] FIG. 2 graphically depicts variation in a suction pressure setpoint of the control valve of FIG. 1 as a function of electrical activation of the control valve.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0006] Referring to the drawing, the reference numeral 10 generally designates a compressor capacity control valve according to the present invention. The control valve 10 is designed to be mounted in the rear head of variable capacity refrigerant compressor such that the ports 12 , 14 and 16 are respectively placed in communication with chambers containing the compressor suction, discharge and crankcase pressures, with the O-rings 18 and 19 positioned to prevent leakage from the discharge port 14 to the suction or crankcase ports 12 , 16 . A third O-ring 20 prevents leakage between the crankcase port 16 and atmosphere. The illustrated arrangement of valve ports is particularly advantageous since it matches the rear head refrigerant chamber configuration most commonly utilized in variable capacity compressors, facilitating fluid coupling between the control valve ports and the respective refrigerant chambers.
[0007] The purpose of the control valve 10 is to control the pressure in the crankcase chamber as a means of controlling the compressor capacity. In the illustrated embodiment, increasing the crankcase pressure causes the compressor pumping capacity to decrease, and decreasing the crankcase pressure causes the compressor pumping capacity to increase. The compressor includes an internal bleed valve between its crankcase and suction chambers to establish a full capacity compressor when the discharge chamber is isolated from the crankcase chamber, and the control valve 10 variably couples the discharge and crankcase chambers to raise the crankcase pressure to reduce the compressor capacity.
[0008] The suction, discharge and crankcase ports 12 , 14 and 16 extend laterally in order through a pressure port 22 that includes an internal axial bore 24 coupling the ports 12 , 14 , 16 . The inboard end of the bore 24 terminates in a suction chamber 25 that houses a pneumatic bellows 26 , and a plunger 30 disposed within the bore 24 is press-fit into the outboard end of bellows 26 as shown. The bellows 26 includes an internal spring 32 axially aligned with the bore 24 , and the inboard end of bellows 26 is seated against a setpoint adjustment screw 34 threaded into the inboard end of pressure port 22 . As explained below, the screw 34 can be manually rotated to change the bellows spring force applied to plunger 30 for purposes of adjusting a pneumatic setpoint pressure of the control valve 10 .
[0009] The plunger 30 includes an inboard portion 30 a having a relatively small diameter and an outboard portion 30 b having a diameter that is larger than the inboard portion 30 a . The inboard portion 30 a fits closely within the portion of bore 24 that couples the suction and discharge ports 12 and 14 , but loosely within the portion of bore 24 that couples the discharge and crankcase ports 14 and 16 , allowing a flow of discharge refrigerant between bore 24 and the inboard portion 30 a of plunger 30 . The outboard portion 30 b of the plunger 30 is sized to fit closely within the portion of bore 24 that couples the discharge and crankcase ports 14 and 16 , so that the plunger 30 can be axially positioned to control refrigerant flow from the discharge port 14 to the crankcase port 16 . In general, inboard movement of the plunger 30 decreases the refrigerant flow to decrease the crankcase pressure, thereby increasing the compressor capacity, while outboard movement of the plunger 30 increases the refrigerant flow to increase the crankcase pressure, thereby decreasing the compressor capacity. The outboard portion 30 b of plunger 30 is provided with balance grooves 31 that tend to fill with refrigerant during operation of the compressor 10 . Lubricating oil is ordinarily suspended in the refrigerant, and the oil captured in the grooves 31 tends to laterally balance plunger 30 within the bore 24 , minimizing the force required to axially displace plunger 30 .
[0010] Bellows spring 32 produces an outboard force or bias on plunger 30 that is countered by an opposing pneumatic force proportional to the amount by which the suction pressure in chamber 25 exceeds a sub-atmospheric air pressure internal to the bellows 26 . When the suction pressure achieves a calibrated setpoint, the spring force and pneumatic forces balance and the control valve 10 is in equilibrium. If system conditions cause the suction pressure to deviate from the setpoint, the bellows 26 expands or contracts, producing a corresponding axial movement of the plunger 30 within the bore 24 to counteract the suction pressure deviation and bring the control valve 10 back into equilibrium. For example, when the suction pressure increases due to increased air conditioning load, the bellows 26 contracts to produce inboard movement of the plunger 30 . This reduces the discharge-to-crankcase refrigerant flow (and hence, the crankcase pressure), which produces increased compressor capacity. The increased compressor capacity eventually lowers the suction pressure, allowing bellows 26 to expand somewhat so that the compressor capacity is decreased to a level that maintains the suction pressure at the calibrated setpoint. Rotating the screw 34 to adjust its axial position within the pressure port 22 changes the bias force of bellows spring 32 , and therefore the suction pressure setpoint. For example, adjusting the screw 34 to decrease its axial penetration into the pressure port 22 decreases the outboard spring force on plunger 30 , which requires a corresponding reduction in the suction pressure if the pneumatic and spring forces are to be maintained in equilibrium; in other words, the suction pressure setpoint is correspondingly decreased. The opposite effect is achieved, of course, by rotating the screw 34 to increase its axial penetration into the pressure port 22 .
[0011] The outboard end of pressure port 22 is received within a cylindrical housing member 40 , compressing an O-ring seal 42 therebetween. The housing member 40 is part of a solenoid assembly 44 that when electrically activated biases plunger 30 in the inboard direction, effectively counteracting the force of bellows spring 26 . This reduces the suction pressure setpoint just as though the screw 34 were adjusted to decrease its axial penetration into the pressure port 22 as described above. The solenoid force is proportional to the level of electrical activation so that the suction pressure setpoint can be controlled as graphically depicted in FIG. 2 , where the solenoid activation level is depicted as a pulse-width-modulation (PWM) duty cycle.
[0012] The solenoid assembly 44 additionally includes a set of permanent magnets 45 and 46 disposed between the housing element 40 and an inner pole piece 48 , and a cup-shaped spool 50 carrying a movable coil 52 . The spool 50 is secured to the outboard end of plunger 30 , and a housing element 54 is secured to the housing element 40 , defining an internal cavity 56 in which the spool 50 can move axially with the plunger 30 . A spring 58 disposed about plunger 30 between the spool 50 and the outboard end of pressure port 22 biases spool 50 and plunger 30 to the retracted position shown in FIG. 1 , effectively aiding the spring force of bellows spring 26 . In the illustrated limit position, the inboard end of plunger 30 rests against the housing element 54 about an aperture 60 axially aligned with the bore 24 . The flexible conductors 62 couple the movable coil 52 to the terminals 64 , and electrically energizing coil 52 via terminals 64 produces a magnetic field that attracts the spool 50 toward the permanent magnet 46 , biasing the spool 50 and plunger 30 inboard against the force of springs 58 and 32 .
[0013] Internal measurement of the discharge pressure is achieved by providing intersecting lateral and axial bores 70 and 72 within the plunger 30 and securing a pressure sensor 74 to the inboard face of housing element 54 about the opening 60 . The pressure sensor 74 , which may be a top-hat stainless steel diaphragm-type sensor, compresses an O-ring 76 against an outboard surface of the housing element 54 , and is held in place by the base housing element 78 and the housing insert 80 . Discharge refrigerant is coupled through the plunger bores 70 , 72 into the aperture 60 of housing element 54 and the inner periphery of the pressure sensor 74 . The discharge refrigerant also enters the cavity 56 (primarily when plunger 30 is displaced inboard from the limit position depicted in FIG. 1 ), and one or more openings 77 formed in the spool 50 ensure pressure equalization across the base of spool 50 during its movement.
[0014] The discharge refrigerant pressure acting on the inner periphery of pressure sensor 74 produces flexure of its diaphragm, and the mechanical strain associated with the flexure is detected by a piezo-resistor circuit (not depicted) formed on the exterior surface of the diaphragm. The piezo-resistor circuits are wire-bonded to bond pads formed on a circuit board 82 (which may also support signal conditioning circuitry), and the circuit board circuitry is coupled to the connector terminals 84 via the wires 86 . The circuit board 82 has a central opening for receiving the outboard end of pressure sensor 74 , and is held in place by the housing element 88 and the connector 90 . The connector 90 is secured to the outboard end of base housing piece 78 as shown, and supports the terminals 64 and 84 in an insulative insert 92 . An O-ring 94 compressed between the connector 90 and the housing piece 78 seals the enclosed area 96 from environmental pressures so that the pressure measured by sensor 74 can be calibrated to indicate the absolute discharge pressure, as opposed to a gauge pressure that varies with ambient or barometric pressure.
[0015] The continual presence of discharge pressure in the lateral bore 70 of plunger 30 creates a small but significant force that biases the plunger 30 inward. This discharge pressure bias effectively aids the suction pressure in suction chamber 25 , thereby compensating for diminution of the refrigerant pressure between the evaporator of the air conditioning system and the suction chamber of the compressor. The compensation is fairly accurate since the evaporator-to-compressor refrigerant pressure diminution or drop is substantially proportional to the discharge pressure. Accordingly, the suction pressure setpoint of the control valve 10 actually occurs at the evaporator instead of the compressor suction port 12 . Although this sort of compensation is known per se in pneumatically-operated valves, it is provided at no additional cost in the control valve 10 since the lateral bore 70 is already provided for purposes of discharge pressure measurement.
[0016] In operation, the energization of movable coil 52 is pulse-width-modulated to dither the plunger 30 within the bore 24 to control the refrigerant pressure in the compressor crankcase. The configuration of solenoid assembly 44 with the movable coil 50 and stationary permanent magnets 45 and 46 significantly reduces the electrical power required to activate the valve 10 , compared to a conventional fixed-coil design. The power requirement is additionally reduced by the balance grooves 31 , which minimize the frictional forces acting on the plunger 30 . In one implementation of this invention, for example, the maximum required coil current was only 300 mA, compared to a 1000 mA maximum current requirement in a conventional fixed-coil design, and the average current requirement under all operating conditions was reduced by at least 67%, compared to a conventional fixed-coil design. This reduction in the power requirement is particularly important in automotive applications because the generated electrical power is limited, particularly at low engine speeds. The system cost is also significantly reduced compared with a conventional approach because the discharge pressure is continuously and accurately measured by the internal sensor 74 . And finally, the discharge pressure in the lateral bore 70 of plunger 30 compensates for the evaporator-to-compressor refrigerant pressure drop so that the control valve 10 can effectively regulate the refrigerant pressure upstream of the compressor suction port.
[0017] While the present invention has been described in reference to the illustrated control valve 10 , it will be recognized that various modifications in addition to those mentioned above will occur to those skilled in the art. For example, a diaphragm can be substituted for the bellows 26 , if desired. Also, the control valve may be modified to include integral suction pressure measurement through the inclusion of an additional pressure sensor and auxiliary suction port. Further, the pressure sensor 74 may be replaced with a temperature sensor since the relationship between pressure and temperature of refrigerant in a closed volume system is known, and so on. Accordingly, capacity control valves incorporating such modifications may fall within the intended scope of this invention, which is defined by the appended claims.
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An integrated capacity control valve for a variable capacity refrigerant compressor includes an integral pressure sensor that is continuously coupled to a discharge port of the valve for measuring the refrigerant discharge pressure. A plunger of the control valve is disposed within a passage coupling the compressor crankcase to the discharge port, and is positioned by pneumatic and electric control elements to regulate the refrigerant suction pressure. The plunger has intersecting axial and lateral bores that define a continuous passage between the discharge port and a cavity in which the pressure sensor is retained so that the sensor is continuously exposed to the discharge pressure regardless of the plunger position, and refrigerant discharge pressure in the lateral bore produces a bias force on the plunger that compensates the pneumatic suction pressure setpoint for a pressure drop between the evaporator and the suction port of the valve.
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REFERENCE TO RELATED APPLICATION
The present application claims priority benefit under 35 U.S.C. §119(e) from U.S. Provisional Application No. 60/846,160, filed Sep. 20, 2006, entitled “Congenital Heart Disease Monitor,” which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Congenital heart disease (CHD) is relatively common, occurring in 5 to 10 of every 1,000 live births. Early diagnosis and treatment has improved outcomes in this population, but still a number of infants with CHD are sent home undiagnosed. Up to 30% of deaths due to CHD in the first year of life are due to such unrecognized cases. Several forms of CHD are the result of a patent ductus arteriosus (PDA).
FIG. 1 illustrates a fetal heart 102 and a portion of a fetal lung 104 . Prior to birth, the lung 104 is non-functional and fluid-filled. Instead, oxygenated blood is supplied to the fetus from gas-exchange in the placenta with the mother's blood supply. Specifically, oxygenated blood flows from the placenta, through the umbilical vein 106 and into the right atrium 122 . There, it flows via the foramen 124 into the left atrium 152 , where it is pumped into the left ventricle 150 and then into the aortic trunk 190 . Also, oxygenated blood is pumped from the right atrium 122 into the right ventricle 120 and directly into the descending aorta 140 via the main pulmonary artery 180 and the ductus arteriosus 130 . The purpose of the ductus arteriosus 130 is to shunt blood pumped by the right ventricle 120 past the constricted pulmonary circulation 110 and into the aorta 140 . Normally, the ductus arteriosus 130 is only patent (open) during fetal life and the first 12 to 24 hours of life in term infants. If the ductus arteriosus remains patent, however, it can contribute to duct-dependent congenital heart diseases, such as those described below.
Patent Ductus Arteriosus
FIG. 2 illustrates a neonatal heart 202 with a patent ductus arteriosus 230 . The ductus arteriosus frequently fails to close in premature infants, allowing left-to-right shunting, where oxygenated “red” blood flows from the aorta 240 to the now unconstricted pulmonary artery 210 and recirculates through the lungs 204 . A persistent patent ductus arteriosus (PDA) results in pulmonary hyperperfusion and an enlarged right ventricle 220 , which leads to a variety of abnormal respiratory, cardiac and genitourinary symptoms.
Persistent Pulmonary Hypertension in Neonates
As shown in FIG. 2 , persistent Pulmonary Hypertension in Neonates (PPHN) is a neonatal condition with persistent elevation of pulmonary vascular resistance and pulmonary artery pressure. The pulmonary artery 210 that normally feeds oxygen depleted “blue” blood from the right ventricle 220 to the lung 204 is constricted. The back pressure from the constricted pulmonary artery 210 results in a right-to-left shunting of this oxygen depleted blood through the ductus arteriosus 230 , causing it to mix with oxygen rich “red” blood flowing through the descending aorta 240 .
Aortic Coarctation
Also shown in FIG. 2 , coarctation of the aorta is a congenital cardiac anomaly in which obstruction or narrowing occurs in the distal aortic arch 290 or proximal descending aorta 240 . It occurs as either an isolated lesion or coexisting with a variety of other congenital cardiac anomalies, such as a PDA. If the constriction is preductal, lower-trunk blood flow is supplied predominantly by the right ventricle 220 via the ductus arteriosus 230 , and cyanosis, i.e. poorly oxygenated blood, is present distal to the coarctation. If the constriction is postductal, blood supply to the lower trunk is supplied via the ascending aorta 240 .
SUMMARY OF THE INVENTION
Once a problematic patent ductus arteriosus (PDA) is detected, closure can be effected medically with indomethacin or ibuprofen or surgically by ligation. Clinical symptoms of duct-dependent CHD, however, can vary on an hourly basis, and the required extended and inherently intermittent testing is difficult with current diagnostic techniques. These techniques include physical examination, chest x-ray, blood gas analysis, echocardiogram, or a combination of the above to detect, as an example, the soft, long, low-frequency murmur associated with a large PDA or, as another example, a retrograde flow into the main pulmonary artery.
As shown in FIG. 2 , a right hand has blood circulating from the left ventricle 250 through the innominate artery 260 , which supplies the right subclavian artery (not shown). Because the innominate artery 260 is upstream from the ductus arteriosus 230 , the oxygen saturation value and plethysmograph waveform obtained from the right hand are relatively unaffected by the shunt and serve as a baseline or reference for comparison with readings from other tissue sites. Alternatively, a reference sensor can be placed on a facial site, such as an ear, the nose or the lips. These sites provide arterial oxygen saturation and a plethysmograph for blood circulating from the left ventricle 250 to the innominate artery 260 , which supplies the right common carotid artery (not shown), or to the left common carotid artery 265 .
Also shown in FIG. 2 , either foot has blood supplied from the descending aorta 240 . A PDA 230 affects both the oxygen saturation and the blood flow in the descending aorta 240 . As stated above, the PDA 230 causes oxygen-depleted blood to be mixed with oxygen-rich blood in the descending aorta 240 . Because the descending aorta 240 supplies blood to the legs, the oxygen saturation readings at the foot will be lowered accordingly. That is, duct-dependent CHD may be manifested as a higher arterial oxygen saturation measured at a right hand tissue site (reference) and a lower oxygen saturation measured at a foot tissue site.
A PDA also allows a transitory left to right flow during systole, which distends the main pulmonary artery 280 as the result of the blood flow pressure at one end from the right ventricle and at the other end from the aortic arch 290 . A left-to-right flow through the shunt 230 into the distended artery 280 alters the flow in the descending aorta 240 and, as a result, plethysmograph features measured at either foot. Duct-dependent CHD, therefore, may also be manifested as a plethysmograph with a narrow peak and possibly a well-defined dicrotic notch at a hand baseline site and a broadened peak and possibly no notch at a foot site.
Further shown in FIG. 2 , a left hand has blood circulating from the left ventricle through the left subclavian artery 270 that supplies the left arm. Because the left subclavian artery 270 is nearer a PDA 230 than the further upstream innominate artery 260 , it may experience some mixing of deoxygenated blood and an alteration in flow due to the PDA 230 . Duct-dependent CHD, therefore, may also be manifested as a reduced saturation and an altered plethysmograph waveform measured at a left hand tissue site as compared with the right hand baseline site, although to a lesser degree than with a foot site.
FIG. 3 illustrates a patient monitoring system 300 , which provides blood parameter measurements, such as arterial oxygen saturation, and which can be adapted as an advantageous diagnostic tool for duct-dependent CHD. The patient monitoring system 300 has a patient monitor 302 and a sensor 306 . The sensor 306 attaches to a tissue site and includes a plurality of emitters 322 capable of irradiating a tissue site 320 with differing wavelengths of light, such as the red and infrared wavelengths utilized in pulse oximeters. The sensor 306 also includes one or more detectors 324 capable of detecting the light after attenuation by the tissue 320 . A sensor is disclosed in U.S. application Ser. No. 11,367,013, filed on Mar. 1, 2006, titled Multiple Wavelength Sensor Emitters, which is incorporated by reference herein. Sensors that attach to a tissue site and include light emitters capable of irradiating a tissue site with at least red and infrared wavelengths are disclosed in one or more of U.S. Pat. Nos. 5,638,818, 5,782,757, 6,285,896, 6,377,829, 6,760,607 6,934,570 6,985,764 and 7,027,849, incorporated by reference herein. Moreover, low noise optical sensors are available from Masimo Corporation, Irvine, Calif.
As shown in FIG. 3 , the patient monitor 302 communicates with the sensor 306 to receive one or more intensity signals indicative of one or more physiological parameters and displays the parameter values. Drivers 310 convert digital control signals into analog drive signals capable of driving sensor emitters 322 . A front-end 312 converts composite analog intensity signal(s) from light sensitive detector(s) 324 into digital data 342 input to the DSP 340 . The DSP 340 may comprise a wide variety of data and/or signal processors capable of executing programs for determining physiological parameters from input data. In an embodiment, the DSP executes the CHD screening and analysis processes described with respect to FIGS. 7-9 , below.
The instrument manager 360 may comprise one or more microcontrollers controlling system management, such as monitoring the activity of the DSP 340 . The instrument manager 360 also has an input/output (I/O) port 368 that provides a user and/or device interface for communicating with the monitor 302 . In an embodiment, the I/O port 368 provides threshold settings via a user keypad, network, computer or similar device, as described below.
Also shown in FIG. 3 are one or more devices 380 including a display 382 , an audible indicator 384 and a user input 388 . The display 382 is capable of displaying indicia representative of calculated physiological parameters such as one or more of a pulse rate (PR), plethysmograph (pleth) morphology, perfusion index (PI), signal quality and values of blood constituents in body tissue, including for example, oxygen saturation (SpO 2 ), carboxyhemoglobin (HbCO) and methemoglobin (HbMet). The monitor 302 may also be capable of storing or displaying historical or trending data related to one or more of the measured parameters or combinations of the measured parameters. The monitor 302 may also provide a trigger for the audible indictor 384 for beeps, tones and alarms, for example. Displays 382 include for example readouts, colored lights or graphics generated by LEDs, LCDs or CRTs to name a few. Audible indicators 384 include, for example, tones, beeps or alarms generated by speakers or other audio transducers to name a few. The user input device 388 may include, for example, a keypad, touch screen, pointing device, voice recognition device, or the like.
A patient monitor is disclosed in U.S. application Ser. No. 11,367,033, filed on Mar. 1, 2006, titled Noninvasive Multi-Parameter Patient Monitor, incorporated by reference herein. Pulse oximeters capable of measuring physiological parameters including SpO 2 , pleth, perfusion index and signal quality are disclosed in one or more of U.S. Pat. Nos. 6,770,028, 6,658,276, 6,157,850, 6,002,952, and 5,769,785, incorporated by reference herein. Moreover, pulse oximeters capable of reading through motion induced noise are available from Masimo Corporation, Irvine, Calif.
A congential heart disease (CHD) monitor advantageously utilizes a patient monitor capable of providing multiple-site blood parameter measurements, such as oxygen saturation, so as to detect, for example, hand-foot oxygen saturation differences associated with a PDA and related CHD.
One aspect of a CHD monitor is a sensor, a patient monitor and a DSP. The sensor is configured to emit optical radiation having a plurality of wavelengths into a tissue site and to detect the optical radiation after attenuation by pulsatile blood flowing within the tissue site. The monitor is configured to drive the sensor, receive a sensor signal corresponding to the detected optical radiation and to generate at least one of a visual output and an audio output responsive to the sensor signal. The DSP is a portion of the patient monitor and is programmed to derive a physiological parameter from sensor data responsive to the sensor signal. The physiological parameter is measured at a baseline tissue site and a comparison tissue site. The outputs indicate a potential CHD condition according to a difference between the physiological parameter measured at the baseline tissue site and the physiological parameter measured at the comparison tissue site.
Another aspect of a CHD monitor is a congenital heart disease screening method providing a patient monitor and corresponding sensor. The sensor is capable of emitting optical radiation having a plurality of wavelengths into a tissue site and detecting the optical radiation after attenuation by pulsatile blood flowing within the tissue site. The patient monitor is capable of receiving a sensor signal corresponding to the detected optical radiation and calculating a blood-related physiological parameter. The physiological parameter is measured at a baseline tissue site and a comparison tissue site. The measured physiological parameter at the baseline tissue site and at the comparison tissue site are compared. A potential CHD condition is indicated based upon the comparison.
A further aspect of a CHD monitor is a detection method determining a plurality of metrics responsive to sensor data derived from a plurality of tissue sites on an infant, testing the metrics with respect to predetermined rules and thresholds, and outputting diagnostics responsive to the test results. The metrics are at least one of a physiological parameter measurement, a cross-channel measurement and a trend. The diagnostics are responsive to the likelihood of congenital heart disease.
Yet another aspect of a CHD monitor comprises a patient monitor, a pre-processor means, an analyzer means and a post-processor means. The patient monitor is configured to receive sensor data from at least one optical sensor attached to a plurality of tissue sites on an infant. The pre-processor means is for deriving at least one metric from the sensor data. The analyzer means is for testing the at least one metric according to at least one rule. The post-processor means is for generating diagnostics based upon results of the testing The at least one rule defines when the at least one metric indicates a potential CHD condition in the infant.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a fetal heart depicting a ductus arteriosis;
FIG. 2 is an illustration of a neonatal heart depicting a patent ductus arteriosis (PDA);
FIG. 3 is a general block diagram of a patient monitoring system adapted for congenital heart disease (CHD) detection;
FIG. 4 is an illustration of a single patient monitor utilized for CHD detection;
FIG. 5 is an illustration of multiple patient monitors utilized for CHD detection;
FIG. 6 is an illustration of a single patient monitor and multi-site sensor utilized for CHD detection;
FIGS. 7A-B is a flow diagram of a CHD screening embodiment;
FIG. 8 is a detailed block diagram of a CHD analyzer embodiment; and
FIG. 9 is a detailed block diagram of a preprocessor embodiment for a CHD analyzer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 4 illustrates CHD detection utilizing a single patient monitor 410 and corresponding sensor 420 . In general, the monitor 410 provides a display or other indicator that directs a caregiver or other user to attach the sensor 420 to an initial tissue site for a first measurement and then to one or more other tissue sites for additional measurements. This procedure is described in further detail with respect to FIGS. 7A-B , below. For example, in a Phase I configuration 401 , the sensor 420 is attached to a neonate's right hand so that the monitor 410 generates baseline site measurements. In a Phase II configuration 402 , the sensor 420 is attached to a neonate's foot so that the monitor 410 generates comparison site measurements. In an optional Phase III configuration 403 , the sensor 420 is attached to a neonate's left hand generating measurements at an additional comparison site. During each phase 401 - 403 , the monitor 410 takes measurements for a length of time sufficient to determine user-selected parameters, which includes SpO 2 and may include PR, PI, signal quality, pleth morphology, other blood parameters such as HbCO and HbMET, and trends over a selected time interval for any or all of these parameters. In an embodiment, baseline right-hand measurements are made first, followed by measurements at either foot, followed by optional left-hand measurements. In other embodiments, the phase-order of measurements can be user-selected and can be in any order and can include or exclude either the foot or the left-hand measurements.
In an embodiment, a monitor-determined time or user-selectable timer defines how long each site measurement is made, and a monitor display and/or audible indicator signals the user when to switch sensor sites. In an embodiment, a user defines time intervals or times-of-day for making repeat measurement cycles so as to obtain site difference trends. A monitor display and/or audible indicator signals the user when to begin a measurement cycle.
FIG. 5 illustrates CHD detection utilizing multiple patient monitors 510 - 520 and corresponding sensors 530 - 540 . In an embodiment, a first monitor 510 and first sensor 530 provide measurements from a right-hand tissue site. A second monitor 520 and second sensor 540 provide measurements from a foot tissue site. An interface cable 550 or wireless link provides communications between the monitors 510 - 520 . For example, the monitors 510 - 520 can communicate respective measurements via RS-232, USB, Firewire or any number of standard wired or wireless communication links. In an embodiment, one monitor, such as the baseline right-hand monitor 510 acts as the master and the comparison (e.g. foot) monitor 520 acts as a slave. The master monitor 510 generates the baseline measurements, transfers the comparison measurements from the slave monitor 520 , calculates the comparison parameters, such as oxygen saturation differences, displays the comparison parameters, calculates alarm conditions based upon the measured and comparison parameters and generates alarms accordingly.
In other embodiments, the comparison site (e.g. foot or left-hand) monitor 520 is the master and the baseline (right-hand) monitor 510 is the slave. In yet another embodiment, there are three networked monitors corresponding to right-hand, left-hand and foot sites, with one monitor acting as a master and the other monitors acting as slaves. The master monitor, in this example, calculates oxygen saturation differences for each pair of sites and generates alarms accordingly.
FIG. 6 illustrates CHD screening utilizing a single CHD patient monitor 610 and a corresponding multi-site sensor 620 . In an embodiment, the multi-site sensor 620 has two sensor heads 622 - 624 and a common sensor cable 628 for communication with the monitor 610 . One sensor head 622 is attached to a baseline tissue site, e.g. a right-hand and another sensor head 624 is attached to a comparison tissue site, e.g. either a foot or a left-hand. In another embodiment, a third sensor head 626 is available for attachment to a second comparison site, e.g. a left-hand. A multiple site patient monitor is disclosed in U.S. Pat. No. 6,334,065 issued Dec. 25, 2001 titled Stereo Pulse Oximeter which is assigned to Masimo Corporation, Irvine, Calif. and incorporated by reference herein.
FIGS. 7A-B illustrate a CHD screening process 700 corresponding to a single monitor CHD detection embodiment, such as described with respect to FIG. 4 , above. In general, the process 700 is described with respect to user actions 701 and monitor responses 702 and, likewise, monitor prompts 702 and user responses 701 . In particular, once the monitor enters a CHD detection mode, the monitor prompts a user to attach the sensor successively to two or more tissue sites. In this manner, the monitor can compute baseline and comparison site measurements and calculate site differences, such as in oxygen saturation, which tend to predict the likelihood or unlikelihood of CHD. In an embodiment, the monitor 702 communicates instructions to the user 701 or otherwise prompts the user with display messages. Alternatively, or in addition to display messages, the monitor 702 can prompt the user via audio messages or indicators, visual indicators such as panel lights or a combination of the above. In an embodiment, the user 701 can trigger the monitor 702 or otherwise respond to monitor 702 prompts via a panel-mounted push button. Alternatively, or in addition to a push button, the user 701 can trigger the monitor 702 or otherwise respond to the monitor 702 via touch screen, touch pad, keyboard, mouse, pointer, voice recognition technology or any similar mechanism used for accomplishing a computer-human interface.
As shown in FIG. 7A , a user 701 initiates CHD screening 705 and the monitor 702 enters a CHD detection mode 710 in response. The monitor 702 then prompts the user 701 to attach a sensor to a baseline site 715 . In response, the user 701 attaches a sensor to a first tissue site 720 , such as a neonate's right hand, and pushes a button 725 to trigger the monitor to take baseline sensor measurements 730 . The monitor 702 displays the resulting baseline measurements 732 and prompts the user 701 to reattach the sensor to a comparison site 735 . In response, the user 701 removes the sensor and reattaches it to a second tissue site 740 , such as either of a neonate's feet, and pushes a button 745 to trigger the monitor 702 to take comparison sensor measurements 750 . The monitor 702 displays the resulting comparison site measurements 755 .
As shown in FIG. 7B , after taking baseline site and comparison site measurements, the monitor 702 determines if a third site measurement is to be taken 760 . If so, the monitor 702 prompts the user 701 to reattach the sensor to an additional comparison site 765 . In response, the user 701 removes the sensor and reattaches it to a third tissue site 770 , such as a neonate's left-hand, and pushes a button 775 to trigger the monitor 702 to take additional comparison site measurements 780 . The monitor 702 then displays the resulting measurements 785 . The monitor 702 determines if trend measurements are being made 787 . If so, then after a predetermined delay the monitor 702 prompts the user to re-attach the sensor at the baseline site 715 ( FIG. 7A ) to begin an additional series of measurements 730 - 785 .
Also shown in FIG. 7B , after all site measurements are taken, the monitor 702 calculates the measurement differences between the baseline and comparison site(s) 790 , calculates trends in measurements and measurement differences 790 and displays the results 792 . The monitor 702 then determines whether any site measurements, site measurement differences or trends are outside of preset limits 794 . If limits are exceeded, the monitor generates visual and/or audio indicators of a potential CHD condition 796 . For example, an audio alert or alarm of a potential CHD condition may be a low-level intermittent beep so as to indicate a diagnostic result and not be confused with other urgent care alarms. In one embodiment, if neonatal SpO 2 measurements from both a right hand and a foot are less than about 95% or a hand-foot difference is greater than about ±3%, the monitor generates one or more indicators alerting a caregiver that a potential CHD condition exists.
FIG. 8 illustrates a CHD analyzer 800 that executes in the DSP 340 ( FIG. 3 ) and indicates a potential CHD or lack thereof. The CHD analyzer 800 is advantageously responsive to multiple channels of sensor data 801 so as to generate CHD diagnostics 803 . In an embodiment, the CHD analyzer 800 executes the CHD screening process described with respect to FIGS. 7A-B , above, receiving sensor data 342 ( FIG. 3 ) derived from one tissue site at a time. In another embodiment, the CHD analyzer 800 receives sensor data 342 ( FIG. 3 ) derived from two or more sensor sites at a time, such as described with respect to FIGS. 5-6 , above. The diagnostic output 803 can be used, for example, to generate displays or indicators useful for grading a neonate with respect to a potential CHD condition and the severity of that condition. In an embodiment, an instrument manager 360 ( FIG. 3 ) convert CHD diagnostics 803 via a display driver 362 ( FIG. 3 ) and an audio driver 364 ( FIG. 3 ) into one or more displays 382 ( FIG. 3 ) and audible indicators 384 ( FIG. 3 ) for use by a physician, clinician, nurse or other caregiver.
In an embodiment, the CHD analyzer 800 has a pre-processor 900 , a metric analyzer 820 , a post-processor 830 and a controller 840 . The pre-processor 900 has sensor data inputs 801 from one or more sensor channels, such as described with respect to FIGS. 4-6 , above. The pre-processor 900 generates metrics 822 that may include, for example, physiological parameters, waveform features, and cross-channel comparisons and trends, as described in further detail with respect to FIG. 9 , below.
As shown in FIG. 8 , the metric analyzer 820 is configured to test metrics 822 and communicate the test results 824 to the post-processor 830 based upon various rules applied to the metrics 822 in view of various thresholds 826 . As an example, the metric analyzer 820 may communicate to the post-processor 830 when a parameter measurement increases faster than a predetermined rate, e.g. a trend metric exceeds a predetermined trend threshold.
Also shown in FIG. 8 , the post processor 830 inputs test results 824 and generates CHD diagnostic outputs 803 based upon output definitions 832 . For example, if the test result is that a trend metric exceeds a trend threshold, then the output definition corresponding to that test result may be to trigger an audible alarm. Thresholds, rules, tests and corresponding outputs are described in further detail with respect to TABLE 1, below.
Further shown in FIG. 8 , the controller 840 has an external communications port 805 that provides predetermined thresholds, which the controller 840 transmits to the metric analyzer 820 . The controller 840 may also provide metric definitions 824 to the pre-processor 900 and define outputs 832 for the post-processor 830 .
In an embodiment, CHD screening grades a neonate with respect to a likelihood of a CHD condition utilizing green, yellow and red indicators. For example, a green panel light signals that no metric indicates a potential CHD condition exists. A yellow panel light signals that one metric indicates a potential CHD condition exists. A red panel light signals that more than one metric indicates that a potential CHD condition exists. In an embodiment, the CHD analyzer 800 provides a diagnostic output 803 according to TABLE 1, below. The terms Sat xy , ΔSat xy and Δt listed in TABLE 1 are described with respect to FIG. 9 , below. Various other indicators, alarms, controls and diagnostics in response to various combinations of parameters and thresholds can be substituted for, or added to, the rule-based outputs illustrated in TABLE 1.
TABLE 1
CHD Analyzer Rules and Outputs
RULE
OUTPUT
If Sat > Sat limit threshold (all channels);
Then illuminate
Sat xy < Sat xy limit threshold (all cross-channels); and
green indicator.
ΔSat xy /Δt < Sat xy trend threshold (all cross-channels).
If Sat < Sat limit threshold (any channel);
Then illuminate
Sat xy > Sat xy limit threshold (any cross-channel); or
yellow
ΔSat xy /Δt > Sat xy trend threshold (any cross-channel).
indicator
If Sat < Sat limit threshold (any channel); and
Then illuminate
Sat xy > Sat xy limit threshold (any cross-channel).
red indicator
If Sat < Sat limit threshold (any channel); and
Then illuminate
ΔSat xy /Δt > Sat xy trend threshold (any cross-channel).
red indicator
FIG. 9 illustrates a preprocessor embodiment 900 that inputs sensor data 801 derived from one or more tissue sites and outputs metrics 822 . The preprocessor 900 has a parameter calculator 910 , a waveform processor 920 , a cross-channel calculator 930 and a trending function 940 . The parameter calculator 910 outputs one or more physiological parameters derived from pulsatile blood flow at a tissue site. These parameters may include, as examples, arterial oxygen saturation (SpaO 2 ), venous oxygen saturation (SpvO 2 ), PR and PI to name a few. In an embodiment, the parameter calculator 910 generates one or more of these parameters for each sensor data channel. The waveform processor 920 extracts various plethysmograph features for each data channel. These features may include, for example, the area under the peripheral flow curve, the slope of the inflow phase, the slope of the outflow phase, the value of the end diastolic baseline and the size and location of the dicrotic notch. The cross-channel calculator 930 generates cross-channel values, such as Sxy=SpO 2 (baseline site)−SpO 2 (comparison site). In an embodiment, the calculator 930 can also generate same-channel values, such as SpaO 2 −SpvO 2 from the same sensor site. The trending function 940 calculates trends from the parameter calculator 910 , the waveform processor 920 or the cross-channel calculator 930 . The trending function 940 stores historical values and compares these with present values. This comparison may include Δp/Δt, the change in a parameter over a specified time interval, which may also be expressed as a percentage change over that interval. An example is ΔSat xy /Δt, the change in the oxygen saturation difference between two tissue sites over a specified time interval.
Although described above with respect to optical sensor inputs responsive to pulsatile blood flow, in an embodiment, the CHD monitor may include sensor inputs and corresponding algorithms and processes for other parameters such as ECG, EEG, ETCO 2 , respiration rate and temperature to name a few. Although a CHD analyzer is described above as a program executed by a patient monitor DSP, the CHD analyzer can be, in whole or in part, hardware, firmware or software or a combination functioning in conjunction with or separate from the DSP. Further, the CHD analyzer can be configured, in whole or in part, as logic circuits, gate arrays, neural networks or an expert system, as examples. In an embodiment, a CHD monitor, such as described above, for example, as incorporating a patient monitor, CHD analyzer and corresponding CHD screening process, is marketed with instructions on grading a neonate, infant or patient with respect to the likelihood of a CHD condition.
A congential heart disease monitor has been disclosed in detail in connection with various embodiments. These embodiments are disclosed by way of examples only and are not to limit the scope of the present invention, which is defined by the claims that follow. One of ordinary skill in the art will appreciate many variations and modification.
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A congenital heart disease monitor utilizes a sensor capable of emitting multiple wavelengths of optical radiation into a tissue site and detecting the optical radiation after attenuation by pulsatile blood flowing within the tissue site. A patient monitor is capable of receiving a sensor signal corresponding to the detected optical radiation and calculating at least one physiological parameter in response. The physiological parameter is measured at a baseline site and a comparison site and a difference in these measurements is calculated. A potential congenital heart disease condition in indicated according to the measured physiological parameter at each of the sites or the calculated difference in the measured physiological parameter between the sites or both.
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RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application Ser. No. 11/380,710, filed Apr. 28, 2006 entitled “VOLUME DEPLETION DETECTION”, herein incorporated by reference in its entirety
BACKGROUND
[0002] Patients having such conditions as heart failure or decreased kidney function requiring dialysis often have undesirable fluid accumulation in the body. In general, fluid accumulation is a failure or over-response of the homeostatic process within the body. The body normally prevents the build up of fluids by maintaining adequate pressures and concentrations of salt and proteins and by actively removing excess fluid. Fluid accumulation can occur, for example, when the body's mechanisms for preventing fluid accumulation are affected by disease, such as heart failure, left sided myocardial infarction, high blood pressure, altitude sickness, emphysema (all which affect pressures), cancers that affect the lymphatic system, kidney failure, and diseases that disrupt the protein concentrations. As a result, providing an adequate monitor of the patient's fluid status can provide physicians and patients with a better tool to manage disease.
[0003] Patients with conditions that contribute to fluid accumulation in the body often uses diuretics to control the fluid level in the body. This can be a delicate balancing act, since fluid accumulation can result in frequent and lengthy hospitalization and overuse of diuretics or other fluid reduction tools can result in dehydration. In some cases, dehydration may become so severe as to result in hypovolemic shock, with symptoms including diminished consciousness, lack of urine output, cool moist extremities, a rapid and feeble pulse (the radial pulse may be undetectable), low or undetectable blood pressure, and peripheral cyanosis.
DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a schematic diagram depicting a multi-channel, atrial and bi-ventricular, monitoring/pacing implantable medical device (IMD) in which embodiments of the invention may be implemented.
[0005] FIG. 2 is a simplified block diagram of an embodiment of IMD circuitry and associated leads that may be employed in the system of FIG. 1 to enable selective therapy delivery and monitoring in one or more heart chamber.
[0006] FIG. 3 is a simplified block diagram of a single monitoring and pacing channel for acquiring pressure, impedance and cardiac EGM signals employed in monitoring cardiac function and/or delivering therapy, including pacing therapy, in accordance with embodiments of the invention.
[0007] FIG. 4 is a flow diagram of a routine in accordance with embodiments of the invention.
[0008] FIG. 5 is a flow diagram of a routine in accordance with embodiments of the invention.
DETAILED DESCRIPTION
[0009] The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. The drawings depict selected embodiments and are not intended to limit the scope of the invention. It will be understood that embodiments shown in the drawings and described below are merely for illustrative purposes, and are not intended to limit the scope of the invention as defined in the claims.
[0010] Fluid Accumulation (“volume overload” or “VO”) and dehydration (“volume depletion” or “VD”) has been typically assessed by monitoring weight gain. In addition, a thoracic fluid accumulation monitor using either an external or internal thoracic impedance measurements has also been proposed. These measurements have been used to simply monitor the condition or to indicate the need for intervention such as the use of diuretics or dialysis. Because thoracic fluid levels change based on body position and other external influences, measurements often had to be taken at various times of the day (i.e., at night and day times or rest and active times) and averaged or otherwise calculated to evaluate the true fluid level in the patient.
[0011] It is believed that volume overload typically develops over a longer period of time than volume depletion. Abrupt onset edema or volume overload is possible, but it is an exception to the general rule. It is also believed that most common instances of volume depletion occur as a result of an excessive response to an incident of volume overload. The treatment of a volume overload condition can require a precise dosage of diuretic, and the consequence of an excessive dose can often be the development of a severe or even dangerous volume depletion condition.
[0012] Certain embodiments of the invention include an implantable medical device capable of monitoring blood pressure or intracardiac pressure. It is believed that intracardiac pressure correlates well to volume overload and volume depletion and in fact may be a better indicator than impedance in some applications. For instance, after treatment of a volume overload condition with a diuretic it may take time for the body to reabsorb fluid from the surrounding tissue. This may result in an impedance measurement acting as a lagging indicator of the efficacy of the diuretic when compared to a intracardiac pressure measurement that more quickly recognizes the reduction in blood volume.
[0013] Turning now to the Figures, FIG. 1 is a schematic representation of an implantable medical device (IMD) 14 that may be used in accordance with certain embodiments of the invention. The IMD 14 may be any device that is capable of measuring hemodynamic parameters (e.g., intracardiac pressure signals) from within a ventricle of a patient's heart, and which may further be capable of measuring other signals, such as the patient's cardiac electrogram (EGM).
[0014] In FIG. 1 , heart 10 includes the right atrium (RA), left atrium (LA), right ventricle (RV), left ventricle (LV), and the coronary sinus (CS) extending from the opening in the right atrium laterally around the atria to form the great vein.
[0015] FIG. 1 depicts IMD 14 in relation to heart 10 . In certain embodiments, IMD 14 may be an implantable, multi-channel cardiac pacemaker that may be used for restoring AV synchronous contractions of the atrial and ventricular chambers and simultaneous or sequential pacing of the right and left ventricles. Three endocardial leads 16 , 32 and 52 connect the IMD 14 with the RA, the RV and the LV, respectively. Each lead has at least one electrical conductor and pace/sense electrode, and a can electrode 20 may be formed as part of the outer surface of the housing of the IMD 14 . The pace/sense electrodes and can electrode 20 may be selectively employed to provide a number of unipolar and bipolar pace/sense electrode combinations for pacing and sensing functions. The depicted positions in or about the right and left heart chambers are merely exemplary. Moreover other leads and pace/sense electrodes may be used instead of the depicted leads and pace/sense electrodes.
[0016] It should be noted that the IMD 14 may also be an implantable cardioverter defibrillator (ICD), a cardiac resynchronization therapy (CRT) device, an implantable hemodynamic monitor (IHM), or any other such device or combination of devices, according to various embodiments of the invention.
[0017] Some or all of the leads shown in FIG. 1 could carry one or more pressure sensors for measuring systolic and diastolic pressures, and a series of spaced apart impedance sensing leads for deriving volumetric measurements of the expansion and contraction of the RA, LA, RV and LV.
[0018] The leads and circuitry described above can be employed to record EGM signals, intracardiac pressure signals, and impedance values over certain time intervals. The recorded data may be periodically telemetered out to a programmer operated by a physician or other healthcare worker in an uplink telemetry transmission during a telemetry session, for example.
[0019] FIG. 2 depicts a system architecture of an exemplary multi-chamber monitor/sensor 100 implanted into a patient's body 11 that provides delivery of a therapy and/or physiologic input signal processing. The typical multi-chamber monitor/sensor 100 includes a system architecture constructed about a microcomputer-based control and timing system 102 which varies in sophistication and complexity depending upon the type and functional features incorporated therein. The functions of microcomputer-based multi-chamber monitor/sensor control and timing system 102 are controlled by firmware and programmed software algorithms stored in RAM and ROM including PROM and EEPROM and are carried out using a CPU or ALU of a typical microprocessor core architecture.
[0020] The therapy delivery system 106 can be configured to include circuitry for delivering cardioversion/defibrillation shocks and/or cardiac pacing pulses delivered to the heart or card iomyostimulation to a skeletal muscle wrapped about the heart. Alternately, the therapy delivery system 106 can be configured as a drug pump for delivering drugs into the heart to alleviate heart failure or to operate an implantable heart assist device or pump implanted in patients awaiting a heart transplant operation.
[0021] The input signal processing circuit 108 includes at least one physiologic sensor signal processing channel for sensing and processing a sensor derived signal from a physiologic sensor located in relation to a heart chamber or elsewhere in the body. Examples illustrated in FIG. 2 include pressure and volume sensors.
[0022] FIG. 3 schematically illustrates one pacing, sensing and parameter measuring channel in relation to one heart chamber. A pair of pace/sense electrodes 140 , 142 , a pressure sensor 160 , and a plurality, e.g., four, impedance measuring electrodes 170 , 172 , 174 , 176 are located in operative relation to the heart 10 .
[0023] The pair of pace/sense electrodes 140 , 142 are located in operative relation to the heart 10 and coupled through lead conductors 144 and 146 , respectively, to the inputs of a sense amplifier 148 located within the input signal processing circuit 108 . The sense amplifier 148 is selectively enabled by the presence of a sense enable signal that is provided by control and timing system 102 . The sense amplifier 148 is enabled during prescribed times when pacing is either enabled or not enabled in a manner known in the pacing art. The blanking signal is provided by control and timing system 102 upon delivery of a pacing or pulse train to disconnect the sense amplifier inputs from the lead conductors 144 and 146 for a short blanking period in a manner well known in the art. The sense amplifier provides a sense event signal signifying the contraction of the heart chamber commencing a heart cycle based upon characteristics of the EGM. The control and timing system responds to non-refractory sense events by restarting an escape interval (EI) timer timing out the EI for the heart chamber, in a manner well known in the pacing art.
[0024] The pressure sensor 160 is coupled to a pressure sensor power supply and signal processor 162 within the input signal processing circuit 108 through a set of lead conductors 164 . Lead conductors 164 convey power to the pressure sensor 160 , and convey sampled blood pressure signals from the pressure sensor 160 to the pressure sensor power supply and signal processor 162 . The pressure sensor power supply and signal processor 162 samples the blood pressure impinging upon a transducer surface of the sensor 160 located within the heart chamber when enabled by a pressure sense enable signal from the control and timing system 102 . Absolute pressure (P), developed pressure (DP) and pressure rate of change (dP/dt) sample values can be developed by the pressure sensor power supply and signal processor 162 or by the control and timing system 102 for storage and processing.
[0025] A variety of hemodynamic parameters may be recorded, for example, including right ventricular (RV) systolic and diastolic pressures (RVSP and RVDP), estimated pulmonary artery diastolic pressure (ePAD), pressure changes with respect to time (dP/dt), heart rate, activity, and temperature. Some parameters may be derived from others, rather than being directly measured. For example, the ePAD parameter may be derived from RV pressures at the moment of pulmonary valve opening, and heart rate may be derived from information in an intracardiac electrogram (EGM) recording.
[0026] The set of impedance electrodes 170 , 172 , 174 and 176 is coupled by a set of conductors 178 and is formed as a lead that is coupled to the impedance power supply and signal processor 180 . Impedance-based measurements of cardiac parameters such as stroke volume are known in the art, such as an impedance lead having plural pairs of spaced surface electrodes located within the heart 10 . The spaced apart electrodes can also be disposed along impedance leads lodged in cardiac vessels, e.g., the coronary sinus and great vein or attached to the epicardium around the heart chamber. The impedance lead may be combined with the pace/sense and/or pressure sensor bearing lead.
[0027] The data stored by IMD 14 may include continuous monitoring of various parameters, for example recording intracardiac EGM data at sampling rates as fast as 256 Hz or faster. In certain embodiments of the invention, an IHM may alternately store summary forms of data that may allow storage of data representing longer periods of time. In one embodiment, hemodynamic pressure parameters may be summarized by storing a number of representative values that describe the hemodynamic parameter over a given storage interval. The mean, median, an upper percentile, and a lower percentile are examples of representative values that may be stored by an IHM to summarize data over an interval of time (e.g., the storage interval). In one embodiment of the invention, a storage interval may contain six minutes of data in a data buffer, which may be summarized by storing a median value, a 94th percentile value (i.e., the upper percentile), and a 6th percentile value (i.e., the lower percentile) for each hemodynamic pressure parameter being monitored. In this manner, the memory of the IHM may be able to provide weekly or monthly (or longer) views of the data stored.
[0028] The IHM may also store pressure data and calculate a long term and a short term average for the pressure data. An exemplary short term average may be on the order of hours while the long term average may be on the order of 30 days.
[0029] The data buffer, for example, may acquire data sampled at a 256 Hz sampling rate over a 6 minute storage interval, and the data buffer may be cleared out after the median, upper percentile, and lower percentile values during that 6 minute period are stored. It should be noted that certain parameters measured by the IHM may be summarized by storing fewer values, for example storing only a mean or median value of such parameters as heart rate, activity level, and temperature, according to certain embodiments of the invention.
[0030] Hemodynamic parameters that may be used in accordance with various embodiments of the invention include parameters that are directly measured, such as RVDP and RVSP, as well as parameters that may be derived from other pressure parameters, such as estimated pulmonary artery diastolic pressure (ePAD), rate of pressure change (dP/dt), etc.
[0031] FIG. 4 is a flow diagram of a routine in accordance with embodiments of the invention. The routine begins with continuous pressure monitoring 200 , This pressure monitoring could be done by an IHM as described above and could include measurements of right ventricular (RV) systolic and diastolic pressures (RVSP and RVDP), estimated pulmonary artery diastolic pressure (ePAD), pressure changes with respect to time (dP/dt), and others. The routine then determines if volume overload is present 210 . This could be determined by any method known in the art. In one embodiment in accordance with the current invention, a short term average and a long term average of a blood pressure measurement are calculated. The routine then determines if the short term average has been greater than the long term average for a certain number of periods. If a short term average, for example a four-hour running average, exceeded a long term average, for example a twenty-day average, for five consecutive days the routine would determine that a volume overload condition is present. This example is illustrative only, and the terms of the averages as well as the duration over which the differential is measured may be modified to any effective values without departing from the claimed invention.
[0032] If a volume overload condition is not sensed 210 , the routine continues to monitor the pressure 200 and watch for volume overload 210 . Only if volume overload is sensed does the routine begin to monitor for volume depletion 220 . In one embodiment in accordance with FIG. 4 , the routine looks for a sudden decrease in pressure by comparing a short term average pressure to a long term average pressure. In this embodiment, if the short term average pressure is below the long term average pressure by at least a threshold value for a number of days within a predetermined timeframe 230 , volume depletion or dehydration, possibly due to over diuresis, has occurred 240 . In one exemplary embodiment, a 3-day running average must be below a twenty-day average by a threshold amount for two consecutive days within the seven days following the detection of volume overload 210 . If volume depletion is not detected within the predetermined timeframe, the routine stops detecting for volume depletion and returns to continuous pressure monitoring 200 . The number of days that are monitored for volume depletion after a volume overload event usually, but not necessarily, fewer than 14 days. By limiting the routine to monitoring for volume depletion only within a predetermined timeframe after volume overload, the routine is less likely to detect false instances of volume depletion because most occurrences of volume depletion are a result of over-treatment of volume overload.
[0033] If volume depletion is detected 240 , a notification may be given to the patient through an audible alarm, to the patient's caregiver through a radio frequency uplink from a telemetry unit, or by other means. In addition recorded data may be periodically telemetered out to a programmer operated by a physician or other healthcare worker in an uplink telemetry transmission during a telemetry session, for example. This historical data may allow the physician or healthcare worker to modify the parameters of the routine to provide more accurate detection algorithms for a given patient and condition.
[0034] FIG. 5 is a flow diagram of a routine in accordance with embodiments of the invention. The routine of FIG. 5 detects volume depletion and begins with continuous blood pressure measurement 250 . This routine may be used to calculate volume depletion after volume overload is detected, either as in the routine in FIG. 4 or by any means known in the art. The routine calculates a reference value (RV), a current deviation from the reference value (CD), and a current cumulative sum of the deviation from the reference value (CCS) over a time-frame 260 . Current deviation is in this case is an absolute value of the difference between the measured value and the reference value (no sign). The reference value may be a long term average or adaptive baseline of the pressure measurement or a fixed value determined by a physician. The deviation from the reference may be calculated as an unmodified difference or may involve additional calculation such as scaling using a multiplier and/or an offset.
[0035] The routine then compares the measured pressure to the reference value 270 . If the measured value is greater than the reference value, the routine resets the cumulative sum to zero and starts over 250 . In an optional embodiment, this step 270 may require the measured value to exceed the reference value for multiple readings. If the routine is being used as part of a larger routine that detects volume depletion only after the onset of volume overload, the routine may return to detecting for volume overload if the measured value exceeds the reference value 270 .
[0036] As long as the measured value remains below the reference value 270 , the routine compares the current cumulative sum to a predetermined threshold 280 . If the current cumulative sum is less than the threshold, the routine returns to continuous pressure monitoring 250 . Once the current cumulative sum exceeds the threshold value 280 , the routine flags the detection of volume depletion in a manner known in the art 290 .
[0037] In another embodiment, one can combine the two examples we provide here by using the cumulative sum algorithm to compute thresholds for the previous embodiment. For example, one can determine volume overload status from the cumulative sum (the same concept in reverse) and activate the depletion detector when volume overload is detected. The depletion detector may use STA and LTA criteria as described previously. In some embodiments, the threshold K used as a threshold or offset as in the formula STA+K<LTA, could be calculated by comparing the normal deviation of the STA about the LTA during periods when the patient is fluid balanced. This K could be actively calculated up to the point where the cumulative sum was last zero—just before raw pressure value was started to deviate (upward) from reference value.
[0038] It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses may be made without departing from the inventive concepts.
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Detection of volume depletion, particularly after an incidence of volume overload is disclosed. Various methods, systems, and devices are disclosed that sense and analyze a physiological parameter related to a patient's fluid level in order to warn patients of potentially dangerous volume depletion conditions while minimizing false notifications.
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FIELD OF THE INVENTION
[0001] The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same.
BACKGROUND OF THE INVENTION
[0002] Fabrics, typically lighter colored fabrics such as white fabrics, that are worn and/or laundered typically discolor. For example, white fabrics which are repeatedly laundered can exhibit a yellowing in color appearance which causes the fabric to look older and worn. In an effort to overcome such fabric discoloration, certain laundry detergent products include a hueing or bluing dye which attaches to fabric during the laundry wash and/or rinse cycle. Unfortunately, such hueing or bluing dye typically tends to accumulate on the fabric, thus giving the fabric an undesirable bluish tint. As a result, a chlorine treatment is generally employed to reduce the aforementioned accumulation of bluing dyes. While a chlorine treatment can be effective, it is an additional, inconvenient step in the laundry process. Additionally, a chlorine treatment is costly and harsh on fabrics—contributing to increased fabric degradation. Accordingly, a need exists for improved laundry care products which can counter the undesirable discoloration of fabrics, including the yellowing of white fabrics.
SUMMARY OF THE INVENTION
[0003] The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same. The dyes, compositions and methods of the present invention are advantageous in providing improved hueing of fabric, including whitening of white fabric, while avoiding significant build up of bluing dyes on the fabric.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0004] As used herein, the term “laundry care composition” includes, unless otherwise indicated, granular, powder, liquid, gel, paste, bar form and/or flake type washing agents and/or fabric treatment compositions.
[0005] As used herein, the term “fabric treatment composition” includes, unless otherwise indicated, fabric softening compositions, fabric enhancing compositions, fabric freshening compositions and combinations there of. Such compositions may be, but need not be rinse added compositions.
[0006] As used herein, the articles including “the”, “a” and “an” when used in a claim, are understood to mean one or more of what is claimed or described.
[0007] As used herein, the terms “include”, “includes” and “including” are meant to be non-limiting.
[0008] As used herein, the term polyether is defined as at least two repeating ether units that are chemically bound via the ethers' oxygen atoms. Such polyethers may be derived from materials including but not limited to ethylene oxide, propylene oxide, butylene oxide, hexylene oxide, glycidol, epichlorohydrin, pentanerythritol, glucose or combinations thereof.
[0009] As used herein capped polyether means a polyether that terminates in an alkyl or aryl moiety, including but not limited to a moiety selected from methyl, ethyl, butyl, isopropyl, tertiary butyl, amyl, benzyl, pentyl, and acetyl moieties.
[0010] As used herein “EO” stands for an ethylene oxide moiety.
[0011] As used herein “PO” stands for a propylene oxide moiety.
[0012] The test methods disclosed in the Test Methods Section of the present application should be used to determine the respective values of the parameters of Applicants' inventions.
[0013] Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
[0014] All percentages and ratios are calculated by weight unless otherwise indicated. All percentages and ratios are calculated based on the total composition unless otherwise indicated.
[0015] It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
[0016] All documents cited are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.
Laundry Care Compositions
[0017] In one aspect, a laundry care composition that may comprise a laundry care ingredient and a suitable thiazolium dye is disclosed. Suitable thiazolium dyes include thiazolium dyes that exhibit good tinting efficiency during a laundry wash cycle without exhibiting excessive undesirable build up after laundering. Thus, undesirable bluing after repeated washings with the detergent compositions of the invention is avoided and costly and harsh chlorine treatments are unnecessary. Suitable thiazolium dyes include those thiazolium dyes that are described under the heading “Suitable Thiazolium Dyes” of the present specification.
[0018] In one aspect, the laundry care compositions disclosed in the present specification can employ the thiazolium dyes disclosed in the present specification as detailed by Formulae V through VIII of the present specification.
[0019] In one aspect suitable thiazolium dyes include thiazolium dye molecules numbers 1-80 as detailed in Tables 1 and 2 of the present specification.
[0020] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 1, 4, 5, 7, 8, 12, 13, 15, 16, 17, 21, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0021] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 12, 13, 15, 16, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0022] In one aspect, the laundry care compositions disclosed in the present specification can employ combinations of any of the suitable thiazolium dyes disclosed in the present specification.
[0023] In one aspect, the laundry care compositions disclosed in the present specification can employ a non-hueing dye in combination with the thiazolium dye. The non-hueing dye may be selected from non-hueing dyes disclosed in U.S. Patent Application 2005/028820 A1, U.S. Pat. No. 4,137,243, U.S. Pat. No. 4,601,725 and U.S. Pat. No. 4,871,371. While not being bound by theory, it is believed that the combination of both a thiazolium dye and a non-hueing dye allows for flexibility to color blend to a desired hue.
[0024] In one aspect, the laundry care compositions disclosed in the present specification can employ a non-hueing dye, that may be non-substantive in nature, in combination with the thiazolium dye. The combination of both a thiazolium dye and a non-hueing dye can allow customization of product color and fabric tint. In one aspect, Acid Blue 7 may be employed as a non-hueing, non-tinting dye.
[0025] In one aspect, any of the components, including the suitable thiazolium dyes, may be employed in the laundry care compositions in an encapsulated form. Such encapsulates may comprise one or more of such components.
[0026] In one aspect a laundry care compositions comprising a thiazolium dye and a laundry care ingredient and having a hueing efficiency of greater than 10 but less than 40, from about 15 to about 35, or even from about 15 to about 30 and a wash removability of from about 30% to about 85%, from about 40% to about 85%, from about 50% to about 85% are disclosed.
[0027] Suitable laundry care ingredients include, but are not limited to, those materials described in the present specification as useful aspects of the present invention, including adjunct materials as described in the present specification.
Liquid, Laundry Detergent Compositions
[0028] In one aspect, the laundry care compositions disclosed herein, may take the form of liquid, laundry detergent compositions. In one aspect, such compositions may be a heavy duty liquid composition. Such compositions may comprise a sufficient amount of a surfactant to provide the desired level of one or more cleaning properties, typically by weight of the total composition, from about 5% to about 90%, from about 5% to about 70% or even from about 5% to about 40% and a sufficient of suitable thiazolium dye that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric washed in a solution containing the detergent, typically by weight of the total composition, from about 0.0001% to about 0.05%, or even from about 0.001% to about 0.01%.
[0029] The liquid detergent compositions comprise an aqueous, non-surface active liquid carrier. Generally, the amount of the aqueous, non-surface active liquid carrier employed in the compositions herein will be effective to solubilize, suspend or disperse the composition components. For example, the compositions may comprise, by weight, from about 5% to about 90%, from about 10% to about 70%, or even from about 20% to about 70% of an aqueous, non-surface active liquid carrier.
[0030] The most cost effective type of aqueous, non-surface active liquid carrier may be water. Accordingly, the aqueous, non-surface active liquid carrier component may be generally mostly, if not completely, water. While other types of water-miscible liquids, such alkanols, diols, other polyols, ethers, amines, and the like, have been conventionally been added to liquid detergent compositions as co-solvents or stabilizers, for purposes of the present invention, the utilization of such water-miscible liquids may be minimized to hold down composition cost. Accordingly, the aqueous liquid carrier component of the liquid detergent products herein will generally comprise water present in concentrations ranging from about 5% to about 90%, or even from about 20% to about 70%, by weight of the composition.
[0031] The liquid detergent compositions herein may take the form of an aqueous solution or uniform dispersion or suspension of surfactant, thiazolium dye, and certain optional other ingredients, some of which may normally be in solid form, that have been combined with the normally liquid components of the composition, such as the liquid alcohol ethoxylate nonionic, the aqueous liquid carrier, and any other normally liquid optional ingredients. Such a solution, dispersion or suspension will be acceptably phase stable and will typically have a viscosity which ranges from about 100 to 600 cps, more preferably from about 150 to 400 cps. For purposes of this invention, viscosity is measured with a Brookfield LVDV-II+ viscometer apparatus using a #21 spindle.
[0032] Suitable surfactants may be anionic, nonionic, cationic, zwitterionic and/or amphoteric surfactants. In one aspect, the detergent composition comprises anionic surfactant, nonionic surfactant, or mixtures thereof.
[0033] Suitable anionic surfactants may be any of the conventional anionic surfactant types typically used in liquid detergent products. Such surfactants include the alkyl benzene sulfonic acids and their salts as well as alkoxylated or non-alkoxylated alkyl sulfate materials.
[0034] Exemplary anionic surfactants are the alkali metal salts of C 10-16 alkyl benzene sulfonic acids, preferably C 11-14 alkyl benzene sulfonic acids. In one aspect, the alkyl group is linear. Such linear alkyl benzene sulfonates are known as “LAS”. Such surfactants and their preparation are described for example in U.S. Pat. Nos. 2,220,099 and 2,477,383. Especially preferred are the sodium and potassium linear straight chain alkylbenzene sulfonates in which the average number of carbon atoms in the alkyl group is from about 11 to 14. Sodium C 11 -C 14 , e.g., C 12 , LAS is a specific example of such surfactants.
[0035] Another exemplary type of anionic surfactant comprises ethoxylated alkyl sulfate surfactants. Such materials, also known as alkyl ether sulfates or alkyl polyethoxylate sulfates, are those which correspond to the formula: R′—O—(C 2 H 4 O) n —SO 3 M wherein R′ is a C 8 -C 20 alkyl group, n is from about 1 to 20, and M is a salt-forming cation. In a specific embodiment, R′ is C 10 -C 18 alkyl, n is from about 1 to 15, and M is sodium, potassium, ammonium, alkylammonium, or alkanolammonium. In more specific embodiments, R′ is a C 12 -C 16 , n is from about 1 to 6 and M is sodium.
[0036] The alkyl ether sulfates will generally be used in the form of mixtures comprising varying R′ chain lengths and varying degrees of ethoxylation. Frequently such mixtures will inevitably also contain some non-ethoxylated alkyl sulfate materials, i.e., surfactants of the above ethoxylated alkyl sulfate formula wherein n=0. Non-ethoxylated alkyl sulfates may also be added separately to the compositions of this invention and used as or in any anionic surfactant component which may be present. Specific examples of non-alkoyxylated, e.g., non-ethoxylated, alkyl ether sulfate surfactants are those produced by the sulfation of higher C 8 -C 20 fatty alcohols. Conventional primary alkyl sulfate surfactants have the general formula: ROSO 3 -M + wherein R is typically a linear C 8 -C 20 hydrocarbyl group, which may be straight chain or branched chain, and M is a water-solubilizing cation. In specific embodiments, R is a C 10 -C 15 alkyl, and M is alkali metal, more specifically R is C 12 -C 14 and M is sodium.
[0037] Specific, nonlimiting examples of anionic surfactants useful herein include: a) C 11 -C 18 alkyl benzene sulfonates (LAS); b) C 10 -C 20 primary, branched-chain and random alkyl sulfates (AS); c) C 10 -C 18 secondary (2,3) alkyl sulfates having formulae (I) and (II):
[0000]
[0000] wherein M in formulae (I) and (II) is hydrogen or a cation which provides charge neutrality, and all M units, whether associated with a surfactant or adjunct ingredient, can either be a hydrogen atom or a cation depending upon the form isolated by the artisan or the relative pH of the system wherein the compound is used, with non-limiting examples of preferred cations including sodium, potassium, ammonium, and mixtures thereof, and x is an integer of at least about 7, preferably at least about 9, and y is an integer of at least 8, preferably at least about 9; d) C 10 -C 18 alkyl alkoxy sulfates (AE X S) wherein preferably x is from 1-30; e) C 10 -C 18 alkyl alkoxy carboxylates preferably comprising 1-5 ethoxy units; f) mid-chain branched alkyl sulfates as discussed in U.S. Pat. No. 6,020,303 and U.S. Pat. No. 6,060,443; g) mid-chain branched alkyl alkoxy sulfates as discussed in U.S. Pat. No. 6,008,181 and U.S. Pat. No. 6,020,303; h) modified alkylbenzene sulfonate (MLAS) as discussed in WO 99/05243, WO 99/05242, WO 99/05244, WO 99/05082, WO 99/05084, WO 99/05241, WO 99/07656, WO 00/23549, and WO 00/23548; i) methyl ester sulfonate (MES); and j) alpha-olefin sulfonate (AOS).
[0038] Suitable nonionic surfactants useful herein can comprise any of the conventional nonionic surfactant types typically used in liquid detergent products. These include alkoxylated fatty alcohols and amine oxide surfactants. Preferred for use in the liquid detergent products herein are those nonionic surfactants which are normally liquid.
[0039] Suitable nonionic surfactants for use herein include the alcohol alkoxylate nonionic surfactants. Alcohol alkoxylates are materials which correspond to the general formula: R 1 (C m H 2m O) n OH wherein R 1 is a C 8 -C 16 alkyl group, m is from 2 to 4, and n ranges from about 2 to 12. Preferably R 1 is an alkyl group, which may be primary or secondary, that contains from about 9 to 15 carbon atoms, more preferably from about 10 to 14 carbon atoms. In one embodiment, the alkoxylated fatty alcohols will also be ethoxylated materials that contain from about 2 to 12 ethylene oxide moieties per molecule, more preferably from about 3 to 10 ethylene oxide moieties per molecule.
[0040] The alkoxylated fatty alcohol materials useful in the liquid detergent compositions herein will frequently have a hydrophilic-lipophilic balance (HLB) which ranges from about 3 to 17. More preferably, the HLB of this material will range from about 6 to 15, most preferably from about 8 to 15. Alkoxylated fatty alcohol nonionic surfactants have been marketed under the tradename Neodol® by the Shell Chemical Company.
[0041] Another suitable type of nonionic surfactant useful herein comprises the amine oxide surfactants. Amine oxides are materials which are often referred to in the art as “semi-polar” nonionics. Amine oxides have the formula: R(EO) x (PO) y (BO) n N(O)(CH 2 R′) 2 .qH 2 O. In this formula, R is a relatively long-chain hydrocarbyl moiety which can be saturated or unsaturated, linear or branched, and can contain from 8 to 20, preferably from 10 to 16 carbon atoms, and is more preferably C 12 -C 16 primary alkyl. R′ is a short-chain moiety, preferably selected from hydrogen, methyl and —CH 2 OH. When x+y+z is different from 0, EO is ethyleneoxy, PO is propyleneneoxy and BO is butyleneoxy. Amine oxide surfactants are illustrated by C 12-14 alkyldimethyl amine oxide.
[0042] Non-limiting examples of nonionic surfactants include: a) C 12 -C 18 alkyl ethoxylates, such as, NEODOL® nonionic surfactants from Shell; b) C 6 -C 12 alkyl phenol alkoxylates wherein the alkoxylate units are a mixture of ethyleneoxy and propyleneoxy units; c) C 12 -C 18 alcohol and C 6 -C 12 alkyl phenol condensates with ethylene oxide/propylene oxide block polymers such as Pluronic® from BASF; d) C 14 -C 22 mid-chain branched alcohols, BA, as discussed in U.S. Pat. No. 6,150,322; e) C 14 -C 22 mid-chain branched alkyl alkoxylates, BAE x , wherein x 1-30, as discussed in U.S. Pat. No. 6,153,577, U.S. Pat. No. 6,020,303 and U.S. Pat. No. 6,093,856; f) Alkylpolysaccharides as discussed in U.S. Pat. No. 4,565,647 Llenado, issued Jan. 26, 1986; specifically alkylpolyglycosides as discussed in U.S. Pat. No. 4,483,780 and U.S. Pat. No. 4,483,779; g) Polyhydroxy fatty acid amides as discussed in U.S. Pat. No. 5,332,528, WO 92/06162, WO 93/19146, WO 93/19038, and WO 94/09099; and h) ether capped poly(oxyalkylated) alcohol surfactants as discussed in U.S. Pat. No. 6,482,994 and WO 01/42408.
[0043] In the laundry detergent compositions herein, the detersive surfactant component may comprise combinations of anionic and nonionic surfactant materials. When this is the case, the weight ratio of anionic to nonionic will typically range from 10:90 to 90:10, more typically from 30:70 to 70:30.
[0044] Cationic surfactants are well known in the art and non-limiting examples of these include quaternary ammonium surfactants, which can have up to 26 carbon atoms. Additional examples include a) alkoxylate quaternary ammonium (AQA) surfactants as discussed in U.S. Pat. No. 6,136,769; b) dimethyl hydroxyethyl quaternary ammonium as discussed in U.S. Pat. No. 6,004,922; c) polyamine cationic surfactants as discussed in WO 98/35002, WO 98/35003, WO 98/35004, WO 98/35005, and WO 98/35006; d) cationic ester surfactants as discussed in U.S. Pat. Nos. 4,228,042, 4,239,660 4,260,529 and U.S. Pat. No. 6,022,844; and e) amino surfactants as discussed in U.S. Pat. No. 6,221,825 and WO 00/47708, specifically amido propyldimethyl amine (APA).
[0045] Non-limiting examples of zwitterionic surfactants include: derivatives of secondary and tertiary amines, derivatives of heterocyclic secondary and tertiary amines, or derivatives of quaternary ammonium, quaternary phosphonium or tertiary sulfonium compounds. See U.S. Pat. No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975 at column 19, line 38 through column 22, line 48, for examples of zwitterionic surfactants; betaine, including alkyl dimethyl betaine and cocodimethyl amidopropyl betaine, C 8 to C 18 (preferably C 12 to C 18 ) amine oxides and sulfo and hydroxy betaines, such as N-alkyl-N,N-dimethylammino-1-propane sulfonate where the alkyl group can be C 8 to C 18 , preferably C 10 to C 14 .
[0046] Non-limiting examples of ampholytic surfactants include: aliphatic derivatives of secondary or tertiary amines, or aliphatic derivatives of heterocyclic secondary and tertiary amines in which the aliphatic radical can be straight- or branched-chain. One of the aliphatic substituents contains at least about 8 carbon atoms, typically from about 8 to about 18 carbon atoms, and at least one contains an anionic water-solubilizing group, e.g. carboxy, sulfonate, sulfate. See U.S. Pat. No. 3,929,678 to Laughlin et al., issued Dec. 30, 1975 at column 19, lines 18-35, for examples of ampholytic surfactants.
Granular Laundry Detergent Compositions
[0047] In one aspect, the laundry care compositions disclosed herein, may take the form of granular, laundry detergent compositions. Such compositions may comprise a sufficient of suitable thiazolium dye that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric washed in a solution containing the detergent, typically by weight of the total composition, from about 0.0001% to about 0.05%, or even from about 0.001% to about 0.01%.
[0048] Granular detergent compositions of the present invention may include any number of conventional detergent ingredients. For example, the surfactant system of the detergent composition may include anionic, nonionic, zwitterionic, ampholytic and cationic classes and compatible mixtures thereof. Detergent surfactants for granular compositions are described in U.S. Pat. No. 3,664,961, Norris, issued May 23, 1972, and in U.S. Pat. No. 3,919,678, Laughlin et al., issued Dec. 30, 1975. Cationic surfactants include those described in U.S. Pat. No. 4,222,905, Cockrell, issued Sep. 16, 1980, and in U.S. Pat. No. 4,239,659, Murphy, issued Dec. 16, 1980.
[0049] Nonlimiting examples of surfactant systems include the conventional C 11 -C 18 alkyl benzene sulfonates (“LAS”) and primary, branched-chain and random C 10 -C 20 alkyl sulfates (“AS”), the C 10 -C 18 secondary (2,3) alkyl sulfates of the formula CH 3 (CH 2 ) x (CHOSO 3 − M + ) CH 3 and CH 3 (CH 2 ) y (CHOSO 3 − M + ) CH 2 CH 3 where x and (y+1) are integers of at least about 7, preferably at least about 9, and M is a water-solubilizing cation, especially sodium, unsaturated sulfates such as oleyl sulfate, the C 10 -C 18 alkyl alkoxy sulfates (“AE x S”; especially EO 1-7 ethoxy sulfates), C 10 -C 18 alkyl alkoxy carboxylates (especially the EO 1-5 ethoxycarboxylates), the C 10-18 glycerol ethers, the C 10 -C 18 alkyl polyglycosides and their corresponding sulfated polyglycosides, and C 12 -C 18 alpha-sulfonated fatty acid esters. If desired, the conventional nonionic and amphoteric surfactants such as the C 12 -C 18 alkyl ethoxylates (“AE”) including the so-called narrow peaked alkyl ethoxylates and C 6 -C 12 alkyl phenol alkoxylates (especially ethoxylates and mixed ethoxy/propoxy), C 12 -C 18 betaines and sulfobetaines (“sultaines”), C 10 -C 18 amine oxides, and the like, can also be included in the surfactant system. The C 10 -C 18 N-alkyl polyhydroxy fatty acid amides can also be used. See WO 9,206,154. Other sugar-derived surfactants include the N-alkoxy polyhydroxy fatty acid amides, such as C 10 -C 18 N-(3-methoxypropyl)glucamide. The N-propyl through N-hexyl C 12 -C 18 glucamides can be used for low sudsing. C 10 -C 20 conventional soaps may also be used. If high sudsing is desired, the branched-chain C 10 -C 16 soaps may be used. Mixtures of anionic and nonionic surfactants are especially useful. Other conventional useful surfactants are listed in standard texts.
[0050] The detergent composition can, and preferably does, include a detergent builder. Builders are generally selected from the various water-soluble, alkali metal, ammonium or substituted ammonium phosphates, polyphosphates, phosphonates, polyphosphonates, carbonates, silicates, borates, polyhydroxy sulfonates, polyacetates, carboxylates, and polycarboxylates. Preferred are the alkali metal, especially sodium, salts of the above. Preferred for use herein are the phosphates, carbonates, silicates, C 10-18 fatty acids, polycarboxylates, and mixtures thereof. More preferred are sodium tripolyphosphate, tetrasodium pyrophosphate, citrate, tartrate mono- and di-succinates, sodium silicate, and mixtures thereof.
[0051] Specific examples of inorganic phosphate builders are sodium and potassium tripolyphosphate, pyrophosphate, polymeric metaphosphate having a degree of polymerization of from about 6 to 21, and orthophosphates. Examples of polyphosphonate builders are the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1-hydroxy-1,1-diphosphonic acid and the sodium and potassium salts of ethane, 1,1,2-triphosphonic acid. Other phosphorus builder compounds are disclosed in U.S. Pat. Nos. 3,159,581; 3,213,030; 3,422,021; 3,422,137; 3,400,176 and 3,400,148. Examples of nonphosphorus, inorganic builders are sodium and potassium carbonate, bicarbonate, sesquicarbonate, tetraborate decahydrate, and silicates having a weight ratio of SiO 2 to alkali metal oxide of from about 0.5 to about 4.0, preferably from about 1.0 to about 2.4. Water-soluble, nonphosphorus organic builders useful herein include the various alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates and polyhydroxy sulfonates. Examples of polyacetate and polycarboxylate builders are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylene diamine tetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, mellitic acid, benzene polycarboxylic acids, and citric acid.
[0052] Polymeric polycarboxylate builders are set forth in U.S. Pat. No. 3,308,067, Diehl, issued Mar. 7, 1967. Such materials include the water-soluble salts of homo- and copolymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid. Some of these materials are useful as the water-soluble anionic polymer as hereinafter described, but only if in intimate admixture with the nonsoap anionic surfactant. Other suitable polycarboxylates for use herein are the polyacetal carboxylates described in U.S. Pat. No. 4,144,226, issued Mar. 13, 1979 to Crutchfield et al., and U.S. Pat. No. 4,246,495, issued Mar. 27, 1979 to Crutchfield et al.
[0053] Water-soluble silicate solids represented by the formula SiO 2 .M 2 O, M being an alkali metal, and having a SiO 2 :M 2 O weight ratio of from about 0.5 to about 4.0, are useful salts in the detergent granules of the invention at levels of from about 2% to about 15% on an anhydrous weight basis. Anhydrous or hydrated particulate silicate can be utilized, as well.
[0054] Any number of additional ingredients can also be included as components in the granular detergent composition. These include other detergency builders, bleaches, bleach activators, suds boosters or suds suppressors, anti-tarnish and anti-corrosion agents, soil suspending agents, soil release agents, germicides, pH adjusting agents, nonbuilder alkalinity sources, chelating agents, smectite clays, enzymes, enzyme-stabilizing agents and perfumes. See U.S. Pat. No. 3,936,537, issued Feb. 3, 1976 to Baskerville, Jr. et al.
[0055] Bleaching agents and activators are described in U.S. Pat. No. 4,412,934, Chung et al., issued Nov. 1, 1983, and in U.S. Pat. No. 4,483,781, Hartman, issued Nov. 20, 1984. Chelating agents are also described in U.S. Pat. No. 4,663,071, Bush et al., from Column 17, line 54 through Column 18, line 68. Suds modifiers are also optional ingredients and are described in U.S. Pat. No. 3,933,672, issued Jan. 20, 1976 to Bartoletta et al., and U.S. Pat. No. 4,136,045, issued Jan. 23, 1979 to Gault et al. Suitable smectite clays for use herein are described in U.S. Pat. No. 4,762,645, Tucker et al., issued Aug. 9, 1988, Column 6, line 3 through Column 7, line 24. Suitable additional detergency builders for use herein are enumerated in the Baskerville patent, Column 13, line 54 through Column 16, line 16, and in U.S. Pat. No. 4,663,071, Bush et al., issued May 5, 1987.
Rinse Added Fabric Conditioning Compositions
[0056] In one aspect, the laundry care compositions disclosed herein, may take the form of rinse added fabric conditioning compositions. Such compositions may comprise a fabric softening active and a sufficient amount of suitable thiazolium dye, that is described under the heading “Suitable Thiazolium Dyes” of the present specification, to provide a tinting effect to fabric treated by the composition, typically from about 0.00001 wt. % (0.1 ppm) to about 1 wt. % (10,000 ppm), or even from about 0.0003 wt. % (3 ppm) to about 0.03 wt. % (300 ppm) based on total rinse added fabric conditioning composition weight. In another specific embodiment, the compositions are rinse added fabric conditioning compositions. Examples of typical rinse added conditioning composition can be found in U.S. Provisional Patent Application Ser. No. 60/687,582 filed on Oct. 8, 2004.
[0057] In one embodiment of the invention, the fabric softening active (hereinafter “FSA”) is a quaternary ammonium compound suitable for softening fabric in a rinse step. In one embodiment, the FSA is formed from a reaction product of a fatty acid and an aminoalcohol obtaining mixtures of mono-, di-, and, in one embodiment, triester compounds. In another embodiment, the FSA comprises one or more softener quaternary ammonium compounds such, but not limited to, as a monoalkyquaternary ammonium compound, a diamido quaternary compound and a diester quaternary ammonium compound, or a combination thereof.
[0058] In one aspect of the invention, the FSA comprises a diester quaternary ammonium (hereinafter “DQA”) compound composition. In certain embodiments of the present invention, the DQA compounds compositions also encompasses a description of diamido FSAs and FSAs with mixed amido and ester linkages as well as the aforementioned diester linkages, all herein referred to as DQA.
[0059] A first type of DQA (“DQA (1)”) suitable as a FSA in the present CFSC includes a compound comprising the formula:
[0000] {R 4-m —N + —[(CH 2 ) n —Y—R 1 ] m }X −
[0000] wherein each R substituent is either hydrogen, a short chain C 1 -C 6 , preferably C 1 -C 3 alkyl or hydroxyalkyl group, e.g., methyl (most preferred), ethyl, propyl, hydroxyethyl, and the like, poly (C 2 -C 3 alkoxy), preferably polyethoxy, group, benzyl, or mixtures thereof; each m is 2 or 3; each n is from 1 to about 4, preferably 2; each Y is —O—(O)C—, —C(O)—O—, —NR—C(O)—, or —C(O)—NR— and it is acceptable for each Y to be the same or different; the sum of carbons in each R 1 , plus one when Y is —O—(O)C— or —NR—C(O)—, is C 12 -C 22 , preferably C 14 -C 20 , with each R 1 being a hydrocarbyl, or substituted hydrocarbyl group; it is acceptable for R 1 to be unsaturated or saturated and branched or linear and preferably it is linear; it is acceptable for each R 1 to be the same or different and preferably these are the same; and X − can be any softener-compatible anion, preferably, chloride, bromide, methylsulfate, ethylsulfate, sulfate, phosphate, and nitrate, more preferably chloride or methyl sulfate. Preferred DQA compounds are typically made by reacting alkanolamines such as MDEA (methyldiethanolamine) and TEA (triethanolamine) with fatty acids. Some materials that typically result from such reactions include N,N-di(acyl-oxyethyl)-N,N-dimethylammonium chloride or N,N-di(acyl-oxyethyl)-N,N-methylhydroxyethylammonium methylsulfate wherein the acyl group is derived from animal fats, unsaturated, and polyunsaturated, fatty acids, e.g., tallow, hardened tallow, oleic acid, and/or partially hydrogenated fatty acids, derived from vegetable oils and/or partially hydrogenated vegetable oils, such as, canola oil, safflower oil, peanut oil, sunflower oil, corn oil, soybean oil, tall oil, rice bran oil, palm oil, etc. Non-limiting examples of suitable fatty acids are listed in U.S. Pat. No. 5,759,990 at column 4, lines 45-66. In one embodiment the FSA comprises other actives in addition to DQA (1) or DQA. In yet another embodiment, the FSA comprises only DQA (1) or DQA and is free or essentially free of any other quaternary ammonium compounds or other actives. In yet another embodiment, the FSA comprises the precursor amine that is used to produce the DQA.
[0060] In another aspect of the invention, the FSA comprises a compound, identified as DTTMAC comprising the formula:
[0000] [R 4-m —N (+) —R 1 m ]A −
[0000] wherein each m is 2 or 3, each R 1 is a C 6 -C 22 , preferably C 14 -C 20 , but no more than one being less than about C 12 and then the other is at least about 16, hydrocarbyl, or substituted hydrocarbyl substituent, preferably C 10 -C 20 alkyl or alkenyl (unsaturated alkyl, including polyunsaturated alkyl, also referred to sometimes as “alkylene”), most preferably C 12 -C 18 alkyl or alkenyl, and branch or unbranched. In one embodiment, the Iodine Value (IV) of the FSA is from about 1 to 70; each R is H or a short chain C 1 -C 6 , preferably C 1 -C 3 alkyl or hydroxyalkyl group, e.g., methyl (most preferred), ethyl, propyl, hydroxyethyl, and the like, benzyl, or (R 2 O) 2-4 H where each R 2 is a C 1 -C 6 alkylene group; and A − is a softener compatible anion, preferably, chloride, bromide, methylsulfate, ethylsulfate, sulfate, phosphate, or nitrate; more preferably chloride or methyl sulfate. Examples of these FSAs include dialkydimethylammonium salts and dialkylenedimethylammonium salts such as ditallowedimethylammonium and ditallowedimethylammonium methylsulfate. Examples of commercially available dialkylenedimethylammonium salts usable in the present invention are di-hydrogenated tallow dimethyl ammonium chloride and ditallowedimethyl ammonium chloride available from Degussa under the trade names Adogen® 442 and Adogen® 470 respectively. In one embodiment the FSA comprises other actives in addition to DTTMAC. In yet another embodiment, the FSA comprises only compounds of the DTTMAC and is free or essentially free of any other quaternary ammonium compounds or other actives.
[0061] In one embodiment, the FSA comprises an FSA described in U.S. Pat. Pub. No. 2004/0204337 A1, published Oct. 14, 2004 to Corona et al., from paragraphs 30-79.
[0062] In another embodiment, the FSA is one described in U.S. Pat. Pub. No. 2004/0229769 A1, published Nov. 18, 2005, to Smith et al., on paragraphs 26-31; or U.S. Pat. No. 6,494,920, at column 1, line 51 et seq. detailing an “esterquat” or a quaternized fatty acid triethanolamine ester salt.
[0063] In one embodiment, the FSA is chosen from at least one of the following: ditallowoyloxyethyl dimethyl ammonium chloride, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, ditallow dimethyl ammonium chloride, ditallowoyloxyethyl dimethyl ammonium methyl sulfate, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, dihydrogenated-tallowoyloxyethyl dimethyl ammonium chloride, or combinations thereof.
[0064] In one embodiment, the FSA may also include amide containing compound compositions. Examples of diamide comprising compounds may include but not limited to methyl-bis(tallowamidoethyl)-2-hydroxyethylammonium methyl sulfate (available from Degussa under the trade names Varisoft 110 and Varisoft 222). An example of an amide-ester containing compound is N-[3-(stearoylamino)propyl]-N-[2-(stearoyloxy)ethoxy)ethyl)]-N-methylamine.
[0065] Another specific embodiment of the invention provides for a rinse added fabric care composition further comprising a cationic starch. Cationic starches are disclosed in US 2004/0204337 A1. In one embodiment, the fabric care composition comprises from about 0.1% to about 7% of cationic starch by weight of the laundry care composition. In one embodiment, the cationic starch is HCP401 from National Starch.
Suitable Thiazolium Dyes
[0066] Suitable thiazolium dyes include azo dyes that may have Formula (I) below:
[0000]
[0067] wherein:
R 3 and R 4 may be identical or different and, independently of one another, are hydrogen, a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl group substituted by a halogen atom, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide or butylene oxide, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a (C 1 -C 22 )-alkyl group terminated in sulfonate, sulfate, or carboxylate, or the radical groups R 3 and R 4 , together with the remaining molecule, can form a heterocyclic or carbocyclic, saturated or unsaturated, substituted or unsubstituted ring system optionally substituted by halogen, sulfate, sulfonate, phosphate, nitrate, and carboxylate; X may be a radical group of the phenol series or a heterocyclic radical group or aniline series or m-toluidine series that may have Formula II below;
[0000]
wherein:
R 5 and R 6 may be identical or different and, independently of one another, are a straight or branched saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl ether group, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide, butylene oxide, glycidyl or combinations thereof, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a linear or branched (C 1 -C 22 )-alkyl group terminated in a linear or branched (C 1 -C 22 )-alkyl, hydroxyl, acetate, sulfonate, sulfate, or carboxylate, group or R 5 and R 6 or R 5 and R 7 or R 6 and R 7 , together with the nitrogen atom, form a 5-membered to 6-membered ring system, which may comprise a further heteroatom; or R 5 and R 6 or R 5 and R 7 or R 6 and R 7 , form with a carbon atom of the benzene six-membered heterocycle which may be substituted with one or more (C 1 -C 22 )-alkyl group; R 7 may be identical or different and, independently of one another, are hydrogen, a halogen atom, a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl ether group, a hydroxyl group, a hydroxy-(C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkoxy group, a cyano group, a nitro group, an amino group, a (C 1 -C 22 )-alkylamino group, a (C 1 -C 22 )-dialkylamino group, a carboxylic acid group, a C(O)O—(C 1 -C 22 )-alkyl group, a substituted or unsubstituted C(O)O-phenyl group;
Q − may be an anion that balances the overall charge of the compound of Formula I, and the index q may be either 0 or 1. Suitable anions include chloro, bromo, methosulfate, tetrafluoroborate, and acetate anions.
R 1 may be a (C 1 -C 22 )-alkyl, an alkyl aromatic or an alkyl sulfonate radical having Formula (III) below;
[0000]
wherein
R 2 is hydrogen, methyl, ethyl, propyl, acetate or a hydroxyl group; m and p are integers from 0 to (n−1), n is an integer from 1 to 6 and m+p=(n−1);
with the proviso that the heterocycle of the Formula (I) comprises at least two and at most three heteroatoms, where the heterocycle has at most one sulfur atom;
[0078] In one aspect, a suitable thiazolium dye may have Formula IV below:
[0000]
[0000] wherein R 8 and R 9 may be identical or different and, independently of one another, may be a saturated or unsaturated (C 1 -C 22 )-alkyl group, a (C 1 -C 22 )-alkyl group, a hydroxy-(C 2 -C 22 )-alkyl group optionally interrupted by oxygen, a polyether group derived from ethylene oxide, propylene oxide or butylene oxide, an amino-(C 1 -C 22 )-alkyl group, a substituted or unsubstituted phenyl group or a benzyl group, a (C 1 -C 22 )-alkyl group terminated in sulfonate, sulfate, or carboxylate, or R 8 and R 9 , together with the nitrogen atom, may form a 5-membered to 6-membered ring system, which may comprise a further heteroatom; or R 8 or R 9 may form, with a carbon atom of the benzene ring, an optionally oxygen-containing or nitrogen containing five or six-membered heterocycle which may be substituted with one or more (C 1 -C 22 )-alkyl groups, and mixtures thereof, and R 10 is hydrogen or methyl. For Formula IV, Q − is as described for Formula I above.
[0079] In one aspect, suitable thiazolium dyes may have Formula (V);
[0000]
[0080] wherein:
a.) R 1 may be selected from a branched or unbranched (C 1 -C 22 )-alkyl moiety, an aromatic alkyl moiety, a polyalkylene oxide moiety or a moiety having Formula (VI) below;
[0000]
wherein
(i) R 2 may be selected from hydrogen, methyl, ethyl, propyl, acetate or a hydroxyl moiety; m and p may be, independently, integers from 0 to (n−1), with the proviso that n is an integer from 1 to 6 and m+p=(n−1) (ii) Y may be selected from a hydroxyl, sulfonate, sulfate, carboxylate or acetate moiety;
b.) R 3 and R 4 :
i.) may be independently selected from hydrogen; a saturated or unsaturated (C 1 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety comprising, in addition to the hydroxyl oxygen, an oxygen atom; a polyether moiety; an amino-(C 1 -C 22 )-alkyl moiety; a substituted or unsubstituted phenyl moiety; a substituted or unsubstituted benzyl moiety; a (C 1 -C 22 )-alkyl moiety terminated in sulfonate, sulfate, acetate, or carboxylate; or ii.) when taken together may form a saturated or unsaturated heterocyclic or carbocyclic moiety; or iii.) when taken together may form a saturated or unsaturated heterocyclic or carbocyclic moiety substituted by, sulfate, sulfonate, phosphate, nitrate, and carboxylate;
c.) X may be moiety having Formula VII below;
[0000]
wherein:
i.) R 5 and R 6 :
(a) may be independently selected from hydrogen; a saturated or unsaturated (C 1 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety; a hydroxy-(C 2 -C 22 )-alkyl moiety comprising, in addition to the hydroxyloxygen, an oxygen atom; a capped or uncapped polyether moiety; an amino-(C 1 -C 22 )-alkyl moiety; a substituted or unsubstituted phenyl moiety; a substituted or unsubstituted benzyl moiety; a (C 1 -C 22 )-alkyl moiety comprising a terminating C 1 -C 4 alkyl ether, sulfonate, sulfate, acetate or carboxylate moiety; a thiazole moiety or (b) when taken together may form a saturated or unsaturated heterocyclic moiety; or (c) when taken together form a saturated or unsaturated heterocyclic moiety substituted by one or more, alkoxylate, sulfate, sulfonate, phosphate, nitrate, and/or carboxylate moieties; (d) when taken together with R 7 , R 8 , or R 7 and R 8 form one or more saturated or unsaturated heterocyclic moieties, optionally substituted by one or more alkoxylate, sulfate, sulfonate, phosphate, nitrate, and/or carboxylate moieties; or (e) when taken together form a thiazole moiety;
ii.) R 7 and R 8 may be independently selected from hydrogen or a saturated or unsaturated alkyl moiety;
d.) Q − may be an anion that balances the overall charge of the compound of Formula I, and the index q is 0 or 1. Suitable anions include chloro, bromo, methosulfate, tetrafluoroborate, and acetate anions.
[0099] In one aspect, for Formula V:
[0100] a.) R 1 may be a methyl moiety;
[0101] b.) R 3 and R 4 may be hydrogen; and
[0102] c.) X may have Formula VIII below:
[0000]
wherein
(i) R 5 and R 6 may be as defined for Formula VII above; (ii) R 7 may be hydrogen or a methyl moiety; and (iii) R 8 may be hydrogen.
[0107] In one aspect, for Formula VII R 5 and R 6 each comprise, independently, from 1 to 20 alkylene oxide units and, independently, a moiety selected from the group consisting of: styrene oxide, glycidyl methyl ether, isobutyl glycidyl ether, isopropylglycidyl ether, t-butyl glycidyl ether, 2-ethylhexylgycidyl ether, or glycidylhexadecyl ether.
[0108] In one aspect, suitable thiazolium dyes are set forth in Table 1 below and are defined as Table 1 Thiazolium Dyes. The chemical names, as determined by ChemFinder software Level:Pro; Version 9.0 available from CambridgeSoft, Cambridge, Mass., U.S.A., for such dyes are respectively provided in Table 2 below. Such dyes are associated, as needed to balance the molecule's charge, with an anion Q − . Such anion is not shown in the structures below but for the purposes of the present specification is assumed to be present as required. Such anion is as described above for Formula (I).
[0000]
TABLE 1
No.
Structure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
[0000]
TABLE 2
No.
Name
1
(E)-2-((4-(benzyl(methyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
2
(E)-2-((4-(dimethylamino)phenyl)diazenyl)-3-methylthiazol-3-ium
3
(E)-2-((4-(bis(2-hydroxyethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
4
(E)-2-((4-(bis(2-(2-(2-hydroxyethoxy)ethoxy)ethyl)amino)phenyl)diazenyl)-
3-methylthiazol-3-ium
5
(E)-2-((4-(bis(2-(2-hydroxyethoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
6
(E)-2-((4-(bis(14-hydroxy-5,8,11-trimethyl-3,6,9,12-
tetraoxapentadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
7
(E)-2-((4-(bis(2-(2-(2-(2-
hydroxypropoxy)propoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
8
(E)-2-((4-(bis(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
9
(E)-2-((4-(bis(35-hydroxy-5,8,11,14,17,20,23-heptamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxapentatriacontyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
10
(E)-2-((4-(bis(3-(2,3-dihydroxypropoxy)-2-hydroxypropyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
11
(E)-2-((4-(bis(2,3-dihydroxypropyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
12
(E)-2-((4-((2-hydroxy-3-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(2-
hydroxy-3-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
13
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
14
(E)-2-((4-(bis(35-hydroxy-17,20,23,26,29,32-hexamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxahexatriacontyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
15
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
16
(E)-2-((4-((2-(2-(2-acetoxyethoxy)ethoxy)ethyl)(2-(2-
acetoxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
17
(E)-2-((4-(benzyl(2,3-dihydroxypropyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
18
(E)-2-(2-((4-(bis(35-hydroxy-17,20,23,26,29,32-hexamethyl-
3,6,9,12,15,18,21,24,27,30,33-undecaoxahexatriacontyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium-3-yl)acetate
19
(E)-2-((4-(benzyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
20
(E)-2-((4-((2-tert-butoxy-15-hydroxy-6,9,12-trimethyl-4,7,10,13-
tetraoxahexadecyl)(2-(tert-butoxymethyl)-17-hydroxy-5,8,11,14-tetramethyl-
3,6,9,12,15-pentaoxaoctadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
21
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
22
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-5-methoxy-3-methylbenzo[d]thiazol-3-ium
23
(E)-2-(2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)acetate
24
(E)-2-((4-(ethyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
25
(E)-2-((4-(benzyl(1,17-dihydroxy-3,6,9,12,15-pentaoxaoctadecan-18-
yl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
26
(E)-2-((4-((2-(2-(2-(2,3-dihydroxypropoxy)ethoxy)ethoxy)ethyl)(2-(2-(2,3-
dihydroxypropoxy)ethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
27
(E)-2-(2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-6-methoxybenzo[d]thiazol-3-ium-3-yl)acetate
28
(E)-2-((4-((3-tert-butoxy-2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(3-
tert-butoxy-2-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
29
(E)-2-((4-((3-butoxy-2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)propyl)(3-
butoxy-2-(2-(2-hydroxyethoxy)ethoxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
30
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)-3-isopropoxypropyl)(2-(2-(2-(2-
hydroxyethoxy)ethoxy)ethoxy)-3-isopropoxypropyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
31
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
32
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)-3-(tridecyloxy)propyl)(2-(2-(2-(2-
hydroxyethoxy)ethoxy)ethoxy)-3-(tridecyloxy)propyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
33
(E)-3-ethyl-2-((4-(ethyl(23-hydroxy-3,6,9,12,15,18,21-
heptaoxatricosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
34
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
35
(E)-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-1,2,3,4-
tetrahydroquinolin-6-yl)diazenyl)-3-methylthiazol-3-ium
36
(E)-2-((4-((2-(2-hydroxypropoxy)ethyl)(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
37
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
38
(E)-2-((4-(ethyl(23-hydroxy-3,6,9,12,15,18,21-heptaoxatricosyl)amino)-2-
methylphenyl)diazenyl)-3-methylthiazol-3-ium
39
(E)-2-((4-(benzyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
40
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
41
(E)-3-(2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)propane-1-sulfonate
42
(E)-4-(2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium-3-
yl)butane-1-sulfonate
43
(E)-2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)-3-ethylthiazol-3-ium
44
(E)-3-benzyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)phenyl)diazenyl)thiazol-3-ium
45
(E)-3-ethyl-2-((4-((2-(2-hydroxypropoxy)ethyl)(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-
ium
46
(E)-3-benzyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
47
(E)-3-benzyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)thiazol-3-ium
48
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)propyl)(2-(2-
hydroxyethoxy)propyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
49
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
50
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2,6-
dimethylphenyl)diazenyl)-3-methylthiazol-3-ium
51
(E)-2-((4-((4-(17-hydroxy-3,6,9,12,15-pentaoxaheptadecyloxy)-3-
methoxybenzyl)(methyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium
52
(E)-2-((1-(1-hydroxy-2,5,8,11,14,17,20,23,26-nonaoxaoctacosan-28-yl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)-3-methylthiazol-3-ium
53
(E)-4-(2-((4-(dimethylamino)phenyl)diazenyl)thiazol-3-ium-3-yl)butane-1-
sulfonate
54
(E)-4-(2-((4-(dimethylamino)phenyl)diazenyl)-5-methylthiazol-3-ium-3-
yl)butane-1-sulfonate
55
(E)-2-((4-((2-hydroxyethyl)(methyl)amino)phenyl)diazenyl)-3-methylthiazol-
3-ium
56
(E)-2-(methyl(4-((3-methylthiazol-3-ium-2-yl)diazenyl)phenyl)amino)ethyl
sulfate
57
(E)-2-((4-(butyl(2-(2-hydroxyethoxy)ethyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
58
(E)-2-((4-(bis(2-(2-(2-
hydroxypropoxy)propoxy)ethyl)amino)phenyl)diazenyl)-3-methylthiazol-3-
ium
59
(E)-2-((4-((2-hydroxyethyl)(isopropyl)amino)phenyl)diazenyl)-3-
methylthiazol-3-ium
60
(E)-2-((4-((14-hydroxy-3,6,9,12-tetraoxatetradecyl)(1-hydroxy-3,6,9,13-
tetraoxapentadecan-15-yl)amino)-2-methylphenyl)diazenyl)-6-methoxy-3-
methylbenzo[d]thiazol-3-ium
61
(E)-2-((4-(benzyl(29-hydroxy-3,6,9,12,15,18,21,24,27-
nonaoxanonacosyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
62
(E)-2-((4-(benzyl(3-(3-(3-(2,3-dihydroxypropoxy)-2-hydroxypropoxy)-2-
hydroxypropoxy)-2-hydroxypropyl)amino)-2-methylphenyl)diazenyl)-3-
methylthiazol-3-ium
63
(E)-3-(2-((4-(bis(2-(2-(2-(2-hydroxyethoxy)ethoxy)ethoxy)ethyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium-3-yl)propane-1-sulfonate
64
(E)-2-((4-(bis(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2,5-
dimethylphenyl)diazenyl)-6-methoxy-3-methylbenzo[d]thiazol-3-ium
65
(E)-3-ethyl-2-((4-(ethyl(14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-2-
methylphenyl)diazenyl)thiazol-3-ium
66
(E)-3-ethyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
67
(E)-3-ethyl-2-((1-(29-hydroxy-3,6,9,12,15,18,21,24,27-nonaoxanonacosyl)-
1,2,3,4-tetrahydroquinolin-6-yl)diazenyl)thiazol-3-ium
68
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
69
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-5-methylthiazol-3-
ium
70
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
71
(E)-3-ethyl-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-5-methylthiazol-3-
ium
72
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium
73
2-((E)-(4-((14-hydroxy-3,6,9,12-tetraoxatetradecyl)(17-hydroxy-3-(4-((E)-
thiazol-2-yldiazenyl)phenyl)-6,9,12,15-tetraoxa-3-
azaheptadecyl)amino)phenyl)diazenyl)-3-methylthiazol-3-ium
74
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methyl-5-
nitrothiazol-3-ium
75
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methyl-5-
nitrothiazol-3-ium
76
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-
ium-4-carboxylate
77
(E)-2-((4-((2-(2-(2-hydroxyethoxy)ethoxy)ethyl)(2-(2-
hydroxyethoxy)ethyl)amino)-2-methylphenyl)diazenyl)-3,5-dimethylthiazol-
3-ium-4-carboxylate
78
(E)-2-((4-(benzyl(2-(tert-butoxymethyl)-17-hydroxy-3,6,9,12,15-
pentaoxaheptadecyl)amino)-2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
79
(E)-2-((4-((2-(tert-butoxymethyl)-14-hydroxy-3,6,9,12-
tetraoxatetradecyl)(ethyl)amino)-2-hydroxyphenyl)diazenyl)-3-methylthiazol-
3-ium
80
(E)-2-((4-((13-(sec-butoxymethyl)-1-hydroxy-3,6,9,12-tetraoxapentadecan-
15-yl)(2-(sec-butoxymethyl)-14-hydroxy-3,6,9,12-tetraoxatetradecyl)amino)-
2-methylphenyl)diazenyl)-3-methylthiazol-3-ium
[0109] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 1, 4, 5, 7, 8, 12, 13, 15, 16, 17, 21, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0110] In one aspect, suitable thiazolium dyes include thiazolium dye molecules numbers 12, 13, 15, 16, 24, 25, 26, 30, 31, 33, 36, 38, 40, 45 and 48 as detailed in Tables 1 and 2 of the present specification.
[0111] The suitable thiazolium dyes disclosed herein may be made by procedures known in the art and/or in accordance with the examples of the present specification.
Adjunct Materials
[0112] While not essential for the purposes of the present invention, the non-limiting list of adjuncts illustrated hereinafter are suitable for use in the laundry care compositions and may be desirably incorporated in certain embodiments of the invention, for example to assist or enhance performance, for treatment of the substrate to be cleaned, or to modify the aesthetics of the composition as is the case with perfumes, colorants, dyes or the like. It is understood that such adjuncts are in addition to the components that were previously listed for any particular embodiment. The total amount of such adjuncts may range from about 0.1% to about 50%, or even from about 1% to about 30%, by weight of the laundry care composition.
[0113] The precise nature of these additional components, and levels of incorporation thereof, will depend on the physical form of the composition and the nature of the operation for which it is to be used. Suitable adjunct materials include, but are not limited to, polymers, for example cationic polymers, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic materials, bleach activators, polymeric dispersing agents, clay soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfume and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. In addition to the disclosure below, suitable examples of such other adjuncts and levels of use are found in U.S. Pat. Nos. 5,576,282, 6,306,812 B1 and 6,326,348 B1 that are incorporated by reference.
[0114] As stated, the adjunct ingredients are not essential to Applicants' cleaning and laundry care compositions. Thus, certain embodiments of Applicants' compositions do not contain one or more of the following adjuncts materials: bleach activators, surfactants, builders, chelating agents, dye transfer inhibiting agents, dispersants, enzymes, and enzyme stabilizers, catalytic metal complexes, polymeric dispersing agents, clay and soil removal/anti-redeposition agents, brighteners, suds suppressors, dyes, additional perfumes and perfume delivery systems, structure elasticizing agents, fabric softeners, carriers, hydrotropes, processing aids and/or pigments. However, when one or more adjuncts are present, such one or more adjuncts may be present as detailed below:
[0115] Surfactants—The compositions according to the present invention can comprise a surfactant or surfactant system wherein the surfactant can be selected from nonionic and/or anionic and/or cationic surfactants and/or ampholytic and/or zwitterionic and/or semi-polar nonionic surfactants. The surfactant is typically present at a level of from about 0.1%, from about 1%, or even from about 5% by weight of the cleaning compositions to about 99.9%, to about 80%, to about 35%, or even to about 30% by weight of the cleaning compositions.
[0116] Builders—The compositions of the present invention can comprise one or more detergent builders or builder systems. When present, the compositions will typically comprise at least about 1% builder, or from about 5% or 10% to about 80%, 50%, or even 30% by weight, of said builder. Builders include, but are not limited to, the alkali metal, ammonium and alkanolammonium salts of polyphosphates, alkali metal silicates, alkaline earth and alkali metal carbonates, aluminosilicate builders polycarboxylate compounds. ether hydroxypolycarboxylates, copolymers of maleic anhydride with ethylene or vinyl methyl ether, 1,3,5-trihydroxybenzene-2,4,6-trisulphonic acid, and carboxymethyl-oxysuccinic acid, the various alkali metal, ammonium and substituted ammonium salts of polyacetic acids such as ethylenediamine tetraacetic acid and nitrilotriacetic acid, as well as polycarboxylates such as mellitic acid, succinic acid, oxydisuccinic acid, polymaleic acid, benzene 1,3,5-tricarboxylic acid, carboxymethyloxysuccinic acid, and soluble salts thereof.
[0117] Chelating Agents—The compositions herein may also optionally contain one or more copper, iron and/or manganese chelating agents. If utilized, chelating agents will generally comprise from about 0.1% by weight of the compositions herein to about 15%, or even from about 3.0% to about 15% by weight of the compositions herein.
[0118] Dye Transfer Inhibiting Agents—The compositions of the present invention may also include one or more dye transfer inhibiting agents. Suitable polymeric dye transfer inhibiting agents include, but are not limited to, polyvinylpyrrolidone polymers, polyamine N-oxide polymers, copolymers of N-vinylpyrrolidone and N-vinylimidazole, polyvinyloxazolidones and polyvinylimidazoles or mixtures thereof. When present in the compositions herein, the dye transfer inhibiting agents are present at levels from about 0.0001%, from about 0.01%, from about 0.05% by weight of the cleaning compositions to about 10%, about 2%, or even about 1% by weight of the cleaning compositions.
[0119] Dispersants—The compositions of the present invention can also contain dispersants. Suitable water-soluble organic materials are the homo- or co-polymeric acids or their salts, in which the polycarboxylic acid may comprise at least two carboxyl radicals separated from each other by not more than two carbon atoms.
[0120] Enzymes—The compositions can comprise one or more detergent enzymes which provide cleaning performance and/or fabric care benefits. Examples of suitable enzymes include, but are not limited to, hemicellulases, peroxidases, proteases, cellulases, xylanases, lipases, phospholipases, esterases, cutinases, pectinases, keratanases, reductases, oxidases, phenoloxidases, lipoxygenases, ligninases, pullulanases, tannases, pentosanases, malanases, β-glucanases, arabinosidases, hyaluronidase, chondroitinase, laccase, and amylases, or mixtures thereof. A typical combination is a cocktail of conventional applicable enzymes like protease, lipase, cutinase and/or cellulase in conjunction with amylase.
[0121] Enzyme Stabilizers—Enzymes for use in compositions, for example, detergents can be stabilized by various techniques. The enzymes employed herein can be stabilized by the presence of water-soluble sources of calcium and/or magnesium ions in the finished compositions that provide such ions to the enzymes.
[0122] Catalytic Metal Complexes—Applicants' compositions may include catalytic metal complexes. One type of metal-containing bleach catalyst is a catalyst system comprising a transition metal cation of defined bleach catalytic activity, such as copper, iron, titanium, ruthenium, tungsten, molybdenum, or manganese cations, an auxiliary metal cation having little or no bleach catalytic activity, such as zinc or aluminum cations, and a sequestrate having defined stability constants for the catalytic and auxiliary metal cations, particularly ethylenediaminetetraacetic acid, ethylenediaminetetra (methyl-enephosphonic acid) and water-soluble salts thereof. Such catalysts are disclosed in U.S. Pat. No. 4,430,243.
[0123] If desired, the compositions herein can be catalyzed by means of a manganese compound. Such compounds and levels of use are well known in the art and include, for example, the manganese-based catalysts disclosed in U.S. Pat. No. 5,576,282.
[0124] Cobalt bleach catalysts useful herein are known, and are described, for example, in U.S. Pat. Nos. 5,597,936 and 5,595,967. Such cobalt catalysts are readily prepared by known procedures, such as taught for example in U.S. Pat. Nos. 5,597,936, and 5,595,967.
[0125] Compositions herein may also suitably include a transition metal complex of a macropolycyclic rigid ligand—abbreviated as “MRL”. As a practical matter, and not by way of limitation, the compositions and cleaning processes herein can be adjusted to provide on the order of at least one part per hundred million of the benefit agent MRL species in the aqueous washing medium, and may provide from about 0.005 ppm to about 25 ppm, from about 0.05 ppm to about 10 ppm, or even from about 0.1 ppm to about 5 ppm, of the MRL in the wash liquor.
[0126] Preferred transition-metals in the instant transition-metal bleach catalyst include manganese, iron and chromium. Preferred MRL's herein are a special type of ultra-rigid ligand that is cross-bridged such as 5,12-diethyl-1,5,8,12-tetraazabicyclo[6.6.2]hexa-decane.
[0127] Suitable transition metal MRLs are readily prepared by known procedures, such as taught for example in WO 00/32601, and U.S. Pat. No. 6,225,464.
Processes of Making Laundry Care Compositions
[0128] The laundry care compositions of the present invention can be formulated into any suitable form and prepared by any process chosen by the formulator, non-limiting examples of which are described in U.S. Pat. No. 5,879,584; U.S. Pat. No. 5,691,297; U.S. Pat. No. 5,574,005; U.S. Pat. No. 5,569,645; U.S. Pat. No. 5,565,422; U.S. Pat. No. 5,516,448; U.S. Pat. No. 5,489,392; and U.S. Pat. No. 5,486,303.
[0129] In one aspect, the liquid detergent compositions disclosed herein may be prepared by combining the components thereof in any convenient order and by mixing, e.g., agitating, the resulting component combination to form a phase stable liquid detergent composition. In one aspect, a liquid matrix is formed containing at least a major proportion, or even substantially all, of the liquid components, e.g., nonionic surfactant, the non-surface active liquid carriers and other optional liquid components, with the liquid components being thoroughly admixed by imparting shear agitation to this liquid combination. For example, rapid stirring with a mechanical stirrer may usefully be employed. While shear agitation is maintained, substantially all of any anionic surfactant and the solid ingredients can be added. Agitation of the mixture is continued, and if necessary, can be increased at this point to form a solution or a uniform dispersion of insoluble solid phase particulates within the liquid phase. After some or all of the solid-form materials have been added to this agitated mixture, particles of any enzyme material to be included, e.g., enzyme prills, are incorporated. As a variation of the composition preparation procedure described above, one or more of the solid components may be added to the agitated mixture as a solution or slurry of particles premixed with a minor portion of one or more of the liquid components. After addition of all of the composition components, agitation of the mixture is continued for a period of time sufficient to form compositions having the requisite viscosity and phase stability characteristics. Frequently this will involve agitation for a period of from about 30 to 60 minutes.
[0130] In another aspect of producing liquid detergents, the thiazolium dye is first combined with one or more liquid components to form a thiazolium dye premix, and this thiazolium dye premix is added to a composition formulation containing a substantial portion, for example more than 50% by weight, more than 70% by weight, or even more than 90% by weight, of the balance of components of the laundry detergent composition. For example, in the methodology described above, both the thiazolium dye premix and the enzyme component are added at a final stage of component additions. In another aspect, the thiazolium dye is encapsulated prior to addition to the detergent composition, the encapsulated dye is suspended in a structured liquid, and the suspension is added to a composition formulation containing a substantial portion of the balance of components of the laundry detergent composition.
[0131] Various techniques for forming detergent compositions in such solid forms are well known in the art and may be used herein. In one aspect, when the laundry care composition is in the form of a granular particle, the thiazolium dye is provided in particulate form, optionally including additional but not all components of the laundry detergent composition. The thiazolium dye particulate is combined with one or more additional particulates containing a balance of components of the laundry detergent composition. Further, the thiazolium dye, optionally including additional but not all components of the laundry detergent composition may be provided in an encapsulated form, and the thiazolium dye encapsulate is combined with particulates containing a substantial balance of components of the laundry detergent composition.
Methods of Using Laundry Care Compositions
[0132] The laundry care compositions disclosed in the present specification may be used to clean or treat a fabric. Typically at least a portion of the fabric is contacted with an embodiment of the aforementioned laundry care compositions, in neat form or diluted in a liquor, for example, a wash liquor and then the fabric may be optionally washed and/or rinsed. In one aspect, a fabric is optionally washed and/or rinsed, contacted with a an embodiment of the aforementioned laundry care compositions and then optionally washed and/or rinsed. For purposes of the present invention, washing includes but is not limited to, scrubbing, and mechanical agitation. The fabric may comprise most any fabric capable of being laundered or treated.
[0133] The laundry care compositions disclosed in the present specification can be used to form aqueous washing solutions for use in the laundering of fabrics. Generally, an effective amount of such compositions is added to water, preferably in a conventional fabric laundering automatic washing machine, to form such aqueous laundering solutions. The aqueous washing solution so formed is then contacted, preferably under agitation, with the fabrics to be laundered therewith. An effective amount of the laundry care composition, such as the liquid detergent compositions disclosed in the present specification, may be added to water to form aqueous laundering solutions that may comprise from about 500 to about 7,000 ppm or even from about 1,000 to about 3,000 pm of laundry care composition.
[0134] In one aspect, one or more of the thiazolium dyes disclosed in the present specification may be provided, for example via a laundry care composition, such that during the wash cycle and or rinse cycle the concentration of such one or more dyes may be from about 0.5 parts per billion (ppb) to about 5 part per million (ppm), from about 1 ppb to about 600 ppb, from about 5 ppb to about 300 ppb, or even from about 10 ppb to about 100 ppb of thiazolium dye. In one aspect such concentrations may be achieved during the washing cycle, and/or rinse cycle, of a 17 gallon automatic laundry washing machine.
[0135] In one aspect, the laundry care compositions may be employed as a laundry additive, a pre-treatment composition and/or a post-treatment composition.
Test Methods
I. Method for Determining of Hueing Efficiency for Detergents
[0000]
a.) Two 25 cm×25 cm fabric swatches of 16 oz white cotton interlock knit fabric (270 g/square meter, brightened with Uvitex BNB fluorescent whitening agent, from Test Fabrics. P.O. Box 26, Weston, Pa., 18643), are obtained.
b.) Prepare two one liter aliquots of tap water containing 1.55 g of AATCC standard heavy duty liquid (HDL) test detergent as set forth in Table 3.
c.) Add a sufficient amount the dye to be tested to one of the aliquots from Step b.) above to produce an aqueous solution absorbance of 1 AU.
d.) Wash one swatch from a.) above in one of the aliquots of water containing 1.55 g of AATCC standard heavy duty liquid (HDL) test detergent and wash the other swatch in the other aliquot. Such washing step should be conducted for 30 minutes at room temperature with agitation. After such washing step separately rinse the swatches and dry the swatches.
e.) After rinsing and drying each swatch, the hueing efficiency, DE* eff , of the dye is assessed by determining the L*, a*, and b* value measurements of each swatch using a Hunter LabScan XE reflectance spectrophotometer with D65 illumination, 10° observer and UV filter excluded. The hueing efficiency of the dye is then calculated using the following equation:
[0000] DE* eff =(( L* c −L* s ) 2 +( a* c −a* s )+( b* c −b* s ) 2 ) 1/2 , wherein the subscripts c and s respectively refer to the L*, a*, and b* values measured for the control, i.e., the fabric sample washed in detergent with no dye, and the fabric sample washed in detergent containing the dye to be screened.
II. Method for Determining Wash Removability
[0000]
a.) Prepare two separate 150 ml aliquots of HDL detergent solution set forth in Table 1, according to AATCC Test Method 61-2003, Test 2A and containing 1.55 g/liter of the AATCC HDL formula in distilled water.
b.) A 15 cm×5 cm sample of each fabric swatch from the Method for Determining of Hueing Efficiency For Detergents described above is washed in a Launderometer for 45 minutes at 49° C. in 150 ml of a the HDL detergent solution prepared according to Step II. a.) above.
c.) The samples are rinsed with separate aliquots of rinse water and air dried in the dark, the amount of residual coloration is assessed by measuring the DE* res , of the dye is assessed by determining the L*, a*, and b* value measurements of each swatch using a Hunter LabScan XE reflectance spectrophotometer with D65 illumination, 10° observer and UV filter excluded. The hueing efficiency of the dye is then calculated using the following equation:
[0000] DE* res =(( L* c −L* s ) 2 +( a* c −a* s ) 2 ( b* c −b* s ) 2 ) 1/2 wherein the subscripts c and s respectively refer to the L*, a*, and b* values measured for the control, i.e., the fabric sample initially washed in detergent with no dye, and the fabric sample initially washed in detergent containing the dye to be screened. The wash removal value for the dye is then calculated according to the formula:
[0000] % removal=100×(1 −DE* res /DE* eff ).
[0000]
TABLE 3
Ingredient
weight percent
C11.8 linear alkylbenzene sulfonic acid
12.00
Neodol 23-9
8.00
citric acid
1.20
C12-14 fatty acid
4.00
sodium hydroxide 1
2.65
ethanolamine
0.13
borax
1.00
DTPA 2
0.30
1,2-propanediol
8.00
brightener 15
0.04
water
balance
1 formula pH adjusted to 8.5
2 diethylenetriaminepentaacetic acid, pentasodium salt
EXAMPLES
[0146] The following examples illustrate the compositions of the present invention but are not necessarily meant to limit or otherwise define the scope of the invention herein.
Example 1
[0147] The following liquid formulas are within the scope of the present invention.
[0000]
1a
1b
1c
1d
1e
1f 5
Ingredient
wt %
wt %
wt %
wt %
wt %
wt %
sodium alkyl ether sulfate
14.4%
14.4%
9.2%
5.4%
linear alkylbenzene
4.4%
4.4%
12.2%
5.7%
1.3%
22.0%
sulfonic acid
alkyl ethoxylate
2.2%
2.2%
8.8%
8.1%
3.4%
18.0%
amine oxide
0.7%
0.7%
1.5%
citric acid
2.0%
2.0%
3.4%
1.9%
1.0%
1.6%
fatty acid
3.0%
3.0%
8.3%
16.0%
protease
1.0%
1.0%
0.7%
1.0%
2.5%
amylase
0.2%
0.2%
0.2%
0.3%
lipase
0.2%
borax
1.5%
1.5%
2.4%
2.9%
calcium and sodium
0.2%
0.2%
formate
formic acid
1.1%
amine ethoxylate polymers
1.8%
1.8%
2.1%
3.2%
sodium polyacrylate
0.2%
sodium polyacrylate
0.6%
copolymer
DTPA 1
0.1%
0.1%
0.9%
DTPMP 2
0.3%
EDTA 3
0.1%
fluorescent whitening
0.15%
0.15%
0.2%
0.12%
0.12%
0.2%
agent
ethanol
2.5%
2.5%
1.4%
1.5%
propanediol
6.6%
6.6%
4.9%
4.0%
15.7%
sorbitol
4.0%
ethanolamine
1.5%
1.5%
0.8%
0.1%
11.0%
sodium hydroxide
3.0%
3.0%
4.9%
1.9%
1.0%
sodium cumene sulfonate
2.0%
silicone suds suppressor
0.01%
perfume
0.3%
0.3%
0.7%
0.3%
0.4%
0.6%
Compound 16 of Table 1
0.005%
0.005%
Compound 24 of Table 1
0.005%
Compound 13 of Table 1
0.008%
Compound 36 of Table 1
0.008%
Compound 21 of Table 1
0.015%
Liquitint Aqua AS 4
0.005%
opacifier 6
0.5%
water
balance
balance
balance
balance
balance
balance
100.0%
100.0%
100.0%
100.0%
100.0%
100.0%
1 diethylenetriaminepentaacetic acid, sodium salt
2 diethylenetriaminepentakismethylenephosphonic acid, sodium salt
3 ethylenediaminetetraacetic acid, sodium salt
4 a non-tinting dye used to adjust formula color
5 compact formula, packaged as a unitized dose in polyvinyl alcohol film
6 Acusol OP 301
Example 2
[0148] The following granular detergent formulas are within the scone of the present invention.
[0000]
2a
2b
2c
2d
Ingredient
wt %
wt %
wt %
wt %
Na linear alkylbenzene
3.4%
3.3%
11.0%
3.4%
sulfonate
Na alkylsulfate
4.0%
4.1%
4.0%
Na alkyl sulfate
9.4%
9.6%
9.4%
(branched)
alkyl ethoxylate
3.5%
type A zeolite
37.4%
35.4%
26.8%
37.4%
sodium carbonate
22.3%
22.5%
35.9%
22.3%
sodium sulfate
1.0%
18.8%
1.0%
sodium silicate
2.2%
protease
0.1%
0.2%
0.1%
sodium polyacrylate
1.0%
1.2%
0.7%
1.0%
carboxymethylcellulose
0.1%
PEG 600
0.5%
PEG 4000
2.2%
DTPA
0.7%
0.6%
0.7%
fluorescent whitening
0.1%
0.1%
0.1%
0.1%
agent
sodium percarbonate
5.0%
sodium
5.3%
nonanoyloxybenzene-
sulfonate
silicone suds suppressor
0.02%
0.02%
0.02%
perfume
0.3%
0.3%
0.2%
0.3%
Compound 15 of Table 1
0.015% 1
Compound 48 of Table 1
0.017% 2
Compound 38 of Table 1
0.017% 3
Compound 33 of Table 1
0.02% 4
water and miscellaneous
balance
balance
balance
balance
1 formulated as a particle containing 0.5% dye, 99.5% PEG 4000
2 formulated as a layered particle containing 2% dye according to US 2006 252667 A1
3 formulated as a particle containing 0.5% dye according to U.S. Pat. No. 4,990,280
4 formulated as a particle containing 0.5% dye with zeolite
Example 3
[0149] The following rinse added fabric conditioning formulas are within the scope of the present invention.
[0000]
Ingredients
3a
3b
3c
3d
Fabric Softening Active a
13.70%
13.70%
13.70%
13.70%
Ethanol
2.14%
2.14%
2.14%
2.14%
Cationic Starch b
2.17%
2.17%
2.17%
2.17%
Perfume
1.45%
1.45%
1.45%
1.45%
Phase Stabilizing
0.21%
0.21%
0.21%
0.21%
Polymer c
Calcium Chloride
0.147%
0.147%
0.147%
0.147%
DTPA d
0.007%
0.007%
0.007%
0.007%
Preservative e
5 ppm
5 ppm
5 ppm
5 ppm
Antifoam f
0.015%
0.015%
0.015%
0.015%
Compound 45 of Table 1
30 ppm
15 ppm
Compound 25 of Table 1
30 ppm
Compound 30 of Table 1
30 ppm
15 ppm
Tinopal CBS-X g
0.2
0.2
0.2
0.2
Ethoquad C/25 h
0.26
0.26
0.26
0.26
Ammonium Chloride
0.1%
0.1%
0.1%
0.1%
Hydrochloric Acid
0.012%
0.012%
0.012%
0.012%
Deionized Water
Balance
Balance
Balance
Balance
a N,N-di(tallowoyloxyethyl)-N,N-dimethylammonium chloride.
b Cationic starch based on common maize starch or potato starch, containing 25% to 95% amylose and a degree of substitution of from 0.02 to 0.09, and having a viscosity measured as Water Fluidity having a value from 50 to 84.
c Copolymer of ethylene oxide and terephthalate having the formula described in U.S. Pat. No. 5,574,179 at col.15, lines 1-5, wherein each X is methyl, each n is 40, u is 4, each R 1 is essentially 1,4-phenylene moieties, each R 2 is essentially ethylene, 1,2-propylene moieties, or mixtures thereof.
d Diethylenetriaminepentaacetic acid.
e KATHON ® CG available from Rohm and Haas Co.
f Silicone antifoam agent available from Dow Corning Corp. under the trade name DC2310.
g Disodium 4,4′-bis-(2-sulfostyryl) biphenyl, available from Ciba Specialty Chemicals.
h Cocomethyl ethoxylated [15] ammonium chloride, available from Akzo Nobel
Example 4
Synthesis of mtol-10EO methylthiazolium
[0150]
[0151] Five hundred and forty-nine grams of 85% phosphoric acid, 75 grams of 98% sulfuric acid and 9 drops of 2-ethyl hexanol defoamer are added to a 100 milliliter three necked flask equipped with a thermometer, cooling bath, and mechanical stirrer. The mixture is cooled and 30.9 grams of 2-aminothiazole is added to the flask. The mixture is further cooled to below 0° C. after which 105 grams of 40% nitrosyl sulfuric acid are added while the temperature is maintained below 5° C. After three hours the mixture gives a positive nitrite test and 25 grams of sulfamic acid are added slowly while the temperature is kept below 5° C. A negative nitrite test is evident after one hour.
[0152] A 2000 milliliter beaker is charged with 190 grams 10 EO m-toluidine intermediate, 200 grams of water, 200 grams of ice and 12 grams of urea. The mixture is cooled to 0° C. The diazo solution is added dropwise to the beaker over about 30 minutes, while maintaining the temperature below 10° C. The resulting mixture is stirred for several hours and allowed to stand overnight, after which 780 grams of 50% sodium hydroxide is added to neutralize excess acid to a pH of about 7 while the temperature is kept below 20° C. The bottom salt layer is removed and the product is washed with 200 milliliters of a 10% sodium sulfate solution. The aqueous layer is removed and the desired product is obtained as an orange liquid (240 grams, 70% actives).
[0153] One hundred grams of the orange liquid from above and 28.40 grams of dimethyl sulfate are placed into a 500 milliliter flask equipped with a reflux condenser, thermometer, heating mantle and mechanical stirrer. The reaction mixture is heated to 70° C. for two hours. The reaction is cooled and the pH is adjusted to 7 with 10 grams of 20% ammonium hydroxide and is used without further purification.
Example 5
[0154] The procedure of Example 4 is used to make N-ethyl-mtol-5EO
[0000]
[0000] with the difference being the use of the following m-toluidine intermediate:
[0000]
Example 6
[0155] The procedure of Example 5, with the noted changes, is used to make:
[0000]
[0156] Twenty grams of the orange liquid per Example 5, as obtained via Example 4, and nine grams of benzyl bromide are placed into a 250 milliliter flask equipped with a reflux condenser, thermometer, heating mantle and mechanical stirrer. The reaction mixture is heated to 70° C. for two hours. The reaction is cooled and the pH is adjusted to 7 with 4 grams of 50% sodium hydroxide and is used without further purification.
[0157] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
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The present invention relates to thiazolium dyes, laundry care compositions comprising one or more thiazolium dyes, processes of making such dyes and laundry care compositions and methods of using same. The dyes, compositions and methods of the present invention are advantageous in providing improved hueing of fabric, including whitening of white fabric, while avoiding significant build up of bluing dyes on the fabric.
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CROSS-REFFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/892,683 filed on Mar. 2, 2007. The disclosure of the above application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to a park servo for an automatic transmission and more particularly to a park servo for an automatic transmission having a pressure assisted return to park piston.
BACKGROUND
[0003] In previous automatic transmissions having an electronic transmission range shift (ETRS) feature, electro-hydraulic solenoid/valves (solenoids) have been used to provide pressurized hydraulic fluid to a hydraulic servo that rotates the manual shaft to release and place the vehicle transmission in park. Particularly in cold environments, the time necessary for the hydraulic servo to return the transmission to park after such a shift command, though not long, may be viewed as less than optimal. Accordingly, it has been determined that improvements in return to park actuators for automatic transmissions are desirable.
SUMMARY
[0004] A pressure assisted park servo assembly for an automatic transmission typically having an electronic transmission range shift (ETRS) configuration includes a multiple port servo or spool valve which receives pressurized hydraulic fluid from various sources including two solenoids and transmission ports. The spool valve controls two flows of pressurized hydraulic fluid to a park servo to quickly place the transmission in or release it from park. The park servo includes a compression spring which also urges the park servo toward its park position. The fluid sources within the transmission maintain or latch the spool valve and park servo on the out of park position.
[0005] Thus it is an object of the present invention to provide a pressure assisted park servo for an automatic transmission having electronic transmission range shift.
[0006] It is a further object of the present invention to provide a pressure assisted park servo assembly for an automatic transmission having a servo or spool valve which receives pressurized hydraulic fluid from solenoids and the transmission.
[0007] It is a still further object of the present invention to provide a servo valve and pressure assisted park servo that provides enhanced operating speed.
[0008] It is a still further object of the present invention to provide a pressure assisted park servo having a compression spring which urges the servo piston toward the park position.
[0009] Further objects and advantages of the present invention will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a pictorial view of an improved pressure assisted park servo assembly according to the present invention installed on an automatic transmission;
[0011] FIG. 2 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention in the park position;
[0012] FIG. 3 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention moving out of the park position;
[0013] FIG. 4 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention in the out of park position;
[0014] FIG. 5 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention illustrating operation of a back up fluid circuit which maintains the pressure assisted park servo in the out of park position.
[0015] FIG. 6 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention illustrating operation of a hydraulic latch which maintains the pressure assisted park servo in the out of park position;
[0016] FIG. 7 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention commencing movement back to the park position;
[0017] FIG. 8 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention moving back to the park position; and
[0018] FIG. 9 is a diagrammatic view of a servo valve and pressure assisted park servo according to the present invention in the park position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring now to FIG. 1 , an automatic transmission is illustrated and generally designated by the reference number 10 . Typically, the automatic transmission 10 will include an electronic transmission range shift (ETRS) feature. The automatic transmission 10 includes a housing 11 which is preferably a metal casting and includes numerous openings, shoulders, flanges and other features (not illustrated) which receive, locate and support various components of the automatic transmission 10 . Extending through one such opening in the housing 11 is a manual shaft 12 which is coupled to and translates park components between Park and Out of Park ranges within the automatic transmission 10 . The manual shaft 12 is coupled though a suitable linkage 14 to the bi-directionally translating output shaft or piston rod 16 of a pressure assisted park servo 20 according to the present invention.
[0020] Also associated and in fluid communication with the pressure assisted park servo 20 is a return to park solenoid 22 , an out of park solenoid 24 which are both connected to a source of pressurized hydraulic fluid (not illustrated) and a hydraulic, multiple port ETRS, servo or spool valve 30 .
[0021] Referring now to FIG. 2 , it will be appreciated that the servo or spool valve 30 includes a housing 32 which defines a cylindrical bore 34 of diverse diameters and a plurality of preferably radial passageways or ports which communicate with the cylindrical bore 34 . A first control port 40 is disposed at one end of the bore 34 and communicates with the outlet or control side of the out of park solenoid 24 . A second control port 42 is disposed adjacent the first port 40 and communicates between the bore 34 and the outlet or control side of a drive and braking solenoid 44 . A first exhaust port 46 is adjacent the second control port 42 and communicates between the bore 34 and a hydraulic sump or reservoir (not illustrated). A third control port 48 communicates through a first hydraulic line 52 to a first chamber 54 in the pressure assisted park servo 20 . Pressurized hydraulic fluid in the first chamber 54 provides force against one face 55 of a piston 56 and extends the shaft or piston rod 16 . Such extension is assisted by a first compression spring 58 disposed in the first chamber 54 about the piston rod 16 . A fluid port 57 communicates with the first chamber 54 and a valve 59 . The valve 59 is illustrated as a ball/check valve, however, other kinds of valves may be employed without departing from the scope of the present invention. The valve 59 allows air or fluid to enter the first chamber 54 in order to prevent a vacuum from forming in the first chamber 54 when the piston 56 is returning to the Park position and when there is no pressurized fluid provided by a pressurized hydraulic fluid source, such as when the engine of the motor vehicle is off. Accordingly, the valve 59 increases the rate of return to the Park position.
[0022] The housing 32 of the servo or spool valve 30 also defines a first inlet port 62 which communicates between a source of pressurized hydraulic fluid (not illustrated) and the cylindrical bore 34 adjacent the third control port 48 . A fourth control port 64 communicates through a second hydraulic line 66 with a second chamber 68 in the pressure assisted park servo 20 . Pressurized hydraulic fluid in the second chamber 68 provides force against an opposite face 69 of the piston 56 and retracts the shaft or piston rod 16 . A second exhaust port 72 adjacent the fourth control port 64 communicates between the bore 34 and the hydraulic sump or reservoir. A fifth control port 74 communicates with the bore 34 and receives pressurized hydraulic fluid from components within the transmission indicating that the transmission is in a forward gear. Finally, a sixth control port 76 is disposed at the second end of the bore 34 and communicates with the outlet or control side of the return to park solenoid 22 .
[0023] Axially, slidably disposed within the cylindrical bore 34 of the housing 32 of the servo or spool valve 30 is a valve spool 80 having various diameters and shoulders which cooperate with the cylindrical bore 34 and the ports 40 , 42 , 46 , 48 , 62 , 64 , 72 , 74 and 76 to control the direction and flow of hydraulic fluid to the pressure assisted park servo 20 .
[0024] The valve spool 80 , from left to right, includes a first shoulder 82 operatively associated with the first inlet port 40 , a second shoulder 84 operatively associated with the second inlet port 42 , a first control disc 86 operatively associated with the first exhaust port 46 and the third control port 48 , a second control disc 88 operatively associated with the fourth control port 64 and the second exhaust port 72 , a third shoulder 92 operatively associated with the fifth control port 74 and a fourth shoulder 94 operatively associated with the sixth control port 76 .
[0025] As illustrated, a first stub potion 96 of the valve spool 80 extends beyond the first shoulder 82 and a second stub portion 98 of the valve spool 80 extends beyond the fourth shoulder 94 to limit translation of the valve spool 80 in left and right directions, respectively. In a portion of the bore 34 communicating with the port 76 and concentrically located about a portion of the valve spool 80 and contacting the fourth shoulder 94 is disposed a second compression spring 102 .
[0026] Operation of the pressure assisted park servo 20 will now be described with serial reference to the drawings, beginning with FIG. 2 . In FIG. 2 , the automatic transmission 10 is in park and the spool 80 of the ETRS or spool valve 30 is at its left limit of travel (as viewed in the drawings). In this condition, pressurized hydraulic fluid, provided to the first inlet port 62 , is present at the third control port 48 and pressurizes the first hydraulic line 52 and the first chamber 54 of the pressure assisted park servo 20 , driving or maintaining the piston 56 and shaft or piston rod 16 of the pressure assisted park servo 20 to or in its park position, to the right as illustrated in FIG. 2 .
[0027] In FIGS. 3 and 4 , the vehicle operator has requested a transmission operating range other than park and the out of park solenoid 24 is activated, providing hydraulic fluid to the first control port 40 , applying pressure to the first shoulder 82 and causing translation of the valve spool 80 to the right. This action causes translation of the first control disc 86 which connects the first chamber 54 and the first hydraulic line 52 through the third control port 48 to the first exhaust port 46 which allows release of hydraulic fluid from the first chamber 54 . Additionally, the second control disc 88 translates to the right and pressurized hydraulic fluid, present at the first inlet port 62 , is provided to the fourth control port 64 , the second hydraulic line 66 and the second chamber 68 to retract the shaft or piston rod 16 and move the manual shaft 12 and automatic transmission 10 out of park.
[0028] In FIG. 5 , the drive and braking solenoid 44 is energized to supply pressurized hydraulic fluid to the second control port 42 and against the second shoulder 84 . This provides an additional force to the valve spool 80 to maintain it in its rightmost (out of park) position and provides a back up or redundant feature to the out of park solenoid 24 to ensure that the transmission remains out of park.
[0029] In FIG. 6 , the automatic transmission 10 is in a forward gear and pressurized hydraulic fluid from the transmission 10 is supplied to the fifth control port 74 and against the third shoulder 92 which also provides a force to the valve spool 80 to maintain it in its rightmost position. Given the redundancy, the out of park solenoid 24 may be turned off. While the drive and braking solenoid 44 may remain on, however, the transmission fluid provided to the fifth control port 74 provides a hydraulic latch which keeps the automatic transmission 10 out of park if the drive and braking solenoid 44 fails or the TEHCM controller stops working.
[0030] In FIG. 7 , the vehicle operator requests park. Both the out of park solenoid 24 and the drive and braking solenoid 44 are de-energized and the return to park solenoid 22 is energized. Pressurized hydraulic fluid is then supplied to the sixth control port 76 and the fourth shoulder 94 of the valve spool 80 adjacent the second compression spring 102 . The combination of hydraulic pressure and spring force moves the valve spool 80 back to the left, to the park position, faster than the compression spring 102 alone would be able to move the valve spool 80 .
[0031] In FIG. 8 , the valve spool 80 has translated to the left, to its park position, translating the second control disc 88 to the left and connecting the fourth control port 64 , the second hydraulic line 66 and the second chamber 68 to the second exhaust port 72 to allow the hydraulic fluid in the second chamber 68 to be released. At the same time, the first control disc 86 translates to the left, the first inlet port 62 is placed in fluid communication with the third control port 48 and the first hydraulic line 52 and pressurized hydraulic fluid begins to fill the first chamber 54 of the pressure assisted park servo 20 .
[0032] In FIG. 9 , the piston 56 and the shaft or piston rod 16 of the pressure assisted park servo 20 have fully returned to the right, to the park position. By utilizing pressurized hydraulic fluid from the first inlet port 62 , the motion of the piston 56 and the piston rod 16 of the pressure assisted park servo 20 is much faster than that achieved by utilizing the first compression spring 58 alone and the park position of the automatic transmission 10 is quickly achieved.
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A pressure assisted park servo assembly for an automatic transmission includes a servo or spool valve which receives pressurized hydraulic fluid from various sources including two solenoid valves and transmission ports. The servo valve controls two flows of pressurized hydraulic fluid to a servo assembly to place the transmission in or release it from park. The improved park servo assembly exhibits enhanced operating speed.
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This is a continuation of co-pending application Ser. No. 618,613, filed 6/8/84, now U.S. Pat. No. 4,535,843, which is a continuation of Ser. No. 380,689, filed 5/21/82, now abandoned.
BACKGROUND
1. Field of the Invention
This invention relates to a method and apparatus for obtaining samples of formation fluids at different levels in a bore hole. The characteristics of formation fluids obtained from various levels within a bore hole are of considerable interest to geologists as an aid to determining subsurface structure as well as to those engaged in well completion and production. This invention provides a method and apparatus for lowering a logging tool into an uncased bore hole on a conventional wireline, positioning the tool at preselected elevations and obtaining formation fluid samples. The samples are tested within the tool without withdrawing it from the bore hole and the test results transmitted to the surface. If it is determined that the sample should be recovered it is transferred to one of a plurality of collection chambers within the tool, and, if not, it is ejected into the bore hole. The logging tool can then be moved to another level, without withdrawal from the well and the process repeated until all of the sample collection chambers in the tool are filled.
2. Description of the Prior Art
Formation fluid sample collection tools have been in use in the industry for a number of years. See for example the descriptive matter found in the Composite Catalog of Oil Field Equipment and Services--1978-1979, pages 3286-3291 for a description of services and equipment provided by Halliburton Services. See also in the 1976-1977 edition of the same catalog the description of the Johnson Inflatable Packer Test Systems at pages 3607-3609. Both the Halliburton and Johnson systems involve attaching the sampling tool to the drill pipe string and are not designed for wireline logging. Moreover, they do not have means for isolating and testing formation fluids at various selected levels within the bore hole to make a determination as to the desirability of collecting and retaining the sample without withdrawal of the tool from the well. These two differences are of considerable significance when the time the well must be out of commission for sampling is taken into consideration. To run a tool into a well on a wireline requires but a small fraction of the time required to run in a drill pipe string and the advantage of being able to collect a number of pretested samples each time the tool is sent down the well further greatly reduces the time during which the well is out of commission.
Wireline formation testers have been available since the early 1950's and have been used to obtain fluids, flow rates and pressures from prospective reservoirs. Because of limited tool capacity and capabilities, however, recovered fluids often are entirely or mostly drilling mud filtrate. Moreover, there is no fluid property monitoring capability. Thus these tools are useful only in the case of reservoirs where adequate flow is obtained and recovered fluids are relatively free of mud filtrate. They tend not to be useful in those cases where geological exploration is involved and fluid samples other than those containing hydrocarbon are desired.
SUMMARY OF THE INVENTION
A primary object of this invention is to provide a method for obtaining a plurality of high quality samples of formation fluids from the wall of a bore hole on a single passage of a logging tool into the bore hole by locating the tool at various levels within the bore hole, isolating an interval of the bore hole, withdrawing fluid from the isolated interval, testing the properties of the withdrawn fluid while within the tool, transmitting the test results to the surface for determination of the suitability of the sample for collection and, if it is found suitable, transferring the sample to a collection chamber within the tool for ultimate removal to the surface.
A second and related object of this invention is to provide a logging and sample collecting tool operable in connection with a conventional wireline for carrying out the method of this invention.
This invention is directed to an improved method and apparatus for obtaining formation fluid samples from a bore hole. The method involves initially lowering a tool suspended by a wireline into the bore hole to a preselected level; and utilizing a pair of packers carried by the tool to isolate an interval of the bore hole by inflating the packers to expand them into sealing contact with said bore hole. Fluid is withdrawn from the isolated interval between the packers and its electrical resistivity is measured in a resistivity test chamber located within the tool. The resistivity measurement is sent to the surface via the wireline and when the resistivity becomes constant, indicating that formation fluids uncontaminated by drilling mud components are being withdrawn into the tool, the withdrawn fluids are directed into a second test chamber wherein the redox potential (Eh), acidity (pH) and temperature of the fluids are measured and the results are sent to the surface by the wireline. It is then determined from the thus transmitted results whether it is desired to retain a sample and, if determination is positive, the fluid is pumped to one of a plurality of sample collection chambers within said tool. If the determination is negative, the fluid is returned to the bore hole, the packers are deflated to free the tool for vertical movement and the tool is moved to another preselected location; where the above-referred to steps are repeated. This procedure is followed until the sample chambers in the tool are filled with desired samples, and finally the wireline is retracted to return the tool and the contained samples to the surface.
A preferred embodiment of the apparatus of this invention comprises a tool adapted to be introduced into a bore hole on a conventional seven conductor wireline and having a pair of spaced apart inflatable packers for isolating an interval of the bore hole. A hydraulic pump is provided within the tool for pumping fluids from the interval between the packers, initially for inflating the packers, and subsequent to their inflation for pumping fluids through a resistivity test chamber and a second test chamber where redox potential (Eh), acidity (pH) and temperature measurements are obtained, and finally into one or more sample collection chambers located within the tool. Conventional means are associated with each of the chambers for performing the above-described measurement and for transmission of the results thereof to the surface through the wireline. In addition, there are provided suitable valve means electrically controlled from the surface for sequentially carrying out the method steps of this invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a preferred embodiment of a logging tool of this invention disposed within a section of a bore hole;
FIG. 2 is a schematic view showing the relationship of the various elements of the tool of this invention during the packer inflation step;
FIG. 3 is a similar view showing the relationship of the elements during the testing step; and
FIG. 4 is a similar view showing the relationship during the sample collection step.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a preferred embodiment of the tool 10 of this invention is shown in a downhole position in a bore hole 11. In this embodiment the tool is made up in tubular sections 12 through 16 which are connected in sealed relationship by collars 17. During movement through the bore hole and when the packers 20 are not set, the tool 10 is suspended from the cable head section 16 to which the supporting wireline 21 is securely attached by coupling 22. The use of individual section 12-16 each containing certain kinds of components is, of course, optional but it provides a convenient way to manufacture, assemble and service the tool 10. The maximum diameter of the tool 10 is, of course, limited by the size of the bore hole 11 and the effectiveness of the expandable packers 20. A convenient arrangement is to make the sections 13-16 of somewhat smaller diameter so that these portions of the tool can be utilized in smaller bore holes and to utilize a packer section 12 appropriately sized to perform adequate sealing in a particular bore hole to be tested and sampled. The following Table gives preferred packer sizes for different bore hole diameters:
TABLE______________________________________Minimum BoreHole Diameter Packer Size Packer ExpansionIn Inches in Inches Capacity in Inches______________________________________6.25 5.00 9.007.88 6.25 11.258.75 7.25 13.00______________________________________
From the foregoing it will be seen that, for a versatile tool, the maximum diameter of the sections 13-16 is about five inches. The length of a tool of five-inch diameter will depend upon the degree of miniaturization in hydraulic and electric circuitry and in the size and number of samples which are to be collected. Usually the lenght is between 6 and 12 feet.
In FIGS. 2-4 the hydraulic relationship of the various parts of the tool 10 during various steps of the preferred method are shown. In each of these Figures the main fluid flow for the particular step involved is indicated by a heavy line.
In FIG. 2 the step of inflating the packers is illustrated. Fluid from the bore hole 11 is withdrawn into the tool 10 through an open port 24 in packer section 12 passing through a filter 25 and resistivity test chamber 26. This test chamber which is preferably conventional can contain a pair of spaced apart electrodes across which a voltage is impressed. The resulting current flow between the electrodes provides an indication of resistivity. Suction for withdrawing the fluid is provided by a pump 27 driven by an electric motor 28 powered from the surface by an electric current delivered through the wireline 21. From pump 27 the withdrawn fluid passes through conduit 30 to the packers 20 which are inflated thereby to engage the wall of the wellbore in sealing relationship and isolate an interval thereof. To prevent the development of a pressure differential in the bore hole 11 above and below the tool 10 when the packers 20 are inflated, a passage 29 is provided through the packer section 12 as shown in FIG. 1. A pressure relief valve shown at 31 vents fluid to the bore hole when the packers 20 are filled. A back flow check valve 32 prevents fluid from flowing back out of the packers 20 when pump 27 is not operating. An electrically controlled packer deflate valve 33 is provided for venting conduit 30 to the wellbore when it is desired to deflate the packers 20.
Following inflation of the packers 20 the pump 27 continues to pump fluid from the bore hole through the resistivity test chamber venting the fluid to the bore hole through valve 31. This action is preferably continued until the resistivity measurement, which is conveyed to the surface through the wireline 21, becomes constant indicating that formation fluids free of drilling mud components are being withdrawn. At such time the pump 27 is stopped and the various valves are set to provide the flow pattern shown in FIG. 3.
To better illustrate the invention the various flow controlling valves have been schematically indicated. A preferred procedure, as will be appreciated by those familiar with the art, is to use a pair of rotary solenoid actuated valves (not shown) which are positioned by pulses sent down from the surface. Preferably, one of these rotary solenoid valves, as will be described later, is employed to control the pumping of samples to the sample containers and the other is preferably employed to control all of the other fluid flows.
After the packers 20 have been set and the resistivity cell 26 indicates that a uniform formation fluid is being withdrawn, the flow control valve (not shown) is rotated to place the schematically indicated valve elements in the positions shown in FIG. 3. Thus the filter control valve element 35 is actuated to cause the fluid to flow through line filter 36 instead of the large coarse filter 25 improving the quality of the withdrawn sample and the control valve 37 is actuated to divert the fluid flow through the second test chamber 38 to the bore hole 11.
The second test chamber 38 preferably contains a three electrode system for measuring acidity (pH) and redox potential (Eh). A temperaure sensor (not shown) is also provided as the temperature at which potential readings are made affects calibration. The preferred electrodes are as follows:
pH Reference--silver
Eh Reference--platinum
Reference electrode-antimony
but as will be appreciated any of the well known arrangements can be utilized. Moreover, in certain cases it may be desirable to adapt the test chamber 38 to perform other or additional kinds of tests such as retractive index, opacity, density of dissolved gas content all of which are known to those familiar with the art. Conventional electrical circuits are utilized to send appropriate signals through the wireline to the surface where pH, Eh and temperature of the formation fluid can be displayed or read out. It should be noted in FIG. 3 that a portion of the fluid does not pass through test chamber 38 but passes through samples control valve 40 and back to the bore hole 11 through conduit 41. By this arrangement test chamber 38 is not overloaded and there is more certainty of obtaining a sample representative of the fluid undergoing test in chamber 38 with the same fluid also simultaneously flowing to and through the sample control valve 40.
When the test results transmitted to the surface indicate that the formation fluids being withdrawn are suitable for collection, the pump 27 is stopped and the sample control valve 40 is electrically actuated to a position to discontinue flow of fluid to the bore hole through conduit 41 and to instead convey fluid to the first sample chamber indicated at 42. The chambers need not be evacuated or vented to the bore hole 11 as downhole pressures are so large that any air brought down from the surface in the tool 10 will be so compressed as to occupy but a small fraction of chamber volume. When sample chamber 42 has been filled the pump 27 is stopped and the rotary control valve is actuated to packer deflate position opening the valve port indicated at 33 to the bore hole and permitting the packers 20 to deflate. Suitable valved connections (not shown) are provided through the side of tool 10 for withdrawal of the samples from the chambers 42.
Following deflation of the packers 20 the tool 10 is again free to be moved to other preselected levels in the bore hole 11, and the above described steps can be repeated. Alternatively if it is decided at the surface that the formation fluid passing through test chamber 38 will not produce a sample desired for retention and transport to the surface no sample is collected at that level in the bore hole; and the pump 27 can be stopped, the packers 20 deflated and the tool moved to another level.
In the preferred embodiment of the logging-sampling tool 10 of this invention, the capability of determining formation fluid pressure is provided by means of a pressure sensor 45 connected to the fluid conduit downstream of the pump 27. This sensor 45 which preferably contains a transducer monitors formation fluid pressure during periods when the pump 27 is not operating and sends appropriate signals through the wireline 21 to the surface.
As will be apparent to those skilled in the art any of the conventional logging techniques, such as gamma ray, neutron, induction, sonic, etc., adaptable for wireline logging, can be practiced in conjunction with the method and apparatus of this invention by incorporating appropriate conventional sensing and transmission apparatus within the tool 10. Information from such ancillary apparatus can be of considerable aid in initially placing the tool in the bore hole for the testing and sampling procedure of this invention. Incidentally the words "bore hole" have been used herein and in the claims in their generic sense and are meant to include any cased or uncased generally cylindrical opening, sealable by means of a packer and whether intended for exploration or production purposes. Thus the expression includes drill hole, well bore and other equivalent terms.
In the foregoing detailed description, the circuitry for obtaining signals from the various sensing devices and transmitting them to the surface and for transmitting electrical commands from the surface to the tool have not been included as these techniques are well known to those skilled in the art and a multitude of different arrangements are available and may be used in the practice of this invention.
Various changes and/or modifications such as will present themselves to those familiar with the art may be made in the method and apparatus described herein without departing from the spirit of this invention whose scope is commensurate with the following claims:
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A method and apparatus operable on a wireline logging cable for sampling and testing bore hole fluids, transmitting the results obtained from such testing to the surface for determination whether or not the particular sample undergoing testing should be collected and brought to the surface. The apparatus comprises a downhole tool having an inflatable double packer for isolating an interval of the bore hole coupled with a hydraulic pump, the pump being utilized sequentially to inflate the double packer and isolate an interval of the bore hole and to remove fluids from the isolated interval to test chamber means where resistivity, redox potential (Eh) and acidity (pH) are determined, and finally to dispose of selected samples to one or more sample container chambers within said tool or to reject them into the bore hole if not selected.
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FIELD OF THE INVENTION
[0001] The present invention relates to telecommunications systems in general, and, more particularly, to delivering filler video streams to telecommunications terminals from an interactive voice response system.
BACKGROUND OF THE INVENTION
[0002] Many enterprises employ an interactive voice response (IVR) system that handles calls from telecommunications terminals. An interactive voice response system typically presents a hierarchy of menus to the caller, receives input keyed in by the caller, receives input spoken by the caller, and performs automated speech recognition (ASR) to interpret the spoken input. For example, a caller to an interactive voice response system might be presented with a menu of five options and might select the third option by pressing the “3” key of the terminal's keypad, or by saying the word “three.” Similarly, a caller might specify his or her bank account number to the interactive voice response system by inputting the digits via the keypad, or by saying the digits. An interactive voice response system is also typically capable of issuing commands in response to a caller's input (e.g., retrieving a customer's records from a database, invoking a software application to process a bank account transaction, etc.), and of connecting the caller to a person in the enterprise.
[0003] FIG. 1 depicts telecommunications system 100 in accordance with the prior art. Telecommunications system 100 comprises telecommunications network 105 , private branch exchange (PBX) 110 , and interactive voice response system 120 , interconnected as shown.
[0004] Telecommunications network 105 is a network such as the Public Switched Telephone Network [PSTN], the Internet, etc. that carries a call from a telecommunications terminal (e.g., a telephone, a personal digital assistant [PDA], etc.) to private branch exchange 110 . A call might be a conventional voice telephone call, a text-based instant messaging (IM) session, a Voice over Internet Protocol (VOIP) call, etc.
[0005] Private branch exchange (PBX) 110 receives incoming calls from telecommunications network 105 and directs the calls to interactive voice response (IVR) system 120 or to one of a plurality of telecommunications terminals within the enterprise, depending on how private branch exchange 110 is programmed or configured. For example, in an enterprise call center, private branch exchange 110 might comprise logic for routing calls to service agents' terminals based on criteria such as how busy various service agents have been in a recent time interval, the telephone number called, and so forth. In addition, private branch exchange 110 might be programmed or configured so that an incoming call is initially routed to interactive voice response (IVR) system 120 , and, based on caller input to IVR system 120 , subsequently redirected back to PBX 110 for routing to an appropriate telecommunications terminal within the enterprise. Private branch exchange (PBX) 110 also receives outbound signals from telecommunications terminals within the enterprise and from interactive voice response (IVR) system 120 , and transmits the signals on to telecommunications network 105 for delivery to a caller's terminal.
[0006] Interactive voice response (IVR) system 120 is a data-processing system that presents one or more menus to a caller and receives caller input (e.g., speech signals, keypad input, etc.), as described above, via private branch exchange 110 . Interactive voice response system (IVR) 120 is typically programmable and performs its tasks by executing one or more instances of an IVR system application. An IVR system application typically comprises one or more scripts that specify what speech is generated by interactive voice response system 120 , what input to collect from the caller, and what actions to take in response to caller input. For example, an IVR system application might comprise a top-level script that presents a main menu to the caller, and additional scripts that correspond to each of the menu options (e.g., a script for reviewing bank account balances, a script for making a transfer of funds between accounts, etc.).
[0007] A popular language for such scripts is the Voice extensible Markup Language (abbreviated VoiceXML or VXML). The Voice extensible Markup Language is an application of the extensible Markup Language, abbreviated XML, which enables the creation of customized tags for defining, transmitting, validating, and interpretation of data between two applications, organizations, etc. The Voice extensible Markup Language enables dialogs that feature synthesized speech, digitized audio, recognition of spoken and keyed input, recording of spoken input, and telephony. A primary objective of VXML is to bring the advantages of web-based development and content delivery to interactive voice response system applications.
[0008] FIG. 2 depicts an exemplary Voice extensible Markup Language (VXML) script (also known as a VXML document or page), in accordance with the prior art. The VXML script, when executed by interactive voice response system 120 , presents a menu with three options; the first option is for transferring the call to the sales department, the second option is for transferring the call to the marketing department, and the third option is for transferring the call to the customer support department. Audio content (in particular, synthesized speech) that corresponds to text between the <prompt>and </prompt>tags is generated by interactive voice response system 120 and transmitted to the caller.
SUMMARY OF THE INVENTION
[0009] As video displays become ubiquitous in telecommunications terminals, it can be advantageous to deliver video content to a telecommunications terminal during a call with an interactive voice response (IVR) system, in addition to audio content. For example, a user of a telecommunications terminal who is ordering apparel via an interactive voice response system might receive a video content stream related to a particular item (e.g., depicting a model who is wearing the item, depicting the different available colors for the item, etc.). Furthermore, in some instances it might be desirable to deliver an audio content stream (e.g., music, news, soundtrack for a video stream, etc.) to the user, perhaps during silent periods in the call, or as background audio throughout the entire call, or during playback of a video stream, etc.
[0010] In some situations, when an interactive voice response system issues a command to initiate delivery of a content stream to a telecommunications terminal, there might be a significant delay before the telecommunications terminal starts receiving the content stream (e.g., due to retrieval and buffering of the content, etc.). Furthermore, other IVR system tasks during a call, such as performing automated speech recognition (ASR) or retrieving a VXML page, might cause delays. When a delay occurs during a call, the caller might prematurely terminate the call because of impatience, or because he or she mistakenly assumes that the interactive voice response system has “frozen.” Such premature call terminations are undesirable because they can result in decreased customer satisfaction and lost sales.
[0011] In accordance with the illustrative embodiments of the present invention, when there is a delay during a call (e.g., due to retrieval and buffering of a content stream, etc.), the interactive voice response system will stream “filler” content to the caller during the delay. The filler content, which typically is relatively short in duration, is stored so that it can be rapidly retrieved and streamed to the calling terminal (e.g., in a cache, on a local disk, in a random access memory that enables concurrent reads, etc.). The streaming of filler content during a delay can reduce the chance that a caller prematurely terminates a call, and can also be used to provide information (e.g., weather, news, stock quotes, etc.), advertise products, and so forth.
[0012] In the illustrative embodiments of the present invention, filler content that is streamed to the caller can be based on one or more of the following: the date and time (i.e., the “calendrical time”); the identity of the caller; a prior call to the IVR system by the caller; the type of the calling telecommunications terminal; and the content stream that is being retrieved by the IVR system and is causing the delay. This enables the interactive voice response system to select and tailor filler content, including any superimposed graphics, advantageously. For example:
An advertisement that is presumably of interest to a particular caller might be selected as the filler content. An animated graphic that depicts the current date and time and the current value of the Dow Jones® stock market index might be overlaid at the bottom of a filler video stream. A high-resolution version of a filler video stream might be delivered to a telecommunications terminal that has a large display. A low-resolution version of a filler video stream might be delivered when network performance is poor. The soundtrack portion of a filler video stream might be delivered to a terminal that has no display. A graphic timer or progress bar that is overlaid at the bottom of a filler video stream might indicate one or more of: the elapsed time since the filler content stream started; the time remaining in the filler content stream; and the estimated time remaining until the original, “non-filler” content stream begins. The filler content might be a video “trailer” for the non-filler content stream. An advertisement might be selected based on an item that was purchased by the caller during a prior call to the interactive voice response system.
[0021] The illustrated embodiments comprise: issuing a first command for initiating delivery of a first content stream to a telecommunications terminal during a call that involves the telecommunications terminal and an interactive voice response system; and issuing a second command for initiating delivery of a second content stream to the telecommunications terminal before the delivery of the first content stream is initiated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 depicts a telecommunications system in accordance with the prior art.
[0023] FIG. 2 depicts a block diagram of the salient elements an exemplary Voice extensible Markup Language (VXML) script, in accordance with the prior art.
[0024] FIG. 3 depicts a telecommunications system in accordance with the illustrative embodiments of the present invention.
[0025] FIG. 4 depicts a flowchart of the salient tasks of interactive voice response system 320 , in accordance with the first illustrative embodiment of the present invention.
[0026] FIG. 5 depicts a flowchart of the salient tasks of interactive voice response system 320 , in accordance with the second illustrative embodiment of the present invention.
DETAILED DESCRIPTION
[0027] The terms appearing below are given the following definitions for use in this Description and the appended Claims.
[0028] For the purposes of the specification and claims, the term “calendrical time” is defined as indicative of one or more of the following:
(i) a time (e.g., 16:23:58, etc.), (ii) one or more temporal designations (e.g., Tuesday, November, etc.), (iii) one or more events (e.g., Thanksgiving, John's birthday, etc.), and (iv) a time span (e.g., 8:00 PM to 9:00 PM, etc.).
[0033] FIG. 3 depicts telecommunications system 300 in accordance with the illustrative embodiments of the present invention. Telecommunications system 300 comprises telecommunications network 105 , private branch exchange (PBX) 310 , interactive voice response system 320 , content server 330 , and content database 340 , interconnected as shown.
[0034] Private branch exchange (PBX) 310 provides all the functionality of private branch exchange (PBX) 110 of the prior art, and is also capable of receiving streamed content (e.g., audio, video, multimedia, etc.) from content server 330 , of forwarding streamed content on to telecommunications network 105 for delivery to a caller's terminal, and of transmitting signals related to streamed content to content server 330 . Furthermore, in addition to conventional telephony-based signaling and voice signals, private branch exchange 310 is also capable of transmitting and receiving Internet Protocol (IP) data packets, Session Initiation Protocol (SIP) messages, Voice over IP (VOIP) traffic, and stream-related messages (e.g., Real Time Streaming Protocol [RTSP] messages, etc.) to and from IVR system 320 . It will be clear to those skilled in the art, after reading this specification, how to make and use private branch exchange (PBX) 310 .
[0035] Interactive voice response system 320 provides all the functionality of interactive voice response system 120 of the prior art, and is also capable of transmitting commands to content server 330 (e.g., starting playback of a content stream, stopping playback of the content stream, queueing another content stream, etc.) and of receiving information from content server 330 (e.g., an indication that playback of a content stream has begun, an indication that playback of a content stream has completed, etc.). It will be clear to those skilled in the art, after reading this specification, how to make and use interactive voice response system 320 .
[0036] Content server 330 is capable of retrieving content from content database 340 , of buffering and delivering a content stream to a calling terminal via private branch exchange 310 , of receiving commands from interactive voice response (IVR) system 310 (e.g., to start playback of a content stream, to queue another content stream, etc.), and of transmitting status information to interactive voice response (IVR) system 310 , in well-known fashion. It will be clear to those skilled in the art, after reading this specification, how to make and use content server 330 .
[0037] Content database 340 is capable of storing a plurality of multimedia content (e.g., video content, audio content, etc.) and of retrieving content in response to commands from content server 330 , in well-known fashion. It will be clear to those skilled in the art, after reading this specification, how to make and use content database 340 .
[0038] FIG. 4 depicts a flowchart of the salient tasks of interactive voice response (IVR) system 320 , in accordance with the first illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 4 can be performed simultaneously or in a different order than that depicted.
[0039] At task 410 , an incoming call is received at interactive voice response (IVR) system 320 , in well-known fashion.
[0040] At task 415 , interactive voice response (IVR) system 320 assigns an instance of an appropriate IVR system application to the incoming call, in well-known fashion. As will be appreciated by those skilled in the art, although in the illustrative embodiments an instance of an IVR system application handles one incoming call at a time, in some other embodiments of the present invention an application instance might handle a plurality of calls concurrently.
[0041] At task 420 , interactive voice response (IVR) system 320 begins executing the IVR application instance, in well-known fashion.
[0042] At task 425 , interactive voice response (IVR) system 320 checks whether the current command to be executed in the IVR application instance initiates delivery of a content stream S to the calling telecommunications terminal. If so, IVR system 320 's execution of the method of FIG. 4 continues at task 435 ; otherwise, IVR system 320 's execution of the method of FIG. 4 proceeds to task 430 .
[0043] At task 430 , interactive voice response (IVR) system 320 checks whether the IVR application instance's execution has completed. If so, IVR system 320 's execution of the method of FIG. 4 continues back at task 410 for the next incoming call; otherwise, IVR system 320 's execution of the method of FIG. 4 proceeds to task 460 .
[0044] At task 435 , interactive voice response (IVR) system 320 issues a command to content server 330 to retrieve content from database 340 and deliver the content to the calling telecommunications terminal in streaming fashion, as is well-known in the art. As will be appreciated by those skilled in the art, in some embodiments of the present invention, the command to deliver content might result in the stopping of a currently-playing stream (e.g., filler content, etc.). as soon as the content is ready to be streamed to the terminal, while in some other embodiments, streaming of the retrieved content does not begin until the currently-playing stream has finished.
[0045] At task 440 , interactive voice response (IVR) system 320 estimates the delay in initiating delivery of content stream S to the calling telecommunications terminal. As will be appreciated by those skilled in the art, There are a variety of methods for estimating performance (and equivalently, delays) that are well-known in the art; such methods take into account a variety of factors including bus/network performance, probabilistic caller patterns, concurrency, storage system performance, and so forth.
[0046] At task 445 , interactive voice response (IVR) system 320 checks whether the estimated delay exceeds a particular threshold. As will be appreciated by those skilled in the art, the value of the threshold might be selected based on empirical observations of caller behavior, customer surveys, intuition, and so forth. If the estimated delay exceeds the threshold, IVR system 320 's execution of the method of FIG. 4 proceeds to task 445 ; otherwise, IVR system 320 's execution of the method of FIG. 4 continues at task 460 .
[0047] At task 450 , interactive voice response (IVR) system 320 determines the filler content to be delivered to the calling telecommunications terminal during the delay in retrieving content stream S and initiating delivery.of content stream S to the terminal. IVR system 320 determines the filler content based on one or more of the following: the estimated delay; the state of the IVR application instance (i.e., the current VXML page, the values of variables and registers, etc.); content stream S; the calendrical time; the identity of the caller; the type of the caller's terminal (e.g., in order to determine the terminal's display capability, bandwidth capability, etc.); and one or more prior calls involving the caller and IVR system 320 .
[0048] At task 455 , interactive voice response (IVR) system 320 issues a command to content server 330 to retrieve the filler content from database 340 and deliver the filler content to the calling telecommunications terminal in streaming fashion, as is well-known in the art. As will be appreciated by those skilled in the art, it is advantageous to store the filler content in a memory from which it can be rapidly retrieved and streamed to the calling terminal (e.g., in a cache, on a local disk, in a random access memory that enables concurrent reads, etc.). Otherwise, retrieval of the filler content might cause an appreciable delay, which is the very problem that the filler content is intended to solve. As will further be appreciated by those skilled in the art, in some embodiments of the present invention, the command to deliver the filler content might specify one of the following:
Playback of the filler content should be looped until a requested content stream (e.g., stream content stream S, etc.) is ready to be delivered. The filler content should be played at most once. When a requested content stream (e.g., stream content stream S, etc.) is ready to be delivered and the filler content is currently being played, playback of the filler content is stopped and playback of the requested content stream is begun. The filler content should be played once. When a requested content stream (e.g., stream content stream S , etc.) is ready to be delivered and the filler content is currently being played, playback of the requested content stream is not begun until playback of the filler content has completed.
[0052] At task 460 , interactive voice response (IVR) system 320 continues the execution of the IVR application instance, in well-known fashion. After task 460 , IVR system 320 's execution of the method of FIG. 4 continues back at task 425 .
[0053] As will be appreciated by those skilled in the art, although the delay in the method of FIG. 4 is caused by the retrieval of content stream S (i.e., task 435 ), the method of FIG. 4 can be employed for other kinds of delays in interactive voice response system 320 (e.g., delays due to automated speech recognition (ASR), delays in retrieving a VXML page, etc.).
[0054] FIG. 5 depicts a flowchart of the salient tasks of interactive voice response (IVR) system 320 , in accordance with the second illustrative embodiment of the present invention. It will be clear to those skilled in the art which tasks depicted in FIG. 5 can be performed simultaneously or in a different order than that depicted.
[0055] The method of FIG. 5 is similar to the method of FIG. 4 , with the exception that the method of FIG. 5 does not estimate the delay in initiating delivery of content stream S and compare this estimate to a threshold (tasks 440 and 445 ); rather, filler content is always played.
[0056] Tasks 510 , 515 , 520 , 525 , 530 , 535 , 555 , and 560 of FIG. 5 are the same as tasks 410 , 415 , 420 , 425 , 430 , 435 , 455 , and 460 of FIG. 4 , respectively.
[0057] Task 550 is similar to task 450 , except that in task 550 , the determination of the filler content is not based on an estimated delay.
[0058] It is to be understood that the above-described embodiments are merely illustrative of the present invention and that many variations of the above-described embodiments can be devised by those skilled in the art without departing from the scope of the invention. For example, in this Specification, numerous specific details are provided in order to provide a thorough description and understanding of the illustrative embodiments of the present invention. Those skilled in the art will recognize, however, that the invention can be practiced without one or more of those details, or with other methods, materials, components, etc.
[0059] Furthermore, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the illustrative embodiments. It is understood that the various embodiments shown in the Figures are illustrative, and are not necessarily drawn to scale. Reference throughout the specification to “one embodiment” or “an embodiment” or “some embodiments” means that a particular feature, structure, material, or characteristic described in connection with the embodiment(s) is included in at least one embodiment of the present invention, but not necessarily all embodiments. Consequently, the appearances of the phrase “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout the Specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments. It is therefore intended that such variations be included within the scope of the following claims and their equivalents.
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An apparatus and method are disclosed that enable an interactive voice response (IVR) system to select, tailor, and deliver a “filler” content stream to a calling telecommunications terminal during a delay in a call (e.g., when performing automated speech recognition, retrieving other content, etc.). The delivery of the filler content can reduce the chance that the caller terminates the call prematurely, and can also be used to provide information to the caller, advertise new products, etc. The filler content can be based on one or more of the following: the date and time, the identity of the caller, a prior call to the IVR system, the type of the calling telecommunications terminal, and a content stream that the IVR system is in the process of retrieving.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] Hastings U.S. Pat. No. 4,236,322, discloses an apparatus for drying articles of clothing and the like in the open, ambient air. As shown therein, a drum of a convenient size having screen-like sides is rotatably supported on a frame. A motor mounted on the support frame is coupled to the drum by a belt and rotates the drum so that the objects therein are tumbled.
[0005] It has been found that a dryer constructed as shown therein performs well and has numerous advantages over conventional enclosed clothes dryers which use heat produced, usually, by electricity or gas. The most obvious advantage, of course, is the great saving in energy since only a small part of the power consumed by a conventional dryer is needed to turn the drum of the dryer disclosed in the above-mentioned patent.
[0006] It has been found, however, that the apparatus shown in U.S. Pat. No. 4,236,322 could be more suitable for use under some circumstances and could be manufactured in a simpler and less expensive manner. The rotating drum is exposed, presenting the hazard that a person, particularly a child, might be injured by inserting a hand, for example, between the drum and frame, coming into contact with the moving drum or being caught between the belt and drum or pulley.
[0007] Accordingly Hastings U.S. Pat. No. 4,702,018, provided an improved drying apparatus having a rotatable drum enclosed within a housing functioning as a guard which provides safety but does not significantly impede air flow and access to the dryer.
[0008] A further object of the above mentioned patent provided such a dryer which can be produced in large quantity at reasonable cost and which is safe and effective to use.
[0009] The dryer with a guard as shown in the above mentioned patent can still pose safety risks. Persons can still approach the dryer while the drum is rotating within the guard and, since the guard must be an open mesh construction, thrust a small item through an opening of the guard. There remains the possibility that persons, children in particular, could pick up small sticks, wire, a nail, screwdriver or other small object and stick it through the openings on the guard causing not only damage to the dryer, but perhaps causing considerable injury to such persons if one of the aforesaid objects were thrown back at them or caught their fingers or clothing. The guard adds significant additional weight to the appliance, making it more cumbersome and difficult to maneuver, while also greatly increasing the cost of the dryer in terms of materials used, time of manufacture and assembly as well as increased shipping costs.
[0010] Perque U.S. Pat. No. 5,809,663 advances a portable solar powered clothes dryer. The Ambient Air Clothes Dryer of U.S. Pat. No. 4,702,018 already depicted the dryer in a portability state with a frame and wheels and made no reference to a specific size. U.S. Pat. No. 5,809,663 further advances the claim that the “perforated hamper” be black to maximize the heat energy from the sun by the dark color of the hamper. While this may enhance the drying capabilities in some way of the aforementioned patent, it is not applicable to this ambient air dryer. The principle of this ambient air dryer is the use of solar heated ambient air entering a perforated rotating drum and expelling moisture laden air, not a device which further collects or heats the air. In the testing of the present embodiment of both a black and a yellow ambient air dryer, there has been no significant noticeable difference in the efficiency of the dryer. The exposed surface area of the present embodiment of the dryer drum contains large numbers of holes, making it difficult to collect any demonstrable amount of heat from the rays of the sun, the dryer drum in motion constantly changes its attitude to the sun's rays and continually expels the moisture laden air within the drum through the perimeter of the drum thereby actually cooling the surface of the drum no matter what the color.
[0011] Ford U.S. Pat. No. 7,178,265 uses a fan to provide axial airflow through the drum. This drum is comprised of an impervious cylindrical wall defining a diameter. The present embodiment in this application of the dryer drum has perforations both on the sides and perimeter of the drum and air is drawn in the sides and expelled out the perimeter by the rotating motion of the drum itself and not with any cumbersome external power consumptive source which blows air through the drum.
[0012] One of the principal benefits of the ambient air clothes dryer is energy savings. Increased energy savings not only with operation, but manufacture, and ease of use coupled with appropriate and additional safety measures are to be desired.
BRIEF SUMMARY OF THE INVENTION
[0013] Accordingly, the object of the present invention is to improve the already energy saving ambient air dryer with more energy and ecologically friendly savings in operation as well as manufacture coupled with appropriate and additional safety features, not impeding, but increasing, the performance and effectiveness of the ambient air dryer. In addition the present improvements make the dryer less cumbersome and easier to operate.
[0014] The preferred embodiment of the drum in the two prior Pat. Nos. 4,236,322 and 4,702,018, was in a shape of a cylinder and in the most recent patent, of injected molded plastic. By definition, a device formed of injected molded plastic must be formed in a mold in which molten plastic resin is injected under pressure. A steel mold of the size needed for this device would be necessarily large and expensive. Parts made with this procedure are cost effective, but only when made in very large quantities. With advances of recent years and broadened experience in manufacturing allowing for lower cost options in the plastic molding industry, this drum can now also be made in different and multiple ways. For ease in description, the two vertical planes of the drum will be referred to as the “sides” of the drum and the cylindrical portion of the drum joining these two sides will be referred to as the “perimeter” of the drum. The preferred embodiment as shown in this patent utilizes more than one process of manufacturing to form separate pieces to be attached and/or fitted together to form the rotatable drum. The frame for the drum is formed of blow molded plastic, roto molded plastic or other suitable material with shaped forms of injected molded plastic, metal mesh and/or other appropriate material attached to the drum frame. This type of manufacture allows the dryer to be made with much smaller, less energy consuming injectors (injectors which initially also cost far less than the huge injectors needed for injecting a large plastic part) or with a combination of plastic and other suitable materials. If the configuration of the drum is cylindrical, it can be driven by rollers or a belt. However, it is not necessary that the sides of the drum be circular in shape so long as there is provision for a carrier for a drive belt included on one location of the drum so a belt can rotate the drum.
[0015] The resin used for the preferred embodiment of the dryer drum provides for the use of re-cycled or partially re-cycled resin, cutting the cost of the resin needed for the manufacture of the parts and dramatically cutting the energy costs of the initial resin production.
[0016] A major factor in any plastic device being used outdoors is the life and durability of the resin. The use of carbon black, the most efficient UV inhibitor in addition to being the most cost effective, substantially extends the life and durability of the resin when this device is used outdoors. Non static electricity additive is also added to the resin primarily as a safety precaution. Leaving clothes in the rotating drum long after they have dried does not damage clothing, but items made of fabrics such as nylon can become full of static electricity if the resin is not treated with an additive to prevent the static electricity.
[0017] To enhance the airflow into the dryer drum, extrusions shaped like scoops are molded into or attached to the frame of the drum to gather and force additional air into the dryer drum as it rotates, to further the efficiency of the drying process by forcing additional dry solar heated ambient air through the tumbling clothes which in turn is expelled when laden with moisture from the wet clothes through the perimeter of the drum as the clothes strike the inside perimeter surface of the drum where they fall.
[0018] The purpose-designed motor used for rotating the drum is high efficiency, equipped with variable speed and a demand sensor. Said motor will not run if the dryer is over-loaded with too much weight. The variable speed makes it possible to control the speed of rotation, thereby making it possible to control the point at which the clothes within the drum free fall. This optimizes the drying process by having the clothes falling and fluttering the greatest distance possible within the drum. It also serves to expel the greatest amount of moisture laden air. Clothes push air out of the openings of the drum when they compress as they land against the inside perimeter of the dryer drum and free falling clothes will push out more air than clothes which are rolling within the drum. The more moisture laden air that is pushed out by the clothes, the more solar heated air is sucked into the dryer drum. The demand sensor on the motor automatically lowers the amount of energy used as the clothes become lighter as they dry, requiring less energy to rotate the dryer drum.
[0019] The frame supporting the rotating drum in the preferred embodiment of this patent is fabricated of hollow metal tubing, but can be fabricated of blow, roto or injected molded plastic or other suitable material.
[0020] The ambient air dryer is used primarily outdoors so safety is essential. In this embodiment there are exposed moving parts that without safety devices could pose a threat of injury to persons or animals. To alleviate this danger of moving parts, the frame on which the dryer drum rotates has motion and/or heat sensors located on each side of the dryer. Each sensor is multi-directional, detecting motion/heat from every direction for a pre-determined distance considered safe. Any motion or heat detection within that distance, whether it be from an adult, child, or animal will immediately stop the motor, rotating drum and any other moving part of the dryer. In addition a sound emitter at frequencies not detectable to human ears will operate to repel small animals and birds from the immediate area of the dryer. Re-starting the dryer will require the operator to enter a start-up code. After entering the start-up code, the dryer will remain motionless until the operator is beyond the range of the motion/heat detectors. Inclusion of a ground fault circuit interrupter (GFCI) in the control panel will insure that protection to the user who may or may not have available use of such a protected circuit.
[0021] The preferred embodiment of this present patent has wheels on the base of the frame supporting the dryer drum, at least two of which have locking capability to keep the dryer from moving.
[0022] An upset switch will immediately stop all the moving parts of the dryer if the dryer moves or tips over. The dryer may not be restarted until in the upright position, operator enters start up code and moves a pre-determined distance away.
[0023] Dust and lint particles drop through the mesh on the dryer drum at the point where the free falling clothes hit the inside perimeter of the drum. A screen type of lint filter is positioned under the drum at this position to catch these particles. In addition a soft brush sweeps the exterior of the drum to brush off any particles as the drum rotates. A fan under the filter draws air through the filter to further enhance the gathering and containment of any particles exiting the rotating dryer drum. A sensor on the filter indicates on the control panel and remote control when the filter requires service.
[0024] Lights are affixed to the frame supporting the dryer drum at the point of the bearing or other suitable location. These lights are directed to shine toward reflectors mounted along the edge of the sides of the dryer drum. When the dryer drum is rotating in the dark these lights and reflectors make the rotating drum visible.
[0025] A control panel is suitably located on the dryer frame with a numeral key pad, messaging display screen, audio alarm, lighted alarm, sound emitter, and menu, functions of said menu which include instructions for operation, humidity reading at dryer location, elapsed time the current load has been in the dryer, programmable settings such as delayed start up, plus time and date. The control panel also includes a ground fault circuit interrupter.
[0026] A typical wireless remote control programmed for the specific needs of the dryer can also operate the dryer, permitting the operator to control the dryer from a distance out of the direct sun and including the same functions as the control panel on the dryer frame.
[0027] Further improvements include portability functions. For ease in storage, the dryer drum can be made of materials allowing it to collapse or shaped in two pieces which fit inside one another. Especially for smaller models, extendable legs for the wheels raise the dryer for ease in use. The dryer frame can be made to fold to a smaller configuration when the dryer drum has been removed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0028] FIG. 1 , item 1 , shows the ambient air dryer in the rotatable configuration of an octagon.
[0029] FIG. 1 , item 2 , shows an affixed circular carrier for a belt driven application.
[0030] FIG. 1 , item 3 , shows the perimeter entry door in the open, “access” position.
[0031] FIG. 1 , item 4 , shows this dryer application rotated on a central bearing.
[0032] FIG. 2 , item 5 , shows the ambient air dryer in the rotatable configuration of a circle.
[0033] FIG. 2 , item 6 , shows the perimeter entry door in the open, “access” position.
[0034] FIG. 3 , item 7 , shows the perimeter view of the dryer rotated on a central bearing on each side.
[0035] FIG. 3 , item 8 , shows a perimeter door in the closed position.
[0036] FIG. 3 , item 8 A, indicates a frame member.
[0037] FIG. 4 , item 9 , shows the perimeter door of the dryer in the open, “access” position.
[0038] FIG. 4 , item 10 , shows the interior of dryer drum through the open door.
[0039] FIG. 5 , item 11 , shows the ambient air dryer in the rotatable configuration of a circle in a roller driven application.
[0040] FIG. 5 , item 12 , shows a centrally located entry door in the closed position.
[0041] FIG. 6 , item 13 , shows the centrally located entry door in an open position.
[0042] FIG. 7 , item 14 , shows an entry door on the side of the drum in a belt driven application.
[0043] FIG. 7 , item 15 , shows a configuration of the frame for an entry door located on the side of the drum in a belt driven application.
[0044] FIG. 8 , item 16 , shows the framework for the side of the dryer drum in an octagon configuration.
[0045] FIG. 9 , item 17 , shows an attachable panel for the perimeter of the dryer drum.
[0046] FIG. 9 , item 18 , shows the open mesh that is attached or molded within the frame.
[0047] FIG. 10 , item 19 , shows frame for attachable piece for side of drum.
[0048] FIG. 10 , item 20 , shows attachable or molded mesh.
[0049] FIG. 10 , item 21 , shows this application attached by screws to frame.
[0050] FIG. 11 , item 22 , shows the frame with mesh of FIG. 10 attached to rigid frame of dryer side.
[0051] FIG. 12 , item 23 , shows some suggested points for attaching extrusions for forcing additional air into the drum.
[0052] FIG. 13 , item 24 , indicates shape of extruded parts for forcing air into the dryer drum.
[0053] FIG. 13 , item 25 , shows closed end of extruded part.
[0054] FIG. 13 , item 26 , shows open space leading into dryer drum.
[0055] FIG. 13 , item 27 , shows two attached parts with open mesh allowing air to freely pass through into dryer drum.
[0056] FIG. 14 , item 28 , shows side view of extruded shape for forcing air into the dryer drum.
[0057] FIG. 14 shows side view of attached open mesh parts for allowing air to pass through, item 29 , indicating direction of air flowing into the dryer drum.
[0058] FIG. 14 , item 30 , indicates passage of air through open mesh into dryer drum.
[0059] FIG. 15 , item 31 , shows the component with an extruded shape with an open front to allow for free passage of air into the openings of the dryer drum.
[0060] FIG. 16 indicates by use of multiple directional arrows from the motion/heat sensors which are located to detect any motion or heat within a pre-determined range of the dryer.
[0061] FIG. 17 , item 32 , is an above view of the dryer with directional arrows indicating the field of detection by the sensors.
[0062] FIG. 18 , item 33 , indicates direction of rotation of dryer drum.
[0063] FIG. 18 item 34 indicates edge of dryer drum.
[0064] FIG. 18 , item 35 , indicates direction of freefalling clothes within dryer drum.
[0065] FIG. 18 , item 36 , indicates motor.
[0066] FIG. 18 , item 37 , indicates soft brush along the edge of filter shroud.
[0067] FIG. 18 , item 38 , indicates filter within shroud.
[0068] FIG. 18 , item 39 , indicates shroud for filter.
[0069] FIG. 18 , item 40 , indicates duct from shroud to fan.
[0070] FIG. 18 , item 41 , indicates supporting frame for shroud.
[0071] FIG. 19 , item 42 , shows view from perimeter of drum of the filter shroud.
[0072] FIG. 19 , item 43 , shows exhaust fan.
[0073] FIG. 19 , item 44 , shows motor with shaft on each side, one end of which shaft operating exhaust fan.
[0074] FIG. 20 shows a portion of the dryer drum, item 45 indicating one of the lights attached to the motor mount on the side of dryer drum frame.
[0075] FIG. 20 , item 46 , indicates directional arrows of illumination from light attached to dryer frame as well as directional arrows of illumination from a light source other than the light on the dryer.
[0076] FIG. 20 , item 47 , indicates reflector positioned to reflect illumination from light attached to frame.
[0077] FIG. 20 , item 48 , indicates a reflector positioned to reflect illumination from sources other than the light attached to the frame.
[0078] FIG. 21 indicates the remote control for the ambient air dryer.
[0079] FIG. 21 , item 49 , indicates a button for turning power on and off.
[0080] FIG. 21 , item 50 , indicates keypad for entering codes and operation of menu options.
[0081] FIG. 21 , item 51 , indicates the menu button.
[0082] FIG. 21 , item 52 , indicates a display screen for messaging, said screen in drawing indicating an “error, plugged filter” message.
[0083] FIG. 21 , item 53 , is flashing alarm button.
[0084] FIG. 21 , item 54 , indicates speaker for alarm sound and other audio alerts.
[0085] FIG. 22 indicates control box located on dryer frame.
[0086] FIG. 22 , item 55 , indicates key receptacle for locking cover down on control box.
[0087] FIG. 22 , item 56 , indicates cover for control box.
[0088] FIG. 22 , item 57 , indicates one of the keys of the keypad.
[0089] FIG. 22 , item 58 , indicates power button for turning power on or off.
[0090] FIG. 22 , item 59 , indicates speaker for sound alarm and other audio alerts.
[0091] FIG. 22 , item 60 , indicates menu button.
[0092] FIG. 22 , item 61 , shows display screen for messaging.
[0093] FIG. 22 , item 62 , indicates flashing alarm button.
[0094] FIG. 22 , item 63 , indicates sound emitter button.
[0095] FIG. 23 , item 64 , indicates brake on stationary or swivel wheel of dryer.
[0096] FIG. 24 , item 65 , indicates rear support member for dryer drum which rotates on rollers.
[0097] FIG. 24 , item 66 , shows dryer wheels on extendable legs.
[0098] FIG. 25 , item 67 , shows back support member in a partial fold down position.
[0099] FIG. 25 , item 68 , shows dryer wheels in the folded up position.
[0100] FIG. 25 , item 69 , shows frame support in a folded down position to facilitate rolling dryer drum off frame.
[0101] FIG. 26 , item 70 , indicates rigid frame members of collapsible dryer drum.
[0102] FIG. 26 , item 71 , indicates attached perforated member between rigid frame members of dryer drum.
[0103] FIG. 26 , item 72 , indicates by dotted lines the collapsible feature of the perforated material attached to frame members of the dryer drum.
[0104] FIG. 27 , item 73 , shows collapsible drum, side view, showing the rigid frame members configured in such a way that they fit within each other when drum is collapsed.
[0105] FIG. 28 , item 74 , shows a perimeter view of half of a dryer drum constructed in such a configuration that it will fit within the other half of the dryer drum.
[0106] FIG. 28 , item 75 , indicates a locking type mechanism to secure together the two halves of the dryer drum.
[0107] FIG. 29 indicates a portion of the central rigid member of the dryer drum and driving roller, which, when in contact with each other, serve to rotate the dryer drum.
[0108] FIG. 29 , item 76 , indicates a suitable surface material such as that used for serpentine belts on the drum to provide proper traction.
[0109] FIG. 29 , item 77 , indicates shape of drum in contact with driving roller.
[0110] FIG. 29 , item 78 , indicates shape of the driving roller.
[0111] FIG. 29 , item 79 , indicates surface material such as that used for serpentine belts on driving roller to provide proper traction with the dryer drum member.
[0112] FIG. 29 , item 80 , indicates how a surface material such as that used for serpentine belts on the drum and driving roller fits together when in contact due to shaping of surface material.
[0113] FIG. 30 shows collapsible frame for dryer.
[0114] FIG. 30 , item 81 , indicates frame member in partial fold down position.
[0115] FIG. 30 , item 82 , indicates wheels folded up position.
[0116] FIG. 30 , item 83 , shows drum support in partial folded down position.
[0117] FIG. 30 , item 84 , shows frame and handle folded down position.
[0118] FIG. 31 , item 85 , shows side view of collapsible drum configuration with door suitable for frame with center bearings on each side of dryer drum.
[0119] FIG. 32 , item 86 , shows frame with vertical member in a belt driven configuration that still allows for a door opening on the side of the dryer drum.
[0120] FIG. 33 , item 87 , shows a center opening door on collapsible drum configuration for the drum driven by rollers.
[0121] FIG. 34 is a view of a belt driven circular drum embodiment of the ambient air dryer with many of the features, which have been shown individually in other drawings, included in one drawing.
[0122] FIG. 34 , item 88 , indicates the telescoping handle.
[0123] FIG. 34 , item 89 , indicates one of the fasteners for side pieces of drum.
[0124] FIG. 34 , item 90 , indicates one of the lights mounted on bearing.
[0125] FIG. 34 , item 91 , indicates one of the set of reflectors on side of drum.
[0126] FIG. 34 , item 92 , indicates one of the air flow extrusions.
[0127] FIG. 34 , item 93 , indicates placement of a swivel wheel, placed so wheel may swivel without interfering with frame member.
[0128] FIG. 34 , item 94 , indicates a one of several heat/motion detectors.
[0129] FIG. 34 , item 95 , indicates shroud/duct/filter system for the containment of lint and particulates.
[0130] FIG. 34 , item 95 , indicates shroud/duct/filter system for the containment of lint and particulates.
[0131] FIG. 34 , item 96 , indicates wheel brake.
[0132] FIG. 35 is identical to FIG. 34 without intrusive markings in order to be used for the view drawing for the patent.
DETAILED DESCRIPTION OF THE INVENTION
[0133] The object of the present invention is to enhance the efficiency and ease of use, increase safety, allow wider application and lower cost of the already energy saving ambient air dryer by utilizing improved manufacturing technology and present availability of materials; and providing cost effectiveness. Use of motion/heat sensors and eliminating the guard as shown in a previous patent makes the dryer lighter in weight and easier to move. In addition, the elimination of the guard makes for easier access to put items in and take items out of the dryer, increases the air flow through the dryer drum reducing drying time, and increases the visibility of items in the dryer when running. Elimination of the guard also lowers the cost of manufacture and shipping, which in turn lowers the retail price to the consumer.
[0134] Previous patents explained in detail a rotatable drum driven by a belt and a rotatable drum driven by rollers. Both of these methods function suitably. Manufacturers in recent years in the plastic molding industry have become more experienced in larger consumer plastic products, making it possible to fabricate the rotating drum utilizing a combination of components. The exact shape of the drum is of no consequence, so long as it is conveniently rotatable either by a belt or rollers, as shown in several different drawings.
[0135] FIG. 1 shows a rotatable drum configuration shaped like an octagon, item 1 , with a centrally located bearing, item 4 , and with an affixed circular carrier, item 2 , for a belt driven application. This particular embodiment shows a door placed on the perimeter of the drum in the open, “access” position, item 3 , said open position allowing for easy access for loading and unloading items. FIG. 2 shows a rotatable drum configuration in a circular shape, item 5 , with a door placed on the perimeter shown in the open, access position, item 6 . This circular shaped configuration of the dryer drum can be either belt or roller driven. FIG. 3 indicates a perimeter view of the drum with a centrally located bearing mounted on each side of the drum, item 7 , with a door located on the perimeter of the drum, item 8 , shown closed in access position. FIG. 4 indicates a perimeter view of the dryer drum with a perimeter door shown in the open, access position, item 9 . Item 10 shows the interior of the drum as seen through the open door. FIG. 5 shows the rotatable drum in the circular shaped configuration driven by rollers, item 11 . The door in this embodiment which is driven by rollers can be placed on the side of the drum, item 12 , and is shown in the closed position. FIG. 6 shows the embodiment of FIG. 5 with the door in the open position, item 13 . FIG. 7 shows yet another embodiment for the dryer drum with a centrally located bearing mounted on each side of the drum. The frame, item 15 , is constructed in such a way, as to permit a door on side of the drum, item 14 .
[0136] When the dryer is switched off, the rotation of the drum slows, then stops at the access position for easy loading and unloading of the drum. FIG. 1 , item 3 and FIG. 2 , item 6 , show two different embodiments of doors located on the perimeter of the drum and indicate the access position shown with open doors. FIG. 3 , item 8 shows the access position of a closed door located on the perimeter of the drum and FIG. 4 , item 9 shows this same embodiment with an open door. FIG. 5 , item 12 shows the access position with a centrally located side door in closed position and FIG. 6 , item 13 shows the access position with a centrally located side door in open position. FIG. 7 , item 14 shows yet another embodiment of the access location of a door located on the side on the dryer drum.
[0137] The dryer drum may also be stopped at “park” which positions the door opposite a frame member of the apparatus frame to interfere with the opening of the door. In “park” position the closed door of FIG. 3 , item 8 , would be positioned with frame member, item 8 A, or any other frame member, opposite the door, thus interfering with the opening of said door. In FIG. 7 , the door, item 14 , is shown in the closed “access” position. The closed door in “park” would be positioned opposite either or both frame members such as the frame member, item 15 , to interfere with the opening of said door.
[0138] The dryer drum must be strong and stable, yet have ample openings for the free exchange of air in order to function properly. The inside of the drum must be free of any protrusions or rough surfaces which could snag or damage clothing as the drum rotates, in addition to having the openings for the free exchange of air small enough so buttons, fasteners and small items do not catch on or fall through the openings. FIG. 8 , using the octagon shaped drum embodiment, shows a rigid, blow molded frame or other suitable material for the side of the dryer drum, item 16 , designed with ample strength, stability and durability for this application. The component part, FIG. 10 , is fabricated to be attached to the ribs and outer edge of the side frame of the dryer. The frame for this component, item 19 , can be plastic, metal or other suitable material; the mesh insert, item 20 , can be plastic, metal or other suitable perforated material; or the entire part can be formed of molded plastic. The pieces for the eight components shown on this particular embodiment, FIG. 10 , can be securely held in place by screws, item 21 , rivets, welded or glued into receptacles molded into the frame, FIG. 8 . With blow molded construction, the molded receptacles for receiving screws or rivets are imbedded within the frame so no sharp edge is exposed inside or outside the dryer drum. FIG. 11 , item 22 , shows one such component attached to the side frame of this embodiment.
[0139] FIG. 9 , the component pieces for the perimeter of the drum, each consisting of a rigid frame, item 17 , with a mesh insert, item 18 , are also attached into receptacles molded into the outer edges of the blow molded side frame, again into receptacles imbedded within the molded dryer drum frame. These components can be fabricated entirely with molded plastic or the frame can be a separate piece with an attached mesh. Both frame and mesh can be formed of plastic, metal or other suitable material or formed entirely of molded plastic.
[0140] The tumbling clothes within the present embodiment of this clothes dryer are dried by the dry air flowing through the clothes and moisture laden air expelled from the dryer drum. The component part, FIG. 10 , can be designed to incorporate extrusions that by design force additional air into the dryer drum as the drum rotates, which necessarily facilitates the efficiency of the drying process. FIG. 12 , item 23 , shows an embodiment with eight typical locations along one edge of each part, such as the FIG. 10 part, for such increased air flow extrusions on the side of the dryer drum designed to force air into the rotating dryer drum.
[0141] FIG. 13 shows a portion of this air flow extrusion. The component part is fabricated with a mesh to the front, item 27 , said mesh perpendicular to the side of the dryer drum. The component part is shaped, item 24 , to function as a scoop with closed ends, item 25 , to force additional air into the dryer drum as the drum rotates. The air enters the open mesh openings in the front, two of which are shown, item 27 , and is forced into the opening to the dryer drum, item 26 . The open mesh is attached along the entire front of the component for maximum efficiency. This component part can be fabricated from plastic or other suitable material with attached mesh inserts; said inserts which can be fabricated from plastic, metal or other suitable perforated material. This component part can be fabricated as a separate part to be attached to the dryer drum or can be directly molded as part of one of the side pieces of the drum. FIG. 14 shows a cut-a-way side view of this component, item 28 , shaped to force air as shown by directional arrow, item 29 , through the mesh openings, item 30 , into the dryer drum. The embodiment of this component part is designed to be used with an opening in the drum under the part. FIG. 15 shows a partial embodiment of this component part indicating one of the closed ends, but the front of the part left open and placed over the mesh, item 31 , on the side of the dryer drum. Either embodiment will function to force air into the dryer drum.
[0142] When this dryer is in operation, safety devices initiate to keep persons and/or animals from harm. FIG. 16 indicates by the multi-directional arrows from motion/heat sensors, such as the type manufactured by Optex and Honeywell, placed on multiple sides of the dryer frame to detect any motion or heat within a pre-determined range of the dryer. These sensors detect motion/heat from every side, above, and below the dryer apparatus. Any motion or heat detected by the sensors will immediately interrupt power to the motor. The dryer will start again only with the use of the start-up code.
[0143] In addition to the heat/motion sensors are sound emitters, inaudible to humans but audible to animals, to keep animals and birds away from the dryer. The sound emitters will automatically function when the dryer is in operation and may be manually set to emit sound with either battery power or an external power source even when the dryer is not in operation, again to keep animals and birds away from the dryer.
[0144] FIG. 17 , item 32 , is a view from above the dryer apparatus with directional arrows indicating a pre-determined field of detection by the sensors located on the dryer's frame. Any motion/heat detected within this pre-determined field of detection will interrupt the power supply to the motor and require the start-up code to re-start the dryer.
[0145] FIG. 18 shows the mechanism for the containment of lint and other particles exiting the drum from the tumbling clothes and items within the dryer drum. As the dryer drum rotates in the direction indicated by item 33 , the free falling items within the drum land in the area designated by the directional arrow, item 35 . As items inside the dryer drum fall against the open mesh they release lint and other particulates, which fall through the openings into the lint filter, item 38 , encased by the shroud, item 39 . Soft brushes, item 37 , are on both sides and across lower edge of the shroud, item 39 , thereby sweeping both edges of the perimeter of the rotating dryer drum to keep lint and particulates from floating or exiting off to the side as well as sweeping across the perimeter of the drum, item 34 , to further aid in the capture of lint and other particulates by sweeping them into the filter. The purpose-designed motor , item 36 , used for rotating the drum is high efficiency, equipped with variable speed and a demand sensor. Said motor will not run if the dryer is over-loaded with too much weight. Start up speed of the motor is slow, then increases to operational speed over a sufficient period of time to prevent loss of traction due to the possible high moment of inertia at start up. The variable speed makes it possible to control the speed of rotation, thereby making it possible to control the point at which the clothes within the drum free fall. This optimizes the drying process by having the clothes falling and fluttering the greatest distance possible within the drum. It also serves to expel the greatest amount of moisture laden air. Clothes push air out of the openings of the drum as they land and compress against the inside perimeter of the dryer drum and free falling clothes will push out more air than clothes which are rolling within the drum. The more moisture laden air that is pushed out by the clothes, the more solar heated air is sucked into the dryer drum. The demand sensor on the motor automatically lowers the amount of energy used as the clothes become lighter as they dry, requiring less energy to rotate the dryer drum.
[0146] In addition to the soft brushes, a motor, item 36 , operated fan, FIG. 19 , item 43 , is positioned to draw additional air through the filter to assist in capturing lint and particulates. This lint containment assembly is supported by a frame, FIG. 18 , item 41 , which is in turn attached to the dryer frame. The shroud is molded plastic or other suitable material and the flat lint filter, item 38 , can be easily removed to clean. A duct, item 40 , is connected to the shroud and leads to the motor driven fan.
[0147] FIG. 19 shows the lint containment assembly from the perimeter view of the dryer. Item 42 indicates the shroud with the duct leading to the fan, item 43 . Item 44 indicates the shaft of the motor which operates the fan as well as the mechanism to rotate the dryer drum.
[0148] This dryer which uses open, ambient air may be used in the dark as well as daylight. As an added safety feature, lights, such as LED lights, are affixed to the frame of the dryer. FIG. 20 shows a partial section of the dryer drum assembly. A light, item 45 , is affixed to the bearing cover of the frame of the dryer. Reflectors are positioned along the edge of the dryer drum side. One reflector, item 47 , is positioned to reflect illumination from the light source on the dryer. The other reflector is positioned to reflect illumination from sources other than on the dryer. The directional arrows, item 46 , indicate the reflected light both from the light affixed to the dryer frame as well as from a light source other than on the dryer assembly. These lights and reflectors make the rotating drum visible in the dark or in partial light.
[0149] FIG. 21 indicates a typical wireless remote control programmed for the specific needs of the clothes dryer and permitting the operator to control the dryer from a distance. Item 49 is an on/off switch. The “off” position slows, then stops the drum in access position. “Access position” stops the dryer drum in a convenient position for the loading and unloading of the drum. A menu option allows the drum to be stopped in “park position” as well to interfere with the opening of said door, particularly useful when dryer is not in use. The “on” position will not start the dryer until the start-up code is entered and the operator has moved away to a pre-determined distance as detected by the motion/heat sensors. The “on” position also activates a sound emitted at a frequency inaudible to humans but audible to animals to keep animals away from the dryer when in operation. Item 50 indicates several pads of the keypad control, said keypad control used for the start-up code and menu functions.
[0150] Item 51 indicates the “menu” button and displays a list of functions on the messaging display screen, item 52 . The menu list includes instructions for general use (ie. on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on again off again cycle for rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, programmable settings such as delayed start up, plus time and date); and error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped). The display screen, item 52 , automatically displays error/general messages and remedies.
[0151] Item 54 is the alarm light which lights up or flashes for pre-determined issues, such as the dryer stopping. Item 55 is a speaker for the alarm which sounds when the alarm light is on. This alarm will sound for several pre-determined issues such as the dryer stopping or error messages such as “dryer tipped”, “fire” or “water on dryer”. Said speaker sounds a lesser sound for pre-determined less critical error messages such as plugged filter, overloaded, and heavy point weight. This speaker can also give audio messaging for all functions on the menu. The alarm functions operate even when the dryer is not in use by using battery power as well as an external power source in order to prevent unauthorized tampering with the dryer when unattended and not in use in an unsecured area.
[0152] FIG. 22 indicates the control box suitably located on the dryer frame. Item 55 indicates the receptacle for a key for locking the closed cover. Item 56 indicates the cover, shown in a partially open position, which fits over the controls for protection from the elements or tampering. Item 57 indicates one of the pads for the keypad control, said keypad control used for the start-up code as well as menu functions. Item 58 indicates the on/off button. The “on” function engages power to the dryer. To initiate the tumbling motion of the drum, a start-up code must be entered and operator must move away from the dryer for a pre-determined distance before the dryer drum will actually begin to rotate. The “on” function also engages the sound emitter. The “off” cuts off power to the dryer. The dryer drum will automatically stop as operator moves toward the operating dryer, but the power source remains engaged until dryer is actually turned off or until not in use for a pre-determined length of time. Item 59 in the speaker for audio alerts. An alarm will sound for several pre-determined issues such as the dryer stopping or error messages such as “dryer tipped”, “fire” or “water on dryer”. The speaker sounds a lesser sound for pre-determined, less critical error messages such as plugged filter, overloaded, and heavy point weight. This speaker can also give audio messaging for all functions on the menu. The alarm functions operate even when the dryer is not in use by using battery power as well as an external power source in order to prevent unauthorized tampering with the dryer when unattended and not in use in an unsecured area.
[0153] Item 60 is the menu button and displays a list of functions of the messaging display screen, item 61 . The menu list includes instructions for general use (ie. on”, “off”, entering secure start up code, manually setting sound emitter to continue to function when dryer is off, setting delayed start, setting on again off again cycle for rotation of drum for pre-drying hard to dry items); information (humidity at dryer location, elapsed time since load put into dryer, estimated dry time, programmable settings such as delayed start up, plus time and date); and error messages (plugged filter, overloaded, heavy point weight, water on dryer, fire, dryer moved or tipped).
[0154] Item 61 is the messaging display screen which automatically displays error/general messages such as the “error plugged filter” as shown, remedies for error messages, plus the menu options. Item 62 is the alarm light which lights up or flashes for all the alarm functions associated with the speaker. The alarm functions, including this alarm light, operate even when the dryer is not in use by using battery power as well as an external power source in order to prevent unauthorized tampering with the dryer when unattended and not in use in an unsecured area. Item 63 is the sound emitter button which when engaged continually emits sound even when the dryer is in “off” mode. Inclusion of a ground fault circuit interrupter (GFCI) in the control panel insures that protection to the user who may or may not have available use of such a protected circuit.
[0155] FIG. 23 shows one typical wheel of the type attached to the dryer frame. Item 64 indicates a standard type of lock for the wheel which can be operated by foot or hand. These locking wheels are on a minimum of two wheels to keep the dryer from moving when positioned and when drum is in motion. These wheels may or may not swivel or may be used in combination.
[0000] FIG. 24 shows a side view embodiment of the clothes dryer with a belt driven drum. Item 65 shows the rear support member for the dryer drum. Item 66 shows wheels with extendable legs in the extended position in order to raise the dryer assembly for more ease in use. The wheels have two positions. The extension leg can swing out as indicated by the curved arrow and slide into a slotted bracket as shown in FIG. 25 .
[0156] It is not necessary that the ambient air dryer be portable. However, all the embodiments of the ambient air dryer in the drawings have been shown in a portable configuration with wheels. In addition to wheels, the ambient air dryer can be further configured to aid in portability and storage. FIG. 25 indicates portability/storage functions of the clothes dryer assembly which is driven with rollers and supported by a rear support member. Item 67 indicates the disengaged rear support member for the dryer drum in a partially folded down position. Item 68 A and 68 B show the wheels with extendable legs. Item 68 A is already slid into position along the frame; item 68 B to be slid into position along the frame. Item 69 indicates a frame member tipped forward to facilitate rolling the dryer drum off the frame.
[0157] FIG. 26 shows the perimeter view of a collapsible drum with silicon or other suitable flexible perforated material affixed to rigid frame members, said drum designed for portability and ease in storage. Item 70 indicates the rigid members of the drum. Item 71 indicates one of the several perforated flexible parts of the dryer drum and item 72 indicates how the flexible parts of the dryer drum fold in order to collapse.
[0158] FIG. 27 shows the side view of the collapsible dryer drum. Item 73 indicates how the rigid members of the drum are configured to allow each part of the collapsible drum to fit inside one another when the dryer drum is collapsed, thus allowing for more convenient and space saving storage.
[0159] FIG. 28 shows the perimeter view of a dryer drum that is configured to come apart at the mid perimeter point, said drum designed for portability and ease in storage. The two halves of the dryer drum are shaped with the outside circumference of the drum smaller than the circumference at the point of attachment to the other half, item 74 , so the two halves of the drum fit inside one another when the dryer drum is disassembled. Item 75 indicates a locking mechanism so the two halves of the dryer drum can be securely fitted together when assembled for use. As shown, the extended portions on the edge of each dryer half are configured so the drum parts are fitted together, then turned to lock together securely. As an added safety precaution, these drum halves are also fitted with a pin or screw to lock and prevent the two halves from rotating separately and coming apart.
[0160] FIG. 29 indicates a portion of the rigid center member on the collapsible dryer drum, such as the drum of FIG. 26 , which, when in operation, is in contact with the driving roller which rotates the drum. Item 76 indicates a surface material attached to the rigid center member on the collapsible dryer drum, this material being suitable for traction, durability and shape, such as the material used for serpentine automotive belts, to adhere to the surface material on the driving roller. Item 77 indicates the shape of a small portion of the flexible material of the dryer drum that is affixed to the rigid frame. Item 78 indicates the shaped driving roller designed to help keep the drum in the proper position while rotating. Item 79 indicates a surface material attached to the drive roller, this material being suitable for traction, durability and shape, such as the material used for serpentine automotive belts, to adhere to the surface material on the rigid center member on the collapsible dryer drum. Item 80 indicates the shape of the surface materials on both the rigid center member on the collapsible dryer drum and the driving roller which, when in contact with each other, fit together in addition to the traction from the material adhered to both parts to provide stability when dryer drum is in motion.
[0161] FIG. 30 indicates a collapsible frame for the dryer drum in a partially collapsed position. Item 81 shows a portion of the frame which can fold outward to help in rolling drum off frame or fold inward as shown for more compact storage of the frame. Item 82 shows the extendable wheels still operational in their folded up position. Item 83 shows the drum support member in a partially folded down position. This member folds down to a horizontal position for more compact storage. Item 84 indicates the portion of the frame which includes the controls telescoped in the “down” position for more compact storage.
[0162] FIG. 31 shows the side view of a collapsible drum configuration with a door configuration, item 85 , suitable for a supporting frame with a center bearing and support on both sides. It is also suitable for a configuration with a back support center bearing only.
[0163] FIG. 32 indicates a frame support consisting of a center bearing on each side of the dryer drum which is rotated by a circular belt that allows for a door opening on the side of the drum with no impediment from the frame.
[0164] FIG. 33 shows the collapsible dryer drum configuration driven by rollers with a center door, item 87 , located on the side of the dryer drum.
[0165] FIG. 34 shows an embodiment of the ambient air clothes dryer with multiple improvements shown on a single drawing. All of these particular improvements have been shown and explained individually in other drawings. Item 88 is the telescoping handle. Item 89 indicates one of the fasteners for attaching drum side pieces to the drum frame. Item 90 indicates one of the lights mounted on the center bearing cover that shines toward the reflectors, one of which is item 91 . Item 92 indicates one of the air flow extrusions on the side of the dryer drum. Item 93 indicates a positioning of one of the wheels on the end of a portion of the frame of the dryer to accommodate a swivel. Item 94 indicates one of several heat/motion sensors. Item 95 indicates the support frame, shroud, duct, filter and brushes for capturing lint and particulates when the dryer drum is in motion. Item 96 indicates a wheel locking mechanism.
[0166] FIG. 35 is identical to FIG. 34 except without intruding item numbers and may be used as the view drawing for the patent.
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The already energy saving ambient air dryer is improved in methods of manufacture, performance, increased safety devices, and storage options which include in part: construction in pieces of different manufacture for assembly to lower cost, added inhibitors to extend life and durability, extrusions on the drum functioning as scoops to cause additional ambient air to be passed through the clothes, light and reflector system so moving drum may be visible at night or in partial light, non-defeating GFCI system, specific designed energy efficient motor, programmed functions such as stopping the drum in “access” or “park” position and sounding alarm for pre-determined operational issues, remote control as well as control box on dryer frame, a system for capturing lint and particulates, motion/heat detectors which eliminate need for safety guard surrounding moving drum, sound emitters to keep animals away, security codes for operation, and collapsible drum and frame for compact storage.
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TECHNICAL FIELD
The subject matter described herein relates to methods that reduce image distortion in near-to-eye (“NTE”) visual displays due to rapid head motion of the viewer wearing an NTE display device.
BACKGROUND
One of the more important features in a cockpit is the Heads Up Display (“HUD”) whereby flight control information is projected onto the wind screen of the aircraft so that the pilot may receive the information without taking his eyes from the airspace in front of him. However, there has been a growing interest in moving away from HUD systems to NTE or to NTE-HUD systems with head mounted viewing and sensor components that may be attached to a pilot's earphones or to his helmet.
A NTE system is characterized by a small display screen that is suspended directly in front of one or both of the pilot's eyes such that the displayed virtual object or image moves about the display screen as the pilot turns his head to look for other aircraft, look at his other controls and instrumentation, etc. The NTE display is otherwise transparent such that the pilot may see through or see past the display.
It would be disconcerting, disorientating and annoying to the pilot if information being sent to the NTE display was constantly visible in his display as he looks around him for other aircraft or for cockpit instrumentation. As such, a NTE display processor is programmed to register or be conformal with the NTE display information within a specific area within the cockpit such that when the pilot is looking at the area of image registration the NTE information is visible in his NTE display and when he turns, nods or cocks his head (i.e. yaw, pitch and roll), the NTE information moves in the opposite direction, and even out of view, until the pilot returns his head to a normal flight position.
The image registration is typically established by attaching one or more markers or marker bars to physical locations in the cockpit. The markers may have a particular shape or pattern, or may emit light at a particular frequency. The shape, pattern or emission frequency can be detected by the pilot's NTE headset and the detected position of the marker then causes the NTE processor to render the display on the NTE display screen only when the pilot's head is in a desired viewing position range relative to the marker.
However, the registration process as practiced in the art has not been perfect. It has been noticed that the majority of head movements are side-to-side (yaw) movements and the speed of the yaw movement has been determined to be in the 1000 degrees per second range compared to a nodding action (pitch) and cocking action (roll), which have been measured to be typically in the 400 degrees per second range. Pitch and roll movements are therefore of lesser concern.
Because of the relatively rapid side-to-side (yaw) speed, blurring and/or swimming of the NTE image or virtual object can occur when a pilot turns his head. Blurring is the loss of contrast due to multiple overlapping image rendering. Swimming is the phenomenon that occurs when different parts of an image move at different speeds.
Both blurring and swimming tend to occur because NTE head positioning sensor only periodically updates the position of a pilot's head. If a rapid yaw motion should occur during the interstitial time period between head position updates, sequential information frames will be presented with an abnormally large physical separation. The size of this separation which is a function of the head's travel time and velocity, and results in distortion such as horizontal blurring. The longer the latency between head position measurements the worse the distortion.
However, even in the absence of head sensor delays, some blurring and swimming will continue to occur due to the NTE display's inbuilt horizontal raster scan periodicities. Typical visual distortions due to horizontal raster scan periodicities include a blurring effect and/or a tilting of the virtual object image. Therefore, there is a need to improve an NTE display to minimize the distortion resulting from a pilot's head movement.
SUMMARY
It should be appreciated that this Summary is provided to introduce a selection of exemplary, non-limiting concepts. In one exemplary embodiment, a method for mitigating the distortion in a NTE raster scan video display due to rapid yaw head motion of a wearer is provided where a raster scan video display is configured such that its scan lines are rendered in a vertical orientation. At the completion of each of the plurality of vertical scan lines, the raster scan video display is advanced one column position horizontally.
In another exemplary embodiment, a computer readable medium is provided containing instructions that include determining a first column address, calculating a head yaw velocity, and determining a column address adjustment.
In another exemplary embodiment, an apparatus is provided comprising a processor and a video display screen that displays a plurality of raster scan lines. The video display screen is configured such that each of the plurality of the raster scan lines is rendered in a vertical orientation and is rendered serially and horizontally across the video display screen at the completion of each vertical scan line of the plurality in response to commands from the processor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified rendering of a NTE apparatus.
FIG. 2 a is an exemplary rendering of a virtual object image as presented in a horizontally oriented raster display with no head movement.
FIG. 2 b is an exemplary rendering of a virtual object image as presented in a horizontally oriented raster display with head movement to the right.
FIG. 3 is an exemplary rendering of a virtual object image as presented in a vertically oriented raster display with head movement to the right.
FIG. 4 illustrates an exemplary flow chart of an exemplary method to reduce tilting by adding or deleting raster image lines.
DETAILED DESCRIPTION
The following disclosure is merely exemplary in nature and is not intended to limit the invention, the application or the uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
The subject matter now will be described more fully below with reference to the attached drawings which are illustrative of various embodiments disclosed herein. Like numbers refer to like objects throughout the following disclosure. The attached drawings have been simplified to clarify the understanding of the systems, devices and methods disclosed. The subject matter may be embodied in a variety of forms. The exemplary configurations and descriptions, infra, are provided to more fully convey the subject matter disclosed herein.
The subject matter herein will be disclosed below in the context of an aircraft. However, it will be understood by those of ordinary skill in the art that the subject matter is similarly applicable to many vehicle types and activities as human head movement is the same in any environment. Non-limiting examples of other vehicle types in which the subject matter herein below may be applied includes aircraft, spacecraft, watercraft and terrestrial motor vehicles. Non-limiting non-vehicle environments may include virtual reality simulators.
The subject matter disclosed herein may be incorporated into any suitable navigation, flight control system, or virtual reality system that currently exists or that may be developed in the future. Without limitation, terrestrial motor vehicles may also include military combat and support vehicles of any description.
Turning now to FIG. 1 , an exemplary embodiment of an NTE display system 100 that may be used, for example, in a vehicle is depicted. No matter the particular end-use vehicle, the display system 100 includes at least a near-to-eye (NTE) display device 102 , a tracking sensor 104 , a processor 106 , and a memory 130 in operable communication with the processor 106 .
The NTE display device 102 is preferably mounted on a headset 108 . The headset 108 may be variously configured, but in the depicted embodiment the headset 108 is configured to be worn by a user (or viewer) 110 , and may include one or more earphones 112 and a microphone 114 . The earphones 112 are adapted to generate audio signals in response to signals received from, for example, a suitable non-illustrated interface. It will be appreciated that the non-illustrated interface may receive signals from, for example, a non-illustrated vehicle radio, the processor 106 , and/or one or more other non-illustrated devices. It will additionally be appreciated that the earphones 112 may be variously implemented. For example, the earphones 112 may be implemented as active noise reduction (ANR) devices or passive devices.
The microphone 114 is adapted to detect viewer utterances or other vehicle noises and to transmit signals representative of the detected utterances or noises via, for example, a suitable non-illustrated interface. It will be appreciated that the non-illustrated interface may supply the signals to, for example, the non-illustrated vehicle radio, the processor 106 , and/or one or more other non-illustrated devices. The microphone 114 may include, for example, a noise cancelling microphone or any one of numerous other suitable devices. In some embodiments, headset 108 also may include a non-illustrated push-to-talk (PTT) switch which, when depressed, causes the non-illustrated vehicle radio to transmit pilot utterances detected by the microphone 114 over the air. In other embodiments, a PTT switch may be disposed at a location remote from the headset 108 .
The NTE display device 102 , as noted above, is preferably mounted on the headset 108 , and may include a monocular or binocular set of displays 116 . Although the configuration of the displays 116 may vary, in one embodiment each display 116 includes a transparent display panel (e.g., a liquid crystal on silicon display), a light source (e.g., light emitting diodes), one or more prisms adapted to deflect light generated by the light source, one or more polarizers, and one or more lenses. With this configuration, the NTE display device 102 may display one or more virtual images to the viewer 110 . That is, the one or more displayed images appear to the viewer 110 to overlie (or otherwise be disposed in proximity to) another surface, such as a vehicle windshield 118 , and/or one or more non-illustrated vehicle instruments, and/or one or more non-illustrated vehicle control components. It is noted that in some embodiments the NTE display device 102 may be adjustably mounted on the headset 108 . By adjustably mounting the NTE display device 102 on the headset 108 , the NTE display device 102 may be moved into and out of the field of view of the viewer 110 .
The sensor 104 is preferably mounted on the headset 108 and is configured to sense movements of at least the viewer's head 122 and/or the NTE display device 102 . More specifically, the sensor 104 is configured to sense movement of the NTE display device 102 , and to supply a signal representative of the sensed movement to the processor 106 . In one particular embodiment, the sensor 104 is configured to sense, either directly or indirectly (e.g., derived from sensed position), at least a movement rate of the NTE display device 102 by sensing the movement rate of the viewer's head 122 , and to supply a signal representative of the sensed movement to the processor 106 . In any case, the movement that the sensor 104 senses preferably includes both translational movements and angular movements. The sensor 104 may also be configured, at least in some embodiments, to sense the position and orientation of the NTE display device 102 and/or the viewer's head 122 .
The viewer's head position may be represented, for example, in terms of offsets from a static, default point in the vehicle. The viewer head orientation may be represented, for example, in terms of angles of rotation about a set of orthogonal reference axis (e.g., axis 124 , 126 , 128 ). For example, viewer head movements to the left or right may be represented in terms of angular rotation about axis 124 , viewer head movements up or down (e.g., nods) may be represented in terms of angular rotation about axis 126 , and viewer head tilts to the left or right may be represented in terms of angular rotation about axis 128 .
It will be appreciated that although FIG. 1 depicts the sensor 104 as a single sensing device, the sensor 104 may be implemented, if needed or desired, as a plurality of sensing devices. Moreover, the particular type and configuration of the sensor 104 may vary, and may be implemented as any one of numerous suitable devices including, for example, an inertial movement unit (IMU), an inertial navigation unit (INU), one or more magnetometers, or auxiliary cameras locking on reference signals, just to name a few.
The NTE display device 102 and the sensor 104 are both in operable communication with the processor 106 . The processor 106 may be implemented as one or more processors and/or other suitable electronic components, and may be configured to implement one or multiple functions. At least one function that the processor 106 implements is a display generator that renders one or more images on the NTE display device 102 . The processor 106 may render the one or more images on the NTE display device 102 in response to various signals it receives from one or more non-illustrated external systems, subsystems, devices, or components. It will be appreciated that the processor 106 may be mounted on the headset 108 , or it may be disposed remote from the headset 108 and form part of one or more other non-illustrated systems.
Processor 106 may be any suitably type of processor of sufficient speed. The processor 106 may be a general purpose processor or a special purpose processor. The processor 106 may be a single processor, multiple co-processors or processors distributed within a wireless or a wired network. Processor 106 is also a non-limiting example of a computer readable medium.
Memory 130 is in operable communication with the processor 106 , and may be any type of suitable volatile or non-volatile memory. As discussed more thoroughly below, memory 130 may store display pixel information that may be used as pseudo or generic raster line information to mitigate distortion resulting from rapid movements of the pilot's head.
Memory 130 may comprise any or combination of memory or memory devices currently existing or that may exist in the future. Non-limiting examples of memory devices include random access memory (RAM), read-only memory (ROM), flash memory, programmable logic devices (PLD), magnetic disks, and optical disks. The preceding memory devices are also non-limiting examples of computer readable media.
FIG. 2 a depicts display 116 rendering an image 220 a when the tracker 104 measures little or no head motion. Thus, the image 220 a is not distorted. The image 220 a rendered in the viewing screen appears to be conformed or registered to a physical location within the cockpit in relation to the marker bar 230 , which is physically attached somewhere in the external background 118 (i.e. the cockpit).
FIG. 2 b is an example of an overlapping image 220 b that is rendered while the viewer 110 moves his head to the right. In such a case the processor 106 causes the overlapping image 220 b to move left in the display 116 . The overlapping image 220 b also appears tilted because a conventional display 116 utilizes a conventional raster scan 240 a that begins at the top left of the display and proceeds to the right in rows and then down the display 116 .
In a conventional raster system, the time that it takes to move the active pixel from left to right across the display 116 is much faster than the time it takes to proceed from the top of the screen to the bottom of the screen. A horizontal traversal of the raster pattern 240 a may be measured in microseconds while a complete vertical traversal may be measured in milliseconds. Because of the relatively slow vertical traversal speed, the bottom row of pixels is naturally the last to be rendered. As such, this may occur at the furthest point in the head movement such that that the bottom row of pixels appears to lead and the top line appears to lag because the top pixels were the first to be rendered and because the blurred image 220 b is actually moving in the direction in the display 116 opposite from the direction of head movement 124 .
FIG. 3 illustrates an exemplary, non-limiting embodiment that at least mitigates the blurring and/or tilting effects resulting from a yawing movement 124 of the pilot's head 122 in which the raster pattern 240 b in the display, is turned 90° in either direction to change the scanning pattern from horizontal to vertical. By using a raster scan 240 b with a vertical orientation, the rate of travel of the raster in the vertical direction is now much faster than it would have been if the raster scan in a horizontal orientation 240 a . As such, the vertical movement of the raster 240 b is also much faster relative to the fastest yaw movement 124 of a pilot's head 122 . The increase in speed in the vertical direction may be on the order of 10×-1000× or more.
It is preferable that the vertical speed of the raster 240 b be at least 10 to 100 times faster than the vertical speed of the raster 240 a . It is more preferable that the vertical speed of the raster 240 b be 100 to 1000 times faster than the vertical speed of the raster 240 a . It even more preferable the vertical speed of the raster 240 b be over 1000 times faster than the vertical speed of the raster 240 a . At faster vertical speeds, the movement of the pilot's head 122 from side to side 124 during the several microseconds required to update an entire column of pixels is negligible and the image blurring therefore is diminished.
Even after changing the orientation of the raster scan, a blurred image 220 b may continue to appear blurred toward the direction of the pilot's head movement 124 than if the pilot's head was stationary. This blurring effect may be reduced by electronically inserting (i.e. “stuffing”) or removing vertical image lines with the raster 240 b in vertical configuration. Specifically, if the pilot's head movement 124 is in the direction of the raster scan 240 b , vertical image lines may be electronically removed from the image to counteract the blurring effect in one direction. Conversely, if the pilot's head movement 124 is in the direction opposite from that of the raster scan 240 b , then vertical image lines may be electronically inserted, or stuffed, into the space between the actual vertical image lines. The inserted vertical image lines may be image lines duplicated from the last actual vertical image line rendered or the inserted vertical image lines may comprise pseudo or generic lines that are stored in the memory 130 . Duplicated vertical image lines may be used in opaque images and pseudo or generic vertical image lines may be used for see through or translucent images. The number of removed or inserted vertical image lines may be proportional to the speed of the pilot's head movement although other relationships may be used as well.
FIG. 4 is an exemplary, non-limiting logic diagram of an embodiment that may be used to implement the insertion and removal of vertical image lines. In this embodiment the raster scan is moving column by column from the top right of the display to the bottom left. However, the process may be implemented in the reverse or converse orientations as well with the commensurate changes of direction throughout the process.
It will be recognized by those of ordinary skill in the art that the embodiment disclosed below is merely exemplary in that some of the process may be broken out into sub-processes, that sub-processes and processes may be combined into combined processes and that functionally equivalent processes may be substituted. It will also be recognized that the method is not direction dependent. The method is just as applicable whether the scan pattern 240 b is rotated 90° to the left or to the right from a conventional horizontal raster scan pattern 240 a.
The method begins at process 300 with the pilot's head position being at a starting position. At process 308 , a first yaw position is detected as the pilot turns his head 122 . At process 316 a first column address is determined that corresponds with the first yaw position. At process 324 the first vertical column of pixels in the display is rendered at the first column address. At process 332 , a second yaw position is determined and a yaw velocity is then calculated, at process 340 , using the first yaw position and the second yaw position and the elapsed time period between the first and second determinations.
At process 348 , the number of raster or pixel columns that would fit in the gap between the first column address where the display raster is currently located in the NTE to where the raster 240 b would begin its next column after the head movement 324 is calculated. This gap may be termed a “Column Address Adjustment”. As a non-limiting example, the Column Address Adjustment may be determined by calculating the integral number of vertical image lines (N) that will fit (or removed from) between two vertical image lines. The Column Address Adjustment may be calculated to be the closest integer produced by the formula:
N=m*R*T *Ω( t )/ W
where,
m=the number of pixel columns in the display
R=the distance from the eye to the display image
T=the image refresh period
Ω(t)=a function of the head movement over time
W=width of the display
At decision point 356 , it is determined if the yaw movement was to the left. If so, then the NTE display would be commanded to decrement (or drop) the number of columns equal to the Column Address Adjustment. In this case actual vertical image lines equal to the Column Address Adjustment will be deleted. If the yaw movement was not to the left, then it would be determined at decision point 372 if the head movement was to the right. If so, then the NTE display would be commanded to increment (or advance) the column address in which the pixels are being rendered by the number determined by the Column Address Adjustment. In such a case, vertical image lines would be added or stuffed into the space equal to the Column Address Adjustment. If the head movement was negligible or indeterminate, then the NTE display column display scan is advanced to the next programmed column and the method proceeds back to process 324 . When vertical image lines are added, previous vertical image lines may be copied in to the Column Address Adjustment space created by the head movement. Alternatively, stored or pseudo vertical image lines may be added instead.
The subject matter described above is provided by way of illustration only and should not be construed as being limiting. Various modifications and changes may be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims.
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Provided are methods and systems for reducing visual distortion in near-to-eye (“NTE”) visual display systems that is worn, at least partially, on a viewer's head. The movement rate of the viewer's head is sensed while an image that comprises individual content frames is displayed on the NTE using a vertically based raster scan. A characteristic of the raster scan is varied to mitigate distortion of the content frames due to the viewer's head movement.
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TECHNICAL FIELD
This invention relates to a fastener clip for securing a furniture spring to a furniture rail of a framework of an article of furniture, and more particularly, to a fastener clip adapted to be disposed on a single surface of the furniture rail in a single operation.
BACKGROUND PRIOR ART
Fastener clips in general are well known for securing furniture springs to furniture rails forming the framework of an article of furniture.
The framework typically includes four elongated furniture rails joined end to end as a rectangle. Corresponding fastener clips are secured by means of staples or depending legs to respective, opposing ones of the rails. The fastener clips typically terminate at one end with a generally curved spring receiving portion. Opposing end bars of a bowed sinuous furniture spring extend between the opposing rails and are secured to the fastener clips within the spring receiving portion. The spring presents a generally inwardly directed spring force on each of the respective opposing rails via the fastener clips.
According to one prior art design, the fastener clip is generally J-shaped having a curved portion defining a spring receiving portion and joining a long leg segment to a short leg segment. The long leg is first manually stapled to the rail, the respective spring end bar is then disposed in the spring receiving portion, and the short leg is finally stapled over the spring end bar to the rail. Thus two manual stapling operations are required to secure the fastener clip to the rail.
Another fastener clip is disclosed in U.S. Pat. No. 3,323,183 to Sterner entitled "Upholstery Spring Attachment Clip For Furniture". This fastener clip incorporates a base portion having a circular hole, a pair of securing prongs extending from a rear end of the base portion, and a re-entrant bend integral with a front end of the base portion. The re-entrant bend terminates with an overlying portion having a pointed prong. The re-entrant bend and overlying portion define a spring receiving portion. The pair of securing prongs are first inserted into the rail, the spring end bar is then inserted in the spring receiving portion and finally the pointed prong is inserted through the circular hole and into the rail. Again a two step operation is required to fully secure this fastener clip to the rail. In addition, this fastener clip results in significant waste of clip material, because unused clip material is removed to form the pair of securing prongs and the pointed prong.
According to another prior art design described in commonly assigned U.S. Pat. No. 4,454,636 to Pearson, entitled "Spring Fastener Clip for Wooden Furniture Rails", a fastener clip ("the '636 fastener clip") has been provided with a depending flange opposite a spring receiving portion for attachably abutting a rear surface of the rail. The '636 fastener clip can be inserted into the rail in a single operation.
As indicated above, the spring presents a generally inwardly directed spring force on each of the opposing rails via the fastener clips. Typically the rails have been rectangular in end-view, defining a first pair of relatively narrow surfaces and a second pair relatively wide surfaces. Traditionally the rail has been oriented such that the clip is mounted on one of the narrow surfaces, causing the spring force to be applied in the direction of the narrow, and hence weakest, dimension of the rail. Thus the rail must be dimensioned sufficiently to withstand the spring force without bowing.
In order to reduce the quantity of wood required in manufacturing the rail, some have rotated the rail 90° such that the fastener clip is mounted on one of the wide surfaces. Accordingly, the spring force is applied in the direction of the relatively wide, and hence stronger, dimension of the rail. Thus the wider dimension of the rail can be reduced. However the fastener clip will still be mounted on a surface of the rail which is wider than when the fastener clip was mounted on the narrow surface.
For applications where the fastener clip is mounted on one of the narrow surfaces of the rail, the above '636 fastener clip is quite satisfactory. However because the '636 fastener clip is necessarily positioned at the rear of the rail, if the rail is rotated and the '636 fastener clip is mounted on one of the relatively wide surfaces, a longer spring is required to reach the fastener clip. A longer spring adds to the material cost of the spring and, further, it can possibly interfere with the front of the rail. To avoid the necessity of a longer spring, the spring receiving portion of the fastener clip can be inwardly extended, but this requires additional fastener clip material, which causes the fastener clip to be more expensive.
The present invention is provided to solve these and other problems.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a fastener clip for securing an end of a furniture spring to a furniture rail, as of wood, of a framework of an article of furniture. It is a further object of the invention to provide a method of inserting the fastener clip into the furniture rail.
According to one aspect of the invention, the fastener clip comprises a base portion having a front section and a rear section. The base portion is adapted to overlie a surface of the furniture rail. The fastener clip further comprises a reverse curved portion integrally joined to the front section of the base portion, the reverse curved portion defining a spring receiving portion adapted for receiving the end bar of the upholstery spring. The fastener still further comprises first and second front legs and a rear leg integrally depending from the base portion and adapted for insertion into the furniture rail. The rear leg is disposed between the first and second front legs and the rear section of the base portion.
It is comprehended that the rear leg is serrated to prevent its removal from the rail as a result of a torque applied to the fastener clip by the spring.
It is further comprehended that each of the first and second front legs are disposed in a mutually non-parallel relationship so that they cross the grain of the rail to minimize the possibility of the wood splitting.
According to another aspect of the invention, a method is provided for inserting a plurality of fastener clips into the furniture rail.
The method includes the steps of providing a plurality of fastener clips according to the first aspect of the invention, providing a machine having a hammer head, sequentially advancing each of the fastener clips between the hammer head and the furniture rail, and selectively actuating the hammer head to hammer the fastener clips into the furniture rail at predetermined locations along the furniture rail.
Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of one prior art fastener clip secured to a furniture rail;
FIG. 2 is a perspective view of another prior art fastener clip secured to a furniture rail;
FIG. 3 is a view of a fastener clip according to the present invention being inserted into a furniture rail;
FIG. 4 is a perspective view of the fastener clip of FIG. 3 inserted into a furniture rail and retaining a spring end bar;
FIG. 5 is a perspective view of the fastener clip of FIG. 3;
FIG. 6 is a perspective view of the fastener clip of FIG. 3 as viewed generally from its underside;
FIG. 7 is a bottom plan view of the fastener clip of FIG. 3; and
FIG. 8 is a side elevational view of the fastener clip of FIG. 3 inserted into a furniture rail.
DETAILED DESCRIPTION
While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail, a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspects of the invention to the embodiment illustrated.
In the following discussion, both with respect to prior art fastener clips as well as the furniture clip according to the invention, the furniture rail is described for clarity as used for construction of a seat of a piece of furniture, i.e., a horizontal framework. It should be understood that the invention is equally applicable for constructing a vertical framework for a back of a piece of furniture, or such other uses of fastener clips as are well known in the art.
Referring to FIG. 1, a first prior art fastener clip 10 is illustrated inserted in a furniture rail 12. The furniture rail 12 is typically an elongated strip of wood rectangular in end view. This first prior art fastener clip 10 is as illustrated in U.S. Pat. No. 4,454,636, issued to Pearson and entitled "Spring Fastener Clip for Wooden Furniture Rails".
The first prior art fastener clip 10 includes a depending flange 14 having a pair of spaced wood penetrating anchors or prongs 18 which are inserted into an outwardly directed surface 12a of the furniture rail 12.
The first prior art fastener clip 10 terminates with a lip 20 defining a spring receiving portion 22 for securely receiving an end bar 23 of a furniture spring 24.
Because the first prior art fastener clip 10 is secured to the outwardly directed surface 12a of the furniture rail 12, the spring receiving portion 22 tends to be toward the outward portion of the furniture rail 12. Accordingly, when the furniture spring 24 downwardly flexes in use, the spring 24 can interfere with an upper front surface 12b of the furniture rail 12. In addition, the furniture spring 24 must be slightly longer in order to reach the spring receiving portion 22.
One way to eliminate this interference problem is to make the furniture rail 12 narrower. However, as discussed above, the current trend in furniture manufacturing is to orient the furniture rail 12 such that it is in fact wider, while reducing its height.
Another way to eliminate this interference problem is by elongating the first fastener clip 12, thereby inwardly extending the first prior art fastener clip 10; however, this results in a more expensive fastener clip 10 because of the additional material required.
A second prior art fastener clip 10' is illustrated in FIG. 2 secured to a furniture rail 12'. The second prior art fastener clip 10' is generally J-shaped defining a spring receiving portion 22' and is secured to the furniture rail 12' by first and second staples 26, 28. The second prior art fastener 10' includes a pair of spaced slots 30. The second prior art fastener clip 10' is secured to the furniture rail 12' by first inserting the first staple 26 through the slots 30 and into the top surface of the furniture rail 12'. An end bar 23' of a spring 24' is inserted in the spring receiving portion 22'. The second staple 28 is inserted through a pair of spaced holes 32, then through the slots 30 and ultimately into the furniture rail 12'. The second staple 28 pulls the second prior art fastener clip 10' tight against the end bar 23'. Thus two stapling operations are required to secure the end bar 23' into the spring receiving portion 22' and to secure the second prior art fastener clip 10' to the furniture rail 12'.
A fastener clip 40 according to the invention is illustrated in FIGS. 3-8. The fastener clip 40 includes a base portion 42 adapted to overlie an upper surface 44a of a furniture rail 44. The fastener clip 40 further includes a reverse curved portion 46 integrally joined to a front section of the base portion 42. The reversed curved portion 46 defines a spring receiving portion 48 adapted for receiving an end bar 49 of a furniture spring 50.
The fastener clip 40 further includes first and second front legs 52, 54 integrally depending from the base portion 42 and adapted for insertion into the upper surface 44a of the furniture rail 44. The fastener clip 40 further includes a serrated leg 56 disposed between the first and second front legs 52, 54 and a rear section 42r of the base portion 42, also integrally dependent from the base portion 42 and adapted for insertion into the top surface 44a of the rail 44. The first and second front legs 52, 54 and the serrated leg 56 are struck from the bodY of the base portion 42, eliminating any wasted clip material.
As illustrated in FIG. 8, the first and second front legs 52, 54 and the serrated rear leg 56 are disposed at an angle of 90° from an under-surface 42a of the fastener clip base portion 42.
Referring to FIG. 7, the first and second front legs 52, 54, respectively, are disposed at an angle of 60° with the longitudinal axis of the fastener clip 40. These front legs 52, 54 are so disposed so that they cut at an angle with respect to the grain of the furniture rail 44 when inserted therein, thereby minimizing splitting of the rail 44.
The fastener clip 40 further includes a centrally formed reinforcing rib 58 to reinforce the reverse curved portion 46. In addition, the reverse curved portion 46 includes outward flares 60 which serve to prevent edges of the reverse curved portion 46 from cutting into the furniture spring 50.
A detent 61 maintains the end bar 49 of the spring 50 within the reverse curved portion 46.
Referring to FIG. 8, the spring 50 applies a substantially horizontal spring-pull, or shear, force S as well as a generally downward load force F. The first and second front legs 52, 54 provide holding power to oppose the shear force S. The serrations of the rear leg 56 resist a levering or prying action on the fastener clip 40 resulting from the downward load force F.
Referring now to FIG. 3, a machine 62 for inserting the fastener clip 40 into the furniture rail 44 is illustrated. A plurality of the fastener clips 40 are manufactured as a continuous strip 64, which can be wound as a coil (not shown). The coil is unwound as the strip 64 is advanced toward a hammer head 66 such that individual ones of the fastener clips 40 are sequentially positioned between the hammer 66 and the furniture rail 44. A sensor (not shown) actuates the machine 62, causing the hammer head 66 to hammer the fastener clip 40 into the furniture rail 44 in a single hammering operation.
Thus, it can be seen that a fastener clip has been provided which can be inserted substantially at an inward portion of an upper surface of a rail in a single operation, thereby permitting its use on substantially wide furniture rails, though requiring no extra material and preventing interference of the spring with the furniture rail.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present embodiment, therefore, is to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.
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A fastener clip for securing an end bar of a furniture spring to a rail of a framework of an article of furniture, and a method of inserting the fastener clip into the rail, are disclosed.
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BACKGROUND
Field of the invention
[0001] The invention relates to the adaptability of the traditional medicine (Bee venom) for treatment of a lot of diseases such as rheumatoid arthritis and viral diseases specially (HCV) in a pharmaceutical form and presents a noble service for many patients.
[0002] Ancient Egyptians and Babilians were innovators; they used the Bee stings to relief pain accompanying Rheumatism and osteoarthritis since 2000 years B.C.
[0003] Chinese have started the bee venom therapy since 1530 In the nineteenth century (1935) French.
[0004] Austrian and Russian doctors began the first clinical studies with bee venom therapy by using live Bee stings. They proved its efficiency in treatment of variety of diseases such as Rheumatoid arthritis and viral infections especially (HCV).
SUMMARY
[0005] Nowadays, Apitherapy is practiced by non-professional Bee keepers for treatment of viral infections (specially HCV), bacterial and rheumatic disease,which leads to many side effects such as cellulites due to contamination of the sting pin with microorganism, also beekeepers unawareness of a time schedule for the stings may lead to many serious toxic complications and anaphylactic shock. VACSERA has succeeded in the separation of the venom by certain electrical device. Then all the pre-clinical studies including the dosage form, treatment dose, toxicity, bioavaiolability, teratogenicity, and safety were established.
[0006] Then the venom undergoes many purification steps, followed by venom dilution and sterilization through 0.2 micron depth filter sheet. Afterwards, dispensing of the venom takes place after addition of the preservative 0.35% Tricresol in vials with known therapeutic concentration. After that the venom is lyophilized, and is ready for use according to the enclosed leaflet and physician instruction in treatment of viral and rheumatoid arthritis diseases.
DETAILED DESCRIPTION OF THE INVENTION
[0007] Project Goal
[0008] Idealistic use of the venom to modulate both immune cells and immune mediators in patients suffering from auto-immune diseases whenever needed.
[0009] Getting the Bee venom by a sterile and scientific way and in large amount, which can
[0010] huge production scale as a pharmaceutical product.
[0011] Manufacturing of the venom locally and no need for importing such product.
[0012] The venom undergoes many purification steps and determination of its toxicity is established as preliminary procedure before applying such pharmaceutical product for human use either by injection or using other routes in certain doses according to the severity of the case.
[0013] Then the venom is sterilized by using depth filter sheet with porosity 0.2 micron. Afterwards, packaging of the venom takes place after its treatment and mixing with other additives in vials with known therapeutic concentration. After that the venom is lyophilized, and is ready for use according to the enclosed leaflet and physician instructions.
Description in Details of Venom Extraction
[0014] Milking Process:
[0015] Venom of bees was obtained by introducing the bees into certain cabinet of glass lined with
[0016] metal frames, then a small voltage is applied (from 11-15 volts) during the passage of the bees through the metal frames, this process can stimulate bees to extrude its venom.
[0017] Purification process:
[0018] After drying of the venom, the plates are removed and washed carefully with sterile physiological saline (NaCl (0.85% )
[0019] Centrifugation in a cold centrifuge for 1 hour must be carried out at 4500 r.p.m
[0020] Discard the precipitate
[0021] The supernatant, is then lyophilized and kept at 4° C. until used.
[0022] After lyophilization process, the venom is dissolved in a certain quantity of physiological saline to meet certain concentration/vial
[0023] Adjust PH to 7
[0024] Addition of preservative (tricresol 0.35%)
[0025] Then the solution undergoes sterile filtration through 0.22μ depth filter
[0026] Filling
[0027] Lyophilization
Pharmacological Properties of the Bee Venom
[0028] More than 30 different substances have been characterized in bee venom, the main pharmacological components that reduce inflammation are the high molecular weight peptides including the following: Mellitin, Apamine, Peptide 401(mast cells degranulating peptide), Adolapin and protease inhibitors.
[0029] Melittin→Stimulates the hypophyseal adrenal system and releases cortisol that is 100 times more potent than hydrocortisone
[0030] Melittin→Stabilizes the lysosomal cell membrane to protect against inflammation and inhibits the complement C 3 system which is involved in the inflammatory process
[0031] Ado lapin→Inhibits the microsomal cyclooxygenase system and is 70 times stronger than Indomethacine in animal models, it also inhibits platelet lipooxygenase, which is involved in the production of hydroperoxy-icotetranonic acid and leukotrienes. Also it inhibits thromboxane and prostacycline, which are activated during inflammation.
[0032] Protease inhibitors→inhibit carrageenin, prostaglandin E1, bradykinin and histamine-induced inflammations as well as chymotripsin
[0033] Also bee venom has strong anti-bacterial, antifungal and radio-protective effect by stimulating the heamopoeitic system.
[0034] Bee venom is a strong immunological agent that stimulates the body protective mechanisms against disease.
Chemical properties of bee venom % of Molecular Allergenic Substrate dry venom mass (d) Activity Low molecular weight <25 <1.000 − Histamine <1 111 − Dopamine <1 153 − Nor epinephrine <1 169 − Amino acids <1 100-200 − Oligo peptides <14 200-1.000 − Phospholipids <5 100-400 − Carbohydrates <2 <200 − Peptides <60 <10.000 (+) Melittin <50 2.840 (+) Apamin <2 Tetramer: − 12.500 Mast cell degranulating <2 2.000 − peptides (401) Secapin <0.5 2.600 − tetriapin <0.1 2.000 − protease inhibitor <1 9.000 − Prcomine A & B <2 5.00 − High molecular weight >10.000 (+++) Phosphlipase A <15 16-19.000 − Phospholipase B <2 22.000 − Hyaluronidases <2 35-50.000 − Acid phosphomonoesterase <2 45-90.000 (+) D-Glucosidase <1 Not ? known
[0035] Bee venom physical characters
[0036] Single bee venom volume is 5-20 ul
[0037] Venom is colorless, proteinaceous, liquid with sharp bitter taste.
[0038] The dry residue is about 12%
[0039] Has an aromatic odor
[0040] Dried venom has slightly yellowish color
[0041] Determination of LD 50
[0042] Once the venom was obtained, determination of the venom lethal dose was carried out as follows:
[0043] Groups of 4 mice (weighing 14-16 gm) were injected in the caudal vein with different concentrations of bee venom
[0044] 1) The first group was injected with 50 ug of bee venom dissolved in 0.5 ml saline.
[0045] 2) The second group was injected with 75 ug venom in 0.5 ml saline.
[0046] 3) The third group was injected with 100 ug venom dissolved in 0.5 ml saline.
[0047] 4) Finally the 4 th group was injected with 150 ug dissolved in the amount of saline as previously mentioned.
Results
[0048] From the previous work, it is clearly demonstrated that, the lethal dose lies between the 3 rd and 4 th groups, then additional injections with concentrations of 100 ug, 120 ug, and 150 ug (these concentrations lie between 100-150ug) take place, all the previous concentrations caused death in all animal groups. Thus we chose 100 ug as lethal dose which can be identified as the minimum dose of venom that causes death in all animal groups within 24 hrs. and the LD 50 between 70-80 ug
[0049] The lethal dose is 100 ug
[0050] And the LD 50 between 70-80 ug
Determination of the Dosage Form
[0051] Our recent work is concerned with the determination of the DOSAGE FORM (either aqueous or haptenuated with complete Freund's adjuvant)of the venom, and testing which is better and more useful for immunization when applying such vaccine treatment for human.
[0052] 3 groups of rabbits weighing 3.5-4 kg were injected and immunized as follows:]
[0053] The first group received 100 ug venom as aqueous preparation, then the schedule was continued for 6 weeks, and before each injection a blood sample is withdrawn to estimate both IgG & IgE levels together with the routine clinical analysis (kidney function, liver function and lipogram tests) to evaluate the effect of the venom on different organs parameters.
[0054] The 2 nd group received 100 ug venom emulsified with complete freunds adjuvant, and then as previously mentioned as rabbit No. 1
[0055] The 3 rd group received 50 ug emulsified venom to test the effect of the adjuvant and the extent of amplification of the immune response to bee venom.
Results
[0056] Group No. 1 which is immunized with 100 ug venom as aqueous preparation, exhibit a gradual increase in the IgG level from 660 mg % to 830 mg %, while IgE level decreased to its minimum level of about 19 EU/ml, and no change in the organ functions were observed. (FIGS. 1,2 illustrate our results).
[0057] Concerning group No. 2, IgG level increased sharply to a maximum level of about 1250 mg %, while IgE level was fluctuating and reached 78 EU/ml after the 6 th venom injection, also no changes in organ functions were observed (FIGS. 3,4 reveal that ).
[0058] While the 3 rd group which received 50 ug emulsified venom showed an increase in IgG level to its maximum and reached 1250 mg %, whereas IgE level was fluctuating and reached about 63 EU/ml without change in the organ functions (FIGS. 5,6 explain the previous data). RESULTS were expressed as mean±S.D.
[0059] From the previous work we can depict that the aqueous preparation can raise the IgG levels gradually and can decrease IgE level to its minimum level in 2 weeks only, on the contrary although the emulsified preparation induces a higher IgG level, it fails to decrease IgE level to its minimum value as compared to the aqueous preparation which means that, the aqueous preparation can induce complete protection (more than emulsified preparation) from any deleterious side effects such as anaphylactic shock when applying such treatment for human trails, also the addition of complete freund's adjuvant causes some abscesses when administered intradermally, due to the composition of the adjuvant itself which contain Tubercle bacilli bacteria that will cause many complications for pre-sensitized patients, also hapten-like adjuvant can increase the incidence of anaphylactic shock.
[0060] Some Facts to be Mentioned
[0061] The aqueous preparation gives complete protection and decreases the IgE level during 2 weeks post immunization with sustained increase in the IgG level.
[0062] Although the administration of the dose as emulsified preparation causes higher increase in the IgG level, we must avoid that form of injection due to the elevation of the IgE level and the abscesses formed during intradermal injection.
Toxicity
[0063] Effect of the Venom on the Renal System
[0064] Female Wister rats weighing 150-200 gm were injected intravenously with Africanized bee venom at a dose of 0.4 ul/100 gm of body weight and used in functional and light microscopy studies. The animals were divided into 2 groups: the early group was studied 3-8 hour after inoculation, and the late group was studied 24-30 hours thereafter. The animals showed acute renal failure characterized by reduction of glomerular filtration rate with elevation of plasma creatinine. They also showed increased fractional sodium and potassium excretions, suggesting changes in the proximal portion of the nephron. The water transport through collecting tubules was reduced, with consequent diuresis, indicating functional changes in the distal portion of the nephron. These functional changes were more marked in the early group, with recovery tending to occur after 24 hr, albuminuria was also observed in this group. Light microscopy showed acute tubular necrosis mainly in cortex and outer medulla, with isolated necrosis in cells or small groups of cells and cast formation in the distal and collecting tubules. After 24 hour frequent mitotic figures were found in the tubular epithelium.
[0065] The observed acute renal failure was due to acute tubular necrosis which in turn was properly caused by multiple effects, mainly hemodynamic changes secondary to cardio-toxicity and systemic vasodilatation caused by the venom, myohemoglobinuria and the direct action of the venom on tubular cells.
[0066] Effect on Cardio-Vascular System
[0067] An infarct like myocardial lesions was observed in Wister rats after inoculation of high amount of the venom intravenously.
Evaluation of Mutagenicity
[0068] The mutagenic effect of bee venom was assessed by salmonella/microsome, the venom exerts an antimutagenic effect against the mutagenicity of 4-nitro-phenylenediamine and daunomycin.
[0069] Bee venom has an excellent tolerability and wide safety margin up to 700 μg/kg of body weight
[0070] Immunotherapy with Bee venom leads to complete protection in more than 98%of the patients with a history of hyperallergy to the venom.
[0071] At much higher doses anaphylaxis, pruritis, nettle rash, myxoedema, spasms of the smooth muscles and sudden decrease of blood pressure may develop.
[0072] Histamine content of Bee venom at a high dose may cause spasms of coronary vessels
[0073] But itching usually shows future good therapeutic results.
[0074] Bee venom therapy also leads to increase masculine differentiation.
[0075] Immune-therapy during pregnancy did not lead to allergic sensitization of patients' children.
Bee Venom Pharmacokinetics
[0076] Concerning the information that have been requested regarding the pharmacokinetics of bee venom.
[0077] First this point is still under research and inexplicit due to multiple components included in the venom (many peptides, polypeptides, enzymes and amino acids ),the molecular weight of the components ranging from 1000 to 90,000 Da, which makes the study lasts more time. However our preliminary data (animal model) elicits that the major allergen component of the venom is Phospholipase A2 and melittin, also the previously mentioned peptides are the most common peptides which induce pharmacological effects together with the Apamin (12,500 Da) of the bee venom, venom fractions of lower molecular weight were pharmacologically inactive.
[0078] Nevertheless, toxicokinetics of both classes of venom components were studied
[0079] After venom intravenous injection with a dose of( 70 ug/kg) the venom plasma level followed a bi-exponetial decline with distribution half life of 45 min. and an elimination half life of 1.8 hr and the systemic clearance 60 ml/h/kg
[0080] Venom level in plasma, after S.C. injection of a dose (700 ug/kg)of venom, increased within a few hours after venom administration to reach a maximum value at 5±0.5 hr. They subsequently followed a monoexponential decline.
Evaluation of Excretion Route
[0081] The route of excretion is determined using intact and nephrectomized rats, after injection of bee venom, the initial 15 min. of the half life was considerably longer in nephrectomized animals after injection, so we concluded that the proximal tubules cells of the kidney participate in the metabolism of circulating venom and higher venom levels persist in plasma of nephrectomized animals. For that reason the immunotherapy with Bee venom is restricted for patients with renal impairment.
Evaluation of Anti-Bacterial Activity
[0082] Also the evaluation of anti-bacterial activity of the bee venom was established by Melittin, the mechanism by which it exerts its action, is not yet clarified but it may be due to the formation of peptide-lipid supramolecular complex pore in the membrane, followed by peptide internalization, simultaneously dissipating the trans-membrane potential and the lipid asymmetry, this also would be of value in developing a more potent antibiotic based on these results.
[0083] All the previously mentioned data is due to preliminary study only, and after the completion of this point we will send all the details in.
CLINICAL TRIALS a) For rheumatoid Arth. Patients b) For Viral infected patients (HCV infected patients)
[0084] Before application of such therapy, patient must fulfill the following record.
[0085] Firstly patient must sign consent form including his agreement to undergo such trials
[0086] Personal sheet includes
[0087] Sex
[0088] Name
[0089] Date of birth
[0090] Marital status
[0091] Address
[0092] Phone
[0093] Present occupation
[0094] Previous occupation
[0095] Main Complaint
[0096] History of the Previous Illness
[0097] Chronic Illnesses Associated
[0098] Hypertension
[0099] D.M.
[0100] Cardiac
[0101] Chest
[0102] Renal
[0103] Liver
[0104] Bilharzias
[0105] Other
[0106] Drug history
[0107] Previous occupation
[0108] Previous blood transfusion
[0109] Investigation Done
[0110] Past History
[0111] Family History
[0112] Medical Examination Report
[0113] General examination
[0114] Blood pressure
[0115] Pulse
[0116] Temp.
[0117] Appearance
[0118] Head &neck
[0119] Chest
[0120] Abdomen
[0121] Limbs
[0122] Local Examination
[0123] Professional Diagnosis
[0124] Investigations Required
[0125] Laboratory
[0126] Radiology
[0127] Others
[0128] Diagnosis
[0129] Recommendations
[0130] Treatment Schedule
[0131] Rush schedule
[0132] Recommended maintenance schedule (including time interval between injections)
[0133] Special Injection Schedule (due to Bernstein et al 1993,1994 and Diaz Gomez et al 1995) was taken and modified according to the type of disease and its severity. This schedule is in conformance with the scientific literature recommendations, which have been published in this field. (Bernstein et al 1993,1994 and Diaz Gomez et al 1995)
[0134] Base line analysis included
[0135] Liver function tests,
[0136] Kidney function tests,
[0137] lipogram, and
[0138] Fasting blood sugar
[0139] to detect the effect of the BEE VENOM on them later on.( for any evidence of toxicity).
Vacsera Schedule can be Summarized as Follow
[0140] Rush Immunization Week
[0141] Day 1:
[0142] Patient is injected with 25u of the venom solution s.c or i.d. divided on both hands.
[0143] Day 3:
[0144] Patient is injected with 50 u of the venom solution s.c or i.d. divided on both hands.
[0145] Day5:
[0146] Patient is injected with 75u of the venom solution s.c or i.d. divided on both hands.
[0147] Day 7:
[0148] Patient is injected with 100 u of the venom solution s.c or i.d. divided on both hands.
[0149] After 2 weeks:
[0150] Patient is injected with another 100 u of the venom solution s.c or i.d. but undivided.
[0151] Maintenance Treatment
[0152] i) For Rheumatic and HCV infected patients
[0153] A dose of 100-200 ug can be administered twice weekly for 6 weeks
[0154] ii) For hyper-allergic patients against bee venom
[0155] Patient is injected monthly with 100 u of the venom for 8 months
[0156] Recommendations
[0157] Patients having high IgE level must be treated carefully and appropriate precautions are taken.
[0158] Analysis recommended for every case is repeated every 21 days to check any evidence of toxicity.
[0159] HCV infected Patients, detection of virus removal by PCR are carried out every month to check the rate of viral eradication together with liver function tests.
[0160] Rheumatoid arthritis patients are checked permanently for
[0161] ESR,
[0162] RF-latex
[0163] Anti-DNA for sero-negative rheumatoid patients,
[0164] ANA,
[0165] Interleukin 1 and Interleukin2
[0166] besides complete check up for any evidence of toxicity.
[0167] Asthmatic patients due to elevation of IgE titer are checked for IgG and IgE every 2 weeks.
[0168] Precautions
[0169] Divided doses should have time interval 30 min.
[0170] Patients with high IgE level should be given Corticosteroids and antiallergic such as Fexofenadin Hcl 180 mg and calcium salts during the days of immunization.
[0171] During the rush immunization week, patient stays under observation for 2 hours for any expected deleterious side effects.
[0172] Avoid intravenous injection of the venom with huge amount that may lead to infarction like lesions (Animal model trial).
[0173] It has no mutagenic effect and does not cross placental barrier
[0174] Intravenous injection of the venom can lead to destruction of kidney microtubules.
[0175] Applications
[0176] Used by individuals, clinics and hospitals as a pharmaceutical biological product
[0177] either inject able according to certain immunization schedules to modulate
[0178] immune cells and immune mediators and eradicates viral infection
[0179] Or in other forms like cream, lotion, and plasters to treat a lot of diseases.
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The traditional treatment for Rheumatoid Arthritis relies on a course of synthetic drugs, which range from the use of gold salts to anti-inflammatory drugs including both steroids and non-steroids. These drugs specially the steroids can affect adrenal and pituitary glands & cause impotence, edema, poor wound healing, reduce neurological response and cardiac irregularities.
VACSERA began the first clinical studies with bee venom therapy and proved its efficiency for treatment of variety of diseases such as Rheumatoid arthritis and viral infections especially (HCV). Bee Venom was separated by a scientific method and then we determine the dosage form, toxicity, bioavailability, teratogenicity, (anti-teratogenic effect), safety and treatment schedule.
The use of Bee venom in treatment of arthritis has been proved to be beneficial to many patients, primarily due to the presence of a number of polypeptides, peptides, enzymes and amines. The venom is administered according to the enclosed leaflet and physician instructions in doses which vary according to the disease and its severity.
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FIELD OF THE INVENTION
This invention relates generally to storage devices, and more particularly to a safety container for storing vnous medications and other potentially dangerous materials and items.
BACKGROUND OF THE INVENTION
The use of tamper resistant containers, or safety containers, is well known in the art and is utilized for many different types of goods and items. Modernly, these containers have been widely used with respect to medications and other related items. Primarily, these containers have been used to store and secure those medications which could represent a potential health hazard if ingested by children, mentally impaired adults, or recovering substance abusers. Historically, these containers have been used to secure prescription medications, especially narcotics, stimulants, sedatives, and other potentially dangerous medications. However, ingestion to the point of abuse of even over-the-counter medications can theoretically cause severe health problems.
The development of these tamper resistant or safety containers has resulted in a number of various devices and configurations. Most of the attention has focused on the caps (also referred to as the lids or tops) of the containers. For example, some types of containers which have locking caps are well known and are widely used commercially. Typically, a key is used to secure and unlock a safety cap which fits snugly over the container which actually stores the medications. In certain devices, a combination lock integrated into the cap secures the cap to the container.
Other devices utilize either pins, bead and recess configurations, sliding bars, or pivoting latching mechanisms to secure the cap to the container. Conventionally, these safety caps have required multiple actions to accomplish removal of the caps. Thus, for example, some safety caps have required the user to press inwardly on a portion of the cap while simultaneously twisting the cap to achieve removal of the cap. Other safety caps have required the user to twist the cap in a first direction, lift it slightly and, then, twist it in a second direction in order to remove the cap. Numerous other multiple action safety caps have been proposed. However, many of them have been so complicated to remove that even authorized persons have had difficulty in removing the caps. Other safety caps have been ineffective and can be removed by anyone with little or no effort. Still other safety caps have been complex devices which have been prohibitively expensive to manufacture and purchase.
Furthermore, most of the safety caps have been useful with either solid or liquid medications, but have not been adaptable for interchangeable or simultaneous multiple media use. The term "simultaneous multiple media" refers to the ability of a safety container to store various medications in both solid and liquid form at the same time without any mingling or contacting of the two forms of medications occurring. Therefore, these previously developed containers may have only been able to store pills or capsules, but could not safely or adequately store liquid medications at the same time. Additionally, these previously developed containers are generally not large enough to safely store several different types of medications, regardless of medium, at the same time.
Finally, these containers are not well suited to storing and securing other potentially dangerous materials or items which are generally used or needed in connection with or in conjunction with the administration of medications. These potentially dangerous materials include, but are not limited to, needles, hypodermic syringes, thermometers, asthma inhalers, medicine droppers, bandages, adhesive tape, tweezers, or scissors.
Examples of various safety containers can be found in U.S. Pat. No. 3,973,687 to Glick; U.S. Pat. No. 4,462,501 to Franchi; U.S. Pat. No. 4,535,903 to Franchi; U.S. Pat. No. 5,284,262 to O'Nan; U.S. Pat. No. 5,346,069 to Intini; and U.S. Pat. No. 5,575,399 to Intini, the entire specifications of which are expressly incorporated herein by reference.
Therefore, there is a need for a container wherein the contents of the container can be secured from unauthorized users, and which can simultaneously and safely store a number of various medications, regardless of form or medium, as well as other potentially dangerous materials or items used in connection with the administration of medications.
OBJECTS OF THE INVENTION
Accordingly, it is an object of the present invention to provide a new and improved container.
It is a further object of the present invention to provide a new and improved safety container.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the combination lock is programmable by the user.
It is a further object of the present invention to provide a new and improved container which is inexpensive to manufacture and purchase and which is simple to operate.
It is a further object of the present invention to provide a new and improved safety container which is inexpensive to manufacture and purchase and which is simple to operate.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the safety container is inexpensive to manufacture and purchase and which is simple to operate.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the safety container is inexpensive to manufacture and purchase and which is simple to operate.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the safety container is inexpensive to manufacture and purchase and which is simple to operate.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the combination lock is programmable by the user, wherein the safety container is inexpensive to manufacture and purchase and which is simple to operate.
It is a further object of the present invention to provide a new and improved container which can be used with solid and liquid substances simultaneously.
It is a further object of the present invention to provide a new and improved safety container which can be used with solid and liquid substances simultaneously.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items which can be used with solid and liquid substances simultaneously.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the safety container can be used with solid and liquid substances simultaneously.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the safety container can be used with solid and liquid substances simultaneously.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the combination lock is programmable by the user, wherein the safety container can be used with solid and liquid substances simultaneously.
It is a further object of the present invention to provide a new and improved container, wherein the container contains a plurality of removable partition means disposed therein.
It is a further object of the present invention to provide a new and improved safety container, wherein the container contains a plurality of removable partition means disposed therein.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the container contains a plurality of removable partition means disposed therein.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the container contains a plurality of removable partition means disposed therein.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the container contains a plurality of removable partition means disposed therein.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the combination lock is programmable by the user, wherein the container contains a plurality of removable partition means disposed therein.
It is a further object of the present invention to provide a new and improved container which can be coupled to at least one other container. It is a further object of the present invention to provide a new and improved safety container which can be coupled to at least one other safety container.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the safety container can be coupled to at least one other safety container.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the safety container can be coupled to at least one other safety container.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the safety container can be coupled to at least one other safety container.
It is a further object of the present invention to provide a new and improved safety container for storing medications and other dangerous items, wherein the lid of the container can be locked in a closed position, wherein the lock means comprises a combination lock, wherein the combination lock is programmable by the user, wherein the safety container can be coupled to at least one other safety container.
These and other objects of the present invention will become more fully apparent from the following detailed description, taken with reference to the figures of the accompanying drawings contained herein.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, the foregoing and other objects are achieved by:
a receptacle, the receptacle having a base, the receptacle having a pair of spaced and opposed endwalls upwardly depending from the base, the receptacle having a pair of spaced and opposed sidewalls upwardly depending from the base, the upwardly depending endwalls having a raised flange extending vertically across the top portion of the upwardly depending endwalls, the flange having an area defining an aperture, the flanges being located at an opposed position on their respective upwardly depending endwalls so as to align their respective apertures;
a lid, the lid having a base, the lid having a pair of spaced and opposed endwalls downwardly depending from the base, the lid having a pair of spaced and opposed sidewalls downwardly depending from the base, the lid being connected to the receptacle by a hinge means, the pair of downwardly depending endwalls having an area defining an aperture located in a centralized area of the pair of downwardly depending endwalls, the apertures of the flanges aligning with the apertures of the pair of downwardly depending endwalls;
an elongated bolt, the elongated bolt having a length substantially equal to the lid, the elongated bolt having a notch in proximity to one end of the elongated bolt, the elongated bolt being housed within the lid, the elongated bolt being supported by supporting means, the elongated bolt being capable of being manipulated back and forth along its horizontal axis, the elongated bolt being capable of passing through the apertures of the flanges and the apertures of the pair of downwardly depending endwalls, the elongated bolt being capable of assuming a position so as to abut the flange in order to prevent the disengagement of the lid from the receptacle, the elongated bolt being capable of assuming a position so as to align the notch with the flange in order to facilitate the disengagement of the lid from the receptacle; and
a lock means, the lock means being housed in the lid, the lock means being capable of engaging the elongated bolt so as to immobilize the elongated bolt.
In accordance with another aspect of the present invention, the foregoing and other objects are achieved by:
a lid having a base, the lid having a pair of spaced and opposed endwalls downwardly depending from the base, the lid having a pair of spaced and opposed sidewalls downwardly depending from the base, the pair of downwardly depending endwalls having an area defining an aperture;
an elongated bolt, the elongated bolt having a length substantially equal to the lid, the elongated bolt having a notch in proximity to one end of the elongated bolt, the elongated bolt being housed within the lid, the elongated bolt being supported by supporting means, the elongated bolt being capable of being manipulated back and forth along its horizontal axis, the elongated bolt being capable of passing through the apertures of the pair of downwardly depending endwalls, the elongated bolt being capable of assuming a position so as to prevent the disengagement of the lid from the receptacle, the elongated bolt being capable of assuming a position so as to align the notch in order to facilitate the disengagement of the lid from said receptacle; and
a lock means, the lock means being housed in the lid, the lock means being capable of engaging the elongated bolt so as to immobilize the elongated bolt.
In accordance with another aspect of the present invention, the foregoing and other objects are achieved by:
a lid, the lid having a first hasp, the lid having at least one downwardly depending sidewall, the lid having at least one downwardly depending endwall, the first hasp being located on the downwardly depending endwall, the downwardly depending sidewall having at least one area defining an aperture, the lid having a downwardly extending projection located on the interior surface of the lid;
a receptacle, the lid being attached to the receptacle by a hinge means, the hinge means allowing the lid to be moved back and forth horizontally with respect to the receptacle, the receptacle having a second hasp, the second hasp being located below the first hasp, the first hasp and the second hasp aligning vertically, the receptacle having at least one upwardly depending sidewall, the receptacle having at least one upwardly depending endwall, the second hasp being located on the upwardly depending endwall, the upwardly depending sidewall having at least one upwardly extending flange, the aperture being capable of assuming a position so as to prevent the disengagement of the lid from the receptacle, the aperture being capable of assuming a position so as to facilitate the disengagement of the lid from the receptacle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a safety container in accordance with one aspect of the present invention.
FIG. 2 is a perspective view of a safety container in accordance with another aspect of the present invention.
FIG. 3 is a partial perspective view of a safety container in accordance with another aspect of the present invention.
FIG. 4 is a cross-sectional view of a safety container in accordance with another aspect of the present invention.
FIG. 5 is a perspective view of a series of safety containers in accordance with another aspect of the present invention.
FIG. 6 is partial perspective view of a safety container in accordance with another aspect of the present invention.
FIG. 7 is partial perspective view of a safety container in accordance with another aspect of the present invention.
FIG. 8a is a partial cross-sectional view of a safety container in accordance with another aspect of the present invention.
FIG. 8b is a partial cross-sectional view of a safety container in accordance with another aspect of the present invention.
FIG. 9 is perspective view of a pair of safety containers in accordance with another aspect of the present invention.
FIG. 10 is perspective view of a pair of safety containers in accordance with another aspect of the present invention.
FIG. 11 is a partial top view of a safety container in accordance with another aspect of the present invention.
FIG. 12a is perspective view of an alternative embodiment of a safety container in accordance with another aspect of the present invention.
FIG. 12b is perspective view of an alternative embodiment of a safety container in accordance with another aspect of the present invention.
FIG. 12c is perspective view of an alternative embodiment of a safety container in accordance with another aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, a safety container in accordance with one aspect of the present invention is illustrated. The safety container is generally denominated by the numeral 1. The safety container 1 consists primarily of a bottom receptacle portion 2 and a top lid portion 3. The bottom receptacle portion 2 is generally rectangular in shape, however other configurations are envisioned (i.e., a square). The bottom receptacle portion 2 consists primarily of a base 4, a pair of spaced and opposed upwardly depending endwalls 5 and 6, and a pair of spaced and opposed upwardly depending sidewalls 7 and 8 (endwall 6 and sidewall 8 are not visible due to the orientation of FIG. 1). Endwall 5 contains a receiving means 21 (i.e., a recessed groove extending vertically from the top of endwall 5 down to point approximately below the midpoint of endwall 5) for receiving another safety container unit, this feature to be more fully explained later in the detailed description. Sidewall 7 includes a top panel 14 which can be extended outwardly and downwardly away from the bottom receptacle portion 2 in order to allow the user to gain easy access to the contents of the bottom receptacle portion 2. The top panel 14 is connected to the bottom panel 16 by a hinge means 15. The hinge means 15 can merely be two strips of plastic or fabric which join the bottom portion of the top panel 14 to the top portion of the bottom panel 16, however other configurations are envisioned. Preferably, the hinge means 15 is integrated between the top panel 14 and the bottom panel 16 as opposed to taking up a large amount of room inside the bottom receptacle portion 2. Base 4 can be adapted to include a rubber or rubber-like material adhered onto its outer surface in order to provide a secure, non-slip grip on various surfaces. Additionally, the base 4 can have rounded corners in order to prevent injuries that might occur with pointed corners or edges.
Still referring to FIG. 1, the top lid portion 3 is also generally rectangular in shape, however other configurations are envisioned (i.e., a square). Preferably, the top lid portion 3 and the bottom receptacle portion 2 have substantially identical area dimensions so that the top lid portion 3 fits snugly over the bottom receptacle portion 2. The top lid portion 3 consists primarily of a panel 9, a pair of spaced and opposed downwardly depending endwalls 10 and 11, and a pair of spaced and opposed downwardly depending sidewalls 12 and 13 (endwall 11 and sidewall 13 are not visible due to the orientation of FIG. 1). The top lid portion 3 is connected to the bottom receptacle portion 2 by means of a hinge means 17 (which is not visible due to the orientation of FIG. 1). The top lid portion 3 also houses a slidable elongated bolt 18 which is used to secure the lid portion 3 to the bottom receptacle portion 2. The slidable elongated bolt 18 is maneuvered back and forth by an actuator means 19. The slidable elongated bolt 18, once it is in the desired position, is kept from being moved by a lock means 20 located in the panel 9. The lock means 20 engages the slidable elongated bolt 18 by any number of suitable means in order to prevent movement of the slidable elongated bolt 18. For example, the lock means 20 may comprise one or more rods which may engage one or more holes, notches, or recesses in the body of the slidable elongated bolt 18, thus preventing movement when in that particular position. Additionally, the lock means 20 may comprise a combination lock which is programmable by the user in order to provide a higher level of security to the contents of the safety container.
Referring to FIG. 2, additional features of the safety container in accordance with another aspect of the present invention are illustrated. Here, the top lid portion 3 is illustrated in its open and raised position. Additionally, the top panel 14 is illustrated in its lowered position, allowing the user to gain easy access to the contents of the safety container 1. In this view, the hinge means 17 is also visible. Additionally, the first endwall 6 is also visible. Attached to the first endwall 6 is an attaching means 22 which is used to attach one safety container to the receiving means 21 of another safety container. The attaching means 22 is a centrally located T-shaped projection extending vertically downwardly from the top of the first endwall 6 to a point approximately below the midpoint of first endwall 6. The attaching means 22 is merely lowered down (in the direction of the arrow) into the recessed grove of the receiving means 21, as is illustrated in FIG. 5 . At the top of endwalls 5 and 6 are flanges 23 and 24, respectively. Flanges 23 and 24 have centrally located notches or apertures 25 and 26 for loosely receiving the slidable elongated bolt 18. The top lid portion 3 also contains a pair of apertures 27 and 28 which loosely receive the slidable elongated bolt 18 in order to allow it to pass therethrough in order to lock and unlock the top lid portion 3 from the bottom receptacle portion 2. Therefore, it is critical that the exact locations of apertures 25, 26, 27, and 28 align properly in order to allow the slidable elongated bolt 18 to pass easily therethrough.
Referring to FIG. 3, additional features of the safety container in accordance with another aspect of the present invention are illustrated. Here, inside the bottom receptacle portion 2, at least one removable partition means 29 is disposed within the bottom receptacle portion 2. Additional removable partition means 30 may be disposed within the bottom receptacle portion if desired. The removable partition means 29 and 30 are generally panels configured in a honeycomb shape for space efficiency purposes, however other configurations are envisioned. The removable partition means 29 and 30 are used to safely store and segregate various medications and medical supplies. However, it should be noted that the safety container of the present invention can store and secure many other types of items besides medications and medical supplies. Therefore, the maximum height of the removable partition means 29 and 30 should be approximately equal to the internal height of the bottom receptacle portion 2.
Referring to FIG. 4, additional features of the safety container in accordance with another aspect of the present invention are illustrated. Here, the removable partition means 29 and 30 are illustrated disposed within the bottom receptacle portion 2. Additionally the lid portion 3 is shown on top of the bottom receptacle portion 2 in the closed position. Additionally, the receiving means 21 and the attaching means 22 are also illustrated. Referring to FIG. 11, an overhead view of the removable partition means 29, 30 is illustrated. A plurality of groove means 33 is provided to secure the removable partition means 29, 30 in order to prevent excessive movement during transportation.
Referring to FIG. 6, additional features of the safety container in accordance with another aspect of the present invention are illustrated. Here, the upper lid portion 3 is shown in a "see-through" manner. In this illustration, the safety container 1 is shown in its "locked" position. The slidable elongated bolt 18, actuator means 19, flanges 23, 24, lock means 20, notches 25, 26 are shown. Additionally, a support means 31 is provided to support the slidable elongated bolt 18. Finally, a notch 32 is provided in one end of the slidable elongated bolt 18. Attention is drawn to the fact that the entire length of the elongated slidable bolt 18 is housed within the panel 9. In this configuration the upper lid portion 3 can not be raised upwardly from the bottom receptacle portion 2 because the slidable elongated bolt 18 would abut flanges 23, 24. Therefore, no matter how much force is used, it would be virtually impossible to open the safety container 1 in its locked position without causing serious and highly visible structural damage to it. In order to keep the slidable elongated bolt 18 in place, a lock means 20 is provided to engage a portion of the slidable elongated bolt 18. It is envisioned that a portion of the slidable elongated bolt 18 can be employed to abut the lock means 20 in order to prevent the movement of the slidable elongated bolt 18. FIG. 9 provides a perspective view of the left and right hand side views of the safety container 1 in the locked position.
Referring to FIG. 7, additional features of the safety container in accordance with another aspect of the present invention are illustrated. Again, the upper lid portion 3 is shown in a "see-through" manner. However, in this illustration, the safety container 1 is shown in its "unlocked" position. The slidable elongated bolt 18, actuator means 19, flanges 23, 24, lock means 20, notches 25, 26 are also shown. However, notch 32 is not visible due to the orientation of the slidable elongated bolt 18. Attention is drawn to the fact that only a portion of the length of the elongated slidable bolt 18 is housed within the panel 9, and that a small end portion of the slidable elongated bolt 18 protrudes outwardly from notch 25. In this configuration the upper lid portion 3 can be raised upwardly from the bottom receptacle portion 2 because the slidable elongated bolt 18 would not abut flanges 23, 24. Specifically, notch 32 would pass freely through flange 23. FIG. 10 provides a perspective view of the left and right hand side views of the safety container 1 in the unlocked position.
FIGS. 8a and 8b provide partial cross-sectional views of the interaction between the slidable elongated bolt 18 and flange 23 in the locked and unlocked positions.
Referring again to FIG. 5, it will be appreciated that the safety containers of the present invention can be joined together by utilizing the "tongue and groove" configuration (i.e., receiving means 21 and attaching means 22) provided on the sides of the containers. Initially, the safety containers should be joined together in the position wherein the slidable elongated bolt is housed entirely within the lid (i.e., no portion of the slidable elongated bolt protrudes out of the lid). This is preferable in order to prevent the end of the slidable elongated bolt of one safety container abutting the top lid portion of another safety container it is to be joined with. Once the safety containers are joined together, their respective lock means can engage their respective slidable elongated bolts. When a user wants to unlock and access all of the joined safety containers, he or she merely disengages all of the lock means and with one simple motion manipulates the slidable elongated bolt of the end or terminal safety container in the direction of the notched ends of the slidable elongated bolts of the other safety containers. Therefore, all of the safety containers can be accessed at the same time, instead of the user having to individually manipulate each and every slidable elongated bolt of every safety container.
Referring to FIG. 12a, there is illustrated an alternative embodiment of the present invention. This version of the safety container consists primarily of a rectangularly shaped lid 100 and a rectangularly shaped receptacle 101. It should be noted that other shapes of this alternate version are envisioned. The lid 100 is connected to the receptacle 101 by a hinge means which allows the lid 100 to move back and forth horizontally with respect to the receptacle 101 (i.e., a sliding pin hinge, spring hinge, or any similar configuration). On one side of the lid 100 is a hasp 102. On the same side of the receptacle 101 is a hasp 103, which is located directly below hasp 102. The safety container can be secured in this position by placing a lock (specifically a padlock) through hasps 102 and 103. On the front downwardly depending sidewall 108 of the lid 100 are a pair of apertures 106, 107. Abutting these apertures are a pair of flanges 104, 105, which prevent the lid 100 from being raised upwardly away from the receptacle 101, even if the hasps 102, 103 are not secured by a lock. Apertures 106, 107 are shaped so as to abut flanges 104, 105 when the lid 100 is in one position, and not abut flanges 104, 105 when the lid 100 is in another position. In this particular illustration the apertures are L-shaped; however, other configurations are envisioned.
Referring to FIG. 12b, in this illustration the lid 100 is shown as being moved horizontally away from the receptacle 101. Here, the apertures 106, 107 have been positioned so as to allow the lid 100 to be raised upwardly because flanges 104, 105 no longer abut apertures 106, 107.
Referring to FIG. 12c, in this illustration the lid 100 is shown in its raised position.
As with the previously described version of the safety container, this version can be equipped with partition means and groove means. Additionally, other units of this safety device can be coupled together. For example, a projection 109 can be provided which extends downwardly from the inner surface of the lid 100. The hasp of another unit can be positioned so that projection 109 extends through both hasps, as lid 100 is being closed. The first unit can be padlocked, thus securing both units simultaneously. It is also envisioned that this embodiment of the safety container can also be equipped with the attaching means 110 and receiving means 111, previously described with respect to other embodiments.
While preferred embodiments of the present invention have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate embodiments falling within the spirit and scope of the invention as defined in the appended claims.
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A safety container is described which can simultaneously store and secure containers of liquid and solid medications without any mingling of the two types of medications occurring. The safety container can also store and secure medical equipment and supplies used in the administration of medications, as well as other items. The lid of the safety container is secured to the receptacle of the safety container by a slidable elongated bolt which engages a flange located on the receptacle. The slidable elongated bolt can be held in place by a lock. Multiple units of the safety container can be joined together through a tongue-and-groove configuration located on opposing walls of the receptacles. In another embodiment, a safety container is described which allows the lid to move horizontally with respect to the receptacle. The lid is prevented from being raised upwardly be at least one flange which abuts at least aperture located on one sidewall of the lid. The lid can be further secured by placing a lock through a pair of hasps located on the endwalls of the lid and receptacle.
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BACKGROUND OF THE INVENTION
The present invention relates to lawn and garden equipment, in particular, the present invention relates to a lawn apparatus known as an aerator. Aerators are generally used to punch holes in soil or to remove cores from soil of approximately one half inch in diameter and three inches long to allow air and moisture and nutrients to enter the soil.
Several problems are present in existing aerators. The most common form of aerator has a reel or a tine assembly equipped with coring tubes or tines that are positioned on the reel or the tine assembly so they extend radially outwardly from the central shaft of the reel. The tines or coring tubes, in addition to providing aeration, provide propulsion for the aerator. As the assembly rotates, the tines rotate and punch into the ground to remove a core from the ground and also push the aerator forward. This arrangement provides excellent traction to propel the aerator along the lawn. However, it presents a substantial impediment to turning the device in a sharp turn, or to making a turn of sufficiently small radius to allow the operator of the aerator to make a second pass across the lawn immediately laterally adjacent to the previous pass. Typically, to accomplish a small radius turn, the user must expend substantial effort to force the aerator into position by lifting the front wheels or rear wheels of the aerator with the handle to remove the tines from the ground and to allow pivoting on one of the aerator wheels. Alternatively, if the tines are left in contact with the ground and allowed to propel the aerator, a turn having a large radius—on the order of eight to ten feet—only can be accomplished. As aerators typically weigh between two and three hundred pounds, the repetitive lifting of the device by the operator can be exhausting to the operator. This can present a serious problem during the operation of a reasonably dangerous piece of equipment.
Yet another problem that exists with current aerators is the assembly of the plugging or coring tines on the reel or tine assembly of the aerator. Typically, aerators have coring tines which are sandwiched between parallel mounting plates. The tines are held in place by bolts passing through the mounting plates and through the tines. The mounting plates are then, typically, welded onto a shaft or a tube which is then mounted onto a shaft to comprise the coring tube reel. It is very difficult, if not impossible, for a user of the device to replace individual components of such a welded tine wheel assembly. In addition, the connection of the tine wheel assembly to the frame of the aerator makes it difficult for a user to remove the tine wheel assembly if it is possible to replace any parts of the tine wheel assembly.
Therefore, it would be an advantage, and is an object of the present invention to provide an aerator which allows the user to change the direction of travel of the aerator while reducing the need to manually lift the aerator tines out of contact with the ground.
Yet another object of the present invention is to provide an aerator that offers a much smaller turning radius and allows the user to re-position the aerator on the reverse line of travel adjacent to the previous line of travel with greatly reduced effort by the operator and without the need to lift and pivot the aerator to achieve pivoting on the front support or wheel of the aerator.
Another object of the present invention is to provide a tine assembly which is easily removable from the aerator and which allows the operator of the aerator to easily change the type of tine which is mounted on the aerator and the number of tines and the spacing between individual tine wheels to allow near complete user selection of the type of aeration process being achieved. It would be a great benefit to users and the small equipment rental industry if an aerator was provided with a easily removable tine wheel assembly which allowed the user to replace any damaged part of the tine wheel assembly.
Yet another object of the present invention is to provide an aerator having a differential in the front axis of the device to allow great maneuverability of the aerator as it is operated.
Another object of the present invention is to provide a front axle having a differential in combination with castered rear wheels to further improve the maneuverability of the aerator.
SUMMARY OF THE INVENTION
The present invention provides an aerator having a tine wheel assembly which is easily removable by an operator. Further, the present invention provides a tine wheel assembly which allows the operator to change the spacing between tine wheels and to change the number and type of tines included in each tine wheel and to individually replace tines which have become damaged. A differential is provided in the front axle to increase maneuverability and to allow the user to reduce the need for manually lifting the aerator by its handle in order to and to reduce the need to remove the tine wheels from contact with the ground during the maneuvering of the aerator. The present invention also provides a combination of a front axle differential with castered rear wheels to assist in maneuverability of the device. Further, the present invention allows the tine wheel assembly to be raised from contact with the earth while power is supplied to the differential of the front axle to assist in maneuverability of the present invention. Another feature of the present is a non-welded, easily removable tine wheel assembly which permits the user to easily replace components of the assembly.
The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is the right side and top perspective view of the aerator of the present invention;
FIG. 2 is an enlarged fragmentary view of the tine wheel assembly of FIG. 8 and which is shown in FIG. 2 from a direction which is the reverse of that shown in FIG. 8;
FIG. 3 is a front and right side perspective view of a tine wheel;
FIG. 4 is an exploded view of the tine wheel shown in FIG. 3 .
FIG. 5 shows the lift handle of the present invention when not engaged;
FIG. 6 shows the lift handle of the present invention engaged to assist in lifting the present invention;
FIG. 7 is a front and top perspective view of the engine and power transfer assembly of the present invention;
FIG. 8 is a front and bottom perspective view of the present invention showing the differential on the front axle of the present invention and showing the tine wheel assembly in position on the front frame of the present invention; and
FIG. 9 is an exploded view of the engine and drive train of the present invention and showing the idler pulley and the connection of the drive chains to the differential and to the tine wheel assembly.
FIG. 10 is an exploded view of an alternative embodiment of the tine wheel shown in FIGS. 3 and 4 in which the shaft is triangular in cross-section.
FIG. 11 is an exploded view of an alternative embodiment of the tine wheel shown in FIGS. 3 and 4 in which the shaft is pentagonal in cross-section.
FIG. 12 is an exploded view of an alternative embodiment of the tine wheel shown in FIGS. 3 and 4 in which the shaft is hexagonal in cross-section.
FIG. 13 is an exploded view of an alternative embodiment of the tine wheel shown in FIGS. 3 and 4 in which the shaft cross-section has multiple longitudinal grooves.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the preferred embodiment of the present invention is shown as aerator 10 . In its general configuration, aerator 10 is comprised of handle 12 which is attached to front frame 14 which contains the operational components of aerator 10 . Attached to front frame 14 is rear frame 16 which is pivotally connected to front frame 14 by bolts 18 . Castered wheels 20 are connected to rear frame 16 and allow the rear of aerator 10 to be easily moved any direction while relying on one of non-castered wheels 22 to act as a pivot for the move of castered wheels 20 . Front frame 14 also holds engine 24 which provides the power for forward movement of aerator 10 and which provides the power for rotation of tine wheel assembly 26 . Also mounted on front frame 14 is weight 28 which is fitted onto weight pins 30 . Weight 28 provides additional downward force on tine wheel assembly 26 to assist in forcing tines 32 of tine wheel assembly 26 into the ground as aerator 10 is operated.
Still referring to FIG. 1, aerator 10 is guided along its path by an operator grasping handle 12 . Within reach of handle 12 , the operator also can control rear frame lift bar 34 which is connected to rods 36 and which are attached to lift flange 38 . Lift flange 38 is pivotally mounted onto front frame 14 and is movable between a first position and a second position to raise or lower rear frame 16 with respect to front frame 14 . A user will wish to raise front frame 14 with respect to rear frame 16 when it is desired to disengage tine wheel assembly 26 from contact with the ground. Conversely, when the user wishes to engage tine wheel assembly with the ground, the user will pull rear frame lift bar toward handle 12 to raise rear frame 16 with respect to front frame 14 and thereby lower tine wheel assembly 26 into contact with the ground. Another component available to the user and which is mounted on handle 12 is engine throttle 40 which permits the user to advance the engine speed. Also mounted on handle 12 is power engagement bar 42 to which is attached cable 44 . As will be later described, cable 44 is connected to an idler pulley which compresses and releases a belt to transfer power between engine 24 and drive shaft 86 (FIG. 7 ).
Referring now to FIG. 2, tine wheel assembly 26 will be described in greater detail. Tine wheel assembly 26 is attached to front frame 14 by pillow bearings 46 . Use of pillow bearings 46 provides the advantage that when maintenance work must be performed upon tine wheel assembly 26 , the entire tine wheel assembly 26 may be removed conveniently and easily by simply unbolting pillow bearings 46 from front frame 14 and removing wheel assembly 26 from beneath aerator 10 . This easy removal of tine wheel assembly 26 and is an important feature of the present invention which, among its other benefits, allows the user to replace individual tines 32 or other component of tine wheel assembly 26 which have become damaged during use of aerator 10 . In addition tine wheel assembly 26 is assembled or constructed without any parts being welded together. Each part of the tine wheel assembly of the present invention can be disassembled thereby allowing the user to replace any part of the tine wheel assembly as desired.
Referring now to FIGS. 2, 3 , and 4 , the construction of tine wheel assembly 26 will be described in detail. Assembly 26 , in general, is comprised of a number of tine wheels 48 mounted on a shaft 50 . Tine wheels 48 are separated by spacers 52 which may be of whatever length the user believes to be appropriate for the work at hand. Each of tine wheels 48 is comprised of a pair of tine lock plates 54 a , 54 b which have secured therebetween a number of tines 32 . Tine lock plates 54 a , 54 b are spaced apart by plate spacer 53 . Plate spacer 53 protects shaft 50 and maintains tine lock plates 54 a , 54 b at the appropriate distance apart for the particular tine size which is mounted on tine wheel 48 . Each of tines 32 is held in place between the opposed tine lock plates 54 by a single mounting bolt 56 . The mounted tine 32 is further supported during operation by support bolt 58 which resists the force placed against tine 32 as tine 32 meets the ground during operation.
Referring now to FIGS. 3 and 4, the assembly of tine wheels 48 and tine wheel assembly 26 will be described. In FIG. 3, a tine wheel 48 is shown with five tines extending therefrom. It should be appreciated that a greater number or a fewer number than five tines can be assembled onto tine wheel 48 . This is accomplished through the use of either providing additional mounting holes or providing alternate tine lock plates 54 which are prepared to hold a greater or lesser number of tines. It will also be appreciated that in any of such tine lock plates which are used in tine wheel 48 that the diameter of the tines can be varied depending on the type of operation being performed. For example, in some cases, the operator may simply wish to use a narrow spike to poke holes into the ground and not actually remove a core of ground as will the tines 32 shown in FIG. 4 . In such a case the operator will simply change the length of spacers 52 and 53 to take-up any extra space along shaft 50 .
Referring now to FIGS. 4 and 10, each tine wheel 48 is assembled by securing each of tines 32 between tine lock plates 54 a , 54 b with mounting bolts 56 which pass through mounting void 60 of tine 32 and through the opposed tine lock plate 54 where the mounting bolt 56 is secured by a nut 62 . When the tines have been mounted between lock plates 54 , support bolts 58 are introduced to pass through tine lock plates 54 and also are secured with a nut 62 . When the assembled tine wheel is to be mounted on shaft 50 , shaft 50 is passed through drive engagement voids 66 of tine lock plates 54 a , 54 b . It will be appreciated that drive engagement void 66 shown in the embodiment of FIG. 4 is rectangular in shape to match shaft 50 which also is rectangular. This shaping of shaft 50 provides a power transferring means which communicates the rotational power of the shaft from to shaft to at least one of tine wheels 48 while avoiding the use of welded connections between the shaft 50 and the tine wheels 48 . It will be appreciated that such welded or permanent connections between the shaft and the tine wheels or other device mounted on shaft 50 would prevent a user from being able to dismantle the tine wheels from the shaft to replace damages parts or to reconfigure the tine wheels on shaft 50 . Alternate shapes such as hexagonal or pentagonal cross-section, or triangular cross-section as shown in FIGS. 10 through 12, or otherwise having longitudinal grooves as shown in FIG. 13, and which are effective for transferring power also could be used for shaft 50 and drive engagement void 66 . Those skilled in the art will appreciate that a round shaft cross-section and a round engagement void 66 would not accomplish a transfer of power from shaft 50 to the tine wheel 48 which is slidably mounted thereon.
Referring now to FIGS. 5 and 6, a lift handle and lockout means will be described which permits the user to conveniently lift aerator 10 which is both a bulky and heavy object. Also the lift handle, simultaneously prevents rear frame 16 from collapsing against front frame 14 during the manual movement of aerator 10 .
Referring now to FIG. 5, lift handle 70 is shown in its unused position in which it is pivoted against rear frame 16 of aerator 10 . When the operator wishes to lift aerator 10 to place aerator 10 in the back of a vehicle or to lift aerator 10 over an obstacle such as a low wall or other obstruction, the user, after shutting down engine 24 , pulls rearwardly on rear frame lift bar 34 . This draws lift flange 38 into the position which lowers rear frame 16 , thus effectively raising front frame 14 and tine wheel assembly 26 off the ground. The user then grasps lift handle 70 and pulls outwardly causing lift handle 70 to rotate around pivot 72 and place lockout flange 74 underneath lift flange 38 . This prevents inadvertent shifting of lift flange 38 into the position which would raise rear frame 16 and which could result in the pinching of the fingers of the user's other hand or the fingers of another person who has placed their hands about rear frame 16 to assist in lifting aerator 10 . Once aerator 10 has been moved into its new position, user simply releases lift handle 70 which pivots back into its at rest position shown in FIG. 5 and restores lift flange 38 to an operable mode.
Referring now to FIGS. 7 and 8, the power train of the present invention will be described. As previously mentioned, the use of a front axle differential in combination with castered rear wheels assists in the maneuverability of aerator 10 and reduces the amount of effort required by the user to turn aerator 10 into a reverse path. This combination also reduces the turning radius required by the present invention as compared to other aerator devices. In FIG. 7, engine power takeoff pulley 80 is shown attached to engine 24 . Belt 82 passes around engine power takeoff pulley 80 and transfers the power to drive shaft pulley 84 which is part of power shaft 86 . Also mounted on power shaft 86 by means of gears are differential chain drive 88 and tine wheel assembly chain drive 90 .
Referring to FIGS. 8 and 9, the connection of differential chain drive 88 is shown on differential 92 and the connection of tine wheel chain drive 90 is shown connecting to a gear which is a part of tine wheel assembly 26 . It will be appreciated that engine power takeoff pulley 80 (FIG. 9) is always rotating when engine 24 is operating although use of engine throttle 40 may reduce or increase the amount of torque being applied to engine power takeoff pulley 80 . Therefore, as shown in FIG. 9, to engage and disengage the transfer of power from engine power takeoff pulley 80 to drive pulley 84 an idler pulley 98 is used to compress belt 82 sufficiently to cause rotation of drive pulley 84 or to release tension on belt 82 and to provide enough slack that drive pulley 84 does not rotate. Referring to FIG. 7, the tensioning and release of idler pulley 98 is accomplished by the user compressing power engagement bar 42 (FIG. 1) against handle 12 which causes tension on cable 44 which is passed to spring 94 which pulls on idler pulley flange 96 and compresses idler pulley 98 against belt 82 to transfer power from engine power transfer pulley 80 to drive pulley 84 .
It will be appreciated by those skilled in the art that at all times when drive pulley 84 is engaged, power is transferred to both tine wheel assembly 26 and to differential 92 . This allows the user to better manipulate the path of travel of aerator 10 when tine wheel assembly is engaged in the ground and especially when the tine wheel assembly has been disengaged from the ground as previously described. The combination of differential 92 on front axle 100 of aerator 10 and the castered wheels at the rear of aerator 10 and the ability to mechanically raise the tine wheel assembly while having power to the front axle, provides the user with far greater maneuverability of aerator 10 than is available in other conventional aerators which either do not have a front axle having a differential or instead of a front axle have a large hollow drum, usually filled with water, to add weight to the aerator. In a typical circumstance, the prior art type of aerator using a weighted drum as a front axle or an axle not containing a differential will require a turning radius of 10 to 15 feet to reverse the direction of the aerator. The present invention reduces this turning radius to a distance of 2 to 5 feet depending upon the slope of the ground being worked.
In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirements of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the description and illustration of the inventions is by way of example, and the scope of the inventions is not limited to the exact details shown or described. Certain changes may be made in embodying the above invention, and in the construction thereof, without departing from the spirit and scope of the invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not meant in a limiting sense.
Having now described the features, discoveries and principles of the invention, the manner in which the inventive aerator is constructed and used, the characteristics of the construction, and advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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An aerator is provided having a front axle, including a differential and a tine wheel assembly which may be raised from the ground during maneuvers of the aerator while power continues to be supplied to the front axle, and a tine wheel assembly is provided which allows the operator to repair and change the configuration of the tines of the tine wheel assembly.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/957,921, filed Jul. 15, 2013, and U.S. Provisional Application No. 61/959,623, filed Aug. 29, 2013. The disclosures of these provisional applications are expressly incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention generally relates to a means for arranging cylindrical elements in a grid or lattice configuration, and more particularly relates to a rod clip stand configured to releasably secure and retain a pair of rods in a perpendicular orientation, and optionally to locate the rods a distance spaced from an adjacent support surface. The present invention is particularly well suited for fabricating a rebar grid used to reinforce concrete flatwork.
BACKGROUND OF THE INVENTION
[0003] In certain construction or fabrication applications, it is necessary to assemble a grid or lattice structure from a set of cylindrical element on the job site. One such application is for concrete construction. In particular, reinforcement bar or rebar for short is used as a tension device in reinforced concrete and reinforced masonry structures, to strengthen and hold the concrete in compression. The surface of the rebar may be patterned to form a better bond with the concrete. In concrete flatwork, the rebar is often assembled into grid generally the dimension of the area to be formed with concrete. It is important that the rebar grid be elevated from the existing surface. In addition, it is beneficial to interconnect the individual rebar elements together so that they remain in the desired location as concrete is poured over the grid. Lastly, it is critical that the concrete be able to flow through and around the rebar grid to ensure the absence of any air pockets, voids or other defects that could weaken the final concrete structure.
[0004] It is common for the concrete contractor to assemble this rebar grid on the job site. To do so, the contractor must first join the rebar elements together at the nodes of the grid. In other words at the point where two rebar elements intersect. This may be done by welding or alternately with some sort of fastening element such as wire, cable ties or the like. Once assembled in a grid, the rebar must be supported in an elevated position, typically on stands placed in spaced relation beneath the rebar elements. Alternately, the rebar may be supported in an elevated position first then wire tied, welded, etc. This process of fabricating a rebar grid can be time consuming in that it involves multiple steps, and thus costly from a labor cost standpoint. In addition, this process of fabricating a rebar grid requires that the contractor have an inventory of several parts, namely rebar, fasteners and stands, and thus costly from a material and storage cost standpoint. Accordingly, it is desirable to provide a simple, cost-effective means for fabricating a rebar grid with a minimum of components. In addition, it is desirable to provide a compact coupling element in the form of a rod clip stand which functions to interconnect a pair of rebar element and to elevate the rebar elements above the ground. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY OF THE INVENTION
[0005] The present disclosure provides a clipping system for connecting, elevating and protecting cylindrical elements. The clipping system includes a rod clip stand for assembling a pair of cylindrical elements. The rod clip stand includes a cradle portion having a first cradle with a first concave surface formed therein and a second cradle laterally spaced from the first cradle with a second concave surface formed therein. The cradle is configured to receive a first cylindrical element such as a rebar element. The rod clip stand also includes an arched portion interconnecting the first and second cradles in a spaced relationship. The arched portion has a third concaved surface formed at a crown of the arched portion and configured to receive a second cylindrical element such as another rebar element. The third concave surface is generally perpendicular to the first and second concave surface such that the rebar elements are arranged in a generally perpendicular manner. The clipping system may be used in various applications including but not limited to assembling and supporting rebar when fabricating concrete structures.
[0006] The present disclosure also provides an assembly forming a rebar grid with a plurality of rebar elements connected with a rod clip stand at the nodes of the grid. The rod clip stand includes a cradle portion having a first cradle with a first concaved surface formed therein and a second cradle laterally spaced from the first cradle with a second concaved surface formed therein. A first rebar element is supported in the first and second concave surfaces. An arched portion interconnects the first and second cradles in a spaced relationship. The arched portion has a third concaved surface formed at a crown of the arched portion. The third concave surface is generally perpendicular to the first and second concave surface axis and supports a second rebar element. A leg extends from the cradle portion opposite the arched portion. The leg preferably includes a first leg extending from the first cradle and a second leg extending from the second cradle. The rod clip stand couples the first rebar element to the second rebar element is generally perpendicular to on another.
[0007] The simple unitary design of the rod clip stand is lightweight and significantly reduces the amount of material compared to that used in conventional rebar support chairs. The rod clip stand can be a plastic molded part arranged in chains of 16 units. These chains can be nested and stacked such that over 7000 units fit into a standard 2 ft×2 ft×2 ft box, thereby reducing storage volume and shipping cost. One or more chains can be carried on a belt so that a reinforcing ironworker or rod buster can quickly and efficiently fabricate a lattice or grid structure using these rod clip stands.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and:
[0009] FIG. 1 is a perspective view of a rod clip stand in accordance with the present disclosure;
[0010] FIG. 2 shows the rod clip stand illustrated in FIG. 1 supporting two rods in a generally orthogonal orientation;
[0011] FIG. 3 is a front elevation of the rod clip stand shown in FIG. 1 ;
[0012] FIG. 4 is a rear elevation of the rod clip stand shown in FIG. 1 ;
[0013] FIG. 5 is a left side elevation of the rod clip stand, it being understood that the right side elevation is a mirror image thereof;
[0014] FIG. 6 is a top plan view of the rod clip stand;
[0015] FIG. 7 is a bottom plan view of the rod clip stand;
[0016] FIG. 8 is a top plan view showing a lattice of rod elements with a rod clip stand at each intersection forming a node;
[0017] FIG. 9 is a perspective view showing 16 rod clip stands interconnected to form a chain; and
[0018] FIG. 10 is a top plan view showing 14 chains of rod clip stands nested together for packaging and shipping.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention.
[0020] With reference now FIGS. 1-7 , a rod clip stand 10 is illustrated which interconnects and supports a pair of rod elements 12 , 14 in a generally orthogonal or perpendicular arrangement. As seen in FIG. 8 , a plurality of rod clip stands 10 can be used to assemble a lattice or grid of rod elements 12 , 14 . In this regard, a rod clip stand 10 couples the rod elements 12 , 14 together at each node, or in other words at each point where the rod elements 12 , 14 intersect. The rod elements 12 , 14 may be reinforcing bars or rebar used to support and strengthen concrete structures. The rod clip stand 10 may have utility in other applications such as pipe, conduit, etc. for fabricating a lattice or grid structure.
[0021] Referring again to FIGS. 1-7 , the rod clip stand 10 includes a cradle portion 16 having a first cradle 18 defined by a first concave surface 18 s and second cradle 20 is laterally spaced from the first cradle 18 . The second cradle 20 is defined by a second concave surface 20 s. As best seen in FIG. 2 , the cradle portion 16 is configured to receive rod element 12 . The rod clips stand 10 also includes an arched portion 22 interconnecting the first and second cradles 18 , 20 in a spaced relationship. The arched portion 22 includes a third concave surface 24 s formed at a crown 24 of the arched portion 22 . As best seen in FIG. 2 , the arched portion 22 is configured to receive the rod element 14 . The rod clips stand 10 , and in particular the generally perpendicular orientation of the third concave surface 24 s with respect to the first and second concave surface 18 s, 20 s, orients the rod elements 12 , 14 in a generally perpendicular manner. The centroid 26 of the first concave surface and the centroid 28 of the second concave surface lie in a common plane defined by the X-Z axes shown in FIGS. 3-5 .
[0022] Rod clip stand 10 further includes leg portions 30 , 32 extending from the first and second cradles 18 , 20 . A centerline of the leg portions 30 , 32 lie in a common plane with the centroid 26 of the first and second concave surface 18 s, 20 s and the centroid 28 of the third concave surface 24 s as best seen in FIG. 5 . Similarly, the centroid 28 of the third concave surface bisects the distance between the first and second leg portions 30 , 32 as best seen in FIGS. 3 and 4 . In this way, any load on the rod elements 12 , 14 is transferred through the rod clips stand 10 in a balanced manner.
[0023] The spaced relationship of the first concave surface 18 s and second concave surface 20 s ensures that the rod clip stand 10 has at least two points of contact with rod element 12 . As presently preferred, the third concave surface 24 s is also configured to have at least two points of contact with rod element 14 . Various structural features may be included in the third concave surface 24 s to provide for at least two points of contact. For example, as shown in FIG. 7 , a plurality of protrusions 34 (shown in broken lines) may be formed on and extend from the third concave surface 24 s. A local feature such as protrusions 34 insures that the rod clip stand 10 contacts of the rod element 14 at more than one point. For example, on rods that have ribs, such as rebar, the protrusions may rest in between the ribs making a stable contact. The protrusions may also function as a spring or biasing element for generating a clamping force on the rod elements as further described below. While the present disclosure describes and illustrates, the protrusions as being formed on the third concaved surface 24 s, one skilled in the art will appreciate that the protrusions may be form on the first concaved surface and/or the second concaved surface in addition to or in place of the protrusions on the third concaved surface.
[0024] The dimensions of the rod clip stand 10 are configured to releasably secure rod elements 12 , 14 together. In this regard, the height h as shown in FIG. 5 is equal to or slightly less than the sum of the diameters of rod elements 12 , 14 for providing interference fit into the rod clip stand 10 . As such, the rod clips stand 10 , and more particularly the cradle portion 18 and the arch portion 20 , generate a clamping force that acts to hold rod elements 12 , 14 together. The rod clip stand 10 may further include a retaining element, which is configured to engage one or both rod elements 12 , 14 and securely couple the rod clip stand thereto. As best seen in FIGS. 1 and 5 , the first and second cradles 18 , 20 have a cam surface 36 , 38 formed on an edge leading to the first and second concave surfaces 18 s, 20 s that define a retaining element. During assembly, the rod clips stand 10 is rotated clockwise (as seen in FIG. 5 ) so that rod element 12 engages the cam surfaces 36 , 38 causing the rod clip stand to elastically deformed. Once the rod element 12 clears the cam surfaces 36 , 38 , the rod clip stand 10 returns to its undeformed state and captures the rod element 12 within the cradle portion 16 .
[0025] With reference now to FIGS. 9 and 10 , the rod clip stand 10 may be a plastic part preferably fabricated using an injection molding process. The rod clip stand 10 is shown in the figured as a solid plastic part. One skilled in the art will readily recognize that the rod clip stand 10 may be molded to have certain voids or pockets to reduce weight and material necessary for its fabrication. In this regard, the rod clip stand 10 must have sufficient strength to support the rod elements 12 , 14 and any load imparted thereon. One skilled in the art will also recognize that a plurality of the rod clip stands 10 may be molded at the same time and arranged in a chain 40 of rod clip stands 10 as shown in FIG. 9 . Adjacent rod clip stands 10 in the chain 40 are interconnected by sprues 42 as best seen in FIG. 10 . With continued reference to FIG. 10 , individual chains 40 may be nested together to form a sheet 44 of rod clip stands 10 . Multiple sheets 44 of rod clip stands 10 may be readily stacked together and packaged for storage and shipping.
[0026] The simple unitary design is lightweight, using about significantly less material of conventional rebar support chairs. While the number of rod clip stands 10 in a chain 40 may vary, it is presently preferred to include sixteen (16) individual rod clip stands 10 in a chain 40 . These chains 40 can be nested into a sheet 44 . Multiple sheets 44 may be stacked on top of one another to form a cube for compact storage and reduced shipping cost. For example, over 450 chains or more than 7200 rod clip stands may be nested and stacked so as to fit into a standard 2 ft×2 ft×2 ft box. One or more chains 40 can be carried on a belt so that a reinforcing ironworker or rod buster can quickly and efficiently fabricate a lattice or grid structure using these rod clip stands.
[0027] In this configuration, the rod clip stand 10 can be used in a quick and efficient manner. For example, the reinforcing ironworker or rod buster may secure one to several chains 40 of rod clip stands 10 to a belt or other garment. Once a rebar grid is laid out, the rod buster simply breaks off a rod clip stand 10 and drops it down on top of rod element 14 so that it sits in the third concaved surface 24 s of the arched portion 22 . Next, rod element 12 is held up against rod element 14 and the rod clip stand 10 is slid into engagement with rod element 12 and rotated clockwise as shown in FIG. 5 ) so that it captures rod element 12 in the first and second concaved surfaces 18 s, 20 s of the cradle portion 16 for securing rod elements 12 , 14 together. So secured, the rod elements 12 , 14 can be positioned on leg potions 30 , 32 in a spaced relationship from a floor or other support surface.
[0028] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. In addition, one skilled in that art will appreciate that the shape and size of the embodiment may be varied to accommodate different types of rod elements. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents.
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A rod clip stand is disclosed which is configured to releasably secure and retain a pair of rods in a perpendicular orientation. The rod clip stand has a cradle portion supporting a first rod and an arched portion supporting a second rod. The rod clip stand is particularly well suited for fabricating a rebar grid used to reinforce concrete flatwork.
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BACKGROUND OF THE INVENTION
This invention relates generally to spark plugs for internal combustion engines, and particularly to the construction of ground electrodes for such spark plugs.
RELATED ART
Spark plugs for use in internal combustion engines typically have a center electrode and a ground electrode with a predefined gap therebetween. It is desirable to maintain the predefined gap distance so that a predictable and repeatable spark can arc between the two electrodes. To improve the useful life of a spark plug, it is known to incorporate precious metals, i.e. iridium-based alloys, platinum alloys, or other precious metals, on the electrodes to maintain the predetermined gap and to resist erosion in use. To ensure that the precious metal maintains the desired gap, it is beneficial to secure the precious metal to the electrode such that the precious metal does not become dislodged or move from its fixed position. To further maintain the desired gap, it is desirable to maximize the surface area of the precious metal exposed to the gap. As disclosed in U.S. Pat. No. 4,771,210 to K. Möhle et al., it is known to insert an electric discharge pad or firing tip in a through bore of a ground electrode and either laser or argon arc weld the firing tip to the electrode. Further, this patent discloses applying a radial load through opposite sides of the ground electrode perpendicular to an axis of the bore to plastically deform the ground electrode inwardly toward the firing tip in a pinched fashion to capture the firing tip.
SUMMARY OF THE INVENTION
A spark plug for an internal combustion engine has a ground electrode disposed adjacent a central electrode defining a spark gap therebetween. The ground electrode has a through hole extending axially toward the center electrode at the spark gap. A firing tip having a longitudinal axis is received at least in part in the through hole and the firing tip is compressed axially along its longitudinal axis to define a bulging portion extending radially outwardly from the longitudinal axis to mechanically retain the firing tip within the through hole.
In accordance with another aspect of the invention, there is provided a spark plug and a ground electrode therefore in which a firing tip is mechanically interlocked within a through hole in the ground electrode by engagement of an enlarged head or otherwise expanded portion of the firing tip with an outer surface of the ground electrode at each end of the firing tip.
Yet another aspect of the invention provides a method of constructing a ground electrode for a spark plug. The method includes providing a segment of metal wire and forming a through hole extending between generally opposite surfaces of the wire. A firing tip having a longitudinal axis is inserted within the through hole and then compressed along its longitudinal axis to mechanically secure the firing tip within the through hole.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred exemplary embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements, and wherein:
FIG. 1 is a fragmentary cross-sectioned view of a spark plug constructed according to one embodiment of the invention;
FIG. 2A is an enlarged fragmentary view of the spark plug of FIG. 1 showing a firing tip partially assembled to a ground electrode of the spark plug of FIG. 1 ;
FIG. 2B is a view similar to FIG. 2A with the firing tip fully assembled to the ground electrode; and
FIG. 3 is a view similar to FIG. 2B showing an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A fragmentary view of a spark plug constructed according to one presently preferred embodiment of the invention is shown in FIG. 1 generally at 10 . The spark plug 10 has a metal shell or housing 12 with a ground electrode 14 extending therefrom. The ground electrode 14 is generally L-shaped and extends from a first end that is welded to shell 12 to a second free end 16 . An electric discharge pad or firing tip 18 is received at least in part in a through hole 20 extending through the ground electrode 14 generally adjacent the free end 16 . The firing tip 18 is mechanically retained within the through hole 20 by compressing the firing tip 18 axially along a longitudinal axis 22 to deform it radially and establish an interference fit between the firing tip 18 and the bore 20 . To further secure the firing tip 18 to the ground electrode 14 , the firing tip 18 is preferably welded to the ground electrode 14 .
The spark plug 10 includes a number of other components that can be made and assembled in a conventional fashion. This includes a center electrode assembly 24 and insulator 36 . The center electrode assembly 24 has a center electrode 25 extending along a central axis 26 of the spark plug 10 and can include additional components (not shown) such as one or more conductive, non-conductive, or resistive glass seals, capsule suppressors and an associated compression spring, as well as a terminal attached to the top end of the insulator 36 . The center electrode 25 has a firing tip or electrical discharge member 28 extending from an end 30 of the center electrode 24 and terminating at a firing end 32 . The firing end 32 of the center electrode firing tip 28 and an upper surface 34 of the ground electrode firing tip 18 define a spark gap of a predetermined distance. It is desirable to maintain the predetermined gap throughout the life of the spark plug 10 so that its performance will not degrade significantly. Insulator 36 is secured within a central bore 37 of the housing 12 . The insulator 36 in turn includes a longitudinal bore in which center electrode assembly 24 is located.
As best shown in FIG. 2A , the firing tip 18 is partially assembled within the through hole 20 of the ground electrode 14 . The ground electrode 14 is preferably fixed to the housing 12 , such as through a resistance weld joint, and is preferably straight, and not yet bent into the L-shaped configuration shown in FIG. 1 . In addition, the casing 12 and ground electrode 14 are preferably coated, for example with nickel or a nickel-based alloy, prior to inserting the firing tip 18 into the through 20 . The ground electrode 14 , has an upper surface 38 and a lower surface 40 generally parallel to one another with the through hole 20 extending between the upper and lower surfaces 38 , 40 . Preferably, a counterbore 42 is formed and extends from at least one of the upper and lower surfaces 38 , 40 , shown here as the lower surface 40 of the ground electrode 14 , into the through hole 20 about 0.005–0.010″. The counterbore 42 is shown having a tapered surface that is oblique relative to the upper surface 38 , and preferably has a chamfer of about 15°–25° relative to axis 22 , though it should be recognized other configurations may be desirable, for example a generally stepped configuration. The ground electrode 14 is preferably constructed from a nickel-based material, for example and without limitation, an Inconel or 836 alloy, and can be made with or without a copper core. With the through hole 20 formed in the ground electrode 14 , the firing tip 18 is inserted within the through hole 20 .
The firing tip 18 has an end 46 generally opposite the end 34 wherein a first length, represented as (L 1 ), is defined between the ends 34 , 46 prior to the firing tip 18 being compressed. Preferably, the end 34 has an enlarged head 48 for abutting the upper surface 38 upon inserting the firing tip 18 into the through hole 20 . As shown in FIG. 2A , the end 46 of the firing tip 18 extends below the lower surface 40 of the ground electrode 14 preferably about 0.030″–0.040″ prior to compressing the firing tip 18 within the bore 20 .
Upon inserting the firing tip 18 at least in part within the through hole 20 , the head 48 is preferably maintained in contact with the upper surface 38 , while the end 46 is axially compressed along the longitudinal axis 22 to define a flared portion 50 of the firing tip 18 ( FIG. 2B ). Preferably, the head 48 is backed-up by a generally fixed surface while compressing the end 46 of the firing tip 18 generally toward the head 48 along the axis 22 . Generally, the axial force to compress the firing tip 18 is in a range of about 300 lbs.–380 lbs., and preferably within a range of 320 lbs.–360 lbs. This axial compression of the firing tip 18 expands the firing tip material at end 46 outwardly to thereby form the flared portion 50 . Upon completing the compression of the firing tip 18 , the firing tip 18 has a second length, wherein the second length, represented here as (L 2 ), is shorter than the first length (L 1 ) of the firing tip 18 . Preferably, the end 46 is compressed to a degree such that it is generally flush with the lower surface 40 . The head 48 preferably presents an enlarged surface area having a diameter of approximately 0.120″–0.125″ to further enhance maintaining the gap and thus, extending the life of the spark plug 10 .
The enlarged head 48 and flared portion 50 form a first mechanical interlock. These features 48 , 50 together retain the firing tip 18 in position by abutting opposing surfaces of the ground electrode. In addition to this first mechanical interlock, a bulging portion 51 is also formed during the compression operation. The bulging portion 51 is located generally between the head 48 and the flared portion 50 of the firing tip and bulges, or extends, radially outwardly about 0.005″–0.010″ on the radius. The bulging portion 51 further retains the firing tip 18 in position by creating additional interference (i.e., a second mechanical interlock) with the ground electrode 14 within the through hole 20 . Either this first mechanical interlock or the second mechanical interlock, or both, can be used without departure from the scope of the invention.
In the alternate embodiment shown in FIG. 3 , similar features as the embodiment above are given similar reference numerals, but are offset by 100 . A firing tip 118 is inserted within a generally straight through hole 120 and, upon being compressed, another head 52 is formed generally opposite a head 148 such that the head 52 defines a spaced or enlarged portion 150 to mechanically retain the firing tip 118 within the bore 120 . Otherwise, the embodiment shown in FIG. 3 functions similarly as the embodiment of FIG. 2B and preferably includes a bulging portion 151 that extends radially into a widened center portion of through hole 120 .
Upon compressing the firing tip 18 , 118 within the bore 20 , preferably the firing tip is welded to the ground electrode 14 , 114 to provide yet another redundant interlocking of the firing tip 18 within the bore 20 . Preferably, a resistance weld is used to impart a weld joint between the ground electrode 14 , 114 and the firing tip 18 , 118 in both the area of the head 48 , 148 and the compressed or coined end 46 , 146 . Other suitable welding processes may be used to impart the weld joint, for example, a laser welding process can be used to form a stitch around the head 48 , 148 .
Once the firing tip 18 , 118 is permanently attached to the through hole 20 , 120 and the ground electrode 14 , 114 is attached to the spark plug shell 12 , the gap can be established between the end 34 , 134 of the firing tip 18 , 118 and the firing end 32 of the electrical discharge member 28 by bending the ground electrode 14 , 114 to the generally L-shape form. With the firing tip 18 , 118 mechanically retained, the gap can be maintained and the life of the spark plug 10 can be extended in use. To further enhance the useful life of the spark plug 10 , it should be recognized that the firing tip 18 , 118 is constructed from materials that resist erosion, for example iridium based materials, platinum based materials, and the like.
Although disclosed embodiment of firing tip is cylindrical, it will be understood that it can have other cross-sectioned shapes, including oval or other curved shapes or rectangular or other polygonal shapes, and that in such instances the term “radial” and its other forms do not require a cylindrical or curved shape but instead refer to a direction orthogonal to longitudinal axis of the tip.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. The invention is defined by the claims.
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A ground electrode for a spark plug has a through hole located adjacent a firing end of the electrode, with a precious metal firing tip extending through the hole. The firing tip is compressed axially to define a bulging portion extending radially outwardly from its longitudinal axis to mechanically retain the firing tip within the through hole. The firing tip additionally has an enlarged head or otherwise expanded portion at each axial end of the tip to provide a second mechanical interlock of the tip to the ground electrode. The firing tip can then also be welded to further strengthen its connection to the ground electrode. A method of manufacturing the ground electrode and a spark plug containing the ground electrode is also disclosed.
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BACKGROUND OF THE INVENTION
The present invention relates to an electronic musical instrument, and in particular to a waveform synthesizing circuit for both producing the synthesized waveform and keying it with the desired envelope.
At the present time, drum sounds, such as bass drums, congas, and the like, are simulated in electronic organs by driving a ringing oscillator with a pulse input. A ringing oscillator is basically a high Q filter or underdamped oscillator, and when it is excited by a pulse input, it rings or oscillates for a brief period of time. The output of this type of circuit is essentially a damped sinusoid waveform having a relatively fast attack and a more gradual decay and having a duration appropriate to the particular rhythm instrument being simulated.
The problem with this type of circuit is that if the Q is set too high, the circuit will become less damped and will tend to oscillate. The sound produced by circuits of this type sound more pleasing when the Q is set as high as possible, and as long as the circuit elements remain within tolerance and are not subjected to excessive temperature conditions, the circuit will perform satisfactorily. As the circuit element tolerance changes and temperature conditions vary, however, the circuit can drift into an oscillatory condition, which produces a very unpleasing howling or humming sound. In order to avoid this condition, most damped sine wave circuits of this type are set to be damped more than is desirable to obtain an optimum sound and the simulation of the percussion instruments in question is correspondingly affected. A further problem is that the circuits are generally made of discrete components which vary from unit to unit and the sound character produced by the units will not be uniform.
Another prior art circuit employed to produce certain percussion sounds comprises generating a square wave in synchronism with a pulse from the rhythm unit counter or ROM output, and a square wave signal is then appropriately filtered to produce a damped sine wave. Difficulty with this type of circuit is that, depending on when the leading edge of the pulse from the rhythm unit occurs in relation to the square wave pulse train, a different sound will be produced. The differences in resultant sound occur primarily to differences in the attack portion of the waveform, which is a function of the relationship between the rhythm pulse and the square wave pulse train.
Although the particular embodiment of the present invention disclosed hereinafter is a circuit for producing a damped sine wave suitable for use in the production of certain drum and other percussion instrument sounds, the invention also relates to other types of waveforms, such as reeds, violins and the like.
Typically, the tones produced by an electronic musical instrument are initially generated by a tone generator, which produces a plurality of tones spanning the entire range of the musical instrument. These tones are then connected to the tone inputs of individual keyers that have control inputs adapted to receive keying signals initiated by depressing keys of the keyboard or from an automatic easy play feature, such as a musical rhythm accompaniment system. The keying signals are often in the form of long duration pulses that are appropriately filtered to impart exponential-type attack and decay leading and trailing portions. The keying signals directly control the amplitude of the tones keyed by the keyers, and by varying the attack and decay characteristics, a wide variety of percussive and sustain-type instruments can be simulated.
A second type of tone generation and keying, which is commonly referred to as digital tone synthesis, comprises storing in a memory a digital representation of the actual waveshape. The digitized and stored waveshape is then read out repetitiously at a particular frequency and converted to analog form to produce the musical note, with the rate at which the waveshape is read out determining the frequency of the resultant tone. Attack and decay are controlled digitally, as by the addition and subtraction of scaling factors.
Both in the keyed oscillator and digital synthesis techniques for tone generation, it is necessary to key the tone to the output with an attack and decay appropriate to the particular instrument being simulated. Although the keying in the digital synthesis technique is usually handled by a pure digital technique, the keyed oscillator systems have often relied on percussive and sustain envelope generators wherein external RC timing circuits are employed. To avoid the necessity for external discrete elements, switched capacitor techniques have been used to produce the keying envelope wherein a pair of alternately switched electronic switches having a capacitor connected to their juncture incrementally transfer the voltage from the input to the output. The advantage to the switched capacitor technique is that it can be fully integrated thereby avoiding the necessity for external timing capacitors. The use of such a circuit in a sustain-type keyer is disclosed in U.S. Pat. No. 4,205,581, and a percussion-type keyer utilizing this technique is disclosed in U.S. Pat. No. 4,205,582. Each of these two patents is expressly incorporated herein by reference.
SUMMARY OF THE INVENTION
The present invention relates to a waveform synthesis system wherein both the waveform amplitude envelope and the waveform itself are generated by a switched capacitor technique. This permits the entire circuit to be completely integrated with the pulse or DC level keying signal being connected to a control input and one or more clocking signals connected to the respective clocking inputs for driving the switched capacitor filters.
Rather than storing the waveform in a memory as in the prior art digital synthesis techniques, the waveform is produced by filtering a series of amplitude steps through a switched capacitor filter and controlling the clocking frequency of the filter to produce waveform segments having varying slopes. Thus, either simple or very complex waveforms can be generated totally internally of the chip and without the necessity for a separate tone input.
The specific embodiment of the invention disclosed comprises a circuit for generating a damped sine wave signal characteristic of certain percussion instruments, such as drums and clave. The control input comprises a DC level shift, such as a pulse, making a transition from one voltage level to another during attack and then making the opposite transition during decay. This DC level change is converted to a pair of envelope waveforms having the appropriate exponential attack portions by means of a first pair of switched capacitor filters. The filters are driven by an attack clock during the attack portion and by a decay clock during the sustain portion, and a positive going envelope and a negative going envelope are produced.
A chopping circuit alternately selects the positive going and negative going envelopes to produce a series of bipolar pulses having amplitudes which follow the amplitudes of the envelopes and which have a frequency equal to the chopping frequency. This signal is then passed through a second switched capacitor filter having a variable frequency clocking input. The amplitude of each pulse is incrementally transferred from the input to the output of the second switched capacitor filter to produce a plurality of discrete amplitude steps generally following the amplitudes of the individual pulses but having a shape dictated by the frequency at which the second filter is clocked.
The waveform generating filter produces the waveform corresponding to each pulse in a plurality of segments wherein the aforementioned discrete steps for each segment are produced at a rate dictated by the clocking frequency. By varying the clocking frequency, the duration of each step can be altered so that the rate of change of slope of each segment is controlled. This permits each half cycle of the resultant waveform to be incrementally synthesized, and since the controlling pulses are bipolar, the same frequency relationship is used for the negative half of the sine wave.
The resultant sine wave will have an amplitude that varies with the keying envelope produced by the first-mentioned pair of switched capacitor filters and will comprise a plurality of discrete amplitude steps. A smoothing filter, which is also of the switched capacitor type, smooths out the waveform to produce a conventional damped sinusoid wave. The smoothing filter is clocked by the same clocking frequency used to generate the sine wave so that the filter will track the frequency of the tone being produced.
As indicated earlier, the circuit according to the present invention can be utilized to produce a wide variety of different wave shapes, even those which are continuously keyed from the keyboard. The "musical waveform" which is produced may be a conventional tone such as a violin, flute, piano and the like, or a percussion instrument such as a drum or clave. The circuit is intended to be completely integrated thereby avoiding the necessity for a separate rhythm unit, as is typical in most prior art electronic organs.
Specifically, the present invention relates to a waveform and envelope generation circuit for an electronic musical instrument comprising means for producing a keying signal for calling forth a desired musical waveform, and an envelope generator responsive to the keying signal for producing on an output an envelope waveform. The envelope generator includes an input connected to the keying signal and an output and charge pump means for incrementally transferring voltage on the input to the output under the control of a first clocking signal. A tone generator having an input operatively connected to the envelope generator is responsive to the envelope waveform and produces a cyclic musical waveform having an envelope following the envelope waveform. The tone generator comprises a charge pump means for repetitively and incrementally generating a complete cycle of the musical waveform under the control of a second clocking signal wherein each cycle of the musical waveform has an amplitude determined by the envelope waveform.
In accordance with another aspect of the invention, the envelope generator produces a series of pulses having respective amplitudes that follow a time varying envelope, and the tone generator incrementally transfers the amplitude of each pulse to its output under the control of its clocking signal whereby the pulse at the input of the tone generator is shaped into a portion of a musical waveform and the amplitude of the musical waveform generally follows the time varying envelope.
The invention also relates to a method for producing a tone of a desired frequency and having a given amplitude envelope comprising generating a keying signal, and incrementally producing a time varying envelope waveform in response to the keying signal wherein the envelope signal comprises a plurality of amplitude steps collectively following the given amplitude envelope. A musical waveform is produced in response to the steps of the envelope waveform by incrementally generating a plurality of musical waveform amplitude steps in response to each step of the envelope waveform, and the resultant musical waveform comprises a plurality of cycles wherein each cycle comprises a plurality of discrete amplitude steps. The discrete amplitude steps in the musical waveform are subsequently smoothed by a filter.
It is an object of the present invention to provide a tone synthesizing system wherein both the keying envelope and the waveform itself are generated internally without the necessity for an external tone generator of keying envelope.
It is a further object of the present invention to provide a tone synthesizing and keying system that is capable of being completely integrated without any external timing capacitors.
A still further object of the present invention is to provide a tone synthesizing and keying circuit that does not require a memory to store the resultant waveform and the attack and decay scaling factors.
These and other objects and features of the present invention will become apparent from the detailed description, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a portion of an electronic organ including rhythm control system circuitry;
FIG. 2 is a block diagram of the keyer control and clock generating circuit;
FIG. 3 is a block diagram of the tone synthesizer and keyer of the present invention;
FIGS. 4, 5 and 6 together form a detailed circuit schematic of the tone synthesizer and keyer;
FIG. 7 is a diagram of a half cycle of the stepped sine wave signal;
FIG. 8 is a diagram of one full cycle of the filtered sine wave; and
FIGS. 9A-9E are diagrams of certain waveforms produced by the system.
DETAILED DESCRIPTION
Referring now in detail to the drawings, FIG. 1 illustrates a fairly conventional rhythm programming section comprising a rhythm program read only memory 10 addressed by the outputs 12 of read only memory 14, wherein the thirty-two parallel lines of ROM 10 are sequentially addressed by the respective thirty-two input lines 12. The clock train for addressing ROM 10 is connected over input 15 to the rhythm control logic block 16, which receives a rhythm on/off control signal on line 18 and a 3/4 pattern control on line 20. Rhythm control logic block 16 is conventional in operation and produces on output 22 a low frequency rhythm clock train, the inversion of which is illustrated in FIG. 9A. The rhythm clock train on line 22 drives counter 24, and counter 24 also receives a rhythm reset control on line 26 and the 3/4 control on line 28, the latter causing counter 24 to delete certain counts if a 3/4 pattern is selected.
Counter 24 produces on outputs 30 a plurality of five bit binary words which are decoded by ROM 14 to thereby sequentially activate the output lines 12 as described above. Pattern select ROM 32, which is controlled by a four bit binary word on inputs 34, selects one of the patterns stored in ROM 10, and output pulses appear on the instrument output lines 36 for certain of the rhythm instruments, such as the snare drum, brush, and cymbal and other control pulses such as strike, rhythm repeat and musical rhythm accompaniment. Collector ROM 38 collects the outputs from rhythm program ROM 10, and enable blocks 40 and 42 produce the appropriate rhythm output pulses on outputs 44 when they are strobed by strobe pulses on inputs 46 and 48. The strobe pulses on lines 46 and 48 are generated by one shots 50 enabled by the rhythm on/off signal on line 18 and the rhythm clock signal on line 52.
Three additional outputs 54 from collector ROM 38 pertain to primarily drum-type rhythm voices, such as a bass drum, low conga and high conga. The output on one of lines 54 is shown in FIG. 9B in response to the activation of that particular line in ROM 10 for the patterns selected. Line 54 is connected to one of the inputs of AND gate 56 (FIG. 2) and the other input 58 is connected to the output of monostable 60, which is clocked by the rhythm clock pulse train on line 62. Strobe circuit 64 comprising NOR flip-flop 66 and D-type flip-flops 68, 70 and 72, produces an instrument strobe pulse on output line 74, and as shown in FIGS. 9A and 9C, this strobe pulse 76 coincides with the trailing edge of the rhythm clock pulse 78.
The control circuitry of FIG. 2 comprises an attack/decay polynomial counter 80 of conventional design and clocked by the two megahertz clocking signal on line 82. Polynomial counter 80 is reset by the instrument strobe pulse on line 74 and its divide counts are selected in a conventional fashion by program lines 84 to produce an output line 86 a clock train having the desired frequency. Lines 84 are selected according to the particular instrument channel to which the tone synthesizer in question pertains so that the attack and decay clock signals will have the appropriate frequency. As discussed earlier, the switched capacitor type technique used for generating the amplitude envelope is controlled by the frequency at which it is clocked, and if a particular instrument requires a longer attack or sustain, for example, polynomial counter 80 would be programmed to produce a clocking train on line 86 having a lower frequency. If a faster sustain or attack is required, then the outputs of counter 80 would be decoded to produce a clocking train having a higher frequency. Decode control lines 84 may be factory set or, in the case where the particular rhythm channel can be employed for producing more than one rhythm instrument, they would be programmed depending on the pattern selected through pattern select ROM 32.
The control circuitry of FIG. 2 also includes a clock counter and logic block 88 having control inputs 90, which perform basically the same function as inputs 84, and outputs 92 and 94 connected to polynominal counter 80. Output 92 causes counter 80 to produce an attack clock signal on line 86 during the attack portion of the keying signal, and output 94 programs counter 80 to produce a decay clock signal on line 86 during the decay portion. The output on line 92 is a pulse 96 illustrated in FIG. 9D, which initiates during the occurrence of strobe 76 and terminates an interval of time later depending on the programming selected by line 90. Attack/decay control pulse 96 is connected to the tone synthesizer and keyer circuit of FIG. 3 over line 98. Basically, the attack/decay control pulse 96 on line 98 is simply a rhythmically occurring pulse on the rhythm instrument channel in question which occurs each time the instrument, such as a bass drum, is to be sounded. Depending on the particular instrument, the pulse 96 may be wider or narrower. As an alternative to the circuitry of FIG. 2, the activating pulse for the rhythm unit could be produced by conventional rhythm unit circuitry with pulse stretching techniques utilized to produce the proper pulse width. In the system disclosed, however, multiple use is obtained from the circuitry and is therefore more efficient from a chip usage standpoint. For example, the same polynomial counter 80 is utilized to generate the attack and decay pulse trains on line 86 in an alternating fashion, and because counter 80 is fully programmable, the rhythm channel can be programmed for more than one rhythm instrument.
Referring now to FIG. 3, the tone synthesis and amplitude envelope generation circuit of the present invention will be described. The attack and decay control signal 96 (FIG. 9D) is connected to the control gates of conventional bidirectional transmission gates 100 and 102 and through inverter 104 to the control terminals of similar bidirectional transmission gates 106 and 108. Transmission gates 100, 102, 106 and 108 are completely conventional in nature and may comprise, for example, field effect transistors. The input 110 of gate 100 is connected to a positive DC voltage, such as plus five volts, and its output is connected to the input 112 of charge pump circuit 114. The input 116 of transmission gate 106 is connected to ground potential and its output is also connected to the input of charge pump circuit 114. The input 118 of transmission gate 102 is connected to a negative DC voltage, such as minus 5 v., and its output 120 is connected to the input of a second charge pump circuit 122. The input 124 of transmission gate 108 is connected to ground potential and its output 126 is also connected to the input of charge pump 122.
When the attack/decay control signal on line 98 goes to a logic 1, transmission gates 100 and 102 are rendered conductive so that the positive and negative voltage inputs, respectively, are connected to the inputs of charge pumps 114 and 122. At the same time, inverter 104 causes gates 108 and 106 to be disabled. When the attack/decay control pulse 96 on line 98 goes back to a logic 0 thereby initiating decay, gates 100 and 102 are disabled and gates 106 and 108 are rendered conductive so that ground potential is applied to the inputs 112 and 120 of charge pumps 114 and 122.
Charge pumps 114 and 122, which will be described in detail hereinafter, are clocked by the same clock train on line 86, which clock train is either the attack frequency or the decay frequency, depending on the control of counter 80 (FIG. 2). Charge pump 114 incrementally transfers the positive voltage on input 112 to its output 128 as it is clocked, and the output waveform 130 is illustrated in FIG. 3. As will be seen, the waveform makes a transition from ground potential to the positive voltage level on its input in an exponential fashion and in a plurality of discrete amplitude steps. Similarly, charge pump 122 incrementally transfers the negative voltage on its input 120 to its output 132 as it is clocked by the pulse train on its clocking input 134. The output waveform 136 is illustrated in FIG. 3 and it will be seen to make a transition between ground potential to the negative voltage potential in an exponential fashion and then hold at the negative voltage until the initiation of decay. Like waveform 130 waveform 136 comprises a plurality of discrete amplitude steps characteristic of charge pump outputs. Charge pumps 114 and 122 are basically of the type disclosed in the aforementioned U.S. Pat. No. 4,205,581.
An additional pair of transmission gates 138 and 140 are alternately enabled by the output from divider 142, which is driven by the F1 select output 302 of clock counter 146. Counter 146 is clocked by the clock signal on line 148 from programmable divider 150, which is driven by the high frequency clock train on line 152. Due to the action of the divided output of programmable divider 150, gates 138 and 140 are alternately rendered conductive so that the positive and negative outputs 130 and 136, respectively, of charge pumps 114 and 122 are selected in an alternating fashion. This produces a series of bipolar pulses 156 at the juncture 158 of transmission gates 138 and 140. As will be seen, the amplitudes of the individual pulses increase with time in accordance with the envelopes 130 and 136.
When the attack/decay control pulse 96 returns to logic 0, transmission gates 100 and 102 will be disabled and gates 106 and 108 enabled so that the ground potential on the inputs 112 and 120 of charge pumps 114 and 122 will be incrementally transferred to their outputs 128 and 132 in an exponential fashion. FIG. 9E illustrates the output wave shape 130 of charge pump 114.
The chopped output 156 of charge pumps 114 and 122 is connected to the input of sine wave generator charge pump 168, which is clocked by the pulse train on line 148 from the output of programmable divider 150. Programmable divider 150 produces three different output frequencies on line 148 depending on the frequency select line 302, 304 or 300 which is activated. Clock counter 146, which is clocked by the output 148 of programmable divider 150 counts a predetermined number of frequency F1 outputs from divider 150 then activates the frequency F3 select line 300 and counts a predetermined number of F3 frequency pulses, and then activates line 304 and counts a predetermined number of F2 pulses before reactivating line 302, which again selects the F1 pulse output from programmable divider 150.
Charge pump 168 incrementally transfers the amplitude peaks of each of the pulses in the chopped envelope waveform 156 to its output 164 to produce the waveform 166 illustrated in FIG. 7. Clock counter 146 selects the lowest frequency F1 for two steps as illustrated in FIG. 7, then selects the next highest frequency F3, which is four times the frequency of F1 for fifteen steps to produce the intermediate portion of waveform 166, and then selects F2, which is the highest frequency eight times as great as F1, for the final forty-five steps of the waveform. As will be seen from FIG. 7, as F1, F3, and F2 are selected, the shape of the respective segments 170, 172 and 174 will change. Specifically, the relative magnitudes of the rates of change of slope, that is, the values without regard to whether the slopes are positive or negative, of the segments 170, 172 and 174 are different, and the lengths of the segments differ as well. The net result of these three segments is exactly one half cycle of a sine wave making the transition from the most negative peak to the most positive peak.
What has been done is to utilize the charge pump technique to incrementally transfer the positive amplitude of the positive going pulses 156 to the output 164 in three segments wherein the clocking frequency for the three segments is varied depending on the wave shape desired. In a similar fashion, the negative amplitudes of the negative going pulses 156 are also transferred incrementally by cycling through the F1, F3 and F2 frequencies. Of course, if waveforms other than a sine wave are desired, the number of segments and the respective frequencies for them would be varied accordingly. The actual frequency utilized will depend on the type of tones which are desired, but the abovedescribed step and frequency relationship between the three segments in question has been found satisfactory for a damped sine wave simulating a drum. As will be noted, the frequencies for producing the steps of waveform 166 have a direct relationship to the frequency utilized for chopping the envelope output 130, and this last frequency is determinative of the frequency of the sine wave tone. Accordingly, once the frequency of the desired tone is determined, the other frequencies can easily be selected.
The output 164 of sine wave generator 168 is then connected to a switched capacitor filter for smoothing out the steps of waveform 166 thereby producing the conventional sine wave 176 illustrated in FIG. 8.
Referring now to FIGS. 4, 5 and 6, the details of the circuitry will be described. As discussed earlier, the outputs of transmission gates 100, 106, 102 and 108 are connected to the inputs of charge pumps 114 and 122. Charge pump 114 comprises a pair of bidirectional transmission gates 178 and 180 connected in series with each other and in series with the output of transmission gate 100 and the input of emitter-follower 182. A 0.001 microfarad capacitor 184 is connected between the juncture of transmission gates 178 and 180 and ground, and a 0.082 microfarad capacitor 186 is connected to the output of transmission gate 180 and ground potential. Transmission gates 178 and 180 are rendered conductive alternately by NOR RS flip-flop 188, which is driven by the attack or decay clock train on line 86. As described in detail on the aforementioned U.S. Pat. No. 4,205,581, charge pump 114 incrementally transfers the voltage level on the output of transmission gate 100 to the input of emitter-follower 182 as a plurality of discrete amplitude steps which generally follow an exponential pattern. If gate 100 is enabled, this causes a transition from ground potential to a potential of positive five volts, and if gate 106 is enabled, this results in a transition from the previous level of positive five volts to ground potential, as illustrated in FIG. 9E.
Charge pump 122 for the negative portion of the envelope comprises bidirectional transmission gates 190 and 192, which are connected in series with each other and with the output of transmission gates 102 and 108 and the input of emitter-follower 194. A 0.001 microfarad capacitor 196 is connected between the juncture of gates 190 and 192 and ground potential, and a second 0.082 microfarad capacitor 198 is connected between the output of transmission gate 92 and the ground. Gates 190 and 192 are similarly rendered alternately conductive by RS flip-flop 188 and function to incrementally transfer either the negative five volt input or the ground potential input to gate 190 to the input of emitter-follower 194.
Transmission gates 138 and 140 are rendered alternately conductive by RS flip-flop 200, which is driven by the Q output 202 of D-type flip-flop 142. Flip-flop 142 is driven by the F1 select signal on clocking input 204. A positive trigger signal is developed from the Q output on line 206. As discussed earlier, gates 138 and 140 function to produce a series of bipolar pulses at the desired sine wave output frequency wherein the amplitudes of the respective pulses generally follow the amplitudes of the keying envelopes 130 and 136.
Referring now to FIGS. 5 and 6, synchronous counter 208 of the aforementioned programmable divider 150 is driven by the high frequency clock train on line 152 and produces a low frequency F1 on output 210, an intermediate frequency F3 on output 212 and the highest frequency F2 appears on line 214. Outputs 210, 212 and 214 are connected to one of the inputs of NOR gates 216, 218 and 220, respectively, the outputs of which are summed by NOR gate 222 and fed through transistor buffer and invertor circuit 224 to RS flip-flop 226. The other input of NOR gate 216 is connected through inverter 228 to input line 300, the other input of NOR gate 218 is connected through inverter 230 to frequency select line 304, and the other input of NOR gate 220 is connected through inverter 232 to frequency select line 302.
As shown in FIG. 6, the selected frequency on line 148 is connected to the clocking input 234 of 74164 polynominal counter 236, the outputs of which are decoded by decoder matrix 238. Matrix 238 decodes the outputs of polynomial counter 236 to count either the F3, F2 or F1 pulse train on line 148 and produce a decode pulse on line 240, depending on whether transmission gate 242, transmission gate 244 or transmission gate 246 is enabled by the decode inputs on lines 162, 160 or 144, respectively. This decode pulse is connected to the D input of flip-flop 248, which is clocked by the clock train on line 250 connected over line 148 to the output of the frequency select circuit illustrated in FIG. 5. The Q output 252 of flip-flop 248 is connected to the clocking inputs of D-type flip-flops 254, 256, and 258, and the Q output is connected over line 260 to the clear input of polynomial counter 236. The outputs of flip-flops 254, 256 and 258 are decoded by matrix 262 to produce on lines 144, 160 and 162 the F1, F2 and F3 decode signals. These lines are connected to the control terminals of transmission gates 242, 244 and 246 in FIG. 6. The Q outputs of flip-flops 254, 256 and 258 produce on lines 300, 302 and 304 the F1, F2 and F3 select signals. These lines are connected to the inputs of invertors 228, 232 and 230 in FIG. 5.
The above circuitry functions to clock the sine waveform generator 168 at three successive frequencies for each of the pulses 156, whether positive going or negative going. The frequency at which the charge pump 168 is clocked is determined by the frequency select signals on lines 300, 302 and 304, and the number of steps for each segment at the respective frequency as determined by the decode outputs 144, 160 and 162 of flip-flop 254, 256 and 258.
Sine wave charge pump 168 comprises a pair of bidirectional transmission gates 270 and 272, which are connected in series with each other and in series between the combined outputs 274 of transmission gates 138 and 140 (FIG. 4) and the input of emitter-follower 276. A 100 picofarad capacitor 278 is connected between the juncture of transmission gates 270 and 272 and ground potential, and a 0.0022 microfarad capacitor 280 is connected between the output of transmission gate 272 and ground. Transmission gates 270 and 272 are alternately rendered conductive by RS flipflop 226 which, as has been described above, is driven by the selected frequency from the outputs of type 40161 synchronous counter 208.
Charge pump 168 functions to incrementally transfer the voltage peaks for both the positive going and negative going pulses 156 to the output in a plurality of discrete amplitude steps wherein the initial segment beginning with either the most negative or most positive peak comprises two steps, the next segment comprises fifteen steps at a frequency four times as high, and the final segment extending to the next peak of the cycle comprises forty-five steps at a frequency eight times as high as the frequency for the first two steps. The resultant waveform 280 has the shape shown above output line 164 in FIG. 5, which is typical of a conventional damped sine wave. Although not evident from FIG. 5, the sine wave comprises a plurality of discrete amplitude steps as illustrated in FIG. 7. The resultant segments have changing slopes that change at different rates to provide the desired waveform.
Output line 164 is connected to smoothing filter 282, which comprises a pair of bidirectional transmission gates 284 and 286 connected in series with each other and in series between output lines 164 and the input of emitter-follower 288. A 100 picofarad capacitor 290 is connected between the juncture of transmission gates 284 and 286 and ground potential, and a 0.0082 microfarad capacitor 292 is connected between the output of gate 286 and ground. Gates 284 and 286 are alternately rendered conductive by RS flip-flop 294 which is driven by the pulse train on line 296 connected to the F2 line 214 by line 297, which is the clocking frequency on line 152.
Output filter 282 is a smoothing filter which functions to eliminate the discrete steps in the output waveform 280 and produce the smooth sinusoidal waveform illustrated in FIG. 8. Since filter 282 is clocked by a frequency that is related to the frequencies used for generating the sine wave output from waveform generator 168 (FIG. 5), filter 282 tracks the frequency of the waveform in question, a condition which is particularly desirable when filtering sine waves.
The output 298 from emitter-follower 288 carries the filtered sine wave, and this output may be connected to additional voicing circuitry or to the output amplifiers for the organ.
While this invention has been described as having a preferred design, it will be understood that it is capable of further modification. This application is, therefore, intended to cover any variations, uses, or adaptations of the invention following the general principles thereof and including such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and fall within the limits of the appended claims.
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The invention relates to a circuit for synthesizing either simple or complex waveforms of the type used in electronic musical instruments, such as electronic organs. In the specific embodiment disclosed herein, the synthesizing circuit is utilized in a rhythm unit for producing a damped sine wave charateristic of certain drum sounds. Opposite polarity waveforms are simultaneously produced by a switched capacitor technique driven by an attack/decay clocking signal and under the control of a keying signal received from a suitable low frequency rhythm clock source. The positive and negative waveforms are alternately selected in order to produce bipolar pulses at the frequency of the desired tone, and these pulses are connected to the input of a switched capacitor filter that modifies the pulses to produce a sine wave signal having an amplitude following that of the desired damped envelope. The individual sine wave cycles are produced by generating a plurality of increments wherein each increment comprises a plurality of discrete amplitude steps. The stepped waveform is then filtered by a second switched capacitor filter that is tracked to the frequency which drives the sine wave generation portion of the circuit. The system is particularly adapted for large scale integration requiring no external capacitors and no external tone generating source. A wide variety of waveforms can be generated by the technique of the present invention, and the waveforms can be keyed from a keyboard, an automatic rhythm unit or other control signal within the instrument.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of U.S. Provisional Application No. 61/318,223, filed on Mar. 26, 2010, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention concerns concrete slipform paving machines that have a propelling unit or tractor from which a paving kit is suspended with which a layer of concrete is shaped and finished over the underlying ground as the tractor travels along a road or airfield alignment. The tractor of a concrete slipform paver has a rectilinear frame which straddles the concrete roadway or airfield pavement section that is being paved. The frame is propelled and supported on either end by crawler tracks mounted on side bolsters. These side bolsters each typically have two hydraulic supporting jacking columns, each of which connects to a crawler track, that allow the tractor frame elevation to be manually or automatically varied relative to the ground. The frame, and in particular a center module thereof, supports a diesel engine-driven hydraulic power unit which supplies power to the tractor and the paving kit.
[0003] The paving kit is conventionally suspended below the tractor frame by mechanical means, such as with hooks and a locking mechanism. The paving kit takes its hydraulic power from the power unit on the tractor. The tractor and the paving kit pass over fresh concrete placed in and distributed over its path as a relatively even and level mass that can be conveniently slipform-paved. During this process, the tractor-attached paving kit spreads the semi-solid concrete dumped in the path of the paver, levels and vibrates it into a semi-liquid state, then confines and finishes the concrete back into a semi-solid slab with an upwardly exposed and finished surface. The sideforms mounted on each side of the slipform paving kit shape and confine the sides of the slab during the slipform paving process. Other kits can be attached to these tractors such as kits for conveying and spreading concrete and trimming and spreading base materials.
[0004] The tractor normally has four crawler tracks, but can also have only three, each mounted to a jacking column, supporting and propelling the frame during use of the paver in the paving direction. The jacking columns are carried on the bolsters, or on bolster swing legs connected to the fore and aft ends of the side bolsters, that are pivotable about vertical axes to change the relative position of the crawlers for a variety of reasons and/or for changing the movement correction of the crawlers and therewith of the paving machine during use. The bolster swing legs with jacking columns and crawlers can also be relocated and mounted directly to the front and rear of the tractor center module, to the outside of the side bolsters or directly to the outside of the tractor center module in some less conventional paving applications. For the purposes of this description, the focus is on the manner in which bolster swing arms and the orientation of the crawlers can be changed and controlled in the more conventional paving configuration of the machine.
[0005] As is well known, tractor frames for slipform paving machines, which typically are extendable/retractable in the lateral direction to change the widths of the tractor frame and the remainder of the paving machine, have a generally rectangularly shaped center module or platform which supports, for example, the power unit including the engine for the paver, an operator platform, and the like. A side bolster is laterally movable and secured to each lateral side of the tractor frame (by means of male support tubes that telescopic in and out of the tractor center module), and bolster swing legs pivotally connect the fore and aft ends of the bolster to the respective jacking columns and crawlers of the paver. The swing legs are pivotally mounted to front and aft ends of the bolsters on vertically oriented hinge pins so that pivotal movement of the swing legs moves their end portions, which mount the jacking column and the crawlers, sideways relative to the paving direction of the paving machine and in a generally horizontal plane for increasing or decreasing the distance between the crawlers, and the distance and orientation of the crawlers relative to the tractor frame of the paving machine. Once the bolster swing legs supporting the jacking column with crawler track have the desired spacing between them and the desired orientation relative to the tractor frame, they are locked in place to prevent the crawler tracks from deviating from the desired direction/position and to absorb any existing tolerances between the bolster ends and the bolster swing legs which, if permitted to exist, allow undesired orientational deviations of the crawlers. In the past, turnbuckles and/or hydraulic cylinders were employed to prevent such tolerance-based play. To eliminate all play, two counteracting turnbuckle and/or hydraulic actuators arrangements were sometimes employed to establish a positive, immovably locked position and orientation for each crawler track.
[0006] The position fixing turnbuckles and/or hydraulic actuators were secured to mounting brackets that were bolted to a hole pattern in the front (or aft) facing surfaces of the tractor frame and the bolster swing legs and/or between the side bolster ends and the bolster swing legs. To be effective, the turnbuckles/hydraulic actuators must have a substantial angular inclination relative to the bolster swing leg. If this angular inclination becomes too small, the turnbuckles/hydraulic actuators lose effectiveness and rigidity, which, if permitted to occur, can lead to undesired deviations in the desired orientation of the crawler tracks, and if the inclination becomes too large, the distance between the point of connection of the turnbuckles/hydraulic actuators to the tractor frame and to the bolster swing leg can exceed the effective length of the turnbuckle or hydraulic actuator.
[0007] Thus, in the past, when the machine width had to be changed by a significant amount it became necessary to reposition the turnbuckle/hydraulic actuator mounting bracket along the length (in a lateral direction that is perpendicular to the travel direction) of the tractor frame to maintain the angular inclination of the turnbuckle/hydraulic actuator within an acceptable range. This was a time-consuming task that required skilled workers and, therefore, was costly. In addition, the time it takes to change the position of the mounting bracket for the turnbuckle/hydraulic actuator is a downtime for the machine during which it is out of use and cannot generate revenues.
[0008] Bolster swing legs are used so that the crawler tracks can be relatively quickly relocated in relationship to the edge of the concrete pavement that is being laid down from the normal straight-ahead position, for example to avoid obstacles in the path of the crawler tracks or to make room that may be required to allow tie bars to pass the inside of the rear crawlers and the like. One of the conventional ways of relocating the crawler track was to support the side bolster of the tractor, using the jacking column to hydraulically lift the crawler off the ground, then to use one or more turnbuckles (or one or more hydraulic actuators) to mechanically pivot the bolster swing leg with the jacking column and crawler track and, once the desired position is reached, to hold it there with a turnbuckle or steamboat ratchet (or actuator). If only one turnbuckle is used in the normal position, which is the inboard side of the bolster swing leg, the swing leg is free to move due to the inevitable manufacturing and assembly clearances and tolerances in the turnbuckle connections. These clearances are undesirable because if the swing leg is allowed to pivot or tilt under varying loads, it can adversely affect steering and elevation control. Because of this connection play, opposing turnbuckle sets were at times employed, one being located in the inboard side and one or more turnbuckles being located on the outboard side of the swing leg. In such an arrangement, after the crawler track is in the desired position, the opposing turnbuckles are tensioned (pulled) against each other to keep the swing leg from moving. This transfers all the clearance in the pin connections to one side of the hole, eliminating any possible movement in the connection. The drawback of this approach is that the outboard turnbuckles increase the overall machine profile outside the edge of concrete and therefore require more room for the machine when paving past obstacles in tight confines. If the outboard turnbuckle angle is decreased to decrease the machine profile, the effectiveness of the turnbuckles at this flat angle in holding the swing leg can decrease to almost nil. Further, every time the crawler track is relocated, all the turnbuckles must be readjusted.
[0009] Attempts have been made to eliminate the need for the outboard opposing turnbuckles by adding a hydraulic cylinder/actuator between the tractor frame and the swing leg behind the turnbuckle on the inboard of the leg. The cylinder effectively pushes the pin connection clearances to the inside of the turnbuckle connection holes and eliminates the risk of swing leg movement by keeping the hydraulic actuator pressurized.
[0010] The relocation of the bolster swing leg and crawler track in relationship to the tractor frame is further adversely affected by the need to relocate the turnbuckle connection on the tractor frame where it connects to the bolsters to which the swing leg is attached. The turnbuckle connection on the bolster swing leg side typically stays at the same connection point. In the past, the turnbuckle connection to the tractor frame posed several problems. One such problem was when the tractor frame was telescoped narrower. At wider tractor widths, the turnbuckle connects to the outboard end of the support beam of the tractor frame with a turnbuckle bracket that is bolted to the male support beam (that telescopes in and out of the tractor center module) with two or more bolts; however, if the tractor frame is telescoped narrower, the bracket will eventually interfere with the tractor center module, which prevents the further narrowing of the tractor frame. Once this point is reached, the turnbuckle mounting bracket therefore had to be unbolted from the male support beam and rebolted to the tractor center module. To maintain the optimum turnbuckle angle to the swing leg so the turnbuckle is effective in holding the leg in the desired position, the turnbuckle bracket had to be relocated along the tractor center module repeatedly, which slowed down the machine width change process during each change. The inboard turnbuckles can also interfere with other attachments required on the front and rear of the machine, such as a spreader plow that is mounted off the front of the tractor frame, which had to be disconnected and reconnected, which increases costs further. Another problem was when the swing leg complete with jacking column and crawler track is relocated to the outside of the side bolster or mounted directly to the tractor center module, in some paving applications there was no place to connect the bolster swing leg or turnbuckles (hydraulic actuators).
[0011] The relocation of the bolster swing legs and crawler track in relationship to the tractor frame is further adversely affected by the steering cylinders that typically were used on the jacking columns. The steering cylinders allow the crawler track angle to be changed in relationship to the jacking column for manual or automatic steering purposes. In the past, the steering cylinders at times protruded to the outside of the associated steering column. This is undesirable because it increases the outside width of the paving machine, which dictates and will limit how close the machine can pave next to a building or obstruction, and the stroke of the steering cylinder dictates how far the swing leg can be swung inboard or outboard. Amongst others, such a jacking column steering cylinder configuration does not allow the crawler tracks to be rotated 90° from their normal operating orientation without the time-consuming repinning or repositioning of the steering, which is a drawback.
[0012] It is however highly advantageous to rotate the crawlers to such a 90° steering position (and being able to steer the crawler track in that position) from their normal position when readjusting the machine for paving different widths, maneuvering the machine around the jobsite, or for readying the machine for transport to a different paving site. In such an event, the swing legs with jacking columns and crawlers are pivoted relative to the tractor frame until the crawlers extend in the lateral direction (which is perpendicular to the normal paving direction) of the paving machine, which minimizes the width of the paving machine so the gauge between the crawler tracks in the transport position is narrow enough to walk the machine onto a trailer and for its transportation over normal roads to a new site. This outboard 90° bolster swing leg orientation is not to be confused with rotating just the crawler tracks in the 90° position using 90° steering.
[0013] Thus, when repositioning the crawler tracks of a paving machine in accordance with conventional methods, the machine is initially appropriately supported so that a first one of the bolster swing leg-mounted crawler tracks can be lifted off the ground. The turnbuckle is then used to pivot the bolster swing leg until the jacking column and the associated crawler are at the desired (lateral) position and have the required crawler orientation. If the needed lateral movement of the crawler is too great, the turnbuckle mounting bracket must be repositioned by unbolting it from the frame and rebolting it thereto at a hole pattern located at the appropriate (lateral) point on the tractor frame or the center module. Thereafter, the turnbuckle is tightened in the new position of the crawler so that the bolster swing leg can no longer move and the orientation of the crawler is maintained. Thereafter, the crawler is lowered to the ground, it is rotated about the vertical axis of the jacking column to place it in the desired orientation, and an orientation measuring transducer is reset for the new crawler orientation to keep the crawler in the straight-ahead position. This has to be repeated for each of the typically four crawlers of the paving machine, a process that is time-consuming, costly and results in a prolonged, unproductive downtime for the machine. This cost is encountered each time the lateral position of the crawler and/or turnbuckle mounting bracket is changed and the crawlers must then be reoriented relative to the frame so that they face in the required transport direction. This procedure is also used to ready the paving machine for transportation to a new work site. In such an event, the swing legs are pivoted relative to the frame until the crawlers extend in the lateral direction (which is perpendicular to the normal paving direction) of the paving machine, which minimizes the width of the paving machine for transportation to a new site.
[0014] In an alternative approach used in the past, the crawlers and the associated jacking columns were connected to the fore and aft ends of the side bolsters and fixed mounted to the end of the parallel linkages and oriented so that the crawlers extend in the paving direction of the paving machine. The parallel linkages typically include a hydraulic actuator to assist in the crawler track relocation and to hold the crawler track in the desired position. This approach simplified the lateral adjustment of the positions/orientations of the crawlers in relationship to the tractor as compared to crawlers mounted on pivoted swing legs because no matter where the crawler track was repositioned, the crawler track always remained oriented straight ahead and the turnbuckle relocation issue went away. However, in such arrangements, the limited range of movement of the parallel linkages with hydraulic actuator limits how narrowly the machine can be collapsed for transporting it over highways (with standard highway width restrictions) to new construction sites. The ability to quickly and efficiently move the paving machine from one site to the next, which is highly desirable for the efficient use of the machine, is lost with this approach. Instead, paving machines employing such parallel linkages for the crawlers required that the tractor frame itself had to be collapsed in order to narrow the width of the machine sufficiently so that it could be transported over highways. This requires that either the paving kit itself be telescopic or that the paving kit is removed from the tractor. In either case, this could significantly increase the overall cost of the machine or the cost or time required for moving the machine and is therefore an undesirable alternative. The only way to overcome this limitation is to add a pivot hinge (with a means to lock/pin the pivot hinge in either the working or transport position) between the side bolster and the parallel linkage to allow the parallel linkage with jacking columns and crawlers to pivot outboard relative to the tractor frame until the crawlers extend in the lateral direction (which is perpendicular to the normal paving direction) of the paving machine required for loading on a trailer and transport. Of course, adding the pivot hinge with a pinning mechanism to each corner of the machine is costly, and pinning and unpinning of the hinge is time-consuming.
BRIEF SUMMARY OF THE INVENTION
[0015] According to a first aspect of the present invention, each bolster swing leg is pivotally mounted on a hinge bracket that is secured to the front (or aft) ends of the side bolsters of the paving machine. This bracket also supports the turnbuckle or, preferably, a hydraulic actuator which eliminates the need to tie the swing leg into the tractor frame for holding the swing leg, and the crawler track secured to it, in a fixed position during paving. One end of the turnbuckle or actuator is tied into the swing leg conventionally, while the other end is mounted to the hinge bracket. This eliminates the need encountered in the past to relocate the turnbuckle mounts on the tractor frame when the width of the tractor frame is changed. Instead, in accordance with the present invention, every time the width of the paving machine is changed, the attachment point for the turnbuckle or hydraulic actuator automatically follows the positional change of the swing leg because the attachment point is mounted on the hinge bracket, that is, in a fixed position relative to the bolster and the swing leg.
[0016] To facilitate the required realignment of the crawler tracks, another important aspect of the present invention preferably replaces the turnbuckles with hydraulic actuators and provides angular position transducers at the pivot connection for the swing leg at the hinge bracket and another such transducer between the jacking column and the crawler track. An onboard computer or other processor receives the outputs from the transducers and generates a signal to pivot the crawler track relative to the associated jacking column to keep the crawler tracks oriented in the paving direction when the angular orientation of the swing leg changes, and also keeps all the crawler tracks' orientations synchronized. Thus, no matter what the swing leg angle is, the crawler track stays straight ahead in the paving direction and position. Of course it is also possible to override this computerized feature so the crawler track orientation can be changed relative to the bolster swing leg, which may be required from time to time for width change, maneuvering on site, etc.
[0017] The bolster swing leg hydraulic actuator and the hydraulic rotary power drive or steering cylinder for pivoting the crawler track relative to the jacking column working in cooperation with the position transducers allow the swing leg with crawler track to be held in a fixed location in relationship to the edge of the concrete. A closed loop feedback system that connects the hydraulic actuator for the swing leg, the rotary power drive for the crawler, and the onboard computer always maintains the swing leg angle at a fixed, preset angle. If the swing leg migrates away from a preset angle, the swing leg hydraulic cylinder is actuated to maintain the preset angle and at the same time the necessary adjustments to the crawler track orientation are made with the hydraulic rotary power drive or steering cylinder. Alternatively, a hydraulic system using a locking valve can be provided instead of the position transducer and feedback loop for holding the swing leg in the desired position.
[0018] Thus, the crawler track positions can be relocated when the machine is walked forward or backward while the crawler tracks at all times stay in their straight-ahead normal operating orientation and position without requiring any manual mechanical or electronic adjustments. The crawler tracks can also be relocated when the machine is stationary by supporting the weight of the machine off the ground, then hydraulically lifting each crawler track (one at a time) off the ground, and thereafter using the swing leg hydraulic cylinder and position transducer working in conjunction with the power drive or steering cylinder between the jacking column and the crawler track for moving the crawler track to another position.
[0019] A still further aspect of the present invention eliminates the need to reposition the steering cylinder on the jacking columns when the crawler track is repositioned within the range of the swing leg cylinder and to allow 90° steering without having to reposition the steering cylinder by employing a hydraulic motor driven rotary actuator (slew gear) with an angular position transducer as the power drive between the crawler track and the jacking column. The rotary actuator also allows a wide range of steering angles while in the 90° steering mode to make the machine highly maneuverable on site. Working in conjunction with the swing leg position transducer, and after unpinning the swing leg hydraulic cylinder from the swing leg, the rotary actuators allow the machine to be preprogrammed to first turn the crawler tracks relative to the jacking columns normal to the paving direction, and then walk the crawler tracks on the ground in an arc around the pivot shaft of the swing legs into their outboard transport position (in which the crawlers are oriented 90°, i.e. substantially transverse to the paving direction) so that the paving machine can be sufficiently narrowed for moving it over ordinary highways to a new paving site with a legal or otherwise approved transport width dimension, or, for maneuvering the paving machine around a paving site which is tightly confined. The heretofore common need to manually move the swing legs with jacking columns and crawler tracks into the outboard position as previously described is thereby eliminated, which significantly reduces the time required to ready the machine for transport and/or for maneuvering the machine at the work site.
[0020] Thus, a paving machine constructed in accordance with the present invention has a main frame that includes a center module, a side bolster that is laterally movably connected to respective lateral sides of the center module for changing a spacing between the bolsters, a crawler track associated with respective aft and forward ends of the bolsters, and a bolster swing leg for each crawler track. An upright jacking column is secured to the free end of the swing leg, and a connection between the jacking column and the crawler track permits rotational movements of the crawler track and the jacking column about an upright axis. A hinge bracket is interposed between each swing leg and an associated surface of the bolsters and includes a fixed, upright pivot shaft that pivotally engages the swing leg for pivotal movements in a substantially horizontal plane. The hinge plate includes a pivot pin that is laterally spaced from and fixed in relation to the pivot shaft. A length-adjustable, preferably hydraulically actuated, holder is capable of being held at a fixed length and has a first end that pivotally engages the pivot pin and a second end that pivotally engages the swing leg. The holder permits pivotal motions of the swing leg about the hinge pin when in its length-adjustable configuration and prevents substantially any motion of the swing leg when the holder is in its fixed-length configuration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a front elevational, perspective view of a complete paving machine having pivotable swing legs with a jacking column and a crawler, each constructed in accordance with the present invention;
[0022] FIG. 2 is a partial, simplified plan view of portions of a paving machine illustrating the pivotal swing leg of the present invention;
[0023] FIG. 3 is a perspective, front elevational view of a hinge bracket for securing the swing leg to the paving machine;
[0024] FIG. 4 is a front elevational view, in section, taken through the vertical center line of the jacking column and crawler, which are only schematically shown in FIG. 1 ;
[0025] FIG. 4A is an enlargement of the portion of FIG. 4 within the circle A-A of FIG. 4 ;
[0026] FIG. 5 is a front elevational view, in section, through the pivot connection between the hinge bracket shown in FIG. 3 and the bolster swing leg attached thereto with a pivot pin;
[0027] FIG. 6 is a schematic plan view similar to FIG. 2 and illustrates the attachment of the bolster swing legs to the aft portion of the paving machine, with the paving machine having an additional cross beam between the tractor frame and the swing legs for additional kits that may be mounted on the paving machine;
[0028] FIG. 6A shows in plan view a paving machine with a DBI Module incorporating special bolt-in short bolster extensions with built-in mounts for DBI longitudinal support beams;
[0029] FIG. 6B is an illustration similar to FIG. 6A with the paving machine and the DBI shown in various relative positions as they are being readied for transportation while in their respective transport orientations;
[0030] FIG. 6C is a side elevation of the paving machine shown in FIG. 6B , in its transport orientation;
[0031] FIG. 7 is a perspective, side-elevational view showing the bolster swing leg that is pivotally secured to the hinge bracket; and
[0032] FIGS. 8A-E are schematic plan views of the paving machine which illustrate reconfiguring the machine into its transportation mode (or vice versa).
DETAILED DESCRIPTION OF THE INVENTION
[0033] Referring initially to FIG. 1 , a concrete slipform paving machine 2 has a main tractor frame 4 defined by a center module or platform 6 that carries the diesel engine powered power unit 8 of the paving machine and from which extendable or telescoping male support beams 10 extend outwardly in a lateral direction. Side bolsters 12 are secured to the respective outboard ends of the support beams. Upright jacking columns 14 are mounted in the vicinity of respective front and aft ends of the bolsters, and crawlers 16 are conventionally secured to the lower ends of the jacking columns. The jacking columns are hydraulically powered for raising and lowering of the paving machine relative to the crawlers on the ground. The crawlers are mounted to the lower ends of the jacking columns, and they are rotatable relative to the jacking columns about vertical axes, an arrangement that is known in the art. The crawlers support the entire machine and move it over the ground.
[0034] The respective bolsters can be moved in the lateral direction relative to the center module so that the machine frame, including the crawlers, straddles a paving kit (not separately shown) that extends over, clears and forms a strip of concrete (not shown) being laid down by the machine. When finished, the strip of concrete defines an upwardly exposed, appropriately leveled and finished concrete surface (not shown) that extends across the strip between the upright sides of the concrete strip.
[0035] In use, the paving machine is aligned with the paving direction 18 so that the concrete strip can be laid between the crawlers 16 of the machine over a width determined by a paving kit 63 suspended from the main tractor frame. Fresh concrete is deposited in front of the machine, a spreader plow or a spreading auger (not shown) approximately levels the concrete over a major portion of the width of the concrete strip, and, as the machine advances forwardly, a metering gate substantially evenly spreads the top of the fresh concrete. Following the “liquification” of the concrete by vibrators supported by a vibrator rack at a fixed elevation on the front side of the paving kit, finishing pans (not shown in FIG. 1 ) are provided on the aft end of the paving kit to finish the top surface of the concrete as the paving kit passes over it, while sideform(s) form the sides of the concrete strip or slab. A finished concrete strip emerges from the aft end of the paving machine and is permitted to conventionally set and harden.
[0036] Referring to FIGS. 1-5 , each crawler 16 and the associated jacking column 14 are mounted to a free end 19 (shown in FIG. 7 ) of a bolster swing leg 20 . The swing leg is typically formed as a box beam 22 and has another end 21 (shown in FIG. 7 ) that is pivotal about a vertically oriented pivot shaft 24 which extends through a bearing bushing 26 that is supported in its vertical orientation on a hinge bracket 28 with spaced-apart support webs 30 .
[0037] The hinge bracket has appropriately positioned fastening holes 32 for securing it to respective end surfaces 34 of side bolsters 12 with conventional bolt and nut fasteners 23 as shown, for example, in FIG. 7 . A female keyway is provided on the jacking column bolting flange 57 (shown in FIG. 4 ) with male keyways provided on the mating bolting flanges to take the shear of the bolts and to eliminate possible misalignment.
[0038] The ends of box beams 22 adjacent bolster end surface 34 have connector plates 36 , secured to the top and bottom surfaces of the box beam by welding, for example. The connector plates project towards the tractor frame past the end of the box beam and have holes that pivotally engage pivot shaft 24 in bearing bushing 26 of the hinge bracket so that the swing legs are free to pivot relative to bolsters 12 in a horizontal plane (as indicated in FIG. 2 ) about an upright axis defined by the pivot shaft.
[0039] The closed end of the cylinder of a hydraulic actuator 38 is pivotally pinned to two spaced-apart support plates which are secured, e.g. welded, to the inside of the hinge bracket 28 and a mid-portion of bearing bushing 26 , as is best seen in FIG. 3 . The support plates include aligned bores 42 that are laterally spaced some distance away from the bearing bushing 26 . The closed end of the hydraulic cylinder is pivotally movably secured to the support plates with a pin that extends through the bores. The piston 44 of the hydraulic actuator is pivotally pinned to a pair of spaced-apart brackets 46 which are located between the ends of the swing leg and typically relatively closer to its free end 19 . When the hydraulic actuator is pinned to the hinge bracket 28 and the brackets on bolster swing leg 20 , it is angularly inclined relative to the paving direction 18 , as best seen in FIGS. 1 and 2 . It is foreseen that on a larger machine more than one, e.g. two, vertically spaced-apart hydraulic cylinders placed above each other may be required to generate the force required to hold the bolster swing leg in a fixed position relative to the male pivot hinge. Further, if desired, for example for cost reasons, hydraulic actuators can be replaced by turnbuckles.
[0040] When assembled installed between hinge bracket 28 and swing leg 20 , hydraulic actuator 38 can be energized to pivot bolster swing leg 20 in a horizontal plane as schematically illustrated in FIG. 2 . Since hinge bracket 28 is secured to end face 34 of bolster 12 , the angular inclination of the actuator relative to the bolster swing leg does not change when the length of the tractor frame 4 (in the lateral direction perpendicular to the normal paving direction 18 ) is changed. There is therefore no need to reposition the hinge bracket that secures one end of the hydraulic actuator to the machine frame, as was necessary in the past. The extendable length of the hydraulic actuator and its attachment points to hinge bracket 28 and swing leg 20 are chosen so that the angular inclination of the hydraulic actuator relative to the bolster swing leg is maintained over a reasonably large arc (as schematically illustrated in FIG. 2 ) that is sufficient to permit repositioning of the swing leg during normal use encountering normal operating conditions of the paving machine without having to disconnect the actuator from the swing leg and/or the hinge bracket.
[0041] However, when the swing legs are to be rotated 90° from the paving direction 18 towards a position that is laterally outward of bolsters 12 , principally for readying the paving machine so that it can be transported by truck and trailer to a new location, hydraulic actuator 38 is disengaged from at least one of the swing leg or the hinge bracket 28 , for example by pulling pin 41 that connects the end of piston 44 to brackets 46 on the swing leg, to prevent interference between the hydraulic actuator and support plates 40 and/or bearing bushing 26 of the hinge bracket.
[0042] When bolster swing legs 20 are longitudinally aligned with tractor frame 4 and its laterally extending support beams 10 , a position in which the legs are oriented approximately perpendicular to paving direction 18 , it is preferred to pin the swing legs in that position during shipment of the paving machine with a turnbuckle or other fastener (not shown) to webs 45 , 47 on the laterally facing surfaces of the bolster and the swing leg as seen in FIG. 2 . The turnbuckle or the like is released at the new location so that the swing legs can be returned to their normal operating position in which they are parallel, or only slightly angularly inclined relative to the paving direction 18 .
[0043] Each time the bolster swing legs 20 are pivoted inwardly or outwardly relative to tractor frame 4 of the paving machine, the relative angular inclination between the bolster swing legs and the tractor frame changes. This change is replicated by crawler tracks 16 mounted below jacking columns 14 at the free end of the swing legs. This change in crawler track orientation has to be compensated for so that, following the pivotal movement of the swing leg, and preferably simultaneously therewith in real time, the crawler tracks extend in the paving direction. This is done by adjusting the angular orientation of the crawler track by an amount that depends on or is a function of the angular displacement of the swing legs relative to the hinge bracket 28 so that the crawler tracks always remain in alignment with paving direction 18 of the paving machine, as is schematically illustrated in FIG. 2 by the parallel orientation of the crawler tracks (in part shown in phantom lines in FIG. 2 ) irrespective of the angular orientation of the swing legs. This relocation process can be accomplished while the machine is supported so the crawler track can be lifted off the ground and relocated to the desired location inwardly or outwardly. With this relocation process, typically each swing leg/crawler track is relocated one at a time. Alternatively, this relocation process can also be accomplished while the machine is walking forward or backward. For example, for moving outwards, the angle of the crawler can be hydraulically “jogged” slightly outward while walking the swing leg/crawler track to the desired location with or without the assistance of the swing leg hydraulic cylinder. Once the desired position is reached and the job switch disengaged, the crawler track will automatically go back to the straight-ahead position. In the alternate case, the crawler track relocation process is done while walking in the forward or reverse direction moving one swing leg/crawler track at a time or moving more or all four at a time.
[0044] Referring to the drawings, and particularly to FIGS. 4 and 7 thereof, jacking column 14 has telescoping outer and inner tubes 48 , 50 of a generally rectangular cross-section, as is typical for jacking columns on paving machines, and a vertically oriented hydraulic actuator 52 having its cylinder and piston appropriately secured, e.g. by pinning, to the outer and inner tubes. Activation of the hydraulic actuator telescopingly moves the outer and inner tubes relative to each other for lengthening or shortening the distance between the crawler track and the bolster swing leg 20 for raising or lowering the paving machine relative to the ground or, while the paving machine is otherwise supported, raising or lowering the crawler track off the ground. Spaced-apart axial bearings 54 keep the tubes aligned and permit them to slide relative to each other in their axial direction while maintaining tight clearances to minimize backlash. A support structure 57 is further provided for securing the jacking columns to free ends 19 of the bolster legs. This construction of jacking column 14 is conventional and is therefore not further described herein.
[0045] A slew or worm gear drive or other rotary actuator 60 is bolted to a mounting plate 56 at the lower end of inner tube 50 of the jacking column. The worm gear drive has a ring gear 58 that is driven by a pair of diametrically opposite, hydraulically activated helical worm drives 61 carried on a ring-shaped member 63 disposed between an inner bearing race 65 of the worm gear drives and a transverse portion 66 of yoke 62 , to which the ring-shaped member is secured. An outer bearing race 67 is secured, e.g. bolted, to the lower end of mounting plate 56 at the end of inner tube 50 . On its periphery, the outer bearing race 67 defines ring gear 58 . Such slew gear drives are commercially available from Kinematics Manufacturing, Inc., of 2221 W. Melinda Lane, Phoenix, Ariz. 85027, as “Slewing Drive s17b-102m-200ra”. Providing the slew gear drive with two oppositely arranged worm drives increases the power available to rotate the crawler track while a portion of the total machine load is carried by it. The slew drive design also effectively minimizes undesirable play or “backlash” during steering of the crawler track and effectively minimizes undesirable play or backlash between the yoke 62 and the jacking column 14 whether the slew gear drive is activated or deactivated.
[0046] An angular position transducer or sensor 70 is arranged inside an upwardly open can 72 (provided to protect the sensor) that is disposed within an opening 69 in the transverse portion 66 of yoke 62 . Supports 74 extend across opening 69 and secure the can with transducer 70 at the rotational center between the jacking column and the yoke. The transducer cooperates with a trigger pin 68 extending downwardly from the under side of plate 56 and a suitable actuator arm that turns the transducer. Alternatively, the trigger pin can cooperate with the transducer via a belt drive 64 as schematically indicated in FIG. 4A .
[0047] Transducer 70 , in cooperation with trigger pin 68 , generates a signal that indicates the angular position of yoke 62 relative to jacking column 14 and any changes in the angular position due to rotational movements of the yoke. Corresponding output signals are generated by the transducer and fed to a lead 84 not shown in FIG. 4 but shown in FIG. 5 .
[0048] Referring to the drawings, and in particular to FIGS. 5 and 7 thereof, another angular position transducer 78 is placed on top of swing leg pivot shaft 24 ( FIG. 5 ). As is best seen in FIG. 7 , the top of the pivot shaft defines a generally drop-shaped head 86 that is engaged by blocks 88 fixed to the upper side of connector plate 36 so that pivot shaft 24 is rotationally fixed to the connector plate and duplicates the angular movements of swing leg 20 about the pivot shaft. Replaceable bearings are provided at the top and bottom of the male hinge bearing (shown in FIG. 3 ) as well as a means to get grease to them (not shown in the drawings) so the pivot shaft 24 does not seize in the bearing, which would prevent the swing leg from freely rotating.
[0049] Angular position transducer 78 is mounted inside a downwardly open protective can 90 , as seen in FIG. 5 , which is bolted to hinge bracket 28 via an upright holding arm 92 .
[0050] A trigger pin 94 projects upwardly from the top surface of pivot shaft 24 and cooperates with angular position transducer 78 to generate an angular position signal which reflects the angular inclination between the pivot shaft and the hinge bracket, and which changes when the bolster swing leg 20 changes its angular position relative to the hinge bracket 28 , and therewith also relative to bolster 12 and tractor frame 4 . The output of transducer 78 is fed to a lead 80 .
[0051] The output signal of the position transducer 78 is fed via lead 80 to an onboard computer 82 of the paving machine, or another suitable processor, which receives as its second input the output signal of position transducer 70 between jacking column 14 and crawler tracks 16 via a lead 84 , as is schematically illustrated in FIG. 5 .
[0052] Onboard computer or processor 82 and the associated transducers 70 , 78 form a feedback loop in which the computer receives the angular position signal from swing leg transducer 78 . When the angular position of the swing leg changes, the output signal from transducer 78 changes correspondingly. As a result of this orientational change of the swing leg, the angular orientation of the crawler tracks becomes angularly inclined relative to paving direction 18 . Computer 82 calculates by how much the angle of the crawler track has to be changed relative to the jacking column (which has also been angularly offset relative to the transport direction by the swivel motion of the swing leg) to reset the crawler track suspended from yoke 62 to the angular orientation of the desired paving direction. The onboard computer then signals by how much worm gear drive 60 must rotationally adjust the orientation of yoke 62 and crawler tracks 16 to again align the crawler tracks with the paving direction. This process is repeated each time the angular position of the swing leg is changed, or when for other reasons the angular orientation of the crawler tracks becomes misaligned from the desired paving direction of the machine.
[0053] Thus, the above-described feedback loop automatically adjusts the angular orientation of the crawler tracks so that the tracks remain oriented in the travel direction without any need to stop operation of the machine or manually adjust the orientation of the tracks and/or the swing legs.
[0054] FIGS. 8A-E illustrate with more particularity how the paving machine of the present invention is readily, quickly and inexpensively reconfigured between its paving orientation shown in FIG. 8A or configuration for laying down the layer of concrete, and its transportation orientation shown in FIG. 8E or configuration in which the width of the machine is reduced to a roadway accepted width with minimal efforts.
[0055] As already mentioned, from time to time the paving machine must be reoriented, either at the work site for maneuvering or repositioning it around, or to ready the machine for transport to a different site, which requires loading the machine on a suitable trailer (not shown) and then hauling it to the new site over available roads.
[0056] Maneuvering the paving machine around the work site is accomplished by rotating the crawlers 16 relative to the jacking column 14 and then, or simultaneously therewith, activating the crawlers to move the machine into the desired position or to a given location at the site.
[0057] For loading the paving machine for transport to a different site on a trailer over standard highways, it is necessary to reduce the transport width of the paving machine to the maximum allowable width for highway vehicles. With the crawlers resting on the ground and initially facing in the paving direction 18 , they are rotated 90° about the vertical jacking column axis with worm gear drive 60 into a position in which they are substantially transverse to the paving direction. The respective hydraulic actuators 38 keep the associated swing legs 20 in their paving orientation as seen in FIG. 8B . The ends of the hydraulic actuators 38 are then disconnected from the associated swing legs 20 by removing a pin, then with the crawler track on the ground, walking in an arc around the pivot shaft of the swing leg as shown in FIG. 8C . Once in this position, the crawlers are again rotated 90° about the vertical jacking column axis with worm gear drive 60 to place the swing legs in their transport orientation (shown in FIG. 8D ) which is perpendicular to the paving direction. Finally, a turnbuckle 95 or like holding device is applied to the main frame side bolster of the paving machine and the swing legs to fix the latter in their transport orientation. This process is repeated at each corner of the machine until each swing leg and crawler track is in the transport orientation and the swing legs are in their transport orientation ( FIG. 8E ) and perpendicular to the paving direction ( FIG. 8D ).
[0058] With the earlier described, cooperating position transducers 70 , angular transducer 78 (not shown in FIGS. 8A-E ) and worm gear drive 60 , or if desired manually, the crawlers 16 are thereby brought into alignment with the bolster swing legs, which, in the transport direction, are oriented perpendicular to the paving direction 18 and do not materially extend laterally past the remainder of the paving machine, so that the entire machine width is within permissible width limits for highway transportation. Once the crawler and the associated swing leg 20 are in their transport orientation, which preferably is slightly more than 90°, e.g. 95°, the tightened transportation turnbuckle 95 having its ends attached to the paving machine frame side bolster and the swing arm prevents movements of the swing leg and the crawler out of their transport orientation while the paving machine is moved to another site.
[0059] Thus, in the transport position the swing legs and crawlers are parallel to and extend past the respective lateral ends of the paving machine while the overall width is kept within width limits allowed for highway vehicles.
[0060] Placing the paving machine in the transport direction requires little time since the operation can be quickly performed and the crawlers can then be used to move the paving machine onto a trailer for transport to a different site without requiring heavy lifting equipment such as a crane to place the paving machine from the paving to the transport directions, and vice versa.
[0061] FIG. 6 shows a paving machine 2 including a center module 6 , laterally extending support beams 10 , side bolsters 12 , jacking columns 14 and crawlers 16 as described above. The paving machine can be used, for example, with a dowel bar inserter 116 for intermittently inserting dowel bars (not shown) into the freshly laid down concrete strip immediately behind the paving kit. Such a dowel bar inserter, its construction and attachment to the paving machine are described, for example, in commonly owned, copending U.S. patent application Ser. No. 12/556,486, filed Sep. 9, 2009, for a Paver Having Dowel Bar Inserter With Automated Dowel Bar Feeder, the disclosure of which is incorporated herein by reference as if it were fully set forth herein.
[0062] To movably support the dowel bar inserter 116 , for example, or another kit of the paving machine from the tractor frame, the lateral ends 112 of a cross beam 110 are tied into, that is, they are typically bolted to, rearwardly extending bolster extensions 114 . The longitudinal support beams 43 for the dowel bar inserter shown (the rest of the dowel bar inserter is not shown) attach to the rear of the tractor frame by means of a mounting bracket attached to the support beam in the front and to the rear cross beam 110 in the rear. The forward ends of the bolster extensions 114 are secured to the rearwardly facing end surfaces of the main tractor frame bolsters 12 that can be provided with or without an additional bolt-in hinge 102 . When no hinge in the bolster is provided, the bolster extension 114 must be removed prior to transporting the machine. Prior to removing the bolster extensions for loading and transporting the paver, the rear hinge 36 and swing leg 20 along with the jacking column 14 and crawler track 16 (the entire assembly) must be removed and then lifted and bolted to the rear of the main frame side bolster 12 and the paver put into the transport orientation. The weight of this entire swing leg, jacking column and crawler track assembly can be handled with a relatively small crane. When the bolster extension is provided with a bolt-in hinge 102 , the bolster extension 114 , swing leg, jacking column and crawler track can be left on the paving machine so that by hinging the bolsters into the outboard transport position, the paving machine is capable of self-loading onto a trailer, with the bolster, swing leg and jacking column with crawler track folded up for transport. The advantage of this is that no crane is required to remove the bolster extension in order to transport.
[0063] A variation to the DBI mounting arrangement shown in FIG. 6 with a bolt-in hinge is the mounting arrangement shown in FIGS. 6A and 6B . Instead of a bolt-in hinge 102 , a special bolt-in short bolster extension 104 with built-in mount 106 for the DBI longitudinal support beam 43 is supplied. Instead of the longitudinal support beams 43 attaching to the rear of the tractor frame by means of a mounting bracket described above, the longitudinal support beams mount to the bolster extension 104 . When the bolster extension is provided with a special bolt-in short bolster extension 104 with built-in mount 106 for the DBI longitudinal support beam, a practical and fast loading/transport solution is possible for both the paver and the DBI, providing a medium-size crane is readily available. Because the bolster extensions are tied to the DBI supporting longitudinal support beam 43 in this configuration and also to the rear cross beam 110 , a rectilinear frame is formed where the DBI, complete with bolster extensions 114 and 104 , becomes a kit (module) 108 of a legally transportable width. If this DBI Module is supported complete with bolter extensions 114 and 104 , while it is still attached to the paver, the rear hinge 36 and swing leg 20 along with the jacking column and crawler track (the entire assembly), it can be lifted with a relatively light small crane (without disconnecting any of the hydraulic or electrical connections) and bolted to the side of the main frame side bolster 12 , using the universal bolting pattern found on the side bolster 12 as shown in FIGS. 6B and 6C (that matches the hole pattern of the swing leg) covered and described in copending, commonly owned U.S. patent application Ser. No. 12/703,101, filed Feb. 9, 2010, for a Slipform Paving Machine With Adjustable Length Tractor Frame. This swing leg, jacking column and crawler track assembly is mounted in the transport orientation as shown in FIG. 6B and FIG. 6C . Once this procedure is completed on the opposite side of the machine, the complete DBI with bolster extensions 114 and 104 and the DBI Module 108 can be lifted as a module 108 on a truck transporting trailer. With the DBI Module 108 removed from the rear of the paver tractor frame, then the other front swing leg and jacking column with crawler track can be walked into the transport orientation as described herein. With all the swing legs and jacking columns with crawler tracks now in the transport orientation, the paver can self-load by walking onto a transporting trailer. The advantage of this arrangement is that if a medium-size crane is available, adding or removing the DBI Module 108 and unloading or loading the DBI Module and paver can be done very rapidly.
[0064] FIG. 6B schematically illustrates the paving machine and the DBI Module arranged for transport in two loads, as a crawler track paver module and as a DBI Module 108 . The right and left rear jacking columns 14 /crawler 16 /swing leg 20 /rear hinge 36 subassembly has been moved into its transport orientation as previously described. The left front jacking column/crawler/swing leg/rear hinge subassembly has been rotated towards its transport orientation, while the right front jacking column, crawler/swing leg/front hinge subassembly is shown in its paving orientation and must still be rotated into its transport orientation before the modules are ready for loading onto a trailer (not shown).
[0065] Cross beam 110 may comprise a non-telescoping or a telescoping cross beam, laterally extendable and retractable support system that has a female center housing 6 ′ which movably receives male support beams 10 ′ that extend in opposite directions from the center housing towards the rearward bolster extensions 76 . The construction and operation of telescoping cross beam 110 and the kits, such as a dowel bar inserter kit suspended therefrom, are described in copending, commonly owned U.S. patent application Ser. No. 12/703,101, filed Feb. 9, 2010, for a Slipform Paving Machine With Adjustable Length Tractor Frame, the disclosure of which is incorporated herein by reference.
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A paving machine which is configured to move in a paving direction for spreading, leveling and finishing concrete into a form having a generally upwardly exposed, finished concrete surface and terminating in lateral concrete sides. The paving machine has a main frame, including a center module, bolsters laterally movably connected to respective lateral sides of the center module for changing a spacing between the bolsters, and a crawler track associated with respective aft and forward ends of the bolsters. A bolster swing leg for each crawler track supports an upright jacking column secured to the swing leg proximate a free end thereof. A worm gear drive between the jacking column and the crawler track permits rotational movements of the crawler track and the jacking column about an upright axis. A hinge bracket is interposed between each swing leg and an associated surface of the bolsters and includes a fixed, upright pivot shaft that pivotally engages the swing leg to enable pivotal movements of the swing leg about an upright axis in a substantially horizontal plane. The hinge bracket further includes a pivot pin that is laterally spaced from and fixed in relation to the pivot shaft. A length-adjustable holder capable of being held at a fixed length has a first end pivotally engaging the pivot pin on the hinge bracket and a second end that pivotally engages the swing leg. The holder permits pivotal motions of the swing leg about the hinge pin when it is in its length-adjustable configuration and prevents substantially any motion of the swing leg when the holder is in its fixed-length configuration. A feedback loop cooperates with angular position transducers and automatically keeps the crawler tracks oriented in the paving direction of the machine when the swing legs move in a horizontal plane relative to a remainder of the paving machine. The paving machine can be reconfigured between its paving orientation and a road transport orientation by activating the crawlers to move the swing legs and the crawlers into a narrowed transport configuration.
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CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY
[0001] The present application claims the benefit under 35 U.S.C. §119(a) of a Korean Patent Application filed in the Korean Intellectual Property Office on Feb. 20, 2008 and assigned Serial No. 10-2008-0015564, the disclosures of which are incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to a method and apparatus for feeding back Channel State Information (CSI) in a Space Division Multiple Access (SDMA) communication system.
BACKGROUND OF THE INVENTION
[0003] Currently, communication systems are evolving into next-generation mobile communication systems that provide high-speed multimedia services. The next-generation mobile communication systems use multiple access schemes proposed to make efficient use of their limited resources to provide high-speed multimedia services.
[0004] SDMA is one of the typical multiple access schemes. In a communication system using SDMA (hereinafter referred to as an “SDMA communication system”), when a Base Station (BS) uses a plurality of antennas, areas which are orthogonal to each other may be formed; the number of areas corresponds to the number of the antennas that also are orthogonal to each other. Thus, signals from Mobile Stations (MSs) located in different areas are removed by orthogonality between beams in antenna beam patterns during their transmission/reception, so the signals do not interfere with each other.
[0005] Meanwhile, the BS of the SDMA communication system can transmit data only to a small number of MSs for a given time. The BS selects MSs satisfying a semi-orthogonal criterion from among the MSs located in its service zone, as MSs to which it will simultaneously transmit data in the same time period. The semi-orthogonal criterion may include a value used for determining whether each MS is in an orthogonal state, a Signal to Noise Ratio (SNR) threshold, and the like. For example, the value used for detecting the orthogonal state can be CSI.
[0006] A description will now be made of an operation in which the BS chooses the MSs to which it simultaneously transmits data in the same time period.
[0007] The BS receives CSI that is fed back from each of multiple MSs, and selects MSs in their semi-orthogonal state by comparing the received CSIs with the semi-orthogonal criterion. In other words, the BS compares CSIs fed back from multiple MSs with a predetermined reference CSI, and chooses MSs that have fed back CSI being greater than or equal to the reference CSI, as MSs in a semi-orthogonal state. In addition, a scheduling method by which the BS receives CSIs from MSs can be roughly classified into a periodic scheduling method and a dynamic scheduling method. In the periodic scheduling method, the BS receives CSIs fed back from MSs only in a specific period of a downlink (DL) frame. In the dynamic scheduling method, the BS sends a CSI feedback request to MSs whenever the need arises.
[0008] Regarding the periodic scheduling method, since the BS receives CSIs from MSs only in a predetermined time period, the MSs may suffer from an increase in CSI feedback delay, and the number of MSs from which the BS can receive CSIs may be limited undesirably. Also, as to the dynamic scheduling method, a downlink control signal needed for the CSI feedback request acts as overhead.
[0009] As described above, when using SDMA, the BS must receive all CSIs from multiple MSs in the same time period, in order to choose MSs in a semi-orthogonal state. The BS selects semi-orthogonal MSs by comparing the received CSIs with the reference CSI, thus causing an increase in computation.
SUMMARY OF THE INVENTION
[0010] To address the above-discussed deficiencies of the prior art, it is a primary aspect of the present invention 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 provides a CSI feedback method and apparatus for reducing overhead in an SDMA communication system.
[0011] Another aspect of the present invention provides a method for reducing overhead caused by CSI feedback and an SDMA communication system supporting the same.
[0012] According to one aspect of the present invention, there is provided a method for feeding back CSI by a BS in a communication system using SDMA. The CSI feedback method includes grouping MSs into at least two groups; allocating a second feedback channel, over which CSI is to be fed back, to semi-orthogonal MSs having a semi-orthogonal relationship with MSs included in a first group, that is one of the at least two groups among MSs included in a second group that is one of the at least two groups and is different from the first group; receiving CSIs being fed back from the semi-orthogonal MSs through the second feedback channel; and selecting at least one MS satisfying a semi-orthogonal criterion to the MSs included in the first group from among the semi-orthogonal MSs that feed back CSIs through the second feedback channel.
[0013] According to another aspect of the present invention, there is provided a method for feeding back CSI by a MS in a communication system using SDMA. The CSI feedback method includes monitoring CSIs which are fed back through a first feedback channel from MSs included in a first group being different from a group in which the MS is included; and transmitting CSI of the MS to a BS through a second feedback channel, when there is any CSI being semi-orthogonal to the CSI of the MS among the monitored CSIs.
[0014] According to yet another aspect of the present invention, there is provided a communication system using SDMA, for feeding back CSI. The communication system includes a BS and a plurality of MSs. The BS groups the plurality of MSs into at least two groups, allocates a second feedback channel over which CSI is to be fed back to semi-orthogonal MSs having a semi-orthogonal relationship with MSs included in a first group that is one of the at least two groups, among MSs included in a second group that is one of the at least two groups and is different from the first group, receives CSIs being fed back from the semi-orthogonal MSs through the second feedback channel, and selects at least one MS satisfying a semi-orthogonal criterion to the MSs included in the first group from among the semi-orthogonal MSs that feed back CSIs through the second feedback channel.
[0015] According to yet another aspect of the present invention, there is provided a communication system using SDMA for feeding back CSI. The communication system includes a BS, a MS, and a first-group of MSs, the MSs included in the first group being different from a group in which the MS is included. The MS monitors CSIs of the first-group of MSs, which are fed back through a first feedback channel, and transmits CSI of the MS to a BS through a second feedback channel when there is any CSI being semi-orthogonal to the CSI of the MS among the monitored CSIs.
[0016] Before undertaking the DETAILED DESCRIPTION OF THE INVENTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0018] FIG. 1 is a diagram illustrating a frame structure for an SDMA communication system according to an embodiment of the present invention;
[0019] FIG. 2 is a diagram illustrating area configuration of a SDMA communication system according to an embodiment of the present invention;
[0020] FIG. 3 is a flowchart illustrating an operation process of a BS in an SDMA communication system according to an embodiment of the present invention;
[0021] FIG. 4 is a flowchart illustration an example of an MS's operation process corresponding to the base station's operation process of FIG. 3 ; and
[0022] FIG. 5 is a flowchart illustrating another example of a mobile station's operation process corresponding to the base station's operation process of FIG. 3 .
[0023] Throughout the drawings, the same drawing reference numerals will be understood to refer to the same elements, features and structures.
DETAILED DESCRIPTION OF THE INVENTION
[0024] 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 clarity and conciseness.
[0025] The present invention provides an apparatus and method in which a BS selects semi-orthogonal MSs to which it will transmit data for the same time period, while reducing feedback overhead for CSI in a communication system using SDMA.
[0026] FIG. 1 is a diagram illustrating a frame structure for an SDMA communication system according to an embodiment of the present invention.
[0027] Referring to FIG. 1 , one frame includes a downlink (DL) subframe 110 and an uplink (UL) subframe 120 . The downlink subframe 110 includes a downlink preamble region 111 , and the uplink subframe 120 includes a first feedback channel region 121 and a second feedback channel region 123 . The first feedback channel region 121 and the second feedback channel region 123 are allocated such that they are spaced by a time period T. In some embodiments, the time period T is assumed to be set longer than an Rx-to-Tx turnaround Time Gap (RTG).
[0028] The first feedback channel region 121 , a region that is allocated in every uplink subframe on a regular basis, has a very small capacity. Further, the first feedback channel region 121 is a region where a first feedback channel is allocated and an MS feeds back its CSI and Channel Quality Information (CQI) to a BS over the first feedback channel.
[0029] The second feedback channel region 123 is a region that is additionally allocated in every uplink subframe. The second feedback channel region 123 is a region where a second feedback channel is allocated. The second feedback channel is a contention-based random access feedback channel.
[0030] Although one UL subframe has been described in FIG. 1 by way of example, when the number of UL subframes constituting one frame is K, the first feedback channel region and the second feedback channel region are allocated in each of K UL subframes.
[0031] FIG. 2 is a diagram illustrating an area configuration of a SDMA communication system according to an embodiment of the present invention.
[0032] Referring to FIG. 2 , only a part of the total area 200 of the SDMA communication system can be an area where it is efficient to use SDMA. For example, an SDMA area 210 can be the area where it is efficient to use SDMA. BS 212 selects semi-orthogonal MSs in the SDMA area 210 that satisfy a predetermined semi-orthogonal criterion. When N MSs exist in the SDMA area 210 , the BS 212 simultaneously schedules the N MSs in the same time period using the same frequency resources. MSs situated in the SDMA area 210 are characterized to have a higher Signal Noise Ratio (SNR) and a lower moving velocity. The semi-orthogonal criterion is identical to a semi-orthogonal criterion generally used to employ SDMA, and has nothing to do with the gist of the present invention, so a detailed description thereof will not be provided.
[0033] With reference to FIGS. 1 and 2 , a description will now be made of a method wherein the BS 212 chooses semi-orthogonal MSs in the SDMA area 210 . In the following description, it will be assumed that the full frame includes K UL subframes and a first feedback channel is allocated at a slot #k in each of the K UL subframes. In such embodiments, k denotes an index of an uplink subframe.
[0034] For example, the BS 212 groups N MSs into M groups. The MSs may undergo grouping according to a predetermined standard, or is subject to random grouping. In such example, M is less than N and, as regards to the number of MSs included in each group, the number of MSs included in the next group is much less than the number of MSs included in the previous group on a sequential basis.
[0035] The BS allocates a first feedback channel at a slot # 1 to MSs included in a first group among the M groups. Thereafter, each of the MSs included in the first group feeds back CSI through the first feedback channel at the slot # 1 . The CSI fed back by each of the MSs includes a Connection Identifier (CID) of the corresponding MS.
[0036] In the meantime, all the remaining MSs except for the MSs included in the first group will listen to CSIs which are transmitted through the first feedback channel at the slot # 1 . On the other hand, in the region where the first feedback channel is allocated, the remaining MSs, except for the MSs included in the first group, cannot transmit traffics.
[0037] MSs belonging to a second group, out of the M groups, determine whether there is any CSI, among the CSIs they have listened to, semi-orthogonal to their own CSI. If it is determined that there is any semi-orthogonal CSI among the CSIs, that the MSs included in the first group have transmitted, the MSs belonging to the second group, that have the semi-orthogonal CSI, feed back their CSI to the BS through a second feedback channel at the slot # 1 . Among the MSs included in the second group, an MS having CSI semi-orthogonal to the CSIs, that the MSs included in the first group have transmitted, will be referred to herein as a “second semi-orthogonal MS.”
[0038] MSs in the remaining groups, except for the MSs included in the first and second groups, will also listen to CSIs of MSs included in the first group being fed back over the first feedback channel, and CSIs of the second semi-orthogonal MSs being fed back through the second feedback channel, like the MSs included in the second group.
[0039] MSs included in a third group determine whether there are any CSI, among the MSs' CSIs being fed back through the first feedback channel and the CSIs of the second semi-orthogonal MSs, being fed back over the second feedback channel, semi-orthogonal to their own CSI. If it is determined that there are any CSI semi-orthogonal to the CSIs transmitted over the first feedback channel and the CSIs transmitted through the second feedback channel, MSs having the semi-orthogonal CSI, among the MSs included in the third group, feed back their own CSI to the BS over the second feedback channel of a slot # 2 . Among the MSs included in the third group, an MS having CSI semi-orthogonal to the CSIs, that the MSs included in the first group have transmitted and the CSIs that the second semi-orthogonal MSs have transmitted, will be referred to herein as a “third semi-orthogonal MS.”
[0040] Similarly, all of MSs included in the remaining groups, except for the MSs included in the first and second groups, will proceed with the above procedure on a sequential basis.
[0041] With reference to FIGS. 3 to 5 , embodiments of the present invention will be described in detail. In the following description, a BS can group MSs into, for example, two groups: a first group and a second group.
[0042] FIG. 3 is a flowchart illustrating an operation process of a BS in an SDMA communication system according to an embodiment of the present invention.
[0043] Before a description of FIG. 3 is given, it will be assumed that N MSs are located in an SDMA area in a service zone managed by the BS.
[0044] Referring to FIG. 3 , in step 300 , the BS groups the N MSs into 2 groups: a first group and a second group. In step 305 , the BS allocates a first feedback channel to MSs included in the first group. Although not separately illustrated in FIG. 3 , among the MSs included in the second group, MSs, CSIs of which are semi-orthogonal to the CSIs being fed back through the first feedback channel, will feed back their CSIs through the second feedback channel. In some embodiments, the MSs that feed back their CSIs over the second feedback channel are MSs that have a semi-orthogonal relationship corresponding to a predetermined semi-orthogonal criterion acquired by monitoring the CSIs transmitted through the first feedback channel from among the MSs included in the second group.
[0045] In step 310 , the BS chooses MSs that have fed back the CSIs received through the second feedback channel, as MSs included in the first group and MSs in a semi-orthogonal state. In such embodiments, the BS chooses the MSs included in the first group and the MSs in the semi-orthogonal state using the predetermined semi-orthogonal criterion. It will be understood that the operation in which the BS selects the MSs included in the first group and the MSs in the semi-orthogonal state is not directly related to the scope of the present invention, so a detailed description thereof will be omitted herein.
[0046] In step 315 , the BS creates a beam forming pattern for the selected MSs. In step 320 , the BS transmits data to the selected MSs using the generated beam forming pattern.
[0047] FIG. 4 is a flowchart illustration an example of an MS's operation process corresponding to the BS's operation process of FIG. 3 .
[0048] Referring to FIG. 4 , in step 400 , each of MSs included in the second group listens to CSIs transmitted over the first feedback channel from MSs included in the first group. In step 405 , each of the MSs included in the second group determines whether there are any CSI, among the listened CSIs, semi-orthogonal to its own CSI. If it is determined that there are any semi-orthogonal CSI, the corresponding MS, i.e., a second semi-orthogonal MS, proceeds to step 410 where the second semi-orthogonal MS feeds back its own CSI over the second feedback channel.
[0049] However, if it is determined, in step 405 , that there is no semi-orthogonal CSI, each of the MSs included in the second group proceeds to step 415 where each of the MSs waits for CSI received through a first feedback channel of the next frame. Thereafter, the MS returns to step 405 upon receiving CSI through the first feedback channel of the next frame and ends the process upon failure to receive the CSI.
[0050] The above MS's operation is carried out in every frame.
[0051] FIG. 5 is a flowchart illustrating another example of an MS's operation process corresponding to the BS's operation process of FIG. 3 .
[0052] Referring to FIG. 5 , in step 500 , each of the MSs included in the second group listens to CSIs transmitted through the first feedback channel from MSs included in the first group. In step 505 , each of the MSs included in the second group determines whether there are any CSI, among the listened CSIs semi-orthogonal to its own CSI. If it is determined that there are any semi-orthogonal CSI, the corresponding MS, i.e., a second semi-orthogonal MS, proceeds to step 510 where the second semi-orthogonal MS determines CSI having the optimal semi-orthogonal relationship with its own CSI, if there are at least two CSIs being semi-orthogonal to its CSI. In step 515 , the second semi-orthogonal MS transmits a CID of the MS included in the first group, which has transmitted the CSI having the optimal semi-orthogonal relationship with its own CSI, to the BS through the second feedback channel.
[0053] However, if it is determined, in step 505 , that there is no semi-orthogonal CSI, each of the MSs included in the second group proceeds to step 520 where each of the MSs waits for CSI received through the first feedback channel of the next frame. Thereafter, the MS returns to step 505 upon receiving CSI through the first feedback channel of the next frame and ends the process upon failure to receive the CSI.
[0054] The above MS's operation is performed in every frame.
[0055] As is apparent from the foregoing description, the present invention contributes to a reduction in CSI feedback needed to select semi-orthogonal MSs in the SDMA communication system. Therefore, the present invention can reduce CSI feedback overhead in the SDMA communication system, thus improving performance of the SDMA communication system.
[0056] Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims.
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According to one aspect of the present invention, there is provided a method for feeding back Channel State Information (CSI) by a Base Station (BS) in a communication system using Space Division Multiple Access (SDMA). The CSI feedback method includes grouping Mobile Stations (MSs) into at least two groups; allocating a second feedback channel over which CSI is to be fed back, to semi-orthogonal MSs having a semi-orthogonal relationship with MSs included in a first group which is one of the at least two groups, among MSs included in a second group which is one of the at least two groups and is different from the first group; receiving CSIs being fed back from the semi-orthogonal MSs through the second feedback channel; and selecting at least one MS satisfying a semi-orthogonal criterion to the MSs included in the first group from among the semi-orthogonal MSs that feed back CSIs through the second feedback channel.
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FIELD OF THE INVENTION
The present invention is generally related to methods of sampling subterranean formations of low permeability particularly tight gas bearing formations.
BACKGROUND
The oil and gas industry typically conducts comprehensive evaluation of underground hydrocarbon reservoirs prior to their development. Formation evaluation procedures generally involve collection of formation fluid samples for analysis of their hydrocarbon content, estimation of the formation permeability and directional uniformity, determination of the formation fluid pressure, and many other parameters. Measurements of such parameters of the geological formation are typically performed using many devices including downhole formation testing tools.
Recent formation testing tools generally comprise an elongated tubular body divided into several modules serving predetermined functions. A typical tool may have a hydraulic power module that converts electrical into hydraulic power; a telemetry module that provides electrical and data communication between the modules and an uphole control unit; one or more probe modules collecting samples of the formation fluids; a flow control module regulating the flow of formation and other fluids in and out of the tool; and a sample collection module that may contain various size chambers for storage of the collected fluid samples. The various modules of such a tool can be arranged differently depending on the specific testing application, and may further include special testing modules, such as NMR measurement equipment. In certain applications the tool may be attached to a drill bit for logging-while-drilling (LWD) or measurement-while drilling (MWD) purposes.
Among the various techniques for performing formation evaluation (i.e., interrogating and analyzing the surrounding formation regions for the presence of oil and gas) in open, uncased boreholes have been described, for example, in U.S. Pat. Nos. 4,860,581 and 4,936,139, assigned to the assignee of the present invention. An example of this class of tools is Schlumberger's MDT™, a modular dynamic fluid testing tool, which further includes modules capable of analyzing the sampled fluids. In a variant of the method the sampler is located between a pair of straddle packers to isolate a section of a well which can then be fractured and sampled.
To enable the same sampling in cased boreholes, which are lined with a steel tube, sampling tools have been combined with perforating tools. Such cased hole formation sampling tools are described, for example, in the U.S. Pat. No. 7,380,599 to T. Fields et al. and further citing the U.S. Pat. Nos. 5,195,588; 5,692,565; 5,746,279; 5,779,085; 5,687,806; and 6,119,782, all of which are assigned to the assignee of the present invention. The '588 patent by Dave describes a downhole formation testing tool which can reseal a hole or perforation in a cased borehole wall. The '565 patent by MacDougall et al. describes a downhole tool with a single bit on a flexible shaft for drilling, sampling through, and subsequently sealing multiple holes of a cased borehole. The '279 patent by Havlinek et al. describes an apparatus and method for overcoming bit-life limitations by carrying multiple bits, each of which are employed to drill only one hole. The '806 patent by Salwasser et al. describes a technique for increasing the weight-on-bit delivered by the bit on the flexible shaft by using a hydraulic piston.
Another perforating technique is described in U.S. Pat. No. 6,167,968 assigned to Penetrators Canada. The '968 patent discloses a rather complex perforating system involving the use of a milling bit for drilling steel casing and a rock bit on a flexible shaft for drilling formation and cement.
U.S. Pat. No. 4,339,948 to Hallmark discloses an apparatus and methods for testing, then treating, then testing the same sealed off region of earth formation within a well bore. It employs a sealing pad arrangement carried by the well tool to seal the test region to permit flow of formation fluid from the region. A fluid sample taking arrangement in the tool is adapted to receive a fluid sample through the sealing pad from the test region and a pressure detector is connected to sense and indicate the build up of pressure from the fluid sample. A treating mechanism in the tool injects a treating fluid such as a mud-cleaning acid into said sealed test region of earth formation. A second fluid sample is taken through the sealing pad while the buildup of pressure from the second fluid sample is indicated.
Methods and tools for performing downhole fluid compatibility tests include obtaining an downhole fluid sample, mixing it with a test fluid, and detecting a reaction between the fluids are described in the co-owned U.S. Pat. No. 7,614,294 to P. Hegeman et al. The tools include a plurality of fluid chambers, a reversible pump and one or more sensors capable of detecting a reaction between the fluids. The patent refers to a downhole drilling tool for cased hole applications.
In the light of above known art it is seen as an object of the present invention to improve and extend methods of sampling downhole formations, particular “tight” formations of low permeability. Prominent examples of such tight formations are shale gas formations.
The sampling of tight shale gas formation, which can be very thick, poses a problem to existing sampling tools and methods as the reservoir fluids are not easily extracted from the formation. Hence it is not easy to determine whether a newly drilled section of tight formation is potentially productive or not, even though important technical and economic decisions depend on correct answers to this question.
Among the methods used are formation sampling with a straddle packer configuration, underbalanced drilling, which allows for influx from the reservoir into the drilled well, and exploration fracturing. The latter is an extensive fracturing process on par in cost and complexity with normal fracturing operations.
However none of the known methods are entirely satisfactory as formations can be too tight for the typical one square meter of wellbore wall between the pair of packers to produce a significant sample. Underbalanced drilling on the other hand is typically vastly more expansive and dangerous compared to conventional drilling and the reservoir depth of any gas influx is difficult to determine with the necessary precision. There is further the suspicion that tight formations may not release trapped gas until fractured.
Therefore it is seen as the only reliable method to fully fracture the formation for a comprehensive test. However fracturing thick formations along their entire length becomes a very expansive operation as shale gas formation may stretch for more than 1000 m and considering that exploration fracturing may only cover 20 m to 50 m intervals at a time and at a cost of several million dollars per interval. The problem of deriving new and improved testing methods is therefore one of great importance for tight formations.
SUMMARY OF INVENTION
Hence according to a first aspect of the invention there is provided a method of sampling a subterranean formation, including the steps of creating a side bore into the wall of a well traversing the formation, sealing the wall around the side bore to provide a pressure seal between the side bore and the well, pressurizing the side bore beyond a pressure inducing formation fracture while maintaining the seal, pumping a fracturing fluid adapted to prevent a complete closure of the fracture through the side bore into the fracture, and reversing the pumping to sample formation fluid through the fracture and the side bore.
The side bore is preferably drilled in direction of the maximum horizontal stress, if this direction is prior knowledge.
In a preferred embodiment the fracturing fluid adapted to prevent a complete closure of the fracture can carry either solid proppant or a corrosive component which is capable of etching away at the exposed surface of a fracture.
The method is furthermore best applied to formations of low permeability, which are believed to confine the spread of a fracture to the desired directions. A formation is considered to be of low permeability if the permeability at the test location is less than 100 mD (millidarcy) or less than 20 mD or even less than 10 mD. The methods is believed to be superior to existing sampling method for tight reservoirs, particularly shale gas reservoirs.
The method enables fracturing opening with minimal use of hydraulic fluids. With the new method the amount of fracturing fluid used and carried within the tool body can be less than 50 liters, preferable less than 20 liters and even less 5 liters including proppant or acidizing components of it. Besides being sufficiently small to be carried downhole with the body of tool, the small amount of fluid allows for the use of more specialized and hence more expensive fracturing fluids. Such specialized fluids include for example fluids with a sufficiently high density to keep proppant buoyant.
These and other aspects of the invention are described in greater detail below making reference to the following drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a typically deployment of a formation drilling and sampling tool while performing steps in accordance with an example of the present invention;
FIG. 2 illustrates the step of drilling a side bore to an existing well in accordance with an example of the present invention;
FIGS. 3A and 3B illustrate the step of fracturing the formation in the vicinity of a side bore in accordance with an example of the present invention; and
FIGS. 4A and 4B illustrate the step of sampling the formation in the vicinity of a side bore through a fracture in accordance with an example of the present invention.
DETAILED DESCRIPTION
In FIG. 1 , a well 11 is shown drilled through a formation 10 . The well 11 includes an upper cased section 11 - 1 and a lower openhole section 11 - 2 . The lower openhole section is shown with a layer 12 of formation damaged and invaded through a prior drilling process which left residuals of the drilling fluids in the layer surrounding the well.
In this example of the invention, a wireline tool 13 is lowered into the well 11 mounted onto a string of drillpipe 14 . The drill string 14 is suspended from the surface by means of a drilling rig 15 . In the example as illustrated, the wireline tool includes a formation testing device 13 - 1 combined with a formation drilling device 13 - 2 . Such tools are known per se and commonly used to collect reservoir fluid samples from cased sections of boreholes. The CHDT™ open hole drilling and testing tool as offered commercially by Schlumberger can be regarded as an example of such a tool. The connection to the surface is made using a wireline 13 - 3 partly guided along the drill string 14 (within the cased section 11 - 1 of the well 11 ) and partly within the drill string (in the open section 11 - 2 ).
The operation of this combined toolstring in a downhole operation in accordance with an example of the invention is illustrated schematically in the following FIGS. 2-4 .
In the example, it is assumed that the stresses around the well 11 have been logged using standard methods such acoustic or sonic logging. At a target depth, the tool 13 is oriented such that it is aligned in directions of the maximum horizontal stress. It is in this direction that fractures typically open first when the whole well is pressurized in a normal fracturing operation. The mounted tool 13 can be rotated by rotating the drill string 14 and thus assume any desired orientation in the well 11 .
Making use of the conventional operation mode of the CHDT tool 13 , the body 20 of the tool as shown in more detail in FIG. 2 includes a small formation drill bit 210 mounted on an internal flexible drill string 211 . While the tool is kept stationary using the sealing pad 22 and counterbalancing arms (not shown), the flexible drill 210 can be used to drill a small side bore 212 into the formation 10 surrounding the well 11 .
In the example, a 9 mm diameter hole 212 is drilled to an initial depth of 7.62 cm (3-in) before reaching the final depth of 15.24 cm (6-in). The drilling operation is monitored with real-time measurements of penetration, torque and weight on bit. The bit is automatically frequently tripped in and out of the hole to remove cuttings. The bit 210 trips can be manually repeated without drilling if a torque increase indicates a buildup of cuttings.
After the drilling of the side bore 212 , reservoir fluids are produced to clean it of any cuttings that could adversely affect the subsequent injection. After the clean-out, the pressure in the side bore 212 is increased by pumping a (fracturing) fluid either from a reservoir with the tool or from within the well through the tool.
As shown in FIG. 3A , the pump module 230 , which is a positive displacement pump when using the CHDT tool, is activated in reverse after completing the clean-out of the side bore 212 and a fluid is injected from an internal reservoir 231 through an inner flow line 232 of the tool into the side bore 212 . In the example the internal reservoir carries a highly viscous fracturing fluid mixed with a proppant. The fracturing fluid can include polymers or visco-elastic surfactants as known in the art of fracturing from the surface. The proppant can be sand or other particulate material including granular or fibrous material. To pump such viscous fluid it can be necessary to use actively controlled valves in the pump in place of simple spring loaded valves which have a propensity of clogging in the presence of a flow containing solid particles.
It is important for the present invention that the pad 22 maintains during the injection stages a seal against the well pressure Pw. The sealing pad in the present example seals an area of 7.3 cm by 4.5 cm. A pressure sensor 233 is used to monitor the pressure profile versus time during the operation. Any loss of seal can be noticed by comparing the pressure in the side bore with the well pressure Pw.
The injection pressure can be increased steps of for example 500 kPa increments, with pressure declines between each increment. Eventually the formation breakdown pressure is reached and a fracture 31 as shown in FIG. 3B develops at the location of the side bore 212 .
In the carbonate formation of 1-10 mD of the example the fracture initiation pressure was established as 19080 kPa. The fracturing fluid 32 and the proppant it carries fill the fracture as shown in FIG. 3B .
In the steps as illustrated in FIG. 4A and FIG. 4B , the pumping direction is reversed and initially the fracturing fluid is cleaned from the fracture leaving the proppant 33 behind. The role of the proppant is to prevent a closure of the fracture and hence maintain a channel of higher permeability through which formation fluid is drawn into the tool. Once the fracturing fluid ceases to block the fracture, formation fluids such as shale gas can enter the flow path into the tool as shown in FIG. 4B .
An optical analyzing module 40 as available in the MDT tool can be used to switch the tool from a clean-out mode to a sampling mode, in which the fluid pumped into a sampling container (not shown).
By confining the pressure to single location and smaller volume a much smaller volume of fluid is required for the fracturing testing. Conventional fracturing tests on open hole formations with pairs of straddle packers generate fractures by pressurizing the much larger volume of the well between the two packers and create hence much larger fractures. With new method volume of less than 100 liters or 50 liters, or even less 20 liters appear sufficient to perform the tests. In turn these small volumes enable the use of smaller high differential pumps which typically have a slow pump rate without extending the downhole test time.
Furthermore given the small volumes needed for the fracturing dedicated and expensive fracturing fluids can be used in the present invention which would otherwise be ruled out for fracturing from the surface for economic reasons.
For example very heavy liquids with densities up to 2.95 g/ml are available from commercial sources. Among these liquids are organic heavy liquids (TBE, bromoform), tungstate heavy liquids such as lithium heteropolytungstates (LST). The latter liquid can reach a density up to 2.95 g/mL at 25 C, and a density of 3.6 g/mL at elevated temperatures.
These heavy liquids will keep the proppant neutrally buoyant in the sample chamber and remove the need to use viscous fracturing fluids. Viscous fluids can damage the permeability of the induced fracture, and may have to be remedied by other “breaker” fluids. Suspending the proppant with buoyancy can be applied in a simpler fashion but is practical when only a small volume of the fluid is required, and when the weight of fracturing fluid does not influence the fracturing pressure. These conditions are not given in conventional fracturing operations when the fracturing fluid fills the well bore from reservoir to surface, and contributes to the pressure with its hydrostatic weight.
Another alternative method for preventing a complete closure of a fracture created is to include in the fluid a corrosive or acid component that damages the surfaces of the induced fracture thus preventing it from resealing. The acid achieves the same purpose as the proppant. This alternative is seen as more practical when small fluid volumes are involved, for example chosen from the range of 5-20 liters, than for conventional fracture operations where the entire well bore from reservoir to surface has to be filled with the fluid.
Moreover, while the preferred embodiments are described in connection with various illustrative processes, one skilled in the art will recognize that the system may be embodied using a variety of specific procedures and equipment. Accordingly, the invention should not be viewed as limited except by the scope of the appended claims.
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There is provided a method of sampling a subterranean formation. The method includes the steps of creating a side bore into the wall of a well traversing the formation, sealing the wall around the side bore to provide a pressure seal between the side bore and the well, pressurizing the side bore beyond a pressure inducing formation fracture while maintaining the seal, pumping a fracturing fluid adapted to prevent a complete closure of the fracture through the side bore into the fracture, and reversing the pumping to sample formation fluid through the fracture and the side bore.
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CROSS-REFERENCE TO RELATED APPLICATIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to machines for removing wrinkles from clothing and in particular to an improved agitator for such devices.
[0002] It has been suggested that wrinkles may be removed from clothing by gentle agitation of drying clothes as they hang on hangers. For example, U.S. Pat. No. 3,739,496 describes a finisher in which clothes are suspended on hangers held by a bar within the cabinet. The bar shaken from side to side while moistened or drying air is blown around the clothes. The combined action of the air flow and agitation of the garments removes the wrinkles with relatively little hand labor.
[0003] The agitation of the clothes may be performed by means of a motor driven crank connected by a crank arm to the bar holding the hangers. A similar crank mechanism for driving a hanger bar is described in U.S. Pat. No. 3,861,179.
[0004] Complete removal of wrinkles from clothing using this technique may require an hour or more to complete. It is therefore desirable that the agitation mechanism be quiet, energy efficient and long-lived. It is further desirable that the force of agitation be limited in the event of an obstruction of the reciprocating mechanism. It is also desirable that the agitation be smooth, reducing unnecessary shifting of and wear to the garments.
[0005] While the crank and crank arm of the prior art is relatively simple, it is not ideal in these other respects.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention provides an agitator that makes use of a natural resonance of the hanger bar to moderate agitating motion. The hanger bar is loosely supported to move freely in at least one dimension at the resonant frequency. In this way, the mass of the hanger bar and the clothes transform periodic force by an actuator into smooth sinusoidal motion. Force is applied to the hanger bar by a compliant elastic cord or other mechanism that may accommodate the hanger bar's natural resonant motion.
[0007] By eliminating the rigid crank drive mechanism of the prior art, noise transmission is decreased and the force of agitation is limited improving safety and decreasing clothes wear. A smaller motor may be used and energy saved because stalling of the motor under high loads is of less concern. The wear and friction associated with a crank arm linkage is eliminated.
[0008] Specifically, the present invention provides an agitator mechanism for use in a garment finisher of a type having a cabinet in which clothes supported on clothes hangers are shaken to remove wrinkles from the clothes. The agitator mechanism includes a hanger bar for holding at least one clothes hanger pendant therefrom and center biasing supports attached between the hanger arm and the cabinet to bias the hanger bar toward a center position so that when displaced from the center position and released, the hanger bar reciprocates at a natural frequency about that center position. An actuator provides a periodic force on the hanger bar near the natural frequency to cause reciprocation of the hanger bar.
[0009] Thus, it is one object of the invention to provide an extremely simple mechanism for producing smooth, near sinusoidal motion, decreasing noise harmonics and providing a gentle agitation of clothing.
[0010] The center biasing supports holding the hanger bar may be pendulum arms having lower ends attached to the hanger bar and upper ends attached to the cabinet allowing the hanger bar to swing therefrom at a natural frequency equal to the pendulum frequency.
[0011] Thus, it is another object of the invention to provide a reciprocation that is to a first order independent of the amount of weight of clothing hung on the hanger bar. Following the normal rules of a pendulum, the frequency of the reciprocation will be determined by the pendulum arm length not the mass of the clothes.
[0012] The pendulum arms may be an elastomeric material and may be mounted so as to flex slightly with reciprocation of the hanger bar.
[0013] It is another object of the invention therefore to dissipate some energy from the pendulum at high amplitudes to control the amplitude of the motion.
[0014] The hanger bar may include at least one outrigger extending perpendicular to a direction of reciprocation of the hanger bar and at least one of the pendulum arms may attach to an outrigger so that the pendulum arm provides at least three points of attachment to the hanger arm defining a plane.
[0015] Thus, it is another object of the invention to provide a simple mechanism for stably supporting the hanger bar to move predominately in one reciprocation direction.
[0016] The actuator may be a motor mounted on the hanger bar receiving power through flexible leads. The pendulum arms may be sound dampening.
[0017] It is thus another object of the invention to reduce sound transmitted to the cabinet and hence to outside the cabinet by placing the motor on the hanger bar isolated by the sound dampening of the pendulum arms.
[0018] The motor may be substantially centered on the hanger bar and the motor may fit within a cover attached to the cabinet having an aperture for passing the hanger bar through the cover.
[0019] It is thus another object of the invention for the balanced application of force to the hanger bar without direct access to the motor.
[0020] The actuator may be a motor positioned on either the hanger bar or the cabinet with an elastic linkage extending between the motor and the other of the hanger bar and the cabinet.
[0021] Thus, it is another object of the invention to provide a mechanism that naturally limits force and the conduction of sound between the cabinet and the hanger bar.
[0022] The force provided by the hanger bar may be a predetermined amount allowing the hanger bar to be stopped by hand without the stopping of the actuator.
[0023] It is another object of the invention to provide a mechanism that limits damage or motor over heating caused by jamming or obstruction of the hanger bar.
[0024] The foregoing objects and advantages may not apply to all embodiments of the inventions and are not intended to define the scope of the invention, for which purpose claims are provided. In the following description, reference is made to the accompanying drawings, which form a part hereof, and in which there is shown by way of illustration, a preferred embodiment of the invention. Such embodiment also does not define the scope of the invention and reference must be made therefore to the claims for this purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a perspective view of the agitation mechanism of the present invention showing a hanger bar suspended by pendulum arms to gently reciprocate pendant hangers, and showing a motor attached directly to the hanger arm and used to provide an exciting force to the hanger arm by means of an elastic strap;
[0026] [0026]FIG. 2 is schematic diagram in elevation of the mechanism of FIG. 1 showing the pendulum motion of the hanger bar under the application of a periodic exciting force;
[0027] [0027]FIG. 3 is a fragmentary perspective view of the pendulum arms of FIG. 1 such as may be constructed from a sound absorbing or elastomeric material to provide sound absorption and/or over travel damping of the pendulum motion;
[0028] [0028]FIG. 4 is a cross-sectional view along lines 4 - 4 of FIG. 1 showing engagement of the hanger with dual holes in the hanger bar to prevent rotation of the hangers about a vertical axis;
[0029] [0029]FIG. 5 is a fragmentary perspective view of a cover fitting over the motor of FIG. 1 and providing illumination of the clothes in the cabinet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring now to FIG. 1, the agitator mechanism 10 of the present invention may be fit within a cabinet (not shown) having sidewalls 12 and a ceiling 14 .
[0031] The agitator mechanism 10 includes a horizontally disposed hanger bar 16 suspended from beneath the ceiling 14 of the cabinet on pendulum arms 18 to reciprocate in a lateral direction 20 . The hanger bar is generally horizontal and includes holes 22 for receiving the hook end of hangers 24 which may hang below the hanger bar 16 .
[0032] At ends of the hanger bar 16 near sidewalls 12 , the hanger bar includes transversely extending outriggers 26 . The lower ends of pendulum arms 18 are attached to the transverse extreme ends of the outriggers 26 so that the points of attachment define a plane, preventing twisting of the hanger bar 16 about the lateral direction 20 .
[0033] Referring now to FIGS. 1 and 3, the upper ends of pendulum arms 18 are attached to hook brackets 28 that in turn are attached the ceiling 14 . Pendulum arms 18 may be “dog bone” shaped, having two transversely separated holes 30 in corresponding lobes 32 in the upper end of the pendulum arm 18 and to transversely separated holes 34 in corresponding lobes 32 in the lower end of the pendulum arm 18 .
[0034] The holes 34 in the lower end of the pendulum arm 18 may be attached to corresponding studs in the outriggers 26 and retained by compression of the elastomeric material around the holes 34 acting on expanded heads on the studs 36 when pushed through the holes 34 . In contrast, the holes 30 in the upper end of the pendulum arm 18 are oversized to be received by hooks 40 hanging from a bracket 28 .
[0035] The body of the pendulum arm 18 in horizontal cross-section has a greater transverse dimension 42 than longitudinal dimension 44 and this, in combination of the transverse orientation of the holes 30 and 34 provide that pendulum arms 18 preferentially allow motion along lateral direction 20 and resist other modes of reciprocation.
[0036] Referring now to FIG. 2, it will be understood that the hanger bar 16 and pendulum arms 18 together form a pendulum having a natural period of reciprocation dependent as a first order only on the length of the pendulum arms 18 . Accordingly, different weights and amounts of clothing on hangers 24 may be supported from the pendulum arm 18 without substantially upsetting the frequency of the oscillation. The ability of the hangers 24 to swing in the holes 22 further decouples the hangers from the hanger bar 16 . More generally, the hanger bar 16 may be mounted in any center-biased arrangement, for example, using springs or the like so that resonant excitation will cause it to reciprocate. Such mass-spring systems, however, do not have the advantage of the pendulum system in being indifferent to the weight of the garments.
[0037] Referring still to FIG. 2, each of the pendulum arms 18 provides for pendulum motion of its lower end about its upper end attached to the ceiling 14 of the cabinet. This causes reciprocation in lateral direction 20 of the hangers 24 and the clothes 46 such as draws wrinkles out of the clothes 46 and improves circulation of air and moisture between the clothes 46 . Normally the pendulum motion will die out, however, a periodic force 50 applied to the hanger bar 16 may sustain that motion.
[0038] At extreme points of travel 52 of the pendulum arms 18 , a flexure will occur in the pendulum arm 18 ′ caused by its rigid mounting to the outriggers 26 . This flexing takes energy from the hanger bar 16 thus controlling its amplitude of motion and making the amount of force 50 required for continued oscillation less sensitive.
[0039] Referring now to FIG. 1, one embodiment the periodic exciting force 50 may be applied to the hanger bar 16 by a motor 54 mounted at the center of the hanger bar 16 . The motor 54 may include an eccentric or crank disk 56 attached to rotate around a motor shaft with a crank point 58 eccentric thereto. The crank point 58 may be tied through elastic cord 60 to one or both opposing sidewalls 12 . By mounting the motor on the hanger arm, the direct path of sound conduction to the cabinet is thereby eliminated with the elastomeric material of the pendulum arms 18 and the elastic cord 60 serving to damp out the conduction of motor noise to the cabinet.
[0040] Equally important, a rigid connection between the hanger bar 16 and the cabinet side walls 12 is eliminated, decoupling motion of the hanger bar 16 from the motion of the motor allowing the resonance of the hanger bar 16 to smooth the reciprocating action. Other mechanisms for applying a force without limiting freedom of motion include, for example, jets of air or pulsating magnetic attraction or the like. The profile over time of the applied force is not critical because the natural resonance of the hanger bar 16 tends to convert it to a sinusoidal motion. Sinusoidal motion reduces harmonic noise and limits the forces applied to the clothes. Nevertheless, in the preferred embodiment, the profile of the force is desirably near sinusoidal and of a frequency near the natural resonant frequency of the hanger bar 16 as loaded with clothing and the motor 54 . The pendulum arms 18 may be freely adjusted in length to control the desired frequency of operation of the reciprocation.
[0041] Referring now to FIGS. 1 and 5, by mounting the motor 54 in a central location on the hanger bar 16 , access on either side of the motor may be had for hangers 24 and the loading of the hanger bar 16 may be evenly distributed reducing any tendency of the hanger bar to reciprocate off the lateral axis 20 . A cover 64 may be placed over the motor 54 and attached to the ceiling 14 (or to an upper cover) and to the rear wall 70 of the cabinet to fully enclose the mechanism of the motor 54 . The coupling between the motor 54 and the side walls 12 of the cabinet is force limited by the elastic cord 60 and thus the hanger bar 16 protruding from the cover 64 may be stopped by hand and high forces are not generated in the event of jamming of the hanger bar 16 or catching of clothing or the like. Adjustment of the force may be by adjustment of the spring constant (i.e., thickness) of the elastic cord 60 and the eccentricity of the crank disk 56 .
[0042] The cover 64 may include courtesy lamps 66 for lighting the inside of the cabinet when the cabinet door is open. A cabinet door switch (not shown) controlling the courtesy lamps 66 may serve as an interlock for the motor 54 .
[0043] Flexible leads 65 may connect the motor 54 to a connector 68 on the rear wall 70 of the cabinet and may be covered by the cover 64 .
[0044] Referring now to FIG. 4, the hanger bar 16 may include two vertically extending rails 17 so as to provide transversely spaced apart holes 22 A and 22 B such as engage the hanger 24 to prevent rotation of the hanger 24 about a vertical axis such as might cause rubbing of the clothing or oscillation of the hangers out of the lateral direction 20 .
[0045] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but that modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments also be included as come within the scope of the following claims.
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An agitator mechanism for a clothes finishing cabinet provides a pendulum mounted hanger bar that may reciprocate under the application of a periodic force by an actuator without rigid connection between the cabinet housing and the hanger bar. Quiet operation is obtained by mounting an actuator motor directly on the hanger bar to be isolated by sound absorbing hanger support materials.
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The present application is a continuation of U.S. application Ser. No. 12/758,733, filed Apr. 12, 2010, entitled Supervisory Control and Data Acquisition System for Energy Extracting Vessel Navigation, which is a continuation of U.S. application Ser. No. 11/942,576, filed Nov. 19, 2007, entitled Supervisory Control and Data Acquisition System for Energy Extracting Vessel Navigation, now U.S. Pat. No. 7,698,024, the entire contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally in the field of supervisory control and data acquisition systems. More specifically, the present invention is embodied in a remote control system particularly for operation and navigation of a mobile structure that optimally recovers energy from an offshore marine environment.
2. Description of the Related Art
While many systems exist today for recovery of wind energy and water current or wave energy, most systems are stationary, mounted on or anchored to the sea floor. Many other hydrokinetic turbine energy systems exist today that affix to sailing vessels overcoming the limitations of fixed stationary structures. Nonetheless, all wind and hydrokinetic systems have the fundamental limitation of total possible recoverable energy at any given time being directly proportional to the cube of the velocity of the motive fluids. This inherent limitation renders most of these systems economically infeasible when considering the manufacturing and operational costs of the system and the typical ambient wind and water current vectors rarely summing to a magnitude greater than twenty knots. While sailing vessel designs exist such as catamarans, which reputedly can exceed true wind speed, the function of immersing a hydrokinetic turbine as an appendage of such a vessel immediately incurs drag upon the vessel ultimately to reduce the speed of the motive fluid through the turbine to unprofitable energy recovery rates. U.S. Pat. No. 7,298,056 for a Turbine-Integrated Hydrofoil addresses an implementation of a drag-reducing appendage as means to an economically viable solution. The specification of this reference application suggests remote controlled operation but does not expressly depict intentional unmanned operation of such a mobile structure for economic benefit into an environment of such high energy as to otherwise present conditions hazardous to human crews. The aforementioned reference patent application also does not delineate the various parts of the communication system in detail, thus does not enable in full, clear, concise, and exact terms, one skilled in the art to reduce such a remote control system to practice.
Therefore, there exists a need for a novel Supervisory Control And Data Acquisition system that remotely controls the operation and particularly the navigation of a mobile structure that can cost-effectively extract energy in an optimal manner from an environment that inherently presents untenable risk to human life.
SUMMARY OF THE INVENTION
The present invention is directed to a novel Supervisory Control And Data Acquisition (SCADA) remote control system for a mobile structure that recovers naturally occurring energy from severe weather patterns. The present specification embodies an offshore energy recovery system wherein an algorithm optimizes efficiency in the system by accounting for data from weather observations, and from sensors on the mobile structure, while relating these data points to performance models for the mobile structure itself. The present specification exemplifies the use of the algorithm in navigating a sailing vessel optimized to reduce drag while responding to wind and water velocity vectors by adjusting points of sail, rudder rotation, openness of turbine gates, and ballast draft, through control outputs from the microprocessor system on-board the sailing vessel. The SCADA system includes computer servers that gather data through diverse means such as Global Position Satellite (GPS) systems, weather satellite systems of the National Aeronautics and Space Administration (NASA), the National Oceanic and Atmospheric Administration (NOAA), and United States Air Force Defense Meteorological Satellite Program (DMSP) communicated through various geographic and weather data resources including but not limited to the Geographic Information System (GIS) of NOAA's National Weather Service (NWS) along with all other weather information sources available from its National Hurricane Center (NHC) and Tropical Prediction Center (TPC). The SCADA computer servers run Human Machine Interface (HMI) secure software applications which communicate to microprocessor systems running client software with a Graphical User Interface (GUI) to allow remote humans to optionally interact and choose mission critical navigation plans.
In addition, the present invention is not limited to implementation of the exemplary referenced Turbine-Integrated Hydrofoil system of U.S. Pat. No. 7,298,056. The present invention applies to remote control of any system that exploits energy from weather patterns that avail formidable amounts of naturally occurring energy. Any mobile structure that extracts energy from electrical storms, windstorms, offshore tropical storms or hurricanes, or any aerodynamic or hydrokinetic electromechanical mobile system for renewable energy recovery under remote control especially benefits from the present invention. Otherwise whereby without the present invention that enables a mobile system to automatically track environmental conditions hazardous to humans anywhere in the universe, such risks of danger renders manned operation undesirable and thus the cost benefits and ease of implementation of such energy exploitation systems unrealizable.
Finally, because the system embodied within the present invention comprises an algorithm that optimizes energy extraction using yield functions derived from weather and geospatial data and vessel performance models, the same system using just the path cost algorithm without weighing energy extraction yield factors into the cost of travel, may guide navigation of vessels for logistics-only purposes past such weather patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a top-level view of all components in an exemplary system in accordance with one embodiment of the present invention.
FIG. 2 illustrates a block diagram of the control, communications, and computer systems running server and client software applications in an exemplary system.
FIG. 3 illustrates electromechanical circuits for actuating control of various mechanisms affecting position and velocity of the mobile structure in an exemplary system.
FIG. 4 illustrates a representation of the graphical user interface on a client computer system in one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention pertains to a remote control system and algorithm for supervisory control and data acquisition enabling navigation and automatic operation of a mobile energy recovery system. The following description contains specific information pertaining to various embodiments and implementations of the invention. One skilled in the art will recognize that one may practice the present invention in a manner different from that specifically depicted in the present specification. Furthermore, the present specification need not represent some of the specific details of the present invention in order to not obscure the invention. A person of ordinary skill in the art would have knowledge of such specific details not described in the present specification. Obviously, others may omit or only partially implement some features of the present invention and remain well within the scope and spirit of the present invention.
The following drawings and their accompanying detailed description apply as merely exemplary and not restrictive embodiments of the invention. To maintain brevity, the present specification has not exhaustively described all other embodiments of the invention that use the principles of the present invention and has not exhaustively illustrated all other embodiments in the present drawings.
FIG. 1 illustrates a top-level diagram of all components of an exemplary practical embodiment of the present invention. Block 100 represents an offshore mobile energy recovery structure in the process of energy extraction in an exemplary embodiment of the present invention. Exemplary embodiments of mobile structure 100 include sailing or propelled vessels or barges or any mobile buoyant energy recovery system known by one of ordinary skill in the art. A non-exhaustive list of mobile structures 100 for energy recovery includes: the Turbine-Integrated Hydrofoil of U.S. Pat. No. 7,298,056; any wave energy conversion system with propulsion means allowing relocation; one or plural wind turbines on floating platforms with propulsion means allowing relocation; or one or plural lightening rods on floating platforms with propulsion means allowing relocation for extracting energy from electrical storms; or any mobile system that extracts energy from pneumatic and/or hydrokinetic sources with aerodynamic and/or hydrodynamic drive means. The aforementioned list of mobile structures 100 represents purely exemplary embodiments by no means restrictive of mobile structure 100 embodiments within the scope and spirit of the present invention. FIG. 1 further depicts mobile structure 100 in the process of energy extraction circumnavigating what appears to be a vortical weather pattern 101 . As one may infer from the counterclockwise vortex streamlines, the weather pattern 101 manifests in the northern hemisphere as implied by the Coriolis effect. Note that this representation of a weather pattern 101 is strictly exemplary and that a weather pattern 101 consistent with a description of a cyclone in the southern hemisphere; a typhoon in south east Asia; a williwaw non-vortical gap flow or barrier jet wind storm offshore from the Alaskan coast or similar weather pattern elsewhere; any tropical storm; or any hurricane, remains well within the scope of a weather pattern 101 for the purposes of the present invention. The exemplary embodiment further comprises a central service facility 102 for the purpose of service logging, maintenance, and bulk energy storage for later distribution, and especially where the remote control of the mobile structure 100 occurs. One may note that energy storage comprises compressed hydrogen, metal hydride storage, or charged batteries or capacitors, as long as the mobile structure 104 and the central service facility 102 employ energy storage systems with compatible upload interfaces. The graphical representation of the central service facility 102 in FIG. 1 evokes the notion of a large vessel such as a tanker ship, but a port facility equally qualifies as a central service facility 102 within the scope of the present invention. The depiction of mobile structure 103 en route to the weather pattern 101 and mobile structure 104 returning to the central service facility 102 emphasizes that complete round-trip operation of one or plural mobile structures 100 , 103 , 104 , whether engaged in energy recovery as in mobile structure 100 or returning a payload as in mobile structure 104 , essentially comprises tasks performed by the remote control system of the present invention.
Essential to the operation of the complete SCADA system is the communication of data from various sources. FIG. 1 further illustrates three types of satellites, Global Position Satellites (GPS) 106 , weather satellites 105 , and telecommunications satellites 107 , comprising the SCADA remote control system in this exemplary embodiment. In practically all embodiments, the SCADA system tracks the position and velocity of the mobile structure 100 through a GPS 106 system. The central service facility 102 , if itself indeed mobile, likely also tracks its own location using a GPS 106 system. This specification will further expound upon the use of the GPS 106 system as a SCADA control algorithm input in subsequent paragraphs describing FIG. 4 . This specification will hereinafter use the generic term weather satellite 105 when referring to any of the weather tracking satellites availing weather data to various government and private entities. A non-exhaustive list of weather satellites 105 able to serve this function includes: the NASA QuikSCAT; the NOAA Synthetic Aperture Radar (SAR) satellites including Radarsat-1, and Envisat satellites; any of the satellites serving the NOAA Satellite Services Division (SSD) National Environmental Satellite Data and Information Service (NESDIS) including Meteosat-7, Eumetsat, MTSAT-IR, Global Earth Observation Systems, GOES-EAST (GOES-12), GOES-WEST (GOES-11), GOES-9, GOES-10, GOES-13, or POES satellites. The aforementioned list of weather satellites 105 represents purely exemplary embodiments by no means restrictive of weather satellites 105 embodiments within the scope and spirit of the present invention. Telecommunications satellites 107 represent how data communicates between the central service facility 102 and one or plural of many possible entities including those accessible through the Internet from where all weather data in this exemplary embodiment disseminates, such as from the National Weather Service 108 Geographic Information System (GIS) computer servers. Besides weather satellite 105 data, the NWS 108 GIS and many other such entities including those accessible through the Internet disseminate weather data from other sources such as: oceanic weather buoys; coastal meteorology stations, Coastal Marine Automated Network Stations (C-MAN); NOAA Aircraft Operations Center; NOAA National Hurricane Center (NHC) Aircraft Reconnaissance “Hurricane Hunters”; United States Air Force 53rd Weather Reconnaissance Squadron; USAF GPS Dropwindsondes; and RIDGE radar. The aforementioned non-exhaustive list of alternate sources of weather information disseminated from the NWS 108 or similar weather data disseminating entities including those accessible through the Internet represents exemplary but not restrictive sources of weather data alternate to weather satellite 105 sources. The physical location of dissemination of data such as within an NWS 108 GIS computer server or similar weather data disseminating entities including those accessible through the Internet appears terrestrial-based; in other words, the hardware resides on physical object 109 , such as a landmass or seamount. Obviously, if the central service facility 102 existed at a port on shore, a more cost-effective and potentially higher bandwidth data communications link such as fiber optic cable thus supplants the telecommunications satellites 107 in communication with the NWS 108 GIS or other similar weather data disseminating computer servers. Telecommunications satellites 107 perform another function in an exemplary system such as communicating between the central service facility 102 and the mobile structure 100 . However, the preferred embodiment employs a more cost-effective wireless communications system communicating between the mobile structure 100 and the central service facility 102 upon which this present specification will subsequently expound.
FIG. 2 illustrates an exemplary system wherein the mobile structure 100 further comprises a control and communications microprocessor system 200 along with the central service facility 102 further comprising a microprocessor system running secure server 204 software applications and workstations 209 running secure client software applications communicating with the server 204 via a Local Area Network (LAN) 207 . In some embodiments, all the secure server and client software applications running within the central service facility 102 may execute on a single large computing system, but given today's state of the art computing technology, a multi-processor server-client LAN 207 topology offers the greatest advantage in terms of flexible architecture, cost-effective computing power, reliability, scalability, and durability. In some embodiments, the control and communications microprocessor system 200 located within the mobile structure 100 comprises a type of microprocessor computing system 200 known as a Programmable Logic Controller (PLC). Traditionally evolving from industrial process control applications, a PLC 200 comprises ruggedized hardware robust to physical environments demanding resistance to mechanical shock and vibration, temperature extremes, and specifically, customization for control and communication purposes fitting SCADA system applications. Regardless of whether the microprocessor system 200 comprises custom hardware or an off-the-shelf product from a renowned PLC vendor, the microprocessor system 200 needs to execute certain functions as depicted in FIG. 2 in practically all embodiments. The microprocessor system 200 will require input, output, and input/output (I/O) functions 201 for communicating with sensors and control circuits. A wide variety of sensor and control circuits communicating with the microprocessor system 200 through I/O 201 necessary for inputting and outputting variables to the preferred SCADA control algorithm exist within most practical embodiments of the mobile structure 100 . A non-exhaustive list of sensor and control circuits 201 includes: accelerometers and gyroscopes for analysis of vessel 100 stability also known as attitude, or heeling and listing, along with heading, or to borrow aviation terms, pitch, roll and yaw, respectively, and rendering virtual contours of immediate local oceanic surface and possibly advanced features such as dead reckoning; ballast draft readings and adjustments; a wind vane and anemometer or if combined into a single unit an aerovane for analysis of apparent wind vectors' direction and magnitude respectively; fuel gauges for both propulsion motor fuel reserves and output fuel from energy recovery functions and thus mobile structure 100 weight and energy efficiency; electrolyzer electrode temperature gauges; energy extracting electric generator armature voltage readings and field current adjustments; energy extracting turbine gate opening readings and adjustments affecting mobile structure 100 drag; a compass for mobile structure 100 direction; a GPS receiver 202 for tracking position, velocity, and using way points to compare wind sensor data comprising local apparent wind vectors, minus mobile structure 100 velocity to determine local true wind vector, then comparing that empirical data to data from weather satellites 105 and other sources measuring and/or estimating true wind velocity; rudder rotation readings and adjustments; propeller rotational speed readings and adjustments; sail trim and/or boom rotation readings and adjustments; radar and/or sonar systems for physical object detection, identification, and avoidance; and one or plural video camera data streams allowing actual views of the surrounding environment of the mobile structure 100 , and physical object visual pattern matching. The aforementioned list of microprocessor I/O functions 201 represents purely exemplary embodiments by no means restrictive of I/O function 201 embodiments within the scope and spirit of the present invention. In terms of SCADA software data structure development, any or all of the aforementioned I/O functions 201 constitute one or plural SCADA object tag definitions, for various software layers to communicate from the mobile structure 100 microprocessor system 200 ; to the central service facility 102 servers 204 ; to the central service facility 102 workstations 209 . Weather satellite 105 data or alternate sources of weather information disseminated from the NWS 108 or similar weather data disseminating entities including those accessible through the Internet will also constitute SCADA object tag definitions. This specification will further expound upon the use of the SCADA object tags within the preferred SCADA control algorithm in subsequent paragraphs describing FIG. 4 .
The remaining functions associated with the microprocessor system 200 in FIG. 2 include the antenna 202 representing the receiver for the GPS system. The other antenna 203 represents the means by which the microprocessor system 200 of the mobile structure 100 receives and transmits over a wireless physical medium to the central service facility 102 server 204 . As previously mentioned, one system of communication 203 embodies satellite 107 telecommunications. In the preferred embodiments, as long as the mobile structure 100 remains within line-of-sight with the central service facility 102 , as one presumes on the open sea, a point-to-point Code Division Multiple Access (CDMA) system permitting high bandwidth data including video camera data streams provides the communications function in the preferred embodiment. Another wireless physical medium in the form of point-to-point Ultra High Frequency (UHF) radio exists. While of lower bandwidth, UHF offers wider range and does not require line-of-sight as does CDMA, and thus an embodiment of the present invention may incorporate UHF as a redundant back-up in case of loss-of-signal for the CDMA. For SCADA systems without video data streams, UHF may actually serve the primary communication channel function. These wireless telecommunications systems represent exemplary embodiments without restriction to other possible wireless telecommunications systems embodied within the scope and spirit of the present invention.
The central service facility 102 houses the server 204 for the primary purpose of aggregating weather data from anyone or plural weather data disseminating entities including those accessible through the internet such as the NWS 108 . Some embodiments achieve robust data reliability through implementing redundant or multiple servers 204 . The telecommunications system represented in FIG. 2 includes the link 205 to the mobile structure 100 and the link 206 to the NWS 108 or similar weather data disseminating entities including the Internet itself. On the central service facility 102 , link 205 and link 206 complete the channel with the mobile structure 100 and weather data disseminating entities including those accessible through the internet such as the NWS 108 , respectively, using physical mediums and protocols as previously discussed. The LAN 207 in exemplary embodiments conforms to such network standards as IEEE 802.3, 802.3u, 802.11a, b, or g or any standard suiting the needs of the server-client software applications in the present invention, and the Network Interface Cards (NIC's) 208 , hardware generally integrated into the workstations 209 , likewise conform to the aforementioned exemplary network standards. All embodiments very likely operate under the most common protocol implemented today, Transmission Control Protocol/Internet Protocol (TCP/IP) for passing of packets of data associated with SCADA object tags between the server 204 , the workstations 209 , and the PLC 200 . In an embodiment wherein the central service facility 102 resides on land 109 , the LAN 207 accesses a Wide Area Network (WAN) 211 for weather satellite 105 data or alternate sources of weather information disseminated from the NWS 108 or similar weather data disseminating entities including those accessible through the Internet through a router 210 instead of through a telecommunications satellite 107 as in an offshore central service facility 102 . Either the server 204 or the router 210 may execute firewall security software during network communications. Other forms of secure communication between the server 204 , the workstations 209 , and the PLC 200 may include Internet Protocol Security (lPSec) with packet encryption and decryption occurring during transmission and reception within TCP/IP for all the aforementioned computer systems. These network standards and protocols examples represent several of many possible network standards and protocols configurations within the scope of the present invention and one must view these network standards and protocols configurations as exemplary, not restrictive.
FIG. 3 illustrates the control-actuating electromechanical circuits in an embodiment of the mobile structure 100 . Exemplary controls on the mobile structure 100 , 103 , 104 include rudder rotation, propeller rotation in propelled embodiments, and sail trim or boom rotation in sailing embodiments. Actuation of all mechanical members begins with motor 300 activation by driving a current 317 through the motor's 300 winding 316 . As shown in FIG. 3 , the rotor 302 of the motor 300 affixed to a small gear 303 couples to a larger gear 306 affixed to an intermediate gear shaft 307 affixed to another small gear 308 coupled to another larger gear 309 affixed to the final drive shaft 310 in a direct drive system or to a worm 310 A in a worm drive system. A system comprising such gear ratios as depicted in FIG. 3 serves the purpose of reducing torque on the motor 300 that generally exhibits a high rotational velocity, low torque characteristic in lightweight, economical motor 300 embodiments. For actuating a propeller, the preferred embodiment obviously installs a motor 300 capable of greater torque and variable speed. In the worm drive embodiment, the worm 310 A and worm gear 311 interface further reduces the torque on the rotor 302 compared to that on the final drive shaft 312 . An embodiment comprising a worm drive also affords the advantage of the braking effect such that the direction of transmission always goes from the rotor 302 to the shaft 312 and not vice versa given an appropriate coefficient of friction between the worm 310 A and the worm gear 311 . Other embodiments rely upon the detent torque of a stepper motor 300 for braking. In other embodiments, such as servo motors 300 or variable reluctance motors 300 may not afford adequate detent torque and thus a solenoid 301 inserts a spring-activated 315 plunger tip 304 between the teeth of the first small gear 303 to lock-in detent and sustain torque against stops 305 when the solenoid 301 coil 314 has no current 313 flowing. Such an embodiment proceeds in actuating a control mechanism first by driving current 313 in the direction shown per the right hand rule causing the solenoid 301 coil 314 to unlock the gear 303 , then driving current 317 in the motor winding 316 , to initiate rotation 318 translated through rotation 319 to rotation 320 or 320 A to rotate a rudder or rotate a sail boom. Once actuation completes, the solenoid 301 coil 314 no longer conducts current, returning the solenoid 301 plunger tip 304 to the locked position. All such control algorithm steps thus have their own unique SCADA object tag definitions. As PLC's 200 have traditionally evolved from industrial process applications including SCADA systems control software, portability of Computer Numeric Controlled (CNC) G-code for servo-motors 300 , and servo mechanisms such as mechanical lead screw, or ball screw systems analogous to worm drive systems enable preferred embodiments of control actuators in the present invention. One must note that partial implementations or minor deviations known by one of ordinary skill in the art of any of the exemplary embodiments of the aforementioned control actuator electromechanical circuits do not represent a departure from the scope or spirit of the present invention.
FIG. 4 illustrates the visual representations that appear on the Graphical User Interface (GUI) 400 of one or plural client workstations 209 at the central service facility 102 , and illustrates how a human can affect the behavior of exemplary SCADA algorithms. The foregoing exemplary SCADA algorithms run on one or plural server 204 processing systems including a GIS that performs all the data collection, processing, storage, analyses and navigation vector determinations accessible through the GUI 400 on one or plural client workstations 209 . Three different workstations 209 A, B, or C displaying information pertaining to one or plural mobile structures 100 , or one workstation displaying three different GUIs 400 at different times, at one time displaying the GUI 400 of workstation 209 A, at another time the GUI 400 of workstation 209 B, and at another time the GUI 400 of workstation 209 C operate at the central service facility 102 . Using typical computer pointing and data entry hardware, a human operating the workstation 209 may interact with the GUI 400 to invoke any of the GUIs 400 on any of the workstations 209 A, B, or C as shown in FIG. 4 . The GUI 400 of workstation 209 A displays position, heading, velocity, and points of sail for the mobile structure 100 in the process of energy extraction in a sailing vessel embodiment. Vessel icon 401 graphically shows direction of the mobile structure 100 relative to true north given by the compass icon 405 . GPS field 402 numerically provides vessel instantaneous location, velocity, and heading. Sail icon 403 and rudder icon 404 along with surface true wind data 406 begotten from various aforementioned weather data. Sources 108 , or empirically derived from GPS 202 and aerovane sensor 201 data as previously described permits observation and control of the points of sail of the mobile structure 100 in a sailing vessel embodiment. Obviously, in a propelled embodiment, a propeller icon serves analogous functions as the sail icon 403 .
Pointing and data entry hardware on the workstation 209 A allows a human operator to point and select the aforementioned icons and data fields to alter visual representations and alter instantaneous control of the mobile structure 100 . For instance, if a human operator points and selects vessel icon 401 , sail icon 403 , or rudder icon 404 , the operator may view a alphanumerical field indicating points of sail using nautical terms such as “Beam Reach” to describe that point of sail shown on the display of workstation 209 A. At this point, the GUI 400 can numerically give displacement angles of the boom and the rudder with an option to the human operator to manually change these values, override auto-navigation, and actuate rotation of the boom or rudder on the mobile structure 100 as previously described. Herein the GUI 400 , the preferred SCADA algorithm invokes performance models for the mobile structure 100 to estimate or forecast energy efficiency thereof, using a Velocity Prediction Program (VPP) performing Computational Fluid Dynamics (CFD) calculations on the sailing vessel along with its energy extracting appendage. The GUI 400 at this point also suggests for instance, a “Broad Reach” point of sail given prevailing wind and optimal least-cost or highest yield path analysis inputs. Selecting the vessel icon 401 also permits the human operator to monitor, adjust, and receive performance predictions based on turbine gate openness and fuel tank fullness affecting the overall drag on the mobile structure 100 , given the VPP performing CFD calculations on the modeled energy extracting turbine appendage. Note for a preferred SCADA algorithm of the present invention, the sailing vessel VPP will output data tabulating generated power, instead of velocity for typical prior art VPP's, for the given true wind speed, turbine gate openness, fuel tank fullness, and heading, along with the accompanying points of sail and control settings. Obviously, an exemplary SCADA algorithm performs an analogous propeller performance VPP and least-cost path analysis for a propelled mobile structure 103 , 104 during these GUI 400 operations. Selecting the GPS field 402 allows the human operator to change viewing options such as converting units of parameters such as position, changing the Universal Transverse Mercator (UTM) kilometer units to miles or to degrees, minutes, seconds of longitude and latitude; velocity, knots to kilometers per hour or miles per hour; or time, from Coordinated Universal Time (UTC) to local time. Selecting the GPS field 402 for a propelled embodiment of mobile structure 103 , 104 allows for manually changing propeller rotational speed. Selecting the compass icon 405 or the true wind data 406 allows the viewing orientation angle of the vessel icon 401 to move relative to the compass icon 405 or true wind data 406 , respectively.
The GUI 400 of workstation 209 B in FIG. 4 illustrates a virtual reality representation 407 , along with the attitude of the vessel, listing and heel angle, or to borrow aviation terms, roll and pitch, respectively, for the mobile structure 100 in the process of energy extraction. The virtual reality rendering 407 indicates a downward or plunging heel angle or pitch, and a port listing or roll. Had the vessel assumed an upward or breaching heel angle, the rendering 407 would display the deck instead of the hull as indicated in the rendering 407 . If the mobile structure 100 sensors include a video camera data stream, actual oceanic surface in the vicinity the vessel will display in this GUI 400 frame. The view parallel 408 to the direction of travel further displays the port listing coordinated with the rendering 407 , along with the angle of listing 409 . A starboard listing or roll would result in an angle 409 in the opposite direction. The view perpendicular 410 to the direction of travel further displays the plunging or downward heel or pitch, coordinated with the rendering 407 and displaying the heel angle 411 . Likewise, a breaching or upward pitch would result in the heel angle 411 displayed in opposite direction. Selecting the virtual reality 407 icon allows for changing the camera angle. Selecting the listing angle 409 icon or the heel angle 411 icon allows the human operator to manually set the threshold for a broach warning and associated control.
The GUI 400 of workstation 209 C in FIG. 4 illustrates a weather map with path analysis lines 417 , 418 , 419 for the mobile structure 100 operating in the weather pattern 101 . Browsing the GUI 400 of workstation 209 C initiates a least-cost and highest yield path analysis whereby a weather semivariogram accounting for spatial structure including physical object 109 , such as a landmass or seamount, global trends and anisotropy, air temperature, water temperature, wind direction, wind speed, and wave data forms a basis for mapping predictive costs, or yields in the case of energy extraction. From the predictive map, the preferred SCADA algorithm assigns weights that average over suggested routes 417 , 418 , 419 based on path length in a weighted cost or yield raster. In the GUI 400 of workstation 209 C, each concentric closed surface 413 , 414 , 415 represents areas of increasing wind and surge current energy inward to the eye 416 for a given weather pattern 101 . While a global trend may indicate a greater degree of symmetry and counterclockwise, in this example northern hemispheric, vortex trend as in the FIG. 1 representation of the weather pattern 101 , anisotropy caused by physical object 109 , such as a landmass or seamount and other stochastic modeled factors such as air temperature, water temperature, wind direction, wind speed, and wave data result in a probabilistic field that the semivariogram 413 , 414 , 415 represents. From this probability field, weather prediction analysis can predict a path 412 for the storm that further affects the least-cost or highest yield analysis. Note that in the GUI 400 of workstation 209 C, the concentric closed surfaces 413 , 414 , 415 can selectively represent semivariogram values or else predictive energy regions, also known as a cost raster for non-energy extracting vessel logistics or a yield raster when referring to energy extraction. The preferred embodiment also includes an advanced detection of physical object 109 , such as a landmass or seamount, identification and avoidance system that remotely utilizes the integrated sensors including but not limited to on-board radar and sonar systems to perform sweeping remotely sensed anomalies returns. A preferred SCADA algorithm then compares the signatures of these electromagnetic energy returns against known libraries of predefined physical object 109 , such as a landmass or seamount, based on size, shape, rate of movement and other characteristics to identify possible type of physical object 109 , such as a landmass or seamount, feature detected. Optionally, an exemplary algorithm further correlates the signatures against a video camera data stream for further classification and confirmation of the physical object 109 , such as a landmass or seamount. A preferred SCADA algorithm then invariably correlates the identified physical object 109 , such as a landmass or seamount, spatially against the vessel's 100 , 102 , 103 , 104 current location, path and velocity in order to assess the need for altering the vessel's 100 , 102 , 103 , 104 course to initiate avoidance and altered path routing and associated cost accounting. A preferred SCADA algorithm then indexes the identified physical object 109 , such as a landmass or seamount, in the algorithmic path controls to include avoidance or least cost path towards the physical object 109 , such as a landmass or seamount, depending on predetermined logic and/or human operator interaction. A preferred SCADA algorithm of the present invention thereby further accounts for VPP modeling of the mobile structure 100 when assigning weights that average over a path 417 , 418 , 419 based on direction and length in a weighted anisotropic energy yield raster. Depending on the cost or yield goal, the highest yield algorithm may select a path 417 or 418 , yielding the highest energy in the shortest time with least risk to structural harm to the mobile structure 100 , while the least-cost algorithm yields the shortest logistical trajectory with least risk to structural harm to an offshore embodiment of the central service facility 102 , a non-energy extracting vessel. Selecting the path lines 417 , 418 , 419 allows the human operator to optionally choose mission critical navigation parameters such as cost and yield weights and cost or yield goals.
For all the aforementioned GUI 400 icons and data fields, a SCADA object tag definition exists for accessing the aforementioned data structures and evoking the aforementioned control. Object tags allow for structured programming techniques facilitating manageability and sustainability of a substantially large code base traversing multiple software application layer interfaces from the workstations 209 , to the server 204 and from the server 204 to the PLC's 200 , and from the server 204 to the one or plural of many possible entities including those accessible through the Internet from where all weather data in this exemplary embodiment disseminates, such as from the National Weather Service 108 . Functional differences within the GUI 400 for workstations 209 A,B, or C clearly do not present a substantial departure from the scope and spirit of the present invention.
From the preceding description of the present invention, this specification manifests various techniques for use in implementing the concepts of the present invention without departing from its scope. Furthermore, while this specification describes the present invention with specific reference to certain embodiments, a person of ordinary skill in the art would recognize that one could make changes in form and detail without departing from the scope and the spirit of the invention. This specification presented embodiments in all respects as illustrative and not restrictive. All parties must understand that this specification does not limited the present invention to the previously described particular embodiments, but asserts the present invention's capability of many rearrangements, modifications, omissions, and substitutions without departing from its scope.
Thus, a supervisory control and data acquisition system for energy extracting vessel navigation has been described.
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A Supervisory Control And Data Acquisition (SCADA) system guides navigation of a vessel enabled to extract energy from wind and/or water currents primarily in offshore marine environments. An exemplary SCADA system could embody server and client software applications running on microprocessor systems at a remote control central service logging and energy distribution facility, and the vessel itself. The remote control service facility runs Human Machine Interface (HMI) software in the form of a Graphical User Interface (GUI) allowing choices to maximize system performance. The central server accesses information to control vessel position based on transmitted Global Position Satellite (GPS) data from the vessel, and weather information from the Geographic Information System (GIS) provided by multiple spatial temporal data sources. A server-side optimization algorithm fed the parameters delivered from vessel aerodynamic/hydrodynamic performance simulation software models, the vessel onboard sensor data, and integrated real-time weather and environmental data determines an optimal navigation through weather systems and presents choices to the HMI.
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BACKGROUND OF THE INVENTION
The present invention relates to a label positioning device for sewing machines and more particularly to such a device for sewing labels on the blind or underside of the material.
It is known for example, from U.S. Pat. No. 2,374,043 or German Patent Publication No. 1955796 that in the sewing of labels on a material, e.g. a garment, the label is brought by hand or automatically into the vicinity of the stitching elements of a sewing machine, in order to be joined to the material. The actual feeding process however, which positions the label between such stitching elements, i.e. the feed drive and needle, and the presser foot in order to be included in the seam produced by the sewing machine, has heretofore been effected manually, i.e. by the seamstress. This requires interruption of the sewing process, and a general slowdown of the overall sewing operation to enable the seamstress to position the label firstly at the given point and secondly as straight as possible relative to the intended seam. This becomes especially difficult when the label is to be sewn on the blind or underside of the material since the operator's view of the label is obstructed by the overlying fabric.
Prior attempts at positioning the label beneath the material so as to avoid interruption of the sewing process, locate the label at the desired point, and position the label straight with respect to the seam to the extent possible, have, as far as is known, been unsuccessful to date.
It is the principal object of the invention to provide a device for the correct positioning of a label for sewing onto a fabric material in order to achieve higher output and improved quality in the application of such labels.
Another object of the invention is to provide a label positioning device which will improve the uniformity with which labels are stitched to garments without slowing down the sewing operation.
Other objects and advantages of the invention will become readily apparent to persons versed in the art from the ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more fully comprehended it will now be described, by way of example, with reference to the accompanying drawing in which:
FIG. 1 is a side elevation view of the front section of a sewing machine with a label positioning device embodying the features of the invention thereon having its clamp opened for introduction of the label, the sewing elements being shown partly in section.
FIG. 2 is a view similar to that of FIG. 1, with the clamp closed and in label positioning location;
FIG. 3 is a front elevation view of the device shown in FIG. 1;
FIG. 4 is a top plan view of the device shown in FIG. 1;
FIG. 5 is a fragmentary top plan view taken along line V--V of FIG. 3;
FIG. 6 is a fragmentary top plan view taken along line VI--VI of FIG. 3; and
FIGS. 7 to 9 show three possible seam patterns for stitching the label to the fabric.
DESCRIPTION OF THE INVENTION
The present invention is applied to conventional sew-machines, illustrated in the drawings as have a table 15 in which is located a material feed comprising a cogged member 5 and a differential cogged member 2 both reciprocable in conventional rectangular motion to feed a fabric 7 beneath a presser foot 3 from right to left as shown by arrow 4 in FIG. 2. Located above the presser foot 3 is one or more needles 6. Operation of the needle 6, presser foot 3, and feeds 2 and 5 can be made conventionally to provide any selected stitch. The machine is provided with a conventional label feed mechanism adapted to feed a label 1 at right angles to movement of the fabric into the presser foot 3, e.g. perpendicular to the plane of the drawings, until such time as it can be engaged by the fabric 7 and conjointly moved with it. The label is supplied in such a way that its front edge is disposed in front and adjacent to the gripping point of differential feed 2 and beneath the upturned edge of the pressure foot 3. The label is located a sufficient distance to the right (FIG. 1) such that it will be engaged and stitched to the material 7 by the needle 6. For purposes of clarity only one ply of material and a single label 1 are shown. Depending upon the type of sewing machine and its attachments, different seam patterns are possible to stitch the label and the material together.
To insure proper positioning of the label 1 and its proper engagement with the fabric, a clamp assembly, generally depicted by numeral 16, is mounted on the front end of the stationary table, in line with the material feed. The clamp assembly comprises a support bracket 8 pivotably mounted on its lower end by an axle 17 mounted on the front skirt of table 15. The bracket extends upwardly and is formed with a blade 8aextending at a generally right angle normal to the bracket 8. The blade 8a extends over the surface of the table top which is formed so as to permit the blade or tong 8a to extend below the label 1 as it is fed and toward the presser foot 3. Pivotably mounted on an axle 19 secured at the upper end of bracket 8 is flat spring-like member 9. The member 9 is bent to have one leg to extend parallel to the blade 8a, at the end of which is formed a clamp or tong member 9a which overlies the tip end of the blade 8a and to have a depending leg which extends the length of the bracket 8. Located between the bracket 8 and the depending leg of member 9 is a compression spring 11 which normally biases the member 9 to the right simultaneously causing the end of its clamp member 9a to be biased downwardly into clamping position with the blade 8a.
Mounted between the skirt of the table 15 and the bracket 8 is a second spring 11a which normally biases the bracket 8 outwardly (to the right) from the table 15. This causes the blade 8a to be normally slid to the right away from the presser foot 3. Thus, the blade 8a is not pivotal with respect to the bracket 8 but has a flat planar reciprocating movement.
Mounted to the rear (as seen in FIG. 1 & 2) of the clamp assembly 16, and in ascending relationship are three compressed air cylinders and pistons, 10, 12, and 14, respectively. Each of these cylinders and pistons are arranged parallel to each other and have their pistons extending toward the clamp assembly 16, as seen in FIGS. 3-6. At the end of the pistons of each of cylinder and pistons 10, 12 and 14 respectively are wedged shape members 23, 28 and 29. The wedge members 23 and 29 have their sloping edge facing the sewing table, while the wedge 28 has its sloping edge facing away from the sewing table.
Further, the lower most cylinder 10 is placed so that its associated wedge 23 will ride against the bottom edge of the member 9 which is crenelated as seen in FIG. 6, causing the member 9 to move inwardly against the spring 11. To insure that the wedge 23 moves positively against the member 9, a bracket 21 is provided at the bottom of the bracket 8 having a small wall 21 a which abuts against the rear face of the wedge 23.
The intermediate cylinder 12 is arranged so that its wedge moves between the bracket 8 and the depending portion of the member 9, as seen in FIG. 5.
The uppermost cylinder 14 is arranged so that its wedge 29 moves to the left and rides against the upper end of the bracket 8 substantially at the pivot axle 19. To insure proper alignment of the wedge 29, the pivot axle 19, as seen clearly in FIG. 4 is provided with a counter wedge 19a and a rear stop 19b secured to the mount 16 for the clamp assembly. Movement of the wedge 29 causes the entire bracket 8 to move against spring 11a inwardly to the left from the position shown in FIG. 1 to that of FIG. 2.
The bracket 21 extends with a collar about the lower cylinder 10 securing it to the bracket 8, while the cylinders 10 & 12 are held together by strap means 25 & 26. The upper cylinder 14 is secured to the table by a bracket 27.
In operation, the label 1, supplied to the sewing machine, is introduced between clamp member 8a and the other clamp 9a. In order to accommodate the label, leg 9 of clamp 16 is opened by means of cylinder assembly 10, moving the wedge in the direction A, shown in FIG. 6. The member 9 is thus provided clockwise about its pivot member 19, against the biasing force of spring 11. The label to be sewn on is then supplied and is supported on the upper surface of the clamp member 8a after which the wedge 23 is retracted and clamp member 9a automatically closes on the clamp member 8a as a result of the influence of the spring 11. Spring 11 retains the label 1 in position on clamp plate 8a in a moderately firm manner by this biasing force.
Actuation of cylinder assembly 12 in the direction of arrow B as shown in FIG. 5, causes the clamp arm 9a to be pressed into closer engagement with the label 1 on clamp plate 8a, by causing the lower end of the member 9 to bow outwardly from bracket 8 causing a bell crank effect on clamp arm 9a. The pressure is such that as the material 7 slides over the label 1 during sewing, neither the material nor the other external influences of the feed will affect the desired position of the label 1.
The material is then fed toward the needle until such time as its front edge is sensed by a control element 13 such as a photo cell, diode, or similar sensor, and a signal is generated which activates a counter which measures the distance of movement of the material 7 by the number of stitches sewn and, after a preselected number (which establishes the position of the label, with respect to the front edge of the material) generates a signal conventional valve means associated with the air and cylinder pistons for insertion of the label into the operative zone of the feeds 2 and 5 by advance of clamp 16, toward the table 15, i.e. in the direction of arrow 4 by operation of the upper cylinder 14 moving the wedge 29 in the direction of arrow C.
Release of the clamping pressure permitting insertion of the label 1 for the sewing operation is effected by cylinder 12. Actuation of cylinder 14 applies moderate pressure on clamp plate 8 to advance it together with label 1 into the operative zone of the feeds 2 and 5. Wedge 29 when actuated thus shifts the entire clamp 16 including the label 1 into operative relatinship with the feeds 2, 5, clamp 16 as a whole being pivoted about its bearing pin 17 (FIG. 2.) Feed 2 withdraws the label 1 from the clamp member 8a & 9a which is closed only under pressure of spring 11. This pressure is sufficient to insure that label 1 cannot be rotated from its proper position or shifted with respect to the material. When label 1 has been seized by feed 2 to the extent that it is retained beneath presser foot 3, the cylinder 10 is once again actuated to shift its piston and wedge 23 so as to open the clamp members 8a and 9a. The compressed air cylinder assembly 14 then is deactivated to effect the return movement of clamp assembly 16 about pivot 17. The timing or moment of the opening and pivoting back of the clamp 16 assembly is adjustable, in order that labels of different widths can be processed.
The cylinder assemblies 10, 12, & 14 are preferably activated by compressed air, although hydraulic cylinder assemblies may be employed. Compressed air may be bottled although most sewing machine plants or factories have a normal line supply of compressed air for other uses which may be used here. The cylinders are preferably double acting to insure accurate, prompt response although single acting spring biased units may be used. Control of the cylinders may be easily made through the use of conventional valves, relay timers, sensing devices and solenoid controls.
When the material to which label 1 is to be sewn is elastic material, as for example knit goods, it is important to give the differential feed 2 a greater stroke than that of the main feed 5. Adjustment of the sewing machine drive in this manner for elastic material, avoids unintended displacement or folding of the label. Alternatively, the differential feed may be disconnected by a known device not shown, the so-called differential rapid adjustment. The differential feed 2 then operates with the same stroke as the main feed 5.
From the foregoing it will be seen that a label positioning device has been provided which obviates the need for manual placement of the label relative to the material on which the label is to be sewn thereby enabling attainment of the objective heretofore stated.
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Sewing labels on a sewing machine having a label feed attachment is provided by a pair of clamp members. The clamp members are pivotably joined at one end to open and close at the other end and are conjointly movable in a path parallel to the path of movement of the material from a first position corresponding to the point at which the labels enter the path of movement of the material to a second position corresponding to the mouth of said presser foot. The labels are grasped and moved by the clamp members into contact with said material and held thereto by a cooperating feed mechanism and presser foot for sewing.
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TECHNICAL FIELD OF THE INVENTION
This invention relates, in general, to perforating a subterranean wellbore using shaped charges and, in particular, to a bi-directional explosive transfer subassembly that is installed within a work string between loaded perforating guns for use in deviated wellbores.
BACKGROUND OF THE INVENTION
Without limiting the scope of the present invention, its background will be described with reference to perforating a subterranean formation using shaped charge perforating guns, as an example.
After drilling the section of a subterranean wellbore that traverses a formation, individual lengths of relatively large diameter metal tubulars are typically secured together to form a casing string that is positioned within the wellbore. This casing string increases the integrity of the wellbore and provides a path for producing fluids from the producing intervals to the surface. Conventionally, the casing string is cemented within the wellbore. To produce fluids into the casing string, hydraulic opening or perforation must be made through the casing string, the cement and a short distance into the formation.
Typically, these perforations are created by detonating a series of shaped charges located within the casing string that are positioned adjacent to the formation. Specifically, numerous charge carriers are loaded with shaped charges that are connected with a detonating device, such as detonating cord, forming perforating guns. The perforating guns are then connected within a tool string that is lowered into the cased wellbore. Once the perforating guns are properly positioned in the wellbore such that the shaped charges are adjacent to the formation to be perforated, the shaped charges are detonated. Upon detonation, each shaped charge creates a jet that blasts through a scallop or recess in the charge carrier, creates a hydraulic opening through the casing and cement and then penetrates the formation forming a perforation therein. Typically, the shaped charges are fired from the near end to the far end of the formation. In the event of a misfire of the shaped charges, however, it may be necessary to reverse the firing sequence to fire the shaped charges from the far end to the near end of the formation.
It has been found that it is sometimes difficult to deploy the desired length of perforating guns into highly deviated or horizontal wells and wells with restrictions. Specifically, in such well configurations, large bending moments act on the string of perforating guns in the plane parallel to the centerline of the perforating guns. These large bending moments can cause failures at the connections between perforating guns, which may result in misfiring. In addition, these large bending moments can prevent relative rotation of the perforating guns about the centerline of the perforating guns such that it is difficult or impossible to orient the perforating guns to fire in the desired direction.
A need has therefore arisen for an apparatus that allows a string of perforating guns to be run into highly deviated or horizontal wells and wells with restrictions. A need has also arisen for such an apparatus that allows for the proper orientation of the perforating guns so that they fire in the desired direction. Further, a need has arisen for such an apparatus that allows for bi-directional firing of the perforating guns.
SUMMARY OF THE INVENTION
The present invention disclosed herein comprises a bi-directional explosive transfer subassembly that can be installed within a tool string between two live perforating guns that allows a string of perforating guns to be deployed into a highly deviated well, a horizontal well or a well with restrictions. In addition, the bi-directional explosive transfer subassembly of the present invention allows for the proper orientation of the perforating guns so that they fire in the desired direction.
The bi-directional explosive transfer subassembly of the present invention comprises a first explosive carrying member having a ball end and a first explosive cavity and a second explosive carrying member having a socket and a second explosive cavity. The ball end of the first explosive carrying member is slidingly received in the socket of the second explosive carrying member such that the first and second explosive carrying members are rotatable and angularly displaceable relative to one another. A first explosive device including, for example, a first shaped charge is disposed in the first explosive cavity. A second explosive device including, for example, a second shaped charge is disposed in the second explosive cavity. The first and second explosive devices are spaced apart such that the first and second shaped charges face one another and are each adapted for sending an explosive jet toward the other shaped charge, thereby providing an explosive transfer therebetween. Accordingly, when one of the first and second explosive devices is initiated, the other of the first and second explosive devices will in turn be initiated.
The first explosive carrying member of the bi-directional explosive transfer subassembly may include a cylindrical portion extending integrally from the ball end. The second explosive carrying member may include a flange portion extending from the socket that has a conically shaped inner surface having an angle that defines the maximum allowable angular displacement between the first and second explosive carrying members. Specifically, the maximum allowable angular displacement occurs when the cylindrical portion of the first explosive carrying member contacts the flange portion of the second explosive carrying member. The maximum angular displacement between the first and second explosive carrying members may be between about 1 and about 10 degrees and is preferably about 5 degrees.
The first and second explosive cavities of the bi-directional explosive transfer subassembly are separated by portions of the first and second explosive carrying members. For example, the first and second explosive carrying members may respectively include first and second wall portions that are adjacent to one another, thereby separating the first and second explosive cavities. Both the first and second explosive devices of the bi-directional explosive transfer subassembly may include a booster, a length of detonating cord connected to the booster and a detonating cord initiator connected to the detonating cord.
In one embodiment, the bi-directional explosive transfer subassembly is positioned between first and second perforating guns in a well perforating apparatus. In this embodiment, the sliding engagement between the ball end of the first explosive carrying member in the socket of the second explosive carrying member provides for rotation and angular displacement of the first and second perforating guns relative to one another. Also in this embodiment, when one of the first and second explosive devices is initiated, the other of the first and second explosive devices will in turn be initiated thereby transferring explosive between the first and second perforating guns.
The bi-directional explosive transfer subassembly is also used in a method of perforating a well. Specifically, the method comprises deploying a string of perforating guns in a wellbore, the string having first and second perforating guns with a bi-directional explosive device disposed therebetween providing relative rotation and angularly displace therebetween. The method also comprises firing one of the first and second perforating guns, igniting one of the first and second explosive devices, igniting the other of the first and second explosive devices and firing the other of the first and second perforating guns, thereby transferring the explosive and sequentially firing the string of perforating guns.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 is a schematic illustration of an offshore oil and gas platform operating a plurality of bi-directional explosive transfer subassemblies of the present invention that are disposed between perforating guns in a work string;
FIG. 2 is a half sectional view of a bi-directional explosive transfer subassembly of the present invention prior to transferring the explosive;
FIG. 3 is a half sectional view of a bi-directional explosive transfer subassembly of the present invention after transferring the explosive;
FIG. 4 is a half sectional view of a bi-directional explosive transfer subassembly of the present invention prior to transferring the explosive and with first and second sections of the bi-directional explosive transfer subassembly angularly displaced relative to one another; and
FIG. 5 is a half sectional view of a bi-directional explosive transfer subassembly of the present invention after transferring the explosive and with first and second sections of the bi-directional explosive transfer subassembly angularly displaced relative to one another.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the present invention.
Referring initially to FIG. 1, a plurality of bi-directional explosive transfer subassemblies of the present invention operating from an offshore oil and gas platform are schematically illustrated and generally designated 10 . A semi-submersible platform 12 is centered over a submerged oil and gas formation 14 located below sea floor 16 . A subsea conduit 18 extends from deck 20 of platform 12 to wellhead installation 22 including subsea blow-out preventers 24 . Platform 12 has a hoisting apparatus 26 and a derrick 28 for raising and lowering pipe strings such as work sting 30 .
A wellbore 32 extends through the various earth strata including formation 14 . A casing 34 is cemented within wellbore 32 by cement 36 . Work string 30 includes various tools including a plurality of shaped charge perforating guns and a plurality of bi-directional explosive transfer subassemblies. When it is desired to perforate formation 14 , work string 30 is lowered through casing 34 until the shaped charge perforating guns are properly positioned relative to formation 14 . Thereafter, the shaped charge perforating guns are sequentially fired such that the shaped charges are detonated. Upon detonation, the liners of the shaped charges form jets that create a spaced series of perforations extending outwardly through casing 34 , cement 36 and into formation 14 .
In the illustrated embodiment, wellbore 32 has an initial, generally vertical portion 38 and a lower, generally deviated portion 40 which is illustrated as being horizontal. It should be noted, however, by those skilled in the art that the shaped charge perforating guns and the bi-directional explosive transfer subassemblies of the present invention are equally well-suited for use in other well configurations including, but not limited to, inclined wells, wells with restrictions, non-deviated wells and the like.
Work string 30 includes a retrievable packer 42 which may be sealingly engaged with casing 34 in vertical portion 38 of wellbore 32 . At the lower end of work string 30 is a gun string, generally designated 44 . In the illustrated embodiment, gun string 44 has at its upper or near end a ported nipple 46 below which is a time domain firer 48 . Time domain firer 48 is disposed at the upper end of a tandem gun set 50 including first and second guns 52 and 54 . In the illustrated embodiment, a plurality of such gun sets 50 , each including a first gun 52 and a second gun 54 are utilized. Each gun set 50 may have at least one orienting fin (not pictured) extending therefrom to insure that the gun set is disposed off-center with regard to casing 34 as described in U.S. Pat. No. 5,603,379 issued to Halliburton Company on Feb. 18, 1997, which is hereby incorporated by reference. While tandem gun sets 50 have been described, it should be understood by those skilled in the art that any arrangement of guns may be utilized in conjunction with the bi-directional explosive transfer subassemblies 56 of the present invention.
Specifically, between each gun set 50 is a bi-directional explosive transfer subassembly 56 which serves as a connector for connecting adjacent gun sets 50 together. As will be discussed in detail below, each bi-directional explosive transfer subassembly 56 has a ball and socket joint that allows adjacent tandem gun sets 50 to not only rotate relative to one another, but also, be angularly displaced relative to one another, which allows gun string 44 to be connected, deployed, oriented and fired in deviated wells. At the far end of gun string 44 is another time domain firer 58 that is attached to a second gun 54 . The other end of time domain firer 58 is attached to a ported closure 60 .
Referring now to FIG. 2, each bi-directional explosive transfer subassembly 56 has a housing 70 defining a housing cavity 72 therein. Housing 70 includes an upper housing portion 74 , a lower housing portion 76 and a pair of intermediate housing portions 78 , 80 . Upper housing portion 74 defines an upper housing cavity portion 82 which is a part of housing cavity 72 . Lower housing portion 76 defines a lower housing cavity portion 84 , which is also a part of housing cavity 72 . Intermediate housing portion 78 defines an intermediate housing cavity portion 86 , which is also part of housing cavity 72 .
It should be apparent to those skilled in the art that the use of directional terms such as top, bottom, above, below, upper, lower, upward, downward, etc. are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure. As such, it is to be understood that the downhole components described herein may be operated in vertical, horizontal, inverted or inclined orientations without deviating from the principles of the present invention.
Upper housing portion 74 is attached to a second gun 54 of one of the gun sets 50 of FIG. 1 at threaded connection 88 . A plurality of O-rings 90 , provides sealing engagement between upper housing portion 74 and the corresponding second gun 54 . Upper housing portion 74 is attached to intermediate housing portion 78 at threaded connection 92 . A plurality of O-rings 94 provides sealing engagement between upper housing portion 74 and intermediate housing portion 78 .
Lower housing portion 76 is attached to a first gun 52 of another gun set 50 of FIG. 1 at threaded connection 96 . A plurality of O-rings (not pictured) provides sealing engagement between lower housing portion 76 and the corresponding first gun 52 . Lower housing portion 76 is attached to intermediate housing portion 80 at threaded connection 98 .
The lower end of intermediate housing portion 78 fits within intermediate housing portion 80 and against the top of lower housing portion 76 to form a ball and socket joint 100 . Specifically, intermediate housing portion 78 has ball end 102 configured as a portion of a sphere having an external bearing surface 104 which is configured as a portion of a spherical surface centered on a center point 106 . The center point 106 is disposed on a pair of axes 108 , 110 . Ball end 102 is integral with the cylindrical portion 112 of intermediate housing portion 78 such that ball end 102 and cylindrical portion 112 are fixed for movement together.
Intermediate housing portion 80 and the top of lower housing portion 76 form socket 114 of ball and socket joint 100 . Socket 114 includes socket wall 116 and socket wall 118 forming a portion of a spherical bearing surface 120 having substantially the same diameter as the spherical external bearing surface 104 of ball end 102 . Bearing surface 120 is centered on center point 106 . Accordingly, spherical external bearing surface 104 on ball end 102 is in sliding engagement with spherical internal bearing surfaces 120 of socket 114 which allows upper housing portion 74 and intermediate housing portion 78 to not only rotate relative to lower housing portion 76 and intermediate housing portion 80 , but also allows relative angular displacement therebetween. The extent of the angular displacement is limited by flange portion 122 that has a conically shaped inner surface having an angle α relative to axis 108 .
A first explosive device 130 is disposed in upper housing cavity 82 and intermediate housing cavity 86 , which is adapted to provide an explosive transfer between a second gun 54 and lower housing portion 76 . Similarly, a second explosive device 132 is disposed in lower housing cavity 84 and is adapted for providing an explosive transfer between a first gun 52 and upper housing portion 74 via intermediate housing portion 78 . Second explosive device 132 is substantially identical to first explosive device 130 but is positioned in an opposite direction. As will be further described, first and second explosive devices provide a bi-directional explosive path through housing 70 .
First explosive device 130 includes an insert 134 that is held in upper housing cavity 82 and an insert 136 that is held in intermediate housing cavity 86 . A booster 138 is disposed in the upper end of insert 134 . Booster 138 has a metallic portion that is crimped around one end of a length of detonating cord 140 . A detonating cord initiator 142 has a metallic portion that is crimped around the other end of detonating cord 140 . Detonating cord initiator 142 is positioned adjacent to shaped charge 144 which has a conical cavity 146 therein. Second explosive device 132 is made of substantially identical components as is first explosive device 130 with the exception that second explosive device 132 only has one insert 148 that houses booster 138 , detonating cord 140 , detonating cord initiator 142 and shaped charge 144 .
Intermediate housing portion 78 has a wall portion 150 that closes the lower end of intermediate housing cavity 86 . Similarly, lower housing portion 76 has a wall portion 152 that closes the upper end of lower housing cavity 84 . Thus, wall portions 150 and 152 are adjacent to one another. It will be seen that wall portions 150 and 152 separate intermediate and lower housing cavities 86 and 84 of housing cavity 72 . In one embodiment, but not by way of limitation, intermediate and lower housing portions 78 and 76 are made of steel, and thus, wall portions 150 and 152 provide a steel barrier between first and second explosive devices 130 and 132 .
In operation, work string 30 with gun string 44 forming a lower end thereof is run into in casing 34 of wellbore 32 . In the case of a deviated wellbore or a wellbore with restrictions, use of bi-directional explosive transfer subassemblies 56 improves the deployability of gun string 44 by allowing gun string 44 to bend during such deployment. Specifically, as best illustrated in FIG. 4, as gun string 44 is run into wellbore 32 , bi-directional explosive transfer subassemblies 56 provide for angular displacement between upper housing portion 74 and lower housing portion 76 via ball and socket joint 100 , thereby reducing bending moments in gun string 44 during deployment which could damage gun string 44 . In addition, use of bi-directional explosive transfer subassemblies 56 allows gun string 44 to be deployed in certain deviated wellbores into which gun string 44 could otherwise not be deployed. As illustrated, the maximum angular displacement is defined by angle α, which may be between about 1 and about 10 degrees and which is preferable about 5 degrees. It should be noted that angle α could also be greater than 10 degrees but through the use of multiple bi-directional explosive transfer subassemblies 56 , such large angular displacements are not typically required and may in fact cause deployment problems in certain wellbore configurations.
As illustrated in FIG. 1, first and second guns 52 and 54 of gun sets 50 have a plurality of perforating charges which are equally angularly disposed around a longitudinal axis of the guns. In this way, a plurality of substantially evenly distributed perforations may be made through casing 34 , in cement 36 and into formation 14 . On many occasions, however, it is desirable to have the perforations be more specifically directed. For example, but not by way of limitation, it may be desirable to have the perforations directed mostly downwardly and located in the lower half of casing 34 . Orienting fins (not pictured) can be used in conjunction with bi-directional explosive transfer subassemblies 56 to help orient gun sets 50 so that the perforation charges are mostly downwardly directed. Specifically, as upper housing portion 74 and lower housing portion 76 of bi-direction explosive transfer subassemblies 56 may rotate relative to one another at ball and socket joint 100 , gun sets 50 are substantially self-orienting when used in conjunction with orienting fins.
Once gun string 44 has been fully deployed, as seen in FIG. 1, the perforation process may begin. In a perforating operation, a firing head, such as time domain firer 48 , is actuated to initiate the uppermost first gun 52 of the uppermost gun set 50 . First gun 52 will then trigger its corresponding second gun 54 which will in turn detonate booster 138 in the uppermost bi-directional explosive transfer subassembly 56 . The explosive powder in booster 138 initiates detonating cord 140 which in turn initiates detonating cord initiator 142 . This subsequently detonates shaped charge 144 which is shaped to send a jet toward wall portion 150 . This explosive jet is sufficient to penetrate through the barrier formed by wall portions 150 and 152 and initiate the facing shaped charge 144 in second explosive device 132 . The explosive transfer occurs through second explosive device 132 in reverse order from that just described for first explosive device 130 resulting in the configuration seen in FIG. 3 . Eventually, a firing device in the first gun 52 attached to lower housing portion 76 is initiated. This sequence is repeated through the other gun sets 50 and bi-directional explosive transfer subassemblies 56 , eventually firing the lowermost second gun 54 , assuming that there is no break in the firing sequence.
There may be occasions when it will be desirable to initiate gun string 44 from the far end. In this event, a firing head, such as time domain firer 58 , is fired which initiates the firing of the lowermost second gun 54 which in turn triggers the lowermost first gun 52 to fire. The lowermost first gun 52 initiates second explosive device 132 in the lowermost bi-directional explosive transfer subassembly 56 . The explosive transfer in this case follows an upward path through bi-directional explosive transfer subassembly 56 to detonate the next gun set 56 . This sequence is repeated upwardly until the uppermost gun set 50 is fired. Since bi-directional explosive transfer subassembly 56 carries essentially identical first and second explosive devices 130 and 132 disposed therein and facing one another, it will be seen that bi-directional explosive transfer subassembly 56 is bi-directional, allowing firing from the top down or from the bottom up.
As described, this bi-directional firing capability allows the operator to select between firing gun string 44 from the top or the bottom. Also, if there is a misfire in one direction, gun string 44 may be then triggered from the other direction to fire the remaining guns, assuming there is not an additional misfire. Thus, the gun string 44 allows for one misfire situation without the necessity of removing the entire work string 30 from casing 34 . In addition, as best seen in FIG. 5, even if a bi-directional explosive transfer subassembly 56 is in an angularly displaced configuration, the explosive transfer function is nonetheless achieved as the jet formed from the first shaped charge 144 that is fired penetrates through wall portions 150 and 152 to initiate the facing shaped charge 144 even at the maximum angular displacement of angle α.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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A bi-directional explosive transfer subassembly ( 56 ) for coupling two explosive tools ( 52, 54 ) comprises first ( 74, 78 ) and second ( 76, 80 ) explosive carrying members that respectively define first ( 82, 86 ) and second ( 84 ) explosive cavities. A ball end ( 102 ) of the first explosive carrying member ( 74, 78 ) is slidingly received in a socket ( 114 ) of the second explosive carrying member ( 76, 80 ) such that the first ( 74, 78 ) and second ( 76, 80 ) explosive carrying members are rotatable and angularly displaceable relative to one another. A first explosive device ( 130 ) is disposed in the first explosive cavity ( 82, 86 ) and a second explosive device ( 132 ) is disposed in the second explosive cavity ( 84 ). The first ( 130 ) and second ( 132 ) explosive devices are spaced apart such that when one of the explosive devices ( 130, 132 ) is initiated, the other of the explosive devices ( 130, 132 ) will in turn be initiated.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of provisional patent application Ser. No. 61/995,156, filed 2014 Apr. 2 by the present inventor.
The mechanics of attaching items to the ground vary from the simple to the complex. Generally speaking, a mechanism is driven into the ground with varying degrees of holding capability.
The majorities of these anchors are meant to be semi-permanent due to the limited capability they possess. Some of the more permanent anchors involve drilling holes in the earth and filling with cement, followed by placing a coupler into the wet cement and then waiting for the application to set up and cure before being able to be utilized.
Common ground anchor systems are known to suffer from a number of disadvantages:
(a) their applications lack strength in performance and durability;
(b) their semi-permanent nature give them a probability of failure when tested;
(c) an anchor required for a large application tends to be an expensive and time consuming installation, yet still deals with the probability of failure.
SUMMARY
In accordance with one embodiment, the ground anchor comprises a coupler, a ground plate, and a main shaft giving direction of installation into ground.
Advantages
Accordingly, several advantages of one or more aspects are as follows: to provide ground anchors that are permanent, minimally invasive to the ground, relatively inexpensive, easily installed, and supply extreme durability in usage. Other advantages of one or more aspects will be apparent from an examination of the drawings and ensuing description.
DRAWINGS
Figures
FIGS. 1A to 1B show two 3-dimensional views of one embodiment.
FIG. 2 shows a direct side view of one embodiment.
FIG. 3 shows a direct top view of one embodiment.
DRAWINGS
Reference Numerals
18 ground anchor device
20 ground plate
22 oblong holes for additional shafts
24 coupler
26 bolt holes
28 main shaft
32 chamfer point
38 coupler opening
42 main shaft protruding
44 additional shaft areas to connect
48 top of coupler areas to connect
DETAILED DESCRIPTION
FIGS. 1 a and 1 b , FIG. 2 , and FIG. 3
First Embodiment
Ground anchor device 18 comprises a main shaft 28 connecting a ground plate 20 , which in turn is connected to a coupler 24 . Length of main shaft 28 is designed for quick and secure placement of ground anchor device 18 . Coupler 24 has bolt holes 26 which allow whatever is inserted to be secured with a bolt. Top of coupler area 48 provides additional area for securing.
Ground plate 20 has oblong holes 22 for insertion of additional shafts into ground plate 20 . The width of the oblong holes 22 are sized according to the diameter of the additional shafts creating a snug fit, while the length of the oblong holes 22 are sized to allow varying angles of installment of additional shafts. After additional shafts are installed they are connected in place.
Main shaft 28 with top of main shaft protruding 42 and bottom of main shaft 28 showing chamfer 32 . Main shaft 28 is connected to ground plate 20 of ground anchor device 18 and additional shafts are driven in place. In addition, additional shafts are left protruding slightly out of ground plate 20 prior to connecting.
Operation
Initially, chamfer 32 end of main shaft 28 is driven vertically into ground to the bottom of ground plate 20 . Driving of main shaft 28 into ground is accomplished with a powered device such as a demolition hammer with driver bit placed over main shaft 28 that is protruding 42 to accompany driver bit. Once ground anchor device 18 is driven snugly into the ground, the next step is driving additional shafts through oblong holes 22 into the ground. Once additional shafts are driven into place, it is time to connect them at areas to connect 44 .
Once the additional shafts are connected, the installed ground anchor device 18 is now ready to accept pipe, pole, cable, chain, rope, wire, also different shaped items such as square or triangle post by the use of an adapter to connect up to coupler 24 , secure attachment by bolt at bolt holes 26 , or a connection at top of coupler connection area 48 or both.
To summarize, my invention comprises a coupler, ground plate, and main shaft able to be accurately driven into the ground where needed and, along with driven additional shafts, becoming more secure with each additional shaft added and then connected in place forming an expanded underground anchorage and support structure.
ADVANTAGES
From the description, a number of advantages of one embodiment of my ground anchor device becomes evident.
(a) The ground plate is able to hold many secondary shafts at a centralized location, providing a reinforced center point of anchor placement and structure.
(b) The nature of additional shafts, uniformly spread out, supplies a broad base of strength, increasing anchor durability.
(c) The connecting of all pieces involved provides a more permanent application, fortifying durability and duration of installation.
CONCLUSION, RAMIFICATIONS, AND SCOPE
Furthermore, the reader will see that the embodiments of the ground anchor device have the additional advantages in that:
It is more durable;
It is quicker to install;
It is minimally disturbing to the ground;
It is more versatile;
It is suitable for a wide range of ground conditions;
It is cost effective;
It is frost heave resistant;
It is suitable for a wide range of anchoring and support duties;
It is earthquake resistant; and
It is suitable for anchoring most anything to the ground.
Although the description above contains many specificities, these should not be thought as to limit the scope of the embodiments, but as simply providing illustration as one of several embodiments. For example, the coupler can have other shapes, such as rectangular, square, etc.; the main shaft and ground plate can have other shapes also.
Thus, the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by examples given.
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One embodiment of an anchor device for ground application and of the type having a main shaft ( 28 ) which connects at its top with a ground plate ( 20 ) with oblong holes for additional shafts ( 22 ) so as to increase holding ability. In addition a coupler ( 24 ) connects to the top side of the anchor. Other possible embodiments are described.
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FIELD OF THE INVENTION
This invention relates to building structures and particularly to a building construction having a reservoir installed in its interior wall and ceiling spaces for catching and containing meltable insulation in the event of fire.
BACKGROUND OF THE INVENTION
It has been known in the construction of residential and commercial buildings and other structures, such as industrial and manufacturing plants, to provide fire barriers or fire baffles between opposed wall members. These baffles conventionally have been integral wooden or metal panels or screens to prevent fires and flames spreading through the building. Kramer U.S. Pat. No. 3,786,604 discloses a pliable steel trough containing an urea formaldehyde resin foam filling an upwardly opening cavity of the trough. Wire screens, such as shown in Charniga U.S. Pat. No. 4,455,802, and metal fire baffles, such as disclosed in York U.S. Pat. No. 3,334,461, are also known. However, such fire barriers or baffles have not been heretofore effectively used in building constructions known to the inventor wherein the fire barriers or baffles also serve as insulation-melt reservoirs in the event of fire.
OBJECTS OF THE INVENTION
A primary object of this invention is to promote effective use of certain insulation materials (such as expanded and extruded polystyrene, hereinafter referred to as EPS or styrene) in residential homes and other structures such as commercial and industrial buildings. To the knowledge of the inventor, these styrene materials are not now being used because of their propensity to melt and flow when heated at relatively low temperatures. However, these styrene materials have higher thermal insulation efficiency ratings than equivalent insulation and also are more cost effective than conventional residential insulation materials.
Another object of this invention is to prevent molten insulation from flowing downwardly between building members while also providing a fire stop to limit expansion of fire, flames and drafts.
Yet another object of this invention is to provide a prefabricated trough formed and dimensioned to be readily and easily installed between building members to form an essentially fireproof and leakproof receptacle for molten insulation.
Still another object of this invention is to provide a trough formed of imperforate material featuring side walls which wedge against opposing building members to capture downwardly flowing molten insulation. Also included in this object is the aim of providing a closure of hood which restricts the flow of oxygen into a cavity of the trough while allowing free flow of molten insulation into that trough.
Another object of this invention is to provide an imperforate trough to collect flowing molten insulation which requires a minimum of structural supports or braces to hold it in place within a building structure.
Other objects will be in part obvious and in part pointed out in more detail hereinafter.
A better understanding of the objects, advantages, features, properties and relations of the invention will be obtained from the following detailed description and accompanying drawings which set forth certain illustrative embodiments and are indicative of the various ways in which the principles of the invention are employed.
SUMMARY OF THE INVENTION
Conventional building structures containing combustible, flowable materials, such as foamed insulation, normally present both safety and fire prevention problems. The trough of this invention limits any risk associated with using such insulation materials by providing a means for catching and containing meltable insulation among building members.
More particularly, a partition or trough having a cavity for receiving and containing such molten insulation is mounted between opposed building members; the partition is positively wedged against opposing building members for catching any downwardly flowing insulation melt. Furthermore, the partition may have a hood which restricts oxygen flow into a restricted partition cavity entrance while also allowing molten insulation to freely flow into the cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end view, partly in section and partly broken away, showing a reservoir trough of this invention between interior and exterior wall members of a building;
FIG. 2 is a plan view, partly broken away, of the trough of FIG. 1;
FIG. 3 is an end view, similar to FIG. 1, showing the reservoir trough of FIG. 1 filled with insulation melt;
FIG. 3A is an end view, partly in section and partly broken away, of a different embodiment of the reservoir trough of this invention having a sealed pouch of liquid flame-retardant and fire extinguishing chemicals contained therein;
FIG. 4 is an end view, partly in section and partly broken away, illustrating another embodiment of this invention;
FIG. 4A is an end view, partly in section and partly broken away, showing still another embodiment of the reservoir trough of this invention having an oval cavity;
FIG. 5 is a plan view, partly broken away, of the trough of FIG. 4;
FIG. 6 is an end view, partly in section and partly broken away, showing yet another embodiment of the trough of this invention having a hood mounted on side walls of the trough;
FIG. 7 is an end view, partly in section and partly broken away, of a further embodiment of a trough of this invention; and
FIG. 8 is a side view, partly in section and partly broken away, of another embodiment of this invention installed within a building soffit.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIGS. 1-3, an elongated chevron-shaped partition or trough 1 is illustrated having a body 3 of appropriate width and length to serve as a reliable fire baffle and reservoir trough for catching and containing insulation melt within a building structure. While the invention of this application is primarily illustrated as being installed in interior hollow walls of a building, it is to be understood that the fire reservoir trough may be installed within ceiling spaces of a building to capture molten insulation from roofing installations and the like.
A building wall structure typically includes spaced confronting wall members, such as interior sheet rock member 11, an exterior plywood or wooden wall member 12 and spaced uprights or spaced studs 14, 14 between members 11 and 12. Studs 14, 14 cooperate with confronting wall members 11 and 12 to define an interior wall compartment 10. Meltable insulation, such as shown at 15, in any suitable form such as blocks or sheets will be understood to be received within wall compartment 10 in overlying relation to reservoir trough 1. This insulation is of a type which, as described more specifically below, becomes a flowable molten mass, or insulation melt, when subjected to heat.
As seen in FIGS. 1 and 3, the elongated partition body 3 is of generally V-shaped cross section with longitudinally extending sides 3A and 3B joined along their bottom edges to form an imperforate upwardly opening cavity 4. Body 3 may be made of fire resistant material, such as sheet metal, or any other suitable material, preferably about 1/2 inch in thickness. Galvanized sheet steel is suitable because of its resistance to deterioration, but other suitable metals may be substituted therefor.
For sealing portions of the interior wall compartments 10, thereby to provide reliable smoke and fire baffles to effectively resist drafts and the propagation of flames through the hollow wall compartments 10, while also forming a cavity 4 to capture insulation melt within the building structure in the event of fire, sidewalls 3A and 3B are dimensioned such that body 3 completely seals off the interior wall compartment 10. In the specifically illustrated embodiment, a contoured reversely bent shoulder 6 is shown formed integrally with an upper longitudinally extending edge of each sidewall 3A and 3B to project toward the adjacent wall member 12, 11.
A section of body sidewalls 3A, 3B (just below its respective reversely bent shoulder 6, 6) engages wall members 11, 12 and are fastened to wall members 11 and 12 (or studs 14, 14) by fasteners 16 (such as screws, nails, or any other suitable fastener) to support body 3 within wall compartment 10.
Accordingly, when any heat or fire reaches a temperature sufficient to melt the insulating material 15, the insulation melt 21 (FIG. 3) flows downwardly. With the trough or partition body 3 so disposed in FIGS. 1-3 between building members, the partition 1 functions to entrap any downward flow of molten insulation 21 within cavity 4. The placement of such partitions throughout the interior compartments formed among the building members will stop the spread of fire by retaining molten insulation in the area where the fire started.
To be more fully effective, a plurality of partitions or troughs 1 may be provided in each individual compartment 10 and preferably staggered at different heights relative to that of the partitions in adjacent compartments to provide a means for containing substantially all of any insulation melt formed during a fire. It is to be understood that cavity 4 of trough 1 may itself be filled with insulation under normal conditions, particularly when the wall compartment 10 is filled with loose or granular insulation in contrast to the above mentioned block or sheet insulation. Moreover, as seen in FIG. 3A, a pouch of fire-retardant chemical 60 also may be placed within cavity 4' or trough 1' to inhibit combustion of molten insulation.
In another embodiment of the invention illustrated in FIGS. 4 and 5, partition body 203 is shown in wedged engagement with wall members 211, 212. Body 203 has opposite end walls 203C and 203D each integral with at least one of the side walls 203A and 203B to define cavity 204. Reversely turned shoulders 206, 206 are formed on sidewalls 203A, 203B to project toward wall members 212, 211; flanges 219, 219 integrally extend from end walls 203C, 203D. Sidewalls 203A, 203B and flanges 219, 219 are each suitably secured to wall members 212, 211 and studs 214, 214, respectively.
While the particular partition of "V" shaped cross-section shown in the several figures described above has been found to be both efficient and convenient in certain installations, it may be desirable to modify the shape of partition body 3 to allow more flexible use in different locations within a given building structure. The partition body may be of any suitable cross-sectional shape, e.g., U-shaped as in FIG. 3A, or annular, and still be within the spirit and scope of this invention. As illustrated in FIG. 4A, body 103 is shown mounted between building members 111, 112 and having an oval shaped cross-section and a restricted, upwardly directed opening 118 defining a constricted entrance to cavity 104 to more readily contain molten insulation and more effectively cut the oxygen supply to any burning insulation received in cavity 104. Such a cross-sectional configuration serves both to restrict the flow of oxygen into cavity 104 and also to reduce any opportunity of the volatile insulation melt within that cavity 104 to oxidize, because that volatile insulation melt does not have the same exposure to open air as it would were it in an open vessel as shown in FIG. 1.
As seen in FIG. 6, yet another embodiment of this invention is shown wherein a closure or hood 315 is suitably mounted (by brackets such as at 317) in overlying relation to partition body 303 and its interior cavity 304. Brackets 317 will be understood to be spaced apart along each side of body 303. Its internal cavity 304 is defined by a pair of sidewalls 303A, 303B extending upwardly from a flat bottom wall 303E to be secured to building members 312, 311. To permit flow of molten insulation while restricting oxygen flow into cavity 304, hood 315 overlies the opening of partition body 303 but does not entirely seal its cavity 304. Rather, hood 315 and body 303 jointly form restricted spaces or gaps 318, 318 each defining a constricted entrance opening into cavity 304 along opposite longitudinally extending side edges of body 303 to permit insulation melt to flow into cavity 304 while reducing its opportunity to oxidize as fully described above.
FIG. 7 illustrates a trough body 403 having one vertically extending sidewall 403A, attached flush with an interior surface of a building wall member 412, with an opposing sidewall 403B is fixed by suitable fasteners, such as at 416, to wall member 411. Sidewall 403B extends downwardly from member 411 at an angle toward wall member 412 and is interconnected to sidewall 403A by a flat base 413. A closure or hood 415 is fixed relative to sidewall 403A and supported by spaced brackets, such as the one shown at 417, on sidewall 403B, thereby to freely permit flow of insulation melt into cavity 404 while restricting oxygen flow through constricted entrance 418. This embodiment may also include end walls, not shown, integrally formed with sidewalls 403A and 403B.
FIG. 8 illustrates yet another modification of this invention wherein a partition 501 having a body 503 of U-shaped cross-section is shown mounted within a conventional roofing soffit 530. Body 503 will be understood to be elongated with opposed sidewalls 503A, 503B in adjacent relation to longitudinally extending members 505, 507 which serve as spaced confronting wall members. It is to be understood that end members, not shown, serve as spaced uprights in the disclosed roofing soffit. Body 503 accordingly extends the length of the internal compartment within soffit 530 of the building structure to provide a channel to capture any insulation melt flowing from roof insulation such as at 515 through vent openings or spacings within the roofing and building structure.
When this invention has been incorporated in a building construction, it will be understood that these partitions provide the building with substantially greater capacity for reducing the spread of a fire. This invention provides, in effect, a multiplicty of individual fire barriers for preventing the spread of flames and oxygen drafts throughout a building structure, and further prevents intensification of any fire by containing insulation melt in the cavities of the disclosed partitions. Such molten masses of insulation will flow into the cavities of the partitions and will be held therein and prevented from falling downwardly and throughout the building construction to spread or intensify a fire. Futhermore, this invention allows for the use of insulation materials such as EPS or styrene having superior insulation qualities yet significantly lower cost than conventional insulation.
As will be apparent to persons skilled in the art, various modifications, adaptations and variations of the foregoing specific disclosure can be made without departing from the teachings of this invention.
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A fire barrier partition having a body with a cavity for receiving and containing molten insulation is disclosed for use in building constructions. The partition is supported between building members in positively wedged engagement. The partition may support a cover which restricts the flow of oxygen into the cavity while allowing molten insulation to flow freely into the partition cavity.
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BACKGROUND OF THE INVENTION
The present invention relates to a hydraulic linear drive, particularly a hydraulic transmission actuator, in which an actuating piston longitudinally displaceably arranged in the cylinder housing in the cylinder space into at least two pressure chambers which can be acted upon by hydraulic oil by way of control conduits, and having a piston rod connected with the actuating piston, as well as having a sealing element arranged on the actuating piston, by means of which sealing element, the at least two pressure chambers are sealed off from one another.
Hydraulic linear drives are used, for example, in the case of automated standard transmissions, for the synchronization of the transmission gears (see, for example, Johannes Loomann, “Zahnradgetriebe”, 2nd Edition, pg, 156, and on).
In the case of the hydraulic linear drives of the above-mentioned type, the dual piston bounded by two pressure chambers is in each case pushed toward the left or right as a result of correspondingly being acted upon by pressure. In many of the application cases, the two pressure chambers are sealed off by sealing elements arranged on the outer circumference of the piston.
Particularly in the case of hydraulic transmission actuators, high actuating forces are applied during the synchronization of the transmission gears-and require a reliable and durable sealing-off or separation of the two pressure chambers.
SUMMARY OF THE INVENTION
An object of the present invention to improve the sealing-off of the two pressure chambers in the area of the piston unit. This object has been achieved by the fact that the actuating piston is constructed in two parts and a sealing element is arranged between the two piston parts. The sealing element is clamped between the two piston parts when the piston unit is adjusted and, because of the actuating forces to be applied, for example, during the synchronization of the transmission gear, is pressed radially toward the outside to a certain extent. Thereby the sealing between the actuating piston and the interior cylinder wall is advantageously improved.
The sealing element constructed as a sealing ring is received on a sealing device carrier which is axially guided on one of the two piston parts.
For a better axial guidance of the sealing device carrier, the latter engages on the face in the first piston part.
The sealing device carrier is shaped in one piece out of one of the two piston parts or, as an alternative, is arranged as a separate component between the two piston parts.
The sealing device carrier is advantageously longitudinally displaceably disposed on the first piston part, for limiting the contact pressure force exercised upon the sealing ring. The relative movement of the sealing device carrier is limited by two stops constructed on the first piston part.
An advantageous embodiment of a hydraulic linear drive which is adapted to the use as a hydraulic transmission actuator is obtained when the two piston parts and the cylinder housing have a stepped construction. As a result of the step piston which provides in this manner, in a first adjusting path, a high adjusting speed can be achieved with a low friction. Because of a large piston diameter, a high actuating force can be generated about the synchronization point and thus a high radial contact pressure force of the sealing ring against the interior wall of the cylinder housing.
A longitudinal groove is formed in the surface area of the piston part section having a reduced diameter. The longitudinal groove in each case connects a first hydraulic chamber section with a second hydraulic chamber section of the two step pistons.
One control conduit respectively is connected to the two first hydraulic chamber sections of the two step pistons, which control conduit is used for the feeding or removal of hydraulic oil.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of a linear drive with a schematically shown hydraulic control according to a first embodiment of the present invention; and
FIG. 2 is a partial cross-sectional view of a linear drive having a hydraulic control according to a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The hydraulic linear drive illustrated in FIG. 1 can be used, for example, as a hydraulic transmission actuator for an automated standard transmission. The drive has a two-part cylinder housing 2 a , 2 b , which parts are both mutually connected, preferably screwed together, on their faces. In the cylinder space formed by the cylinder housing 2 a , 2 b , two piston parts called step pistons 4 , 6 are received and, both being equipped with one piston rod 8 , 10 respectively guided out of the cylinder housing 2 , are longitudinally displaceably guided in the cylinder housing 2 . In this case, the sealing-off of each of the two pistons rods 8 , 10 takes place by one respective sealing ring 12 , 14 . The two step pistons 4 , 6 each have two piston sections 4 a , 4 b and 6 a , 6 b respectively, in which a sealing device carrier 18 with a sealing ring 16 is arranged between the mutually facing faces of the pistons section 4 b , 6 b provided with a larger diameter.
The sealing device carrier 18 is disposed on an interior ring flange section 20 of the piston section 4 b and, on its right face, is screwed to the piston section 6 b of the step piston 6 , while, on its left face, it engages by way of a ring flange 22 in a gearing manner in a ring groove 24 constructed between a central ring flange section 23 and an outer ring flange section 25 of the piston section 4 b . The sealing ring 16 is pushed onto the ring flange 22 and correspondingly seals off the two pressure chambers 26 , 28 from one another which are separated by the step pistons 4 , 6 .
For limiting the sealing device carrier 18 longitudinally displaceably disposed on the interior ring flange section 20 , a left and a right stop is provided. The left stop is formed by the central ring flange section 23 of the piston section 4 b , and the right step 32 is formed by a limit stop washer 32 a which is axially secured by a snap ring 32 b received in a ring groove. Further, a flat coil spring 34 , which is arranged on the interior ring flange section 20 , is accommodated in a ring groove forming between the interior and central ring flange section 20 , 23 and is therefore clamped in between the sealing device carrier 18 and the piston section 4 b.
The surface area of the two piston sections 4 a , 6 a respectively has a respective longitudinal groove 36 , 38 each of which hydraulically connects the respective pressure chamber 26 , 28 with a respective second pressure chamber 40 , 42 . The two pressure chambers 40 , 42 , namely, first pressure chambers, are bounded in each case by the respective face 41 , 42 of the piston section 4 a , 6 a and the face of the respective sealing ring 12 , 14 . One hydraulic conduit 44 , 46 respectively is connected to the two first pressure chambers 40 , 42 so that by way of a 7/2-way control valve 48 , the pressure chambers 40 , 42 can optionally be supplied with hydraulic oil from a tank 50 . One return flow conduit 49 , 51 is in each case connected to the respective two pressure chambers 26 , 28 , namely, second pressure chambers. The return flow conduit 49 , 51 can optionally be connected by way of the control valve 48 with the tank 50 .
In the control position of the 7/2-way valve 48 , the first pressure chamber 42 is acted upon by hydraulic oil by the hydraulic conduit 46 for the displacement of the two step pistons 4 , 6 toward the left. The actuating force exercised on the face 43 of the piston section 6 a displaces the piston unit consisting of the two step pistons 4 , 6 toward the left. In that case, after a first adjusting path, by way of the longitudinal groove 38 connecting the two pressure chambers 42 , 28 , the second pressure chamber 28 is also filled with hydraulic oil.
After moving a further distance, the hydraulic oil arrives in an unthrottled manner from the first pressure chamber 42 in the second pressure chamber 28 and acts exclusively with respect to the piston section 6 b with the larger diameter. Thus, on the one hand, the adjusting rate of the actuating piston 4 , 6 is reduced but, on the other hand, the actuating force acting upon the step piston 6 is increased. Simultaneously, the hydraulic oil situated in the first and second pressure chamber 40 , 26 of the opposite side is returned into the tank 50 by the return conduit 49 and the hydraulic conduit 44 . The fact that the piston unit 4 , 6 is displaced against a resistance, has the effect that the sealing ring 16 clamped in between the exterior ring flange section 25 of the piston section 4 b and the sealing device carrier 18 deforms elastically and is thereby pressed radially against the interior wall of the cylinder housing 2 .
The hydraulic linear drive can be used, for example, as a hydraulic transmission actuator, in which case a shift fork engaging in a gearshift sleeve unit is axially displaced by the transmission actuator for establishing a non-rotatable connection between the gearshift sleeve and the transmission gear. In such case, a high adjusting speed with a low friction is reached by way of a first adjusting path via the two piston sections 4 a , 6 a respectively which have the smaller diameter, while about the synchronization point, a high radial contact pressure force of the sealing ring 16 can be achieved with respect to the interior cylinder wall via the two piston sections 4 b , 6 b respectively which have a larger diameter.
The second embodiment of the hydraulic linear drive illustrated in FIG. 2 differs from that of FIG. 1 only with respect to the hydraulic control. Instead of the 7/2-way control valve 48 used in the first embodiment, the controlling of the feeding and removal of hydraulic oil now takes place by way of a first 4/2 control valve 56 and a second 3/2 control valve 58 . By way of the first 4/2 control valve 56 , the two first pressure chambers 40 , 42 respectively can optionally be acted upon by hydraulic oil, while the return of the hydraulic oil from the first two pressure chambers 26 , 28 respectively is controlled by the control valve 58 . The difference with respect to the first embodiment consists of the fact that, by the respective closing of the conduit 49 , 51 , the hydraulic oil to be returned from the respective second pressure chamber 26 , 28 into the tank 50 is returned in this second embodiment by way of the longitudinal groove 36 , 38 respectively, the respective first pressure chamber 40 , 42 and the respective hydraulic conduit 44 , 46 . As a result, an additional damping of the adjusting movement can be achieved, particularly when reaching one of the two end positions of the actuating pistons 4 , 6 .
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A hydraulic linear drive, particularly a hydraulic transmission actuator, having a piston/cylinder unit, in which an actuating piston longitudinally displaceably arranged in the cylinder housing divided into at least two pressure chambers which can be acted upon by hydraulic oil by way of control conduits. A piston rod is connected with the actuating piston, and a sealing element is arranged on the actuating piston to seal off the two pressure chambers from one another. The actuating piston has a two-piece construction and consists of a first and a second piston part between whose facing faces, a sealing element is arranged.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an apparatus for treating digested sludge generated when organic waste matter is subjected to anaerobic digestion.
[0002] In another aspect, the present invention relates to a method and an apparatus for preventing scale precipitation, particularly MAP scale precipitation, on the inside of a pipe when digested sludge generated by subjecting sludge to anaerobic digestion is transported by the pipe.
[0003] In a further aspect, the present invention relates to digested sludge treatment, and more particularly to a treatment method and a treatment apparatus with which phosphorus can be recovered efficiently from digested sludge generated by subjecting sludge to anaerobic digestion.
[0004] In a treatment facility for treating organic waste water containing phosphorus and nitrogen, such as sewerage, waste water, and night soil, first the raw sludge (also referred to as primary sludge hereafter) is subjected to solid-liquid separation in a primary sedimentation tank, whereupon the separated supernatant liquid undergoes an activated sludge process to remove organic matter. The activated sludge produced in the activated sludge process is discharged as excess sludge. When raw sludge, excess sludge, or organic waste matter such as night soil or raw refuse is subjected to anaerobic digestion, the organic matter in the waste matter is broken down by the action of acidic bacteria and methanogenic bacteria, leading to a reduction in the amount of sludge, and waste water having high concentrations of methane gas, carbon dioxide, nitrogen, and phosphorus is generated. Today, active investigations are being conducted into methods of utilizing the generated methane gas as a heat source, producing MAP (magnesium ammonium phosphate) from the digested sludge liquor obtained by dewatering the digested sludge, and making effective use of this MAP in fertilizers, chemical raw materials, and so on (Japanese Unexamined Patent Application Publication 2003-117306).
[0005] Moreover, anaerobic digestion tanks have recently increased in efficiency in order to save energy and reduce sludge. For example, sludge is solubilized by subjecting raw sludge, excess sludge, or mixed sludge containing both raw sludge and excess sludge to physical/mechanical treatment, chemical liquefaction treatment, heat treatment, and so on, thereby enabling an improvement in the methane gas recovery rate of the subsequent anaerobic digestion process and promoting sludge reduction. Ultrasonic treatment, crushing using a mill, and so on may be cited as examples of such physical/mechanical treatment, while treatment with ozone, hydrogen peroxide, acid, or alkali is included in the chemical liquefaction treatment. Heat treatment includes treatment with thermophilic bacteria and so on Japanese Unexamined Patent Application Publication 2002-336898, for example, discloses a method of solubilizing sludge by treating the sludge in an ultrasonic treatment process.
[0006] Nowadays, in order to achieve effective utilization and efficient treatment of digested sludge, regions exist in which all wastewater treatment plants and the like are connected by sewers, and generated digested sludge is transported through the sewers to be treated collectively in a single treatment plant. The construction cost of the sewers is cheaper than that of a treatment facility, and since the advantage of scale applies to sludge treatment facilities (i.e. the unit cost thereof decreases as the scale increases), sewers are considered to be more economical in locations such as urban areas, where residential buildings are in close proximity.
[0007] When digested sludge is transported by pipes, so-called MAP precipitate, generated when the magnesium ions of the sludge combine with phosphorus ions and ammonium ions, is generated, leading to possible blockages of the sludge pipe.
[0008] To solve this problem, a method of transporting the sludge through a sludge pipe after removing and recovering the MAP by aerating the sludge in a reactor in advance to generate MAP particles, and then subjecting the sludge containing the MAP particles to centrifugal separation, is known.
[0009] Furthermore, as the efficiency of anaerobic digestion improves, the nitrogen and phosphorus concentrations of the generated waste water increase. Organic waste matter initially contains elements such as nitrogen, phosphorus, and magnesium, and when the organic waste matter is solubilized, these elements migrate to the liquid. When waste water containing high concentrations of nitrogen and phosphorus is returned to a water treatment system, increased nitrogen and phosphorus loads are applied to the water treatment system, causing a deterioration in the quality of the treated water.
[0010] In a known technique for solving this problem, digested sludge or digested sludge liquor is subjected to aeration treatment to generate MAP, and a part of the sludge that is submerged in a sedimentation tank is returned to the aeration tank top serve as seed crystals. In so doing, the phosphorus concentration of the return water decreases, and. MAP recovery is facilitated. In Japanese Examined Patent Application Publication H7-115979, digested sludge is decarbonated, whereupon a magnesium compound is added to precipitate MAP, thereby reducing the phosphorus concentration of liquid. In both cases, the phosphorus concentration of the liquid is decreased by precipitating MAP, and therefore phosphorus can be prevented from circulating endlessly during water treatment and sludge treatment processes.
[0011] A method of transporting the sludge through a sludge pipe after removing and recovering MAP by aerating the digested sludge in a reactor in advance to generate MAP particles, and then subjecting the sludge containing the MAP particles to centrifugal separation, is also known. By means of this operation, problems such as blockages of the sludge pipe caused by the MAP particles can be avoided.
[0012] As noted above, the nitrogen and phosphorus concentrations of generated waste water increase as the efficiency of anaerobic digestion improves. Organic waste matter initially contains elements such as nitrogen, phosphorus, and magnesium, and when the organic matter is solubilized, these elements migrate into the solution. Nitrogen, phosphorus, and magnesium are constituent components of MAP, and at high concentrations, or when alkali increases, the nitrogen, phosphorus, and magnesium easily equal or exceed the solubility product of the MAP such that the MAP precipitates spontaneously in a digestion tank. When the MAP precipitates onto a draft tube in the digestion tank, the flow of the digested sludge deteriorates, and scale trouble such as blockages during pump extraction occur frequently.
[0013] Moreover, the MAP is disposed of together with the dewatered sludge rather than being recovered, and hence there is demand for an efficient MAP recovery method.
[0014] When MAP is precipitated by decarbonating the digested sludge or adding a magnesium compound thereto, the phosphorus concentration of the dewatered separated liquid decreases, and therefore the phosphorus load on the water treatment system is reduced so that the treated water can be maintained at a favorable quality. However, this method focuses on phosphorus removal rather than the recovery of phosphorus resources, and hence there is demand for a treatment method which satisfies aspects of both phosphorus removal and phosphorus recovery. Moreover, when MAP is recovered through aeration and centrifugal separation, the recovered substance contains digested sludge and coarse contaminant particles such as night soil residue as well as the MAP, and hence it is not always possible to recover MAP having a high degree of purity. When recycling phosphorus, purity is required, and hence there is demand for a method of recovering MAP having a high degree of purity.
[0015] Further, when digested sludge containing MAP is transported by pipe to a facility for treating sludge collectively, a large amount of MAP scale is generated in the pipe, leading to a deterioration in the efficiency with which the sludge is transported. Following its initial generation, MAP scale continues to grow. If MAP scale is left on the inside of the pipe, the entire sewer is eventually covered in MAP scale, making sludge transportation difficult, and as a result, cleaning must be performed periodically and maintenance becomes troublesome.
[0016] Furthermore, when MAP is removed and recovered by aerating digested sludge in a reactor in advance to generate MAP particles and then subjecting the sludge containing the MAP particles to centrifugal separation in an attempt to solve the problems described above, coarse contaminant particles such as night soil residue in the digested sludge often cause blockages in the centrifugal separator, particularly when a liquid cyclone is used as the centrifugal separator. As a result, stable treatment is difficult, while cleaning and maintenance are laborious.
SUMMARY OF THE INVENTION
[0017] An object of the present invention is to solve the problems described above by providing a method and an apparatus for stably preventing scale, particularly MAP scale, from forming on the inside of a pipe during the transportation of digested sludge, and/or providing a digested sludge treatment method and a digested sludge treatment apparatus which satisfy aspects of both phosphorus removal and phosphorus recovery, and enable the recovery of MAP having a high degree of purity.
[0018] To achieve the objects described above, a first aspect of the present invention provides a digested sludge treatment apparatus for treating digested sludge generated by subjecting organic waste matter to anaerobic digestion, comprising: an apparatus for decarbonating the digested sludge; a removal apparatus for removing coarse contaminant particles from the digested sludge; and an apparatus for separating or concentrating crystals containing magnesium ammonium phosphate from the digested sludge after the digested sludge passes through the decarbonation apparatus and removal apparatus.
[0019] Another aspect of the present invention provides a digested sludge treatment apparatus for treating digested sludge generated by subjecting organic waste matter to anaerobic digestion, comprising: a crystallization reactor for precipitating magnesium ammonium phosphate from the digested sludge; a removal apparatus for removing coarse contaminant particles from the digested sludge; and an apparatus for separating or concentrating crystals containing magnesium ammonium phosphate from the digested sludge after the digested sludge passes through the crystallization reactor and coarse contaminant particles removal apparatus.
[0020] A further aspect of the present invention provides a method of preventing scale from forming on the inside of a pipe when digested sludge generated by subjecting organic waste matter to anaerobic digestion is transported by the pipe, wherein the digested sludge is treated in a decarbonation process and a coarse contaminant particles removal process, micro-particles containing MAP are separated from the digested sludge following decarbonation and coarse contaminant particles removal, and following removal of these micro-particles, the digested sludge is transported by the pipe.
[0021] In this method of the present invention, the digested sludge is preferably subjected to processing to lower the pH and/or processing to reduce at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration following micro-particle removal, and then transported by the pipe. The anaerobic digestion may be performed following a discharge process for discharging phosphate ions from the organic waste matter and a concentration process for concentrating the organic waste matter following the discharge process. Further, the digested sludge that is transported by the pipe should have a magnesium ion concentration of no more than 20 mg/L, and preferably no more than 5 mg/L.
[0022] A further aspect of the present invention provides an apparatus for preventing scale from forming on the inside of a pipe when digested sludge generated by treating organic waste matter in an anaerobic digestion tank is transported by the pipe, comprising: an apparatus for decarbonating the digested sludge; a removal apparatus for removing coarse contaminant particles from the digested sludge; and an apparatus for separating micro-particles containing MAP from the digested sludge after the digested sludge passes through the decarbonation apparatus and coarse contaminant particles removal apparatus.
[0023] This apparatus of the present invention preferably further comprises a chemical adding apparatus for lowering the pH of the digested sludge following micro-particle removal, and/or a chemical adding apparatus for reducing at least one of the magnesium ton concentration, phosphate ion concentration, and ammonium ion concentration thereof. Further, discharging means for discharging phosphate ions from the organic waste matter and a concentration apparatus for concentrating the organic waste matter following the discharge process may be disposed before the anaerobic digestion tank.
[0024] A further aspect of the present invention provides a digested sludge treatment method for treating digested sludge generated by subjecting organic waste matter to anaerobic digestion, wherein the digested sludge is treated in a crystallization process for precipitating MAP by adding a magnesium compound and coarse contaminant particles such as night soil residue removal process for removing coarse contaminant particles from the digested sludge, micro-particles containing MAP are recovered from the digested sludge in a separation process following the crystallization process and coarse contaminant particles removal process, and following removal of these micro-particles, the digested sludge is dewatered in a dewatering process. In this method of the present invention, the MAP-containing micro-particles recovered in the separation process, or a portion or all of MAP-containing effluent generated in the separation process, may be returned to the crystallization process, while a portion or all of the coarse contaminant particles removed in the coarse contaminant particles removal process may be supplied to the dewatering process. Further, following micro-particle removal, the digested sludge is preferably subjected to processing to lower the pH and/or processing to reduce at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration, and then transported to the dewatering process.
[0025] A further aspect of the present invention provides a digested sludge treatment apparatus for treating digested sludge generated by subjecting organic waste matter to anaerobic digestion, comprising: a crystallization apparatus having adding means for adding a magnesium compound in order to precipitate MAP during treatment of the digested sludge; a coarse contaminant particles removal apparatus for removing coarse contaminant particles from the digested sludge: a separation apparatus for recovering micro-particles containing MAP from the digested sludge after the digested sludge passes through the crystallization apparatus and coarse contaminant particles removal apparatus; and a dewatering apparatus for dewatering the digested sludge following removal of the micro-particles. In this apparatus of the present invention, a return path may be provided for returning a portion or all of the MAP-containing micro-particles recovered by the separation apparatus to the crystallization apparatus, and supply means may be provided for supplying a portion or all of the coarse contaminant particles removed by the coarse contaminant particles removal apparatus to the dewatering apparatus. Further, a chemical adding apparatus for lowering the pH of the digested sludge following micro-particle removal, and/or a chemical adding apparatus for reducing at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration thereof, may be provided after the separation apparatus.
[0026] According to the present invention, by employing the constitution described above, MAP scale on the inside of a pipe for transporting digested sludge can be reduced greatly, and/or phosphorus can be recovered efficiently from the inside of a digestion tank.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a flow diagram showing an example of the flow of digested sludge treatment according to the present invention;
[0028] FIG. 2 is a flow diagram showing another example of the flow of digested sludge treatment according to the present invention;
[0029] FIG. 3 is a flow diagram showing another example of the flow of digested sludge treatment according to the present invention;
[0030] FIG. 4 is a flow diagram showing the flow of treatment used in a third example:
[0031] FIG. 5 is a flow diagram showing the flow of treatment used in a first comparative example:
[0032] FIG. 6 is a flow diagram showing another example of the flow of digested sludge treatment according to the present invention;
[0033] FIG. 7 is a flow diagram showing another example of the flow of digested sludge treatment according to the present invention;
[0034] FIG. 8 is a flow diagram showing another example of the flow of digested sludge treatment according to the present invention; and
[0035] FIG. 9 is a flow diagram of an apparatus used in a second comparative example.
[0036] The various reference numerals in the drawings denote the following components.
1 : introduced sludge 2 : anaerobic digestion tank 3 : digested sludge (extracted sludge) 4 : decarbonation process 5 : coarse contaminant particles removal process 6 : coarse contaminant particles 7 : process for separating micro-particles containing MAP 8 : recovery of micro-particles containing MAP 9 : out of the system 10 : pH adjustor 11 : concentrated excess sludge 12 : phosphorus discharge tank 13 : BOD source 14 : concentration process 15 : separated water 16 : dewatering process 17 : concentration-adjusted water 18 : sludge liquor 101 : introduced sludge 102 : anaerobic digestion tank 103 : extracted sludge (digested sludge) 104 : crystallization process 105 : Mg compound 106 : coarse contaminant particles removal process 107 : coarse contaminant particles 108 : process for separating micro-particles containing MAP 109 : recovery of micro-particles containing MAP 110 : dewatering process 111 : sludge liquor 112 : out of the system 113 : micro-particle transportation pipe 114 : coarse contaminant particles transportation pipe
DETAILED DESCRIPTION OF THE INVENTION
[0069] Embodiments of the present invention will now be described in detail with reference to the drawings.
[0070] Note that in the drawings, constitutional elements having identical functions have been allocated identical reference numerals.
[0071] Examples of organic waste matter treated in the present invention include night soil, treatment tank sludge, sewerage sludge, agricultural sludge, livestock waste, raw refuse, and food waste. The organic waste matter is typically in liquid slurry form, or has a high moisture content when in solid form. To enable smooth treatment, it is preferable to introduce non-slurry form waste matter into waste water or the like such that the waste matter is treated in slurry form. In the following, an example in which sewerage sludge is used as the organic waste matter will be described.
[0072] FIG. 1 is a flow diagram showing an example of a treatment flow according to the present invention, which is constituted by an anaerobic digestion tank 2 , a decarbonation process 4 for decarbonating digested sludge, a coarse contaminant particles separation process 5 , and a micro-particle separation process 7 for separating and recovering micro-particles containing MAP.
[0073] Excess sludge and/or primary sludge are introduced into the anaerobic digestion tank 2 . The interior of the anaerobic digestion tank is heated and maintained at a temperature of approximately 55° C. or approximately 35° C. In the anaerobic digestion tank, the sludge is broken down into methane, carbon dioxide, a gas such as hydrogen sulfide, water-soluble nitrogen, phosphorus, and so on by the action of acid-fermentative bacteria and methanogenic bacteria. The generated methane gas may be recovered and used as energy. The amount of generated methane gas is increased by introducing easily decomposable raw sludge in addition to excess sludge. As the sludge decomposes, phosphorus, magnesium, and ammonium migrate to the liquid side, and thus MAP is generated spontaneously in the anaerobic digestion tank. As a result of this MAP precipitation, scale trouble occurs on the draft tube, the base portion of the anaerobic digestion tank, the sludge discharge pipe, and so on.
[0074] The ratio of the phosphorus, magnesium, and ammonium in the digested sludge is generally phosphorus magnesium:ammonium=100 to 500: several to several tens: 1000, and hence the magnesium concentration is overwhelmingly lower than the phosphorus and ammonium concentrations During MAP generation in the digestion tank, the magnesium concentration clearly serves as a rate control.
[0075] The digested sludge contains micro-particles containing MAP, and has a pH in the vicinity of 7, a phosphorus concentration between 100 and 500 mg/L, a magnesium concentration between several and several tens of mg/L, and an ammonium concentration between 500 and 4000 mg/L. Conventionally, a large amount of MAP scale is generated in a sewer when digested sludge having these properties is transported by pipe, leading to problems such, as blockages.
[0076] As a result of committed research into the phenomenon of scale generation, performed by the present inventors and others, it was ascertained that pH variation and gas phase intermixing inside the pipe leads to decarbonation, causing the generation of MAP and hence scaling. In other words, the digested sludge continues to possess a latent ability to generate MAP (MAP generation ability hereafter). To make matters worse, the MAP micro-particles generated spontaneously in the digested sludge act as seed crystals, promoting scale generation.
[0077] The present inventors focused on the remnant MAP generation ability described above, and thus discovered a need to reduce the remnant MAP generation ability before the digested sludge is introduced into a sewer. The present inventors discovered that the MAP generation ability of digested sludge is greatly reduced by decarbonating the digested sludge to raise the pH such that MAP is generated in advance, and then separating the MAP contained in the digested sludge and the MAP generated in the decarbonation process from the digested sludge, as in the present invention.
[0078] Aeration treatment or decompression treatment may be employed in the decarbonation process 4 . Aeration treatment involves aerating the digested sludge such that the carbon gas in the sludge is dispersed into the gas phase, thereby raising the pH such that MAP is generated in a quantity corresponding to the amount of remaining magnesium. In decompression treatment, a degassing apparatus (referred to as a thin film vacuum degassing apparatus hereafter) such as that disclosed in Japanese Unexamined Patent Application Publication H7-136406 is preferably used. Specifically, a subject liquid is increased in speed by the centrifugal force of a sifting body which has a base and is rotated in a vacuum container, whereby the subject liquid collides with the inner wall surface of the vacuum container such that the gas in the subject liquid is removed. As a result of the decompression treatment, decarbonation occurs, leading to an increase in the pH and the generation of MAP.
[0079] In the treatment described above, if the magnesium ion concentration of the liquid decreases, the MAP generation ability disappears, and hence scale generation is suppressed. For example, if the pH is raised from 7 to 8, the magnesium ion concentration of the digested sludge generally falls to 1/10 to ½. In the present invention, the magnesium ion concentration of the digested sludge is set at no more than 20 mg/L, and preferably no more than 5 mg/L. When the,magnesium ion concentration is no more than 20 mg/L, almost no MAP supersaturation occurs even when the pH in the sewer varies, or when the gas phase is intermixed such that the pH rises, for example, and hence MAP precipitation can be prevented.
[0080] Decarbonation through chemical addition may be employed as a decarbonation method instead of aeration and decompression. Needless to say, these operations may be combined and performed in any order. The decarbonated digested sludge is then introduced into the coarse contaminant particles removal process 5 . Conventionally, no coarse contaminant particles separation process is performed, and therefore when a liquid cyclone is used in the subsequent micro-particle separation process 7 , blockages caused by coarse contaminant particles and the like occur. For this reason, there is demand for a treatment method exhibiting long-term stability. In the present invention, coarse contaminant particles are removed, enabling a vast improvement in the stability of the subsequent micro-particle separation process 7 , particularly when this process employs a liquid cyclone.
[0081] The removed coarse contaminant particles 6 may be discharged outside of the system or mixed into the digested sludge following the micro-particle separation process 7 . When a dewatering process is provided, the coarse contaminant particles 6 may be introduced in the dewatering process. In this case, the dewatering performance is enhanced, and it is therefore preferable to introduce the coarse contaminant particles 6 into the dewatering process if such a process is provided.
[0082] Note that the decarbonation process 4 and coarse contaminant particles removal process 5 may performed in any order. The decarbonation process 4 may precede the coarse contaminant particles removal process 5 , or the coarse contaminant particles removal process 5 may precede the decarbonation process 4 , as shown in FIG. 1 and so on.
[0083] Following the decarbonation process 4 and coarse contaminant particles removal process 5 , the micro-particles containing MAP precipitated in the digestion tank and during the decarbonation process are separated from the digested sludge. A liquid cyclone, a centrifugal settler, a sedimentation tank employing gravity separation, and so on may be employed as a method of separating the micro-particles from the digested sludge using the specific gravity difference between the two, while a vibrating screen, a drum screen, a filter layer, a classification layer-type separation tank, and so on may be employed as a micro-particle separation method using differences in particle diameter.
[0084] A liquid cyclone has a reverse conical-form lower portion structure, and is constituted by a liquid cyclone inflow pipe, a micro-particle discharge pipe, and a sludge discharge pipe. In the liquid cyclone, the digested sludge containing MAP is caused to swirl down the wall surface of the reverse conical form by the pressure of an extractor pump. The MAP-containing micro-particles, which have a greater specific gravity than the digested sludge, are collected and concentrated on a lower wall surface side by means of centrifugal force. The concentrated micro-particles are extracted either continuously or intermittently.
[0085] In the present invention, coarse contaminant particles are separated before the MAP-containing micro-particle separation process 7 , and therefore problems such as blockages of the liquid cyclone caused by coarse contaminant particles and the like are solved. Having passed through the decarbonation process 4 , coarse contaminant particles separation process 5 , and micro-particle separation process 7 , the digested sludge is transported through a sewer to a collective sludge treatment facility, other type of sludge treatment facility, or a sludge treatment facility within the same premises. As a result of the processes described above, the magnesium ion concentration of the digested sludge is greatly reduced and MAP micro-particles are removed from the digested sludge. Hence, according to the present invention, the MAP generation ability is reduced even upon pH variation or gas phase intermixing, and therefore MAP scale generation is reduced greatly.
[0086] In the example shown in FIG. 2 , processing to lower the pH and/or processing to reduce at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration are performed following the micro-particle separation process 7 . A pH adjustor may be added as a method of reducing the pH. A chemical for lowering the pH of digested sludge, such as hydrochloric acid, sulfuric acid, aluminum salt, or iron salt, is used as the pH adjustor. With aluminum salt and iron salt, the soluble phosphorus contained in the digested sludge is fixed, causing a reduction in the solubility concentration. Ammonia stripping, fixation by adhesive, and so on may be used as a method of reducing ammonium ions. MAP is precipitated when any of the phosphorus concentration, magnesium concentration, ammonium concentration, and pH rises. Conversely, as described above, when the pH of the digested sludge falls or at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration is reduced, the MAP generation ability deteriorates. According to the present invention, the MAP generation ability deteriorates, reducing the likelihood of MAP scale generation. Note that with the addition of iron salt, the generation of hydrogen sulfide and the like from the digested sludge can be suppressed.
[0087] In the example shown in FIG. 3 , excess sludge or concentrated excess sludge 11 is introduced into a phosphorus discharge tank 12 . Phosphorus is discharged from the sludge by adding a BOD under anaerobic conditions. A BOD source 13 uses organic waste matter containing raw sludge, a portion of the solubilized sludge that is generated when sludge solubilization treatment is performed, or a portion of the organic waste water from which the excess sludge is generated. A chemical such as methanol may be added as a separate BOD source. In the phosphorus discharge tank 12 , phosphorus is discharged from the excess sludge and concentrated excess sludge, and a part of the magnesium contained in the sludge is also eluted to the liquid side. Particularly when a biological dephosphorylation method such as an anaerobic/aerobic process is performed in a water treatment system, the phosphorus concentration and magnesium concentration of the liquid increase dramatically. When phosphorus is discharged from concentrated excess sludge, the phosphorus concentration and magnesium concentration of the liquid fall to approximately 50 to 400 mg/L and 50 to 200 mg/L, respectively. Meanwhile, ammonium elution is small, leading to an ammonium concentration of approximately 50 to 150 mg/L. Having undergone this phosphorus discharge treatment, the discharged sludge is separated into concentrated sludge 1 and concentrated sludge liquor 15 in a sludge concentration apparatus 14 , or separated into sludge cake and sludge liquor in a dewatering apparatus. The sludge concentration apparatus 14 employs a method such as flotation separation, gravity separation, or mechanical separation. The dewatering apparatus employs a dewatering method such as centrifugal dewatering, belt pressing, or screw pressing.
[0088] The separated liquid and sludge liquor 15 contain concentrated phosphorus, and it is of course desirable that the phosphorus be removed and recovered by precipitating a phosphorus compound from this waste water. In the anaerobic digestion tank 2 , the sludge is broken down such that the phosphorus, magnesium, and ammonium migrate to the liquid side, but by discharging the phosphorus and magnesium from the sludge in advance, before introduction into the anaerobic digestion tank, such that the phosphorus and magnesium concentrations decrease, as in the present invention, the amount of MAP that is generated spontaneously in the anaerobic digestion tank can be reduced. As a result, scale trouble caused by MAP and the like can be suppressed. Moreover, the amount of MAP that is discharged together with the digested sludge can be reduced. In FIG. 3 , the digested sludge is decarbonated, coarse contaminant particles are removed, and the MAP-containing micro-particles are separated. The effects of these processes are as described above.
[0089] Another example of the treatment flow according to the present invention is illustrated in FIG. 6 . The flow in FIG. 6 is constituted by an anaerobic digestion tank 102 , a crystallization process 104 , a coarse contaminant particles removal process 106 , a micro-particle separation process 108 , and a dewatering process 110 . Note that in the flow illustrated in FIG. 6 and the following FIGS. 7 and 8 , the dewatering process 110 is not essential, and may be omitted.
[0090] Excess sludge and/or primary sludge 101 are introduced into the anaerobic digestion tank 102 . The interior of the anaerobic digestion tank is heated and maintained at a temperature of approximately 55° C. or approximately 35° C. In the anaerobic digestion tank, the sludge is broken down into methane, carbon dioxide, a gas such as hydrogen sulfide, water-soluble nitrogen, phosphorus, and so on by the action of acid-fermentative bacteria and methanogenic bacteria. The generated methane gas may be recovered and used as energy. The amount of generated methane is increased by introducing easily decomposable raw sludge in addition to the excess sludge. As the sludge decomposes, phosphorus, magnesium, and ammonium migrate to the liquid side. When the respective ion concentrations thereof reach or exceed the MAP solubility product, MAP is generated spontaneously in the anaerobic digestion tank. As a result of this MAP precipitation, scale trouble occurs on the draft tube, the base portion of the anaerobic digestion tank, the sludge discharge pipe, and so on.
[0091] Normally, the ratio of the phosphorus, magnesium, and ammonium in the digested sludge is generally phosphorus:magnesium:ammonium=100 to 500: several to several tens: 1000. The magnesium concentration is overwhelmingly lower than the phosphorus and ammonium concentrations, and therefore during MAP generation in the digestion tank, the magnesium concentration clearly serves as a rate control.
[0092] In the following crystallization process 104 , MAP is precipitated by adding a magnesium compound to the digested sludge and digested sludge liquor extracted from the anaerobic digestion tank 102 . If aeration decompression, or the like is also performed at this time, the sludge is decarbonated, leading to an increase in the pH, and hence MAP can be precipitated more efficiently. Needless to say, a chemical such as sodium hydroxide, magnesium hydroxide, or magnesium oxide may be added to raise the pH. As the added magnesium compound, magnesium chloride, magnesium hydroxide, magnesium oxide, sea water, and so on may be used. As regards the amount of added magnesium, a molar ratio between 0.1 and 10, preferably between 0.5 and 3.0, and more preferably between 0.8 and 1.2 in relation to the aqueous orthophosphoric acid concentration of the digested sludge is suitable. The pH in the reaction should be between 7.0 and 11.0, and preferably between 7.5 and 8.5.
[0093] Seed crystals are preferably added to the crystallization process 104 to ensure that MAP is generated efficiently. The MAP that precipitates spontaneously in the digestion tank, the MAP that precipitates in the crystallization process 104 , or MAP precipitated in a separate reactor may be used as the seed crystals.
[0094] As shown in another flow diagram of the present invention in FIG. 7 , MAP-containing micro-particles and so on recovered in the separation process 108 may be supplied to the crystallization process 104 through a pipe 113 and used as seed crystals. Separated water generated midway through the separation process or MAP contained in effluent or the like may also be used.
[0095] Alternatively, a powder or granular substance such as rock phosphate, dolomite, bone charcoal, activated carbon, silica sand, or calcium silicate may be used as seed crystals. The particle diameter of the seed crystals is arbitrary, but is preferably set between 0.05 and 3.0 mm, and more preferably between 0.1 and 0.5 mm. By precipitating new MAP on the surface of the seed crystals, separation of the digested sludge and MAP in the subsequent separation process can be performed favorably. The seed crystal charging amount is extremely important for precipitating MAP on the surface of the seed crystals. The charging amount is determined in consideration of the introduced phosphorus amount and the seed crystal particle diameter such that the phosphorus introduction amount in relation to the seed crystal surface area (the phosphorus surface area load hereafter) is no more than 100 g-P/m 2 /d, preferably no more than 30 g-P/m 2 /d, and more preferably no more than 10 g-P/m 2 /d.
[0096] Next, the digested sludge is introduced into the coarse contaminant particles removal process 106 . Conventionally, no coarse contaminant particles separation process is performed, and therefore when a liquid cyclone is used in the subsequent micro-particle separation process, blockages caused by coarse contaminant particles and so on occur. For this reason, there is demand for a treatment method exhibiting long-term stability. In the present invention, coarse contaminant particles are removed, enabling a vast improvement in the stability of the subsequent micro-particle separation process 108 , particularly when this process employs a liquid cyclone. Furthermore, when a sedimentation tank is used, the coarse contaminant particles, digested sludge, and MAP are mixed together, and hence in the past it has been impossible to obtain MAP having a high degree of purity. In the present invention, MAP with a high degree of purity can be obtained by separating the coarse contaminant particles in advance. The separated coarse contaminant particles may be discharged outside of the system or introduced into the dewatering process 110 through a pipe 114 , as shown in another flow diagram of the present invention in FIG. 8 . In this case, the dewatering performance is enhanced, and hence the coarse contaminant particles 6 are preferably introduced into the dewatering process. The crystallization process 104 and coarse contaminant particles separation process 106 may performed in any order. The crystallization process 104 may precede the coarse contaminant particles separation process 106 , as shown in FIG. 6 , or the coarse contaminant particles separation process 106 may precede the crystallization process 104 , as shown in FIG. 7 .
[0097] Following the crystallization process 104 and coarse contaminant particles removal process 106 , the micro-particles containing MAP precipitated in the digestion tank and during the crystallization process are separated from the digested sludge. A liquid cyclone, a centrifugal settler, a sedimentation tank employing gravity separation, and so on may be employed as a method of separating the micro-particles from the digested sludge using the specific gravity difference between the two, while a vibrating screen, a drum screen, a filter layer, a classification layer-type separation layer, and so on may be employed as a micro-particle separation method using differences in particle diameter. The digested sludge is viscous, making it difficult to separate the MAP from the digested sludge through natural sedimentation, and therefore a mechanical separation method using a liquid cyclone or the like is preferable. A liquid cyclone has a reverse conical-form lower portion structure, and is constituted by a liquid cyclone inflow pipe, a micro-particle discharge pipe, and a sludge discharge pipe. In the liquid cyclone, the digested sludge containing MAP is caused to swirl down the wall surface of the reverse conical form by the pressure of an extractor pump. The MAP-containing micro-particles, which have a greater specific gravity than the digested sludge, are collected and concentrated on a lower wall surface side by means of centrifugal force. The concentrated micro-particles are extracted either continuously or intermittently.
[0098] In the present invention, coarse contaminant particles such as night soil residue are separated before the MAP-containing micro-particle separation process 108 , and therefore problems such as blockages of the liquid cyclone caused by coarse contaminant particles and the like are solved.
[0099] In the dewatering process 110 , the digested sludge separated from the MAP-containing micro-particles is dewatered. Belt pressing, screw pressing filter pressing, centrifugal dewatering, and so on may be used as a dewatering method. As noted above, by introducing the coarse contaminant particles separated in the coarse contaminant particles separation process 106 into the dewatering process 110 , the dewatering effect can be improved, and hence this is preferable.
[0100] To prevent pipe blockages caused by MAP scale following this process, processing to lower the pH and/or processing to reduce at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration are preferably performed following the micro-particle separation process 108 . A pH adjustor may be added as a method of reducing the pH. A chemical for lowering the pH of digested sludge, such as hydrochloric acid, sulfuric acid, aluminum salt, or iron salt, is used as the pH adjustor. With aluminum salt and iron salt, the soluble phosphorus contained in the digested sludge is fixed, causing a reduction in the solubility concentration.
[0101] Ammonia stripping, fixation by adhesive, and so on may be used as a method of reducing ammonium ions. MAP is precipitated when any of the phosphorus concentration magnesium concentration, ammonium concentration, and pH rises. Conversely, as described above, when the pH of the digested sludge falls or at least one of the magnesium ion concentration, phosphate ion concentration, and ammonium ion concentration is reduced, the MAP generation ability deteriorates. According to the present invention, the MAP generation ability deteriorates, reducing the likelihood of MAP scale generation. Note that with the addition of iron salt, the generation of hydrogen sulfide and the like from the digested sludge can be suppressed. Needless to say, each of the above processes may be performed in the same treatment facility, or the sludge may be piped to a different treatment facility for each process.
[0102] By means of the above processes, phosphorus can be recovered efficiently from the digested sludge. In the past, it has been particularly difficult to recover MAP generated spontaneously in a digestion tank, but with the present system, MAP can be recovered easily.
EXAMPLES
[0103] The present invention will now be described in further detail using examples.
Example 1
[0104] In this example, treatment was performed using a treatment flow such as that shown in FIG. 1 . The excess sludge of an anaerobic/aerobic process was used as the subject organic waste matter. The treatment flow was constituted by an anaerobic digestion tank, an aeration tank serving as a decarbonation tank, a coarse contaminant particles separation process, and a micro-particle separation process. The amount of sludge introduced into the anaerobic digestion tank was set at 90 L/d. Digestion took place over twenty days at a digestion temperature of 35° C. Approximately 90 L/d of digested sludge was discharged from the digestion tank as extracted sludge. The extracted sludge was aerated to raise the pH. Aeration took place over two hours at an air intake rate of 40 L/min. In the coarse contaminant particles separation process, coarse contaminant particles were removed using a vibrating screen with an aperture of 2.0 mm. Following decarbonation and coarse contaminant particles removal, the digested sludge was separated into digested sludge and MAP-containing micro-particles using a 4-inch liquid cyclone.
[0105] Note that the decarbonation process, coarse contaminant particles separation process, and micro-particle separation process were performed as semibatch operations. The water quality in each process is shown in Table 1.
[0106] The sludge introduced to anaerobic digestion (introduced sludge hereafter) contained 42 g/L of TS, 35 g/L of VS, and 920 mg/L of T-P. Following extraction from the anaerobic digestion tank, the sludge (extracted sludge hereafter) had a pH of 7.2, and contained 21 g/L of TS, 17 g/L of VS, 920 mg/L of T-P, 300 mg/L of soluble PO 4 —P, and 15 mg/L of soluble magnesium.
[0107] Following aeration of the extracted sludge to raise the pH to 8.2, the soluble magnesium concentration was measured and found to have decreased to 3 mg/L. The amount of MAP-containing micro-particles recovered in the micro-particle separation process was 1.9 g/L, of which 1.5 g/L was MAP.
[0108] After undergoing this treatment, a simulation was conducted in which the digested sludge was transferred continuously into a stainless steel pipe having an inner diameter of 130 mm. The sludge was retained in the pipe for 15 days. After approximately three months, no scale-like crystals could be found in the pipe. The amount of scale that had become adhered to a test piece provided in advance was only 2 g. Hence, it may be determined that by performing the treatment described above, it was possible to prevent scale generation.
TABLE 1 DIGESTED SLUDGE DECAR- FOLLOWING INTRO- EX- BONATED MICRO- DUCED TRACTED DIGESTED PARTICLE SLUDGE SLUDGE SLUDGE SEPARATION PH(−) — 7.2 8.5 8.5 TS (g/L) 42 21 21 19 VS (g/L) 35 17 17 17 T-P (mg/L) 920 920 920 720 PO4-P (mg/L) — 300 280 280 Mg (mg/L) — 15 2 2 AMOUNT OF — — — 1.9 RECOVERED MICRO- PARTICLES (g/L)
Example 2
[0109] In this example, treatment was performed using a treatment flow such as that shown in FIG. 1 . The excess sludge of an anaerobic/aerobic process was used as the subject organic waste matter. The treatment flow was constituted by an anaerobic digestion tank, decompression treatment serving as a decarbonation tank, a coarse contaminant particles separation process, and a micro-particle separation process. The amount of sludge introduced into the anaerobic digestion tank was set at 90 L/d. Digestion took place over twenty days at a digestion temperature of 35° C. Approximately 90 L/d of digested sludge was discharged from the digestion tank as extracted sludge.
[0110] The extracted sludge was decompressed to raise the pH. The degree of vacuum was set at −94 kPa, and the rotation speed of the rotary body was set at 1650 rpm.
[0111] In the coarse contaminant particles separation process, coarse contaminant particles were removed using a vibrating screen with an aperture of 2.0 mm. Following decarbonation and coarse contaminant particle removal, the digested sludge was separated into digested sludge and MAP-containing micro-particles using a 4-inch liquid cyclone.
[0112] Note that the decarbonation process, coarse contaminant particles separation process, and micro-particle separation process were performed as semibatch operations.
[0113] The water quality in each process is shown in Table 2.
[0114] The sludge introduced to anaerobic digestion (introduced sludge hereafter) contained 42 g/L of TS, 35 g/L of VS, and 920 mg/L of T-P. Following extraction from the anaerobic digestion tank, the sludge (extracted sludge hereafter) had a pH of 7.2. and contained 21 g/L of TS, 17 g/L of VS, 920 mg/L of T-P, 300 mg/L of soluble PO 4 —P, and 15 mg/L of soluble magnesium.
[0115] Following decompression of the extracted sludge to raise the pH to 8.2, the soluble magnesium concentration was measured and found to have decreased to 3 mg/L. The amount of MAP-containing micro-particles recovered in the micro-particle separation process was 1.9 g/L, of which 1.5 g/L was MAP.
[0116] After undergoing this treatment, a simulation was conducted in which the digested sludge was transferred continuously into a stainless steel pipe having an inner diameter of 130 mm. The sludge was retained in the pipe for 15 days. After approximately three months, no scale-like crystals could be found in the pipe. The amount of scale that had become adhered to a test piece provided in advance was only 2 g. Hence, it may be determined that by performing the treatment described above, it was possible to prevent scale generation.
TABLE 2 DIGESTED SLUDGE DECAR- FOLLOWING INTRO- EX- BONATED MICRO- DUCED TRACTED DIGESTED PARTICLE SLUDGE SLUDGE SLUDGE SEPARATION PH(−) — 7.2 8.2 8.2 TS (g/L) 42 21 21 19 VS (g/L) 35 17 17 17 T-P (mg/L) 920 920 920 720 PO4-P (mg/L) — 300 280 280 Mg (mg/L) — 15 3 3 AMOUNT OF — — — 1.9 RECOVERED MICRO- PARTICLES (g/L)
Example 3
[0117] In this example, treatment was performed using a treatment flow such as that shown in FIG. 4 . The excess sludge of an anaerobic/aerobic process was used as the subject organic waste matter. The treatment flow was constituted by a phosphorus discharge tank, a dewatering process, a concentration adjustment process, an anaerobic digestion tank, a decarbonation tank (aeration tank), a coarse contaminant particles separation process, and a micro-particle separation process. The excess sludge was retained in the phosphorus discharge tank for one day. The anaerobic digestion tank, decarbonation tank (aeration tank), coarse contaminant particles separation process, and micro-particle separation process were performed similarly to those of the first example. The water quality in each process is shown in Table 3.
[0118] The concentrated excess sludge contained 42 g/L of TS, 35 g/L of VS, 920 mg/L of T-P, 20 mg/L of PO 4 —P, and 10 mg/L of soluble Mg. At the outlet of the phosphorus discharge process, the soluble PO 4 —P and Mg had increased to 300 mg/L and 100 mg/L, respectively. Following phosphorus discharge, the concentrated excess sludge was dewatered, whereupon the TS of the sludge was adjusted to 42 g/L using secondary waste water effluent. Following this adjustment, the sludge contained 42 g/L of TS, 35 g/L of VS, 600 mg/L of T-P, 60 mg/L of PO 4 —P, and 20 mg/L of soluble Mg.
[0119] The extracted sludge contained 20 g/L of TS, 17 g/L of VS, 600 mg/L of T-P, 180 mg/L of PO 4 —P, and 20 mg/L of soluble Mg. Following aeration of the extracted sludge to raise the pH to 8.2, the soluble magnesium concentration was measured and found to have decreased to 3 mg/L.
[0120] The amount of MAP-containing micro-particles recovered in the micro-particle separation process was 0.3 g/L, of which 0.25 g/L was MAP.
[0121] After undergoing this treatment, a simulation was conducted in which the digested sludge was transferred continuously into a stainless steel pipe having an inner diameter of 130 mm. The sludge was retained in the pipe for 15 days. After approximately three months, no scale-like crystals could be found in the pipe. The amount of scale that had become adhered to a test piece provided in advance was only 2 g. Hence, it may be determined that by performing the treatment described above, it was possible to prevent scale generation.
TABLE 3 INTRODUCED CONCEN- PHOSPHORUS SLUDGE TRATED DISCHARGE (FOLLOWING TS EXCESS TANK CONCENTRATION SLUDGE OUTLET ADJUSTMENT) PH(−) — — — TS (g/L) 42 38 42 VS (g/L) 35 31 35 T-P (mg/L) 920 830 600 PO4-P (mg/L) 20 300 60 Mg (mg/L) 10 100 20 AMOUNT OF — — — RECOVERED MICRO- PARTICLES (g/L) DIGESTED SLUDGE DECAR- FOLLOWING EX- BONATED MICRO- TRACTED DIGESTED PARTICLE SLUDGE SLUDGE SEPARATION PH(−) 7.2 8.2 8.2 TS (g/L) 20 20 19 VS (g/L) 17 17 17 T-P (mg/L) 600 600 560 PO4-P (mg/L) 180 160 160 Mg (mg/L) 20 3 3 AMOUNT OF — — 0.3 RECOVERED MICRO- PARTICLES (g/L)
Comparative Example 1
[0122] In the following, the results of a comparison with the first example will be illustrated. As shown in FIG. 5 , the first comparative example is identical to the first example except that the decarbonation process, coarse contaminant particles separation process, and micro-particle separation process have been omitted. The water quality in each process is shown in Table 4.
[0123] The introduced sludge contained 42 g/L of TS, 35 g/L of VS, and 920 mg/L of T-P. The extracted sludge contained 21 g/L of TS, 17 g/L of VS, 920 mg/L of T-P, 300 mg/L of PO 4 —P, and 9 mg/L of soluble magnesium. After undergoing this treatment, a simulation was conducted in which the digested sludge was transferred continuously into a stainless steel pipe having an inner diameter of 130 mm. The sludge was retained in the pipe for 15 days. After approximately three months, scale having a thickness of approximately 3 mm had formed on the wall surface of the pipe. The scale was subjected to component analysis using an X-ray diffraction apparatus and a fluorescent X-ray apparatus, in which the scale was found to be MAP. It is believed that the MAP was generated due to MAP accumulation in the digested sludge and pH variation caused by decarbonation and the like in the pipe.
TABLE 4 INTRODUCED EXTRACTED SLUDGE SLUDGE PH(−) — 7.2 TS (g/L) 42 21 VS (g/L) 35 17 T-P (mg/L) 920 920 PO4-P (mg/L) — 300 Mg (mg/L) — 9 AMOUNT OF RECOVERED — — MICRO-PARTICLES (g/L)
Example 4
[0124] In this example, treatment was performed using a treatment flow such as that shown in FIG. 6 . The excess sludge of an anaerobic/aerobic process was used as the subject organic waste matter.
[0125] The treatment flow was constituted by an anaerobic digestion tank, a crystallization tank, a coarse contaminant particles separation process, and a micro-particle separation process. The amount of sludge introduced into the anaerobic digestion tank was set at 90 L/d. Digestion took place over twenty days at a digestion temperature of 35° C. Approximately 90 L/d of digested sludge was discharged from the digestion tank as extracted sludge. Magnesium chloride was added to the crystallization tank at an Mg/P molar ratio of 1 in relation to the orthophosphoric acid ion concentration of the digested sludge, and a pH adjustor was added to adjust the pH to 8.0. Further, 7 kg of the MAP-containing micro-particles recovered in the micro-particle separation process was added as seed crystals.
[0126] A vibrating screen with an aperture of 2.0 mm was used in the coarse contaminant particles separation process.
[0127] A 4-inch liquid cyclone was used in the micro-particle separation process.
[0128] Note that all processes other than the anaerobic digestion tank were performed as semibatch operations.
[0129] The water quality in each process is shown in Table 5.
[0130] The sludge introduced to anaerobic digestion (introduced sludge) contained 42 g/L of TS, 35 g/L of VS, and 920 mg/L of T-P. Following extraction from the anaerobic digestion tank, the sludge (extracted sludge: digested sludge) had a pH of 7.2, and contained 21 g/L of TS, 17 g/L of VS, 920 mg/L of T-P, and 300 mg/L of soluble PO 4 —P. The sludge discharged from the crystallization tank had a pH of 8.0, and contained 24 g/L of TS, 17 g/L of VS, 920 mg/L of T-P, and 10 mg/L of soluble PO 4 —P. The amount of MAP-containing micro-particles recovered in the micro-particle separation process was 4.3 g per liter of digested sludge, of which 4.0 g was MAP. The discharged sludge had a pH of 8.0, and contained 19 g/L of TS, 17 g/L of VS, 440 mg/L of T-P, and 10 mg/L of soluble PO 4 —P. Of the 920 mg/L phosphorus concentration introduced into the digested sludge, 480 mg/L was recovered.
TABLE 5 SLUDGE SLUDGE DISCHARGED FROM DISCHARGED FROM INTRODUCED EXTRACTED CRYSTALLIZATION MICRO-PARTICLE SLUDGE SLUDGE TANK SEPARATION PROCESS PH(−) — 7.2 8 8 TS (g/L) 42 21 24 19 VS (g/L) 35 17 17 17 T-P (mg/L) 920 920 920 440 PO4-P (mg/L) — 300 10 10 AMOUNT OF RECOVERED — — — 4.3 MICRO-PARTICLES (g/L)
Comparative Example 2
[0131] In the following, the results of a comparison with the fourth example will be illustrated. As shown in FIG. 9 , the second comparative example is identical to the fourth example except that the crystallization process, coarse contaminant particles separation process, and micro-particle separation process have been omitted The water quality in each process is shown in Table 6.
TABLE 6 INTRODUCED EXTRACTED SLUDGE SLUDGE PH(−) — 7.2 TS (g/L) 42 21 VS (g/L) 35 17 T-P (mg/L) 920 920 PO4-P (mg/L) — 300 AMOUNT OF RECOVERED — — MICRO-PARTICLES (g/L)
[0132] The introduced sludge contained 42 g/L of TS, 35 g/L of VS, and 920 mg/L of T-P. The extracted sludge contained 21 g/L of TS, 17 g/L of VS, 920 mg/L of T-P, and 300 mg/L of PO 4 —P. The extracted sludge also contained 1 . 5 g/L of MAP. The MAP in the extracted sludge was not recovered, but dewatered and then incinerated.
[0133] The amount of recovered phosphorus in the comparative example described above was zero.
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A first aspect of the present invention relates to a digested sludge treatment apparatus for treating digested sludge generated by subjecting organic waste matter to anaerobic digestion, comprising: an apparatus for decarbonating the digested sludge; a removal apparatus for removing coarse contaminant particles from the digested sludge; and an apparatus for separating or concentrating crystals containing magnesium ammonium phosphate from the digested sludge after the digested sludge passes through the decarbonation apparatus and removal apparatus. Another aspect of the present invention relates to a digested sludge treatment apparatus for treating digested sludge generated by subjecting organic waste matter to anaerobic digestion, comprising: a crystallization reactor for precipitating magnesium ammonium phosphate from the digested sludge; a removal apparatus for removing coarse contaminant particles from the digested sludge; and an apparatus for separating or concentrating crystals containing magnesium ammonium phosphate from the digested sludge after the digested sludge passes through the crystallization reactor and coarse contaminant particles removal apparatus.
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BACKGROUND OF THE INVENTION
It is found that the prior art tool rests for milling planers can only be moved either horizontally or vertically. That is, it is impossible to adjust such tool rests to cut inclined surfaces and so the workpiece must be manually rotated to adapt to the tool rest thereby causing user inconvenience and lost labor time.
It is, therefore, an object of the present invention to provide a universal tool rest for a milling planer which can be adjusted in angular position so as to permit cutting of an inclined surface as required.
SUMMARY OF THE INVENTION
This invention relates to a universal to a universal tool rest for a milling planer.
It is the primary object of the present invention to provide a universal tool rest for a milling planer which can be adjusted in any angular position.
It is another object of the present invention to provide a universal tool rest for a milling planer which is simple in construction.
It is still another object of the present invention to provide a universal tool rest for a milling planer which is easy to operate.
It is a further object of the present invention to provide a universal tool rest for a milling planer which is of high efficiency.
It is still a further object of the present invention to provide a universal tool rest for a milling planer which is economic to produce.
Other objects and merits and a fuller understanding of the present invention will be obtained by those having ordinary skill in the art when the following detailed description of the preferred embodiment is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a universal tool rest for a milling planer according to the present invention;
FIG. 2 is a sectional view taken along line A--A of FIG. 1;
FIG. 3A is a sectional view taken along line B--B of FIG. 1;
FIG. 3B is a sectional view taken along the sectional line C--C of FIG. 3A;
FIG. 4 show how the universal tool rest is mounted on a milling planer;
FIG. 5 is a front view showing an application of the universal tool rest;
FIG. 6 is a top view of FIG. 5;
FIG. 7 is a front view showing another application of the universal tool rest;
FIG. 8 is a top view of FIG. 7; and
FIG. 9 is a top view showing a further application of the universal tool rest.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings and in particular to FIGS. 1 and 2 thereof, the universal tool rest for a milling planer according to the present invention mainly comprises a large housing 1, a small housing 2, a first transmission shaft 3, a second transmission shaft 4 and a third transmission shaft 5.
The large housing 1 is provided at the upper end with a connection disc 11 having four holes 12 for the passage of bolts 61 which, in association with nuts 62, may fix the housing 1 on the lower end of a driving stand 6 of the milling planer (see FIG. 4). Since the head of the bolt 61 is received in the T-shaped annular groove, the housing 1 may be adjusted in position as required. Further, the front side of the housing 1 has a connection disc 13 provided with a T-shaped annular groove 14 engage with four bolts 15 (see FIG. 3). On the connection disc 13 there is an angle calibration ring 16.
The small housing 2 has a connection disc 21 at the rear side which also has four holes 22 for the passage of the bolts 15 which in association with the nuts 23 may fix the small housing 2 on the large housing 1. Moreover, the small housing 2 may be adjusted in position as required.
The transmission shaft 3 is vertically mounted into the housing 1 via a sleeve 31 and two bearings 32, which has a bevel gear 33 at the lower end and a transmission disc 34 at the upper end. The transmission disc 34 has two opposite slots 35 for engaging the driving stand 6 thereby connecting the driving stand 6 with the transmission shaft 3.
The transmission shaft 4 is horizontally mounted into the lower part of the housing 1 by means of the front cover 41, the rear cover 42 and the bearings 43. The front end of the transmission shaft 4 extends into the small housing 2 and has a first bevel gear 44 at the front end and a second bevel gear 45 at the intermediate portion. The bevel gear 45 is engaged with the bevel gear 33 of the transmission 3 so that the transmission shaft 3 may drive the transmission shaft 4 to rotate.
The transmission shaft 5 is vertically mounted into the small housing 2 via the upper cover 51, the lower cover 52 and the bearings 53. A tool post 55 is fitted into the lower end of the housing 2 by means of a bolt 54. The tool post 55 has at the lower end a threaded hole 56 and an engaging member 57 by the means of which a milling cutter 7 may be mounted thereon by a bolt. In addition, the transmission shaft 5 has a bevel gear 58 for engaging the bevel gear 44 of the transmission shaft 4 such that the transmission shaft 3 may drive the milling cutter 7 via the transmission shafts 4 and 5.
FIGS. 5, 6, 7, 8 and 9 show how the universal tool rest works. As illustrated, the housings 1 and 2 may be randomly adjusted in angular position simply by loosening the nuts 62 and 23 hence rendering the universal tool rest to work at any angle.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure is made by way of example only and that numerous changes in the construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed.
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This invention relates to a universal tool rest for a milling planer and in particular to one mainly including two housings which may be rotated with respect to each other and three transmission shafts whereby the milling cutter thereon may be rotated in position with the tool rest so as to permit cutting of an inclined surface.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a conductive paste used for forming an electrode of a ceramic electronic component and to a ceramic electronic component.
2. Description of the Related Art
Ceramic electronic components are provided with sintered ceramic body made of ceramic materials, for example, dielectrics, semiconductors, and piezoelectric materials. Conductive pastes have been frequently used as materials for electrodes and wirings accompanying these ceramic electronic components.
In the conductive paste used for forming an electrode of a ceramic electronic component, a glass powder is added in some cases. The addition of the glass powder to the conductive paste generally has the effect, for example, of softening and fluidizing during the firing of an electrode so as to accelerate sintering of the conductive powder, of improving adhesive strength of a thick film electrode, and furthermore, of filling in pores generated at the interface between the thick film electrode and the sintered ceramic body so as to prevent capacitance from decreasing in the case in which the electronic component is a ceramic capacitor.
As conventional conductive pastes used for forming electrodes of ceramic electronic components, Pb glasses have been frequently used. In recent years, however, in consideration of environmental problems, it is necessary to substitute these with non-Pb glasses.
Ceramic electronic components, in particular, medium and high voltage ceramic capacitors with electrodes formed using conductive pastes containing conventional non-Pb glass, for example, Bi glass, have problems in that the heat-generating temperatures of sintered ceramic body are higher than those of medium and high voltage ceramic capacitors with electrodes formed using conventional conductive pastes containing Pb glass. This is believed to be due to the Bi in the glass diffusing into the ceramic and being reduced so as to become a semiconductor while being applied with a high voltage and high frequencies, and therefore, tan δ of the sintered ceramic body increases.
SUMMARY OF THE INVENTION
The present invention was made to solve the aforementioned problems. Accordingly, objects of the present invention are to provide a conductive paste containing no Pb glass and suppressing heat generation in a sintered ceramic body, and to provide an electronic component with thick film electrodes formed thereof.
So as to achieve the aforementioned objects, a conductive paste according to the present invention is a conductive paste containing substantially no Pb and used for forming a thick film electrode of a ceramic electronic component, comprising a conductive powder containing Ag; a glass powder containing Bi, B and at least one alkaline earth metal selected from the group consisting of Ca, Sr, and Ba; and a vehicle, wherein when the alkaline earth metal, bismuth, and boron are expressed as oxides MO, Bi 2 O 3 , and B 2 O 3 , respectively, the content of the oxides are in the following ranges on a basis of % by mole relative to 100% by mole of the glass composition, 30<MO≦40; 10≦Bi 2 O 3 ≦60; and 10≦B 2 O 3 ≦60, where M indicates the alkaline earth metal.
The content of the aforementioned glass powder is preferably about 1 to 15% by volume relative to 100% by volume of the aforementioned conductive powder.
A ceramic electronic component according to the present invention comprises a sintered ceramic body and thick film electrodes formed on two end faces of the sintered ceramic body using a conductive paste according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a ceramic electronic component according to an embodiment of the present invention; and
FIG. 2 is a ternary compositional diagram of a conductive paste according to a first aspect of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The conductive paste according to the present invention contains an “alkaline earth metal—B—Bi—O glass” so as to exhibit a superior effect of suppressing heat generation, especially in a medium and high voltage ceramic capacitor with a rated voltage of 250 volts or more, and furthermore, of 500 volts or more. This is considered to be due to the fact that diffusion of the Bi in the glass into a sintered ceramic body is suppressed even while being used even at such a high voltage, and therefore, tan δ of the sintered ceramic body is prevented from increasing.
An alkaline earth metal component, being one of the primary components, has a function of suppressing the diffusion of Bi in the glass into the sintered ceramic body. As the alkaline earth metal component, at least one metal selected from the group consisting of Ca, Sr and Ba can be appropriately used. Ca or Sr are preferably used in consideration of handling in manufacture of the glass and in view of the burden on the environment.
The content of the aforementioned alkaline earth metal component must be more than about 30 mole % and be about 40 mole % or less calculated as the oxide relative to 10 mole % of glass composition. When the content is about 30 mole % or less, the effect of suppressing diffusion of bismuth of the glass into the sintered ceramic body is decreased. On the other hand, when the content exceeds about 40 mole %, vitrification becomes difficult.
The content of bismuth must be about 10 mole % or more and about 60 mole % or less as the oxide relative to 100 mole % of the glass composition. When the content is less than about 10 mole %, vitrification becomes difficult. On the other hand, when the content exceeds 60 mole %, bismuth is likely to diffuse into the sintered ceramic body so as to cause heat generation of the sintered ceramic body.
The content of boron must be 10 mole % or more and 60 mole % or less as the oxide relative to 100 mole % of glass composition. When the content is either less than 10 mole % or more than 60 mole %, vitrification becomes difficult.
Furthermore, a variety of arbitrary components may be present as long as the effects and the composition rates of the present invention are maintained. For example, the aforementioned glass may contain substantially no silicon oxide; silicon oxide may be, however, added in small amounts within the range 10 mole % or less as the oxide relative to 100 mole % of glass composition so as to control softening point, to improve plating resistance, etc.
The content of the glass to the conductive paste is preferably about 1 to 15% by volume relative to 100% by volume of the conductive powder. When the content of the glass is less than about 1% by volume, the effect of the addition of the glass is small, and the effect of accelerating firing of the Ag powder due to softening and fluidizing, the effect of improving adhesive strength of the thick film electrodes, and the effect of suppressing decrease in capacitance by preventing pores from being generated cannot be sufficiently exhibited. On the other hand, when the content of the glass exceeds about 15% by volume, the glass may segregate on the surfaces of the electrodes so as to cause non-wetting of solder and inferior plating.
A ceramic electronic component according to the present invention, for example, a ceramic capacitor 1 as shown in FIG. 1, is composed of a sintered ceramic body 2 , a pair of thick film electrodes 3 formed on two end faces of the sintered ceramic body 2 using a conductive paste according to the present invention, lead wires 4 electrically connected to the thick film electrodes 3 , solders 5 electrically and mechanically connecting the thick film electrodes 3 and the lead wires 4 , and a protective resin 6 completely covering the sintered ceramic body 2 , the thick film electrodes 3 and the solders 5 , and covering one end of the lead wires 4 .
The sintered ceramic body 2 is composed of a fired single plate type or laminate type green ceramic structure made of a material functioning as, for example, a dielectric, a magnetic material and an insulator. A sintered ceramic body in a ceramic electronic component of the present invention is, however, not limited to these. In the case in which a ceramic electronic component of the present invention constitutes a medium and high voltage ceramic capacitor, a sintered ceramic body containing a dielectric ceramic composition, for example, barium titanate, calcium titanate, barium zirconate and magnesium titanate, as a primary component is preferable.
The thick film electrodes 3 are made of the aforementioned conductive paste according to the present invention, and are made by, for example, steps of coating the conductive paste on two end faces of the sintered ceramic body 2 , drying and thereafter, baking. The thick film electrodes 3 may also be formed by steps of coating the conductive paste according to the present invention on two end faces of a green ceramic structure before firing so as to form electrode films, and thereafter firing the electrode films and the green ceramic structure at the same time. That is, the forming manner therefor is not specifically limited.
The shape of the ceramic electronic component of the present invention is not limited to that of a ceramic capacitor as shown in FIG. 1 . For example, a ceramic electronic component according to the present invention may be a laminated ceramic electronic component providing a sintered ceramic body made by firing a ceramic structure which is a laminate of a plurality of ceramic green sheets and a pair of thick film electrodes formed using the conductive paste according to the present invention on two end faces of the sintered ceramic body. Materials for the lead wire and the protective resin are not specifically limited, and these may not be present.
EXAMPLES
Starting materials, that is, an alkaline earth metal hydroxide, Bi 2 O 3 and H 3 BO 3 , were blended so as to prepare samples having compositions as shown in Tables 1 to 3. Each sample was put into a crucible made of alumina and was kept at 900 to 1,300° C. for 1 hour in a furnace. After confirming that the samples were completely fused, they were taken out of the furnace and were put into purified water so as to produce bead glasses. The resulting bead glasses were wet milled using a ball mill so as to produce the glass powders designated Samples 1 to 21. In a manner similar to that for the aforementioned samples, the starting materials were also blended so as to produce a Pb glass and a B—Ba—Zn—O glass, and were vitrified after fusing so as to prepare glass powders designated Samples 22 and 23, respectively.
32% by volume of Ag powder having particle diameters of 0.1 to 5 μm, 5% by volume of glass powder of Samples 1 to 23, and 63% by volume of vehicle were blended and kneaded using a three-roll mill so as to produce conductive pastes of Samples 1 to 23. The aforementioned vehicle was prepared by dissolving ethyl cellulose into terpineol in a ratio of 20% by weight.
Both primary faces of the sintered ceramic body 2 , containing BaTiO 3 as a primary component so as to have a capacitance of 1 nF, were screen printed with 3 mm diameter patterns of the conductive pastes of Samples 1 to 23, and were fired in air at 800° C. for 2 hours so as to form thick film electrodes 3 . Then, lead wires 4 were soldered to the thick film electrodes 3 of Samples 1 to 23 with solders 5 , and the sintered ceramic body 2 , the thick film electrodes 3 , one end of the lead wires 4 , and the solders 5 were covered using a protective resin 6 so as to produce ceramic capacitors 1 , as shown in FIG. 1, of Samples 1 to 23.
Next, 3 kVp-p of AC voltage was applied to the ceramic capacitors 1 of Samples 1 to 23, and the surface temperatures of the protective resins 6 were measured using thermocouples. The results are shown in Tables 1 to 4, respectively.
In the evaluation results, a Sample having an equivalent or lower heat-generating temperature compared to a ceramic capacitor 1 of Sample 22 using a conventional Pb glass is indicated by “∘”. A Sample having a higher heat-generating temperature compared to the ceramic capacitor 1 of Sample 22 is indicated by “x”.
TABLE 1
Heat
Glass Composition
Generating
(mole %)
Temperature
Sample
CaO
Bi 2 O 3
B 2 O 3
(° C.)
Evaluation
1
20
40
40
37.7
X
2
31
57
12
27.1
◯
3
31
33
36
27.3
◯
4
31
12
57
27.4
◯
5
40
50
10
27.2
◯
6
40
30
30
27.3
◯
7
40
10
50
27.0
◯
TABLE 2
Heat
Glass Composition
Generating
(mole %)
Temperature
Sample
SrO
Bi 2 O 3
B 2 O 3
(° C.)
Evaluation
8
20
40
40
36.7
X
9
31
57
12
27.3
◯
10
31
33
36
27.3
◯
11
31
12
57
27.2
◯
12
40
50
10
27.l
◯
13
40
30
30
27.3
◯
14
40
10
50
27.2
◯
TABLE 3
Heat
Glass Composition
Generating
(mole %)
Temperature
Sample
BaO
Bi 2 O 3
B 2 O 3
(° C.)
Evaluation
15
20
40
40
36.9
X
16
31
57
12
27.1
◯
17
31
33
36
27.3
◯
18
31
12
57
27.2
◯
19
40
50
10
27.4
◯
20
40
30
30
27.2
◯
21
40
10
50
27.3
◯
TABLE 4
Glass
Heat Generating
Sample
Composition
Temperature (° C.)
Evaluation
22
PbO glass
27.4
—
23
Ba—Zn—B—O glass
38.2
X
As is clear from the results of measurements of the conventional conductive pastes, that is, Sample 22 using Pb glass as a glass powder and Sample 23 using B—Ba—Zn—O glass, as shown in Table 4, the heat generating temperature of Sample 22 regarded as the standard of the conventional techniques was 27.4° C., while a heat-generating temperature of Sample 23 was 38.2° C.
Among Samples 1 to 21 as shown in Tables 1 to 3, Samples 2 to 7, 9 to 14, and 16 to 21 were composed of alkaline earth metals, that is, Ca, Sr and Ba, in a total amount within the range of more than about 30 mole % and 40 mole % or less in terms of CaO, SrO and BaO, respectively, bismuth in an amount of about 10 to 60 mole % in terms of Bi 2 O 3 , and boron in an amount of about 10 to 60 mole % in terms of B 2 O 3 . The resulting heat generating temperatures of these samples were 27.0 to 27.4° C., and therefore, these temperatures were equivalent to or less than the heat generating temperature of 27.4° C. of Sample 22 regarded as a standard of conventional techniques. These are superior results. A ternary compositional diagram regarding Samples 2 to 7, 9 to 14, and 16 to 21 is shown in FIG. 2 .
On the other hand, heat-generating temperatures of Samples 1, 8 and 15 were 36.7 to 37.7° C. These temperatures far exceeded the heat generating temperature of 27.4° C. of Sample 22 which is regarded as the standard of the conventional techniques.
As described above, by using the conductive paste of the present invention, a ceramic electronic component in which heat generation of a sintered ceramic body can be suppressed to an extent equivalent to or greater than that of the Pb glass is provided.
When the content of the aforementioned glass powder is about 1 to 15% by volume relative to 100% by volume of the conductive powder, and when thick film electrodes are formed using the conductive paste, the effects of suppressing segregation of glass on the surfaces of the electrodes, non-wetting of solder and inferior plating are increased.
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A conductive paste containing no Pb and able to suppress heat generation in a sintered ceramic body, and a medium and high voltage ceramic capacitor with thick film electrodes formed thereof, are provided. The conductive paste containing substantially no Pb is composed of an Ag powder, a glass powder having on a % by mole basis, 30<MO≦40; 10≦Bi 2 O 3 ≦60; and 10≦B 2 O 3 ≦60, where M indicates at least one alkaline earth metal, and a vehicle. The medium and high voltage ceramic capacitor provides thick film electrodes made of the aforementioned conductive paste on two end faces of the sintered ceramic body made of, for instance, barium titanate.
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SUMMARY
[0001] A pavement system may be characterized by different combinations of distributor plates with or without longitudinal and/or cross stiffener frameworks, with all their elements designed in reinforced concrete to meet the requirements of structural capacity derived from its function of transferring vehicular or static loads to the foundation soil.
[0002] The pavement system may include a reinforced concrete diaphragm that may or may not include stiffening elements, either engaged or overhanging from its faces, placed over natural terrain or over layers of non-native materials without separation joints and the usual spacing intervals.
[0003] The pavement system may not require granular bases and sub-bases as support material. The pavement system may also not require the expansion joints, contraction joints or structural joints presently used. Instead, the system may be characterized as monolithic over considerable lengths of some hundreds of meters.
[0004] The pavement system may include elements of reinforced concrete in directions parallel and perpendicular or diagonal to the axis of the structure, located level with, above or under the traffic surface.
[0005] The pavement system may be made up of poured concrete diaphragm structures, solid or relieved, reinforced with steel rods arranged in longitudinal, cross or diagonal directions with respect to the axis of the structure.
[0006] The pavement system may take advantage of the structural integration of functional and esthetic elements of roads, such as curbs, ditches, berms ditches, canals and spillways into roads.
[0007] It is understood that other embodiments of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described various embodiments of the invention by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Aspects of the present invention are illustrated by way of example, and not by way of limitation, in the accompanying drawings wherein:
[0009] [0009]FIG. 1 includes a top and cross-sectional views of an embodiment of a pavement system;
[0010] [0010]FIG. 2 includes top view and cross-sectional views of an alternative embodiment of a pavement system;
[0011] [0011]FIG. 3 includes top view and cross-sectional views of another alternative embodiment of a pavement system;
[0012] [0012]FIG. 4 includes a top view and cross-sectional views of yet another alternative embodiment of a pavement system;
[0013] [0013]FIG. 5 is a cross-sectional view of a further embodiment of a pavement system;
[0014] [0014]FIG. 6 is a cross-sectional view of yet a further embodiment of a pavement system;
[0015] [0015]FIG. 7 is a cross-sectional view of another embodiment of a pavement system;
[0016] [0016]FIG. 8 is a cross-sectional view of yet another embodiment of a pavement system;
[0017] [0017]FIG. 9 is a cross-sectional view of a further embodiment of a pavement system;
[0018] [0018]FIG. 10 is a cross-sectional view of yet a further embodiment of a pavement system;
[0019] [0019]FIG. 11 is a cross-sectional view of another embodiment of a pavement system;
[0020] [0020]FIG. 12 is a cross-sectional view of yet another embodiment of a pavement system;
[0021] [0021]FIG. 13 includes top and cross-sectional views of a further embodiment of a pavement system;
[0022] [0022]FIG. 14 includes top and cross-sectional views of yet a further embodiment of a pavement system;
[0023] [0023]FIG. 15 is a cross-sectional view of another embodiment of a pavement system; and
[0024] [0024]FIG. 16 is a cross-sectional view of yet another embodiment of a pavement system.
DETAILED DESCRIPTION
[0025] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments in which the present invention may be practiced. Each embodiment described in this disclosure is provided merely as an example or illustration of the present invention, and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for the purpose of providing a thorough understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. In some instances, well-known structures and devices are shown in block diagram form in order to avoid obscuring the concepts of the present invention. Acronyms and other descriptive terminology may be used merely for convenience and clarity and are not intended to limit the scope of the invention.
[0026] A system of pavement for the transfer of vehicular and static loads by means of different combinations of distributor plates 1 with or without stiffener framework 2 , 3 , 4 , with all its reinforced concrete elements 7 , 8 , 9 , with no longitudinal or cross joints, such as those used in rigid pavements, capable of distributing the contact pressures of the loads over a larger area of support soil 5 without the need of granular interface(s).
[0027] The long-life pavement system is constructed of reinforced concrete, continuous, without the longitudinal or cross joints used in rigid pavements. There is only one cross joint 14 defined by the stretch of concrete poured daily, spaced hundreds of meters apart. The long-life pavement system has a distributor plate that 1 accepts the loads from the vehicles and redistributes them to existing support soil 5 in the current condition of unpaved road, or in urban or rural roads with deteriorated pavement or in new roads with the addition of solid, compacted substrata. The distributor plate that 1 is poured over the support soil without the requirement of intermediary granular coatings, although the system allows them without the thickness and qualities usual in traditional pavements being necessary, and their task when used is to play the role of granular interface 18 , optional in accordance with design conditions.
[0028] The distributor plate 1 is contemplated in various types, as a solid distributor plate 20 or a relieved distributor plate 21 —the latter consisting of concrete ribs poured on-site, with alleviators 6 that may be of any size, in accordance with the design, cast rigid in ceramic clay or concrete, or of the flexible type manufactured of rough wood, bamboo tubes, wood composites (chipboard), treated cardboard or any system of rigid or flexible engaged alleviators. When the relieved distributor plate 21 is used, the upper finish consists of a reinforced concrete plate to strengthen the distributor plate 9 , consisting of electrically welded steel mesh, preferably poured solid with the ribs and over the alleviators so as to form the diaphragm of the relieved distributor plate 16 .
[0029] The solid distributor plate 20 and the relieved distributor plate 21 both end laterally in the border elements of the distributor plate 22 with longitudinal reinforcement 23 or cross reinforcement 24 .
[0030] The long-life pavement system contemplates various possibilities for establishing longitudinal or cross rigidity, utilizing monolithic elements similar to beams, that increase rigidity by increasing the thickness from the lower face downward, from the upper face upward, with or without curbs or separators 13 . The stiffening elements may combine increases in thickness simultaneously upward and downward as in the case of the berm ditch 12 . Stiffeners are of the type of the lateral longitudinal element 2 , central longitudinal element 3 in the axis of the road 19 , intermediate longitudinal elements 25 and cross elements 4 . The location and size of the longitudinal and cross stiffening elements may be in different positions throughout the length and breadth of the road, depending on the stretch of road, the surface finish and the design selected. Specifications for materials the longitudinal reinforcement 7 and the cross reinforcement 8 vary in accordance with the designs of the system.
[0031] The lateral finishes of the long-life pavement system have all the diversity of the usual surface paving materials in the world, but monolithically integrated to the system and poured onsite in reinforced concrete. They may end in an overlap 17 with or without stiffener, with longitudinal lateral-axis beam 2 downwards in the edge, or with jutting overlap with the border integrated or not as a stiffener in the edge of the overlap, and with or without addition of thickness downwards.
[0032] The long-life pavement system requires a sub-surface drainage system by means of a longitudinal filter 26 with geometry, materials and location depending on the design of the road.
[0033] All the elements of the structure of the pavement form an integrated monolithic whole, with a powerful capacity for distributing loads and pressures, even in weak soils. In the distributor plate the stiffeners, longitudinal and cross elements, berms 10 , ditches 11 , berm ditches 12 form geometric sections of great mechanical capacity, which, with appropriate specification of materials and longitudinal reinforcements 7 and cross reinforcements 8 added to mesh reinforcements, generate very large resistance to mechanical forces that make their work efficient.
[0034] The reinforced concrete structure proposed is very versatile. Using reinforced concrete is within the reach of all the communities in the country and around the globe. The fact that it does not require a sub-base or base eliminates dependence on heavy machinery. The configuration of the reinforcements, the production of concrete, supplies, equipment and tools, transportation and the pouring of concrete are broadly known and these processes, to a large extent, may be administered and carried out by the communities themselves with great savings and improvement in the income of the citizens. This facilitates road construction in isolated and poor communities, but if the paving of an urban street is required, or a project with high specifications that merit the use of installment technologies, nothing is better known in the world, with leading-edge technology ready to serve, than reinforced concrete.
[0035] The invention and its application reduce the costs of road improvements and facilitate the processes. The application of long-life pavement eliminates shortcomings in the operation, durability, resistance and use of traditional pavements, eliminates, in rigid pavement, the wear and tears due to the joints, resolving the problems of vehicle vibration. Vibration induced by the joints prevents the use of rigid pavement in many road systems such as in airports and high-speed highways. Long-life pavement, by not having joints, and by using a reinforcement system, eliminates bumps, which cause rigid pavement to deteriorate. In this system there is only one joint every hundred or so meters, the cross joint 14 which separates the concrete pour process and resolves the problems of transfer by means of the joint transfer key 15 , always accomplished in deep double cross elements 4 . The absence of joints facilitates the extension of the use to pavements in pedestrian walkways or industrial roadways.
[0036] The integral nature of the system resolves the problem of relative vertical displacements, the raising of edges by the passage loads, sinkage due to excessive pressure on the edge, differentiated settling caused by pumping on an edge or the breaking of a segment, or due to deficiency or a lack of homogeneity in the foundation soil. The defects of rigid pavements on slopes due to the displacement of concrete sections as the result of braking, friction and vibration disappear as well. Differences in resistance between reinforced concrete and other materials is immense in terms of cost, and it would be unnecessary to explain it, but it is required to say that the rupture module that defined the limit of force and durability of traditional pavement has completely lost its effectiveness.
[0037] This long-life pavement system has a much greater capacity to transfer loads and lesser pressures on the supporting soil than the world's traditional pavements, which allows it to use the present structure on most of the compacted roads in the world, including those of earth with a slight improvement of the subsoil.
[0038] Conceptual development for the invention of the long-life pavement system has a solid and dense conceptualization, the fruit of years of study, application and development of the knowledge of the inventor in the subject; he who is available to give detailed explanations in this regard.
[0039] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
[0040] The present application claims priority under 35 U.S.C. § 119(a)-(d) based on a patent application filed with the Superintendency of Industry and Commerce under No. 02-68559 on Aug. 6, 2002, the contents of which is expressly incorporated herein by reference.
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A pavement system may be characterized by different combinations of distributor plates with or without longitudinal and/or cross stiffener frameworks, with all their elements designed in reinforced concrete to meet the requirements of structural capacity derived from its function of transferring vehicular or static loads to the foundation soil.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Applications Ser. No. 60/763,713, filed Jan. 31, 2006, and Ser. No. 60/844,866, filed Sep. 15, 2006. The above applications are incorporated herein by reference in their entirety.
TECHNICAL FIELD
[0002] This invention relates to railroad snow removal systems. More particularly, the present invention relates to a monitoring and control system for a network of snow removal devices.
BACKGROUND OF THE INVENTION
[0003] During the winter it is not uncommon for snow and ice to accumulate on and around railroad tracks. To maintain optimal track performance it is desirable to keep certain areas of the track free of snow and ice year round. For example, it is particularly desirable to keep the areas where tracks cross each other (frogs) and where tracks merge or split (switches) free of snow and ice. Though the system of the present disclosure will be described herein primarily with reference to railroad track switches, the description is not meant to be limiting. It should be appreciated that the system is applicable to other applications as well.
[0004] Railroad track switches are used to divert a train from one train track to another train track. The railroad switches typically include a pair of rails that move from a first position to a second position. The switches typically include moving parts that are exposed to the environment. Snow and ice build-up on the switch can cause the switch to malfunction.
[0005] A number of different types of railroad track switch snow removers are known. See, for example, U.S. Pat. No. 5,824,997 to Reichle et al.; U.S. Pat. No. 4,391,425 to Keep, Jr.; and U.S. Pat. No. 4,081,161 to Upright. The railroad track switch snow remover often includes a blower that blows heated air or ambient air across the switch. Though some heaters and blowers of the snow removing devices are electric powered, most are gas powered, as they are typically located in remote locations. Sometimes the snow removers include temperature and moisture sensors so that an operator at a remote location can determine when to turn the devices on or off. Some devices are programmed to automatically turn themselves on or off depending on the reading from the sensors.
[0006] A problem with the existing systems is that malfunctioning device can be difficult to identify. In some cases, the devices are turned on when it is not snowing or turned off when it is snowing. In the first case, fuel is wasted, and in the second, the switch may malfunction due to undesirable snow accumulation in the tracks. Moreover, existing switch snow removal control systems are not configured to collect, store, and/or report data regarding performance and other conditions of the device. A system that can be used to effectively monitor and control snow removal devices located in remote locations is desirable.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a system for controlling and monitoring snow removal devices. According to one embodiment, the snow removal devices include sensors for measuring data, and a processor remotely transmits the measured data to a base station. In some embodiments the measured data is environmental data that can be accessed by an operator remotely on a handheld device or at a computer terminal operably connected to the snow removal devices. In such an embodiment, the operator can monitor the device and choose to override the automated operation of the snow removal devices.
[0008] According to another embodiment, the geographic location of each snow removal device is stored in a memory location on the device or at the base station, and the base station is configured to query the weather conditions at the stored geographic location.
[0009] In one embodiment, the measured data is compared with the queried data. If the measured data is within a certain predetermined acceptable range compared to the queried weather data, the snow removal device is characterized as being operational. However, if the sensor reading is outside of a predetermined range the operator is alerted. In an alternative embodiment the query data is processed to determine whether the snow removal device that corresponds with the particular geographic location should be on or off. The base station then determines whether the snow removal device is in fact on or off. If there is a discrepancy, the base station automatically notifies an operator.
[0010] In another embodiment the queried and measured data relate to the operational conditions of the device rather than environmental conditions. For example, the data may relate to the amount of fuel consumed by the device or amount of fuel remaining in the device. The measured data can be compared with data stored on a database that can be accessed by the base station. If a discrepancy is detected, the operator is alerted.
[0011] According to another embodiment the user can monitor and control the device via a computer or a handheld wireless computing device. The data is represented graphically to the operator via icons on a map, and the devices can be controlled by the user remotely.
[0012] A variety of additional inventive aspects will be set forth in the description that follows. The inventive aspects can relate to an individual feature or to a combination of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a flow chart of a method of monitoring and controlling railroad switch snow removal devices in accordance with an embodiment of the invention;
[0014] FIG. 2 is a flow chart of an alternative method of monitoring and controlling railroad switch snow removal devices in accordance with an embodiment of the invention;
[0015] FIG. 3 depicts the network including a plurality of railroad switch snow removal devices according to an embodiment of the invention;
[0016] FIG. 4 is a schematic block diagram of a snow removal control unit according to an embodiment of the invention;
[0017] FIG. 5 depicts a user interface according to an embodiment of the invention;
[0018] FIG. 6 is a schematic illustration of a fuel tank monitoring system according to one embodiment of the invention;
[0019] FIG. 7 is a schematic illustration of several possible scenarios that are used to describe the operations of the invention;
[0020] FIG. 8 is a screen shot that displays a summary of the operating conditions of related snow melters according to an embodiment of the invention;
[0021] FIG. 9 is a screen shot that displays the detailed operating conditions of a selected snow melter according to an embodiment of the invention;
[0022] FIG. 10 is a screen shot that displays the control modes and on/off parameters of a selected snow melter according to an embodiment of the invention;
[0023] FIG. 11 is a screen shot that displays user rights to snow melters according to an embodiment of the invention;
[0024] FIG. 12 is a screen shot that displays fault notifications of snow melters according to an embodiment of the invention;
[0025] FIG. 13 is a screen shot that displays the location and identification of snow melters according to an embodiment of the invention;
[0026] FIG. 14 is a schematic diagram of an embodiment of the network according to the present disclosure; and
[0027] FIG. 15 is a schematic diagram of the embodiment of the network shown if FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Referring primarily to FIGS. 1 and 3 , a method of monitoring railroad switch snow removal devices 200 is shown. The first step includes identifying 10 a device and checking if the device 200 (shown schematically in FIG. 4 ) is on or off. In some embodiments the geographic location is stored at the base station 202 corresponding to a particular device identification number. In another embodiment the geographic location is stored at a memory location 301 at snow removal device 200 .
[0029] The geographic location can be any number of references. In some embodiments, the geographic location is identified as specific geographic coordinates (e.g., longitude and latitude), while in other embodiments the geographic location is identified as a particular zip code. For example, referring to FIG. 13 , the snow melter is shown associated with a serial number, name, zip code, latitude, longitude, region, division, subdivision, and mile post. In some embodiments the above information is recorded and tracked by a provider upon installation of the snow removal devices. Next, the base station 202 collects 20 weather data from a secondary source 204 that corresponds to the particular identified geographic location. Some exemplary secondary sources for weather data include: www.weather.com, www.cnn.com/weather/, and www.wunderground.com. Once the weather data is queried, the base station 202 determines 30 whether the device 200 should be on or off and checks 40 for any discrepancy. For example, if the secondary source indicates heavy snow at the particular geographic location, then the device should be on. In contrast, if the secondary source indicates that it is warm and sunny at the particular geographic location, the device should probably be turned off. If a discrepancy is detected, an operator 206 is alerted 50 so that the operator can investigate the discrepancy.
[0030] Referring to FIGS. 2 and 4 , an alternative method of monitoring and controlling railroad switch snow removal devices 200 is shown. The first step includes measuring 100 operating and environmental conditions. This step, for example, may include the step of measuring the ambient temperature, the ambient moisture content, and the available fuel. The next step is processing the data 112 by comparing 120 the measured data to a predetermined set of criteria. This step can include comparing the data with a predetermined set of criteria saved in a local memory location 301 to determine if snow is falling and if the device has enough fuel to run properly. In some embodiments this step is accomplished locally by the processor 300 that is located at the snow removal device 200 . In some embodiments, depending on the rate of snowfall, the ambient temperature, and the available fuel, the snow removal device 200 may automatically turn on or off as appropriate to ensure that snow and ice do not accumulate on the rails 402 of the switch 400 . In some embodiments the temperature of the heating or lack thereof is determined based on the measured criteria. For example, if the snow is determined to be dry and light, the heater 302 of the snow removal device 200 may be left off to conserve fuel and only the blower 304 will be turned on.
[0031] Referring primarily to FIGS. 2, 3 and 4 , in some embodiments if the measured values are outside of a predetermined set of values an alert is transmitted 116 to the base station 202 . In some embodiments the base station 202 is configured to translate the received signal and determine, for example, whether a particular sensor 306 , 308 , 310 , 312 has malfunctioned or if the device is out of fuel. When an alert is sent, an operator 206 can view the alert remotely when connected to the base station 202 . In some embodiments the base station 202 is configured to page the operator 206 whenever a certain type of alert is received. For example, the base station 202 may be programmed to page the operator 206 when a snow removal device 200 has run out of fuel and snow is falling at that particular location. Such an alert enables an operator 206 to anticipate the failure of the particular switch 400 and make alternative arrangements as necessary.
[0032] Still referring primarily to FIGS. 2, 3 and 4 , in the depicted embodiment the base station 202 measures 100 data from the snow removal devices 200 according to a maintenance check schedule. In some embodiments the collection of data is accomplished by configuring the snow removal devices 200 to periodically or continuously transmit measured data back to the base station 202 . In other embodiments, the base station 202 is configured to query data from the snow removal devices 200 at certain times or on command. The base station 202 also collects 118 a comparable set of data from a secondary source 204 . It should be appreciated that the step of collecting data from a secondary source can occur before, after, or simultaneously with the step of collecting data from the devices 200 . The secondary source 204 in some embodiments includes real time weather information. In other embodiments the secondary source includes maintenance records, such as the last time the snow removal devices 200 were refueled. Subsequently, the data collected from the snow removal devices 200 is compared with the data collected from the secondary sources 204 . If the datum from the snow removal devices 200 and the secondary sources 204 are outside of an acceptable range, an alert is triggered at the base station.
[0033] An alert may indicate, for example, that the snow removal device 200 is apparently low on fuel, even though the secondary source 204 maintenance records indicate that the snow removal device 200 was recently refueled. Once alerted to the discrepancy, the operator can investigate the issue further to determine if the snow removal device 200 is leaking, if the secondary source 204 maintenance records are inaccurate, or if the fuel sensor is inaccurate. If the operator 206 decides that the measured value is inaccurate, the operator 206 can reset (e.g., recalibrate) 122 the sensor or otherwise dismiss 126 the alert. In some embodiments the recalibration can be accomplished remotely, and in other embodiments the recalibration is accomplished via the user interface 314 located locally on the snow removal device 200 . In such embodiments the device 200 includes a receiver in addition to the transmitter 612 .
[0034] Alternatively, an alert may indicate, for example, that the measured temperature is substantially different than the temperature collected from the secondary weather data source that corresponds to the particular geographic location, which is measured and stored in a memory location. Once alerted of the discrepancy, the operator 206 may choose to override 124 the automatic on off control of the snow removal device 200 if appropriate, or otherwise dismiss 126 the alert. In such embodiments the device 200 includes a receiver in addition to the transmitter 612 . An operator 206 can check other nearby sensors or other secondary sources to determine whether the measured data or the queried data is more likely accurate.
[0035] Finally, the base station 202 can be configured to store 128 all the dates and times that the measured data from each snow removal device 200 was checked against data from a secondary source 204 . In some embodiments the next date and time that the measured data from that particular snow removal device 200 is check against data from a secondary source 204 is dependent on when the last check occurred and the outcome of the last check. In some embodiments, a number of different types of measured data is stored at the base station for maintenance purposes.
[0036] Referring primarily to FIG. 5 , according to one embodiment of the invention the data transmitted and processed at the base station can be accessed via an internet webpage. The data can in some embodiments be graphically represented via icons 401 , 403 , 404 , 406 , and 408 along tracks 410 on a map displayed on a computer screen 414 . The user can check the operational parameters and the measured data by clicking on the icon that corresponds with the snow removal device 200 of interest. In some embodiments an alert is indicated on the map by a flashing icon or an icon that turns a particular color, such as orange or red. In other embodiments, the color of the icon 401 , 403 , 404 , 406 , and 408 corresponds with whether the particular corresponding snow removal device 200 is on or off or is full or low on fuel.
[0037] According to some embodiments the data can be accessed by the operator 206 wirelessly on a handheld device 500 . In such an embodiment the operator can be in transit to service a particular snow removal device 200 and access real time data regarding the snow removal devices 200 in the field.
[0038] Referring to FIG. 6 , an embodiment is shown where fuel tank related data is measured to determine if the tank 600 is expected to be operational. To be operational the tank 600 must be able to supply fuel to the burner 604 . In the depicted embodiment the supplied fuel 618 is in gas form (e.g., propane or natural gas). To enable larger amounts of fuel 602 to be stored within the tank 600 , the fuel 602 in the depicted embodiment is pressurized so that most of the fuel 602 in the tank 600 is in liquid form. Fuel must change phase from liquid to gas to be effectively used. Accordingly, the mere fact that the tank 600 is not empty does not necessarily mean that the tank 600 is expected to be operational. Since whether a particular liquid will change into a gas is dependent on the temperature of the liquid and the pressure in the tank 600 , the temperature of the fuel 602 within the tank 600 and the pressure within the tank 600 factor into whether the tank 600 is operational (the colder a liquid is, the less likely the liquid will vaporize at a given pressure). In view of the above, as compared to only knowing the amount of fuel 602 in the tank 600 , also knowing the temperature of the fuel 602 , and the pressure within the tank 600 enables one to more accurately predict whether the tank 600 is operational.
[0039] According to one embodiment, to accurately estimate whether the tank 600 will be operational under certain conditions, preferably at least the following types of data are measured: the temperature in the tank 600 or the fuel 602 therein, the pressure within the tank 600 , and the level of liquid fuel within the tank 600 . Accordingly, to such an embodiment the system includes a temperature sensor 606 , a pressure sensor 608 , and a fuel level sensor 610 . It should, however, be appreciated that in alternative embodiments sensors measuring different data may be included. It should also be appreciated that alternative embodiments may include more or fewer sensors in part depending on the specific methodology used to analyze the data, which will be discussed in greater detail below. It should be appreciated that in alternative embodiments an electric heat non-combustion source may be employed (e.g., electric calrod heater). Such systems could include a system for measuring whether the necessary electric energy exists, similar to the fuel tank monitoring system described above.
[0040] In the depicted embodiment the sensors are connected to a transmitter 612 that is configured to transmit the measured data to a remote base station 614 or a network server 616 or both. In one embodiment the base station 614 uses equations to calculate whether or not the tank 600 is expected to be operational based on the measured data and known or inputted data. In other embodiments the base station 614 relies on empirical data to make its determination regarding the operability of the tank 600 . In yet other embodiments, a combination of empirical charts and equations are used in the analysis. In embodiments where empirical data is used in the analysis, the empirical data may be stored locally on a remote database and accessible via a network. In the depicted embodiment the empirical data is stored on a remote server 616 and accessible via the internet 620 . Base station 614 can be connected to the transmitter 612 via the cellular telephone network directly, or via a short range wireless communication system such as any of a variety of 802.11 wireless networks (e.g., Wi-MAX or Wi-Fi) or any radio or other wireless or wire communication systems.
[0041] In some embodiments the base station 614 tracks and stores the measured data to analyze the fuel usage history. For example, in some embodiments the level of fuel in the tank 600 is tracked over a set period of time. Such tracking can be used for many purposes including, for example, determining whether the measured data is likely accurate or inaccurate, or whether the sensors are operable and/or whether the tank 600 is leaking. For example, if the tracked history indicates that the tank 600 was initially full and has been in use for a very short period of time or no time at all but is now empty, the tank 600 may be leaking or the measured data may be inaccurate. In some embodiments the base station 614 is configured to alert the operator when a potential problem is detected.
[0042] The system disclosed in FIG. 6 , may also be used by an operator in determining the type of fuel that should be used for a particular application. In some embodiments the conditions, such as the expected ambient temperatures, may make a certain type of fuel preferable. The effectiveness and efficiency of particular fuels can be analyzed at the base station 614 based on the data collected by the sensors 606 , 608 , and 610 . It should be appreciated that many other analyses can be conducted based on data measured by the sensors and/or data queried from a local or remote server 616 .
[0043] Referring to FIG. 7 , the process of determining when it is appropriate to alert the operator of a failure or otherwise initiate the process of override, the operations of a failed device is illustrated. It is desirable to avoid false detection of device failures, which are the results of normal error. For example, for a period of time the device might be ON while it is snowing. During this period the operation of the system may be characterized by the upper left quadrant (i.e., the device is ON and the device should be ON). The snow might stop, but for a relatively short period of time the device might still be ON. During this period the operation of the system can be characterized as having moved to the lower left quadrant (i.e., the device is ON and the device should be OFF). During this time period, fuel is being wasted. This might occur because the sensors on the device, or the empirical data, or both, are slightly off. To avoid alerting the operator relating to small discrepancies which in time correct themselves, the system can be set up such that the system must operate in the lower left state for more than an hour before an alert is sent to the operator or a failure is otherwise deemed. On the other hand, the system be might be operating in the upper left quadrant and move to the upper right quadrant. This would occur if snow continue to fall, but the device turns itself off (i.e., the device is OFF and the device should be ON). Since it is important to prevent railroad switch failure, the system might be set to alert an operator or otherwise consider the discrepancy a failure after a relatively shorter period of time, for example, 10 minutes instead of an hour.
[0044] Still referring to FIG. 7 , as discussed above the time period for acceptable discrepancies is dependent on the type of discrepancy (i.e., if the device is ON when it should be off versus the device is off when it should be on). Another factor can relate to the context (i.e., what quadrant was the device previously operating in). For example, there may exist reasons to set different acceptable time periods of discrepancies based on whether the device moves into the upper right quadrant from the upper left quadrant or from the lower right quadrant. If the device moves to the lower right quadrant from the upper right quadrant (i.e., it starts from the state where it is OFF and it should be OFF, and moves to the state where it is OFF but should be on), the period of time of acceptable discrepancy might be longer than if the device moves to the same quadrant from the upper left quadrant. The latter occurrence might more likely indicate a failure, whereas the former might more likely indicate normal sensor variations.
[0045] Referring to FIGS. 8-13 , a specific embodiment of an internet based system is described in greater detail below. FIG. 8 is a screen shot showing a summary of the operating condition of snow melters under the control of a particular user. In the depicted embodiment, the summary of the snow melters can be organized by the user according to region, division, subdivision, mile post, or site group. In the depicted screen shot the designated region is North and the designated division is Twin Cities. Three snow melters fall within this category (i.e., East Wayzata, West Delano, and West Wayzata). The subdivision, mile post, and temperature for each of the three melters are displayed. In addition, the status and whether the melters are running are also displayed. From this screen the user can select any one of the three snow melters for further analysis.
[0046] FIG. 9 is a screen shot that corresponds with the East Wayzata snow melter shown in FIG. 8 . In addition to the summary information regarding the snow melter, detailed information relating to the control and operation parameters are displayed. In the depicted screen shot, East Wayzata is not running due to the air temperature, as shown under the machine status column. Other status options include Idle, Running-OK, Not Running-Faulted, Not Running-Timed Out, Not Running-Should Be-Weather, Running-Should Not Be-Weather, and Communication Failure. In the depicted embodiment, action is called (not running due to air temperature) for by the Weather Watcher system, which is driven by the secondary source data. In the depicted embodiment the secondary source data can be used as a check on the local sensors and controls on the snow melter, or it can be used to drive the system. If the local controls and sensors are used to drive the action of the system, the secondary weather data is used as a check and issues alerts when a discrepancy is detected.
[0047] Still referring to FIG. 9 , from this view the user can view an array of current status data that includes: fuel tank level, temperature set points, run time data, air temperature, rail temperature, motor voltage, duct pressure, gas pressure, total gas used, motor current, etc. Also, a link is provided to view a snapshot of the site to enable the operator to view the site. The fuel tank level is used to determine if the tank needs to be refilled, and also to calculate whether the tank is operational based on the temperature and other factors. The motor voltage and current are used to determine if the snow melter motor is operational, and also if the motor is running optimally or likely to fail. The duct pressure and gas pressure are used to troubleshoot, and also used to determine if the tank is expected to be operational. In addition, from this view the user clicks on tabs to further investigate the last fault reading, the operational history, and other control settings.
[0048] FIG. 10 is a screen shot that corresponds with the Controls tab of FIG. 9 . From this view the user can remotely operate the snow melter. The user can turn on or off the snow melter, adjust the temperature set points, and adjust the run times. In the depicted view the snow melter is configured to turn on continually when the air temperature is less than one degree Fahrenheit. The air temperature set point can also be used to prevent the snow melter from turning on. For example, the system can be configured such that if a sensed temperature is above a certain level, the device does not turn on.
[0049] Referring to FIG. 11 , a screen shot of the user assignment page is shown. The user assignment function allows for different levels of access rights to be assigned to different operators. Some operators can be authorized only to view the system, and others can be authorized to edit and modify the system. Moreover, those who are authorized to edit and modify the system may be authorized to edit and modify specific aspects of the system (e.g., gas, run hours, fault counts, and overtemp latch). In the depicted embodiment, all of the operators have full authorization to the system.
[0050] Referring to FIG. 12 , a screen shot of the notification setup is shown. The notification function allows for selective notification. Particular types of notification can be sent to particular users via particular means. For example, in the depicted embodiment, Peter Molenda is set to receive notification of fuse 2 faults by email only, whereas Eric Schneider is set to receive fuse 1 faults via cell phone, temperature faults via pager, and fuse 2 faults via email and work phone. In the depicted embodiment, the system administrator is set to receive notification of all of the faults. This system enables the messages to be sent to the person who is responsible for or best suited to dealing with the particular issue. FIG. 13 , as discussed above, is used to log in the identifying information of each of the snow melters.
[0051] Referring to FIGS. 14 and 15 , a general overview of a particular embodiment of a network according to the present disclosure is included below. The components of the network architecture include: SMC—Snow Melter Controller; RCC—Remote Communications Controller; WEB—Web services and portal hosting; SQL—SQL Server database; RR—Railroad client accessing web portals.
[0052] The general messaging flow scenarios are summarized below in outline form:
1. SMC initiated
SMC RCC SMC detects a change of operating state (i.e. from off to running) and initiates a conversation with the RCC. SMC sends a message to the RCC containing the current snow melter operating and configuration parameters. RCC accepts and acknowledges the message from the SMC. SMC closes the conversation with the RCC after 1 minute of idle time. RCC captures the parameter values from the message. RCC WEB RCC initiates a conversation with the WEB. RCC sends the current snow melter parameters to the WEB. WEB acknowledges the message from the RCC. RCC closes the conversation with the WEB immediately. WEB captures the parameter values from the message. WEB updates the SQL database with the snow melter parameter values. WEB USER WEB analyzes the snow melter change of state to determine notification requirements. WEB issues notification messages to railroad clients for new snow melter conditions.
2. RCC initiated
RCC SMC RCC initiates a conversation with the SMC. RCC sends a message to the SMC containing the command number. SMC accepts and acknowledges the message from the RCC. Included in the acknowledgement are all SMC parameter values. RCC closes the conversation with the SMC after 1 minute of idle time. RCC captures the parameter values from the message. RCC WEB RCC initiates a conversation with the WEB. RCC sends the current snow melter parameters to the WEB. WEB acknowledges the message from the RCC. RCC closes the conversation with the WEB immediately. WEB captures the parameter values from the message. WEB updates the SQL database with the snow melter parameter values. WEB USER WEB analyzes the snow melter change of state to determine notification requirements. WEB issues notification messages to railroad clients for new snow melter conditions.
3. WEB initiated
WEB RCC WEB user presses the “Refresh Values” button on a web page. WEB initiates a conversation with the RCC. WEB sends a message to the RCC containing the command number. RCC accepts and acknowledges the message from the WEB. RCC SMC RCC initiates a conversation with the SMC. RCC sends a message to the SMC containing the command number. SMC accepts and acknowledges the message from the RCC. Included in the acknowledgement are all SMC parameter values. RCC closes the conversation with the SMC after 1 minute of idle time. RCC captures the parameter values from the message. RCC WEB RCC initiates a conversation with the WEB. RCC sends the current snow melter parameters to the WEB. WEB acknowledges the message from the RCC. RCC closes the conversation with the WEB immediately. WEB captures the parameter values from the message. WEB updates the SQL database with the snow melter parameter values. WEB USER WEB analyzes the snow melter change of state to determine notification requirements. WEB issues notification messages to railroad clients for new snow melter conditions.
[0109] From the foregoing detailed description, it will be evident that modifications and variations can be made in the devices and methods of the disclosure without departing from the spirit and scope of the invention.
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A snow removal system wherein snow removers located in remote locations can be monitored and controlled at a computing device. Data collected by sensors on the snow removal unit or data collected from a secondary source can be used to control the operation of the snow removers. In one embodiment, data regarding whether it is snowing at a particular location can be collected by moister sensors on the snow removal device and verified by on-line contemporaneous weather reports corresponding to the same location.
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FIELD OF THE INVENTION
[0001] This invention relates generally to simulanting materials suitable for use as training articles for training and calibration purposes, in particular in the training of detecting dogs and security personnel, and for calibrating sensitive analytical instruments. The materials are safe for handling (use, training, storage etc.) on the one hand and, on the other hand, are applicable in a variety of applications and compatible with different requirements.
BACKGROUND OF THE INVENTION AND STATUS OF PRIOR ART
[0002] Various methods and apparatus have been developed for detecting explosives and other hazardous materials, e.g. chemical agents used in the course of manufacturing nuclear weapons and chemical weapons, as well as for detection of drugs. All such materials are hereinafter in the specification and claims referred to collectively as hazardous materials.
[0003] As the concern of terrorist and criminal actions increases worldwide, the need to develop effective detection of hazardous materials increases, in particular when concerned with explosive materials, however not restricted thereto. One common way is use of detecting dogs and sensitive analytical technologies. To enable the training of such dogs and their accompanying personnel, and/or the calibrating of sensitive instruments, it has been necessary to use significant quantities of explosives (in most cases ‘neat’ materials) which pose a hazard as well as preventing dog training or instrument utilization in some critical or restricted areas. For example, during the training and utilization of detecting dogs, quantities of hazardous explosives are carried in vehicles and placed in buildings which resulted in the possibility of explosive detonation. The need for explosive materials thus complicates detection training in populated areas such as airports, train stations, office buildings, etc. Furthermore, use of explosive materials is admitted for authorized personnel, and also, special logistics are required, e.g. for storage, transportation, etc.
[0004] Similarly, calibrating of sensitive analytical instruments used for the detection of explosives could only be accomplished by the presence of ‘neat’ explosives, though in small quantities, but creating a hazard to the handling personnel and to the equipment. Thus, there has been a need to develop safe methods of training explosives detecting dogs and personnel, and/or calibrating sensitive analytical instruments, and other applications, without the use of actual hazardous explosives.
[0005] Apart for safety issues and logistic complications concerned with hazardous materials, in the case of drugs detection training, a different issue evolves when utilizing actual drugs. This positions a problem with criminals which may take advantage of different situations and try some criminal acts.
[0006] U.S. Pat. Nos. 5,359,936 and 5,413,812 (the later divided out of U.S. Ser. No. 08/027,366, now said U.S. Pat. No. 5,359,936) disclose an explosive simulant which is chemically equivalent to an explosive, but is not detonable. The simulants are manufactured either by slurry coating technique to produce a material with a very high binder to explosive ratio without masking the explosive vapor, or by coating inert beads with thin layers of explosive molecules.
[0007] U.S. Pat. No. 5,648,636, (which is a Combination-In-Part of U.S. Ser. No. 08/221,568 and now said U.S. Pat. No. 5,413,812), discloses a simulant which is chemically equivalent to an explosive, but is not detonable or explodable. The simulant is a combination of an explosive material with an inert material, either in a matrix or as a coating, where the explosive has a high surface ratio but small volume ratio. The simulant has particular use in the training of explosives detecting dogs, calibrating analytical instruments which are sensitive to either vapor or elemental composition, or other applications where the hazards associated with explosives is undesirable but where chemical and/or elemental equivalence is required. The explosive simulants may be fabricated by the use of standard slurry coatings to produce a material with a very high binder to explosive ratio without masking the explosive vapor, or by coating inert substrates with thin layers of explosive molecules.
[0008] Other simulant materials are disclosed, for example, in U.S. Pat. Nos. 5,756,006 and 5,958,299.
[0009] The present invention satisfies the need of providing simulant materials which are chemically equivalent to the actual hazardous materials required for training and for operational uses, in nearly all aspects. However in the case of explosive materials simulants they cannot chemically react violently (no to detonation, or deflagration, or explosion), whereby the use of actual hazardous explosives is eliminated, thereby removing the hazards associated with the use of explosives. Furthermore, the simulant materials can also be used for detection by instruments that do not rely on odors, e.g. density, crystallographic structure, chemical structure, etc.
[0010] In connection with explosives (defined herein to mean explosives as well as gun and rocket propellants), an explosion is defined as a rapid energy release while detonation is energy release at supersonic velocities. Thus a non-detonable material may still be explodable. Therefore, safe materials are required, which are referred to in the art as Non-hazardous Explosives for Security, Training and Testing (NESTT). Hence safe use NESTT materials are those which are non-detonable and also non-explodable.
[0011] The materials according to the above prior art patents are in the form of loose material, which have some deficiencies, such as causing an irritation to the sniffing dogs, difficulties in placing/applying the material, the need for special ‘sniffing containers’, etc.
[0012] Hereinafter in the specification and claims, the term ‘non-explosive material’ denotes a material which may be considered as a non-explodable, non-deflagradable and non-detonable material (i.e. compatible as a non class 1 material, as per definitions of the UN Regulations, the US Department Of Transportation (DOT) and other safety standards).
[0013] It is an object of the present invention to provide simulant materials which as a primary condition are safe for handling, i.e. being non-explosive materials and substantially non-hazardous, and which on the other hand are easy and cheap to manufacture and are easily applicable in a variety of forms and for different applications. It is a further object of the present invention to offer a method for manufacturing simulant materials of the aforementioned type.
SUMMARY OF THE INVENTION
[0014] In view of the foregoing, the main object of this invention is to provide a simulant material and articles made thereof, for simulating hazardous materials useful as articles for training and calibration purposes, in particular in the training of detecting dogs and security personnel, and for calibrating sensitive analytical instruments, which is safe, requires simple logistics and eliminates crime activity occurring in particular at the presence of drugs.
[0015] More particularly, an object of this invention is manufacture of a non-explosive simulant material comprising an explosive material and an inert material; wherein the simulant material is in the form of a homogenous non-particulated material.
[0016] A salient feature of the invention is that the simulant material simulates explosive materials in four main aspects:
‘odor print’ of the simulant material resembles that of the simulated material; the simulant material has like chemical structure properties of the simulated material, though in substantially reduced ratio; the simulant material has like crystallographic structure as of the simulated material; the simulant material is user and environmentally friendly and safe.
[0021] The simulant material according to the present invention has many significant features and advantages, for example:
the simulant material is available in solid form or in paste form, where it may be applied manually or by different paste/putty applicators; where the simulant material is in solid form it may be in the form of spaghetti-like elements or as continuous sheet of material, where it may be worked in different ways including cutting, piercing and may be imparted any desired shape, manually or by tools; the simulant material may be readily used (self sustained) eliminating use of special containers; when in solid form, the simulant material is flexible/pliable; the material may be adhered using readily available adhesives; the material is foldable; the simulant material is chemically and mechanically stable; the simulant material is not effected by common organic dissolvers, rendering it resistant in different operative conditions; the simulant material is free of non inherently associated volatiles (e.g. solvents), whereby sniffing dogs or ‘sniffers’ (analytical instruments for detection of hazardous materials) are not likely to be confused/misled; a wide variety of ‘cocktails’ may be prepared for simulation of different materials, however using one simulant article only. Such cocktails may also involve simulation of explosive materials, chemical agents and drugs, as well as deliberately confusing/masking agents; the simulant agent may comprise different additives, e.g. fire retardants, pigment agents so as to offer visible differentiation between such articles; metallic powder (ferrous, tungsten, etc.) so as to render the simulant article detectable also by magnetometers, etc; the manufacturing process of the simulant material and articles is rapid and at relatively low cost as compared with other simulant materials. the simulant material according to the invention is resistant to hostile environments such as, humidity, sea water, corrosive conditions, oils and fuels, extreme temperature condition (e.g. in the range of about −54° C. to +70° C.), UV resistance, radiation resistance. density of the simulant material could be adjusted to resemble that of the simulated material; It is a further an object of the present invention to provide a method for manufacturing simulant materials of the above disclosed type, and simulant articles made thereof. Said method comprising the steps of:
obtaining a mixture of at least one explosive material with at least one inert material; and mixing the materials to obtain a homogenous, flexible and non-particulated, paste-like material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] For a better understanding of the invention as well as other objects and further features thereof, reference is now made to the annexed drawings wherein:
[0040] FIG. 1 is a schematic representation of a manufacturing process of a simulant material according to a first embodiment of the present invention, where said simulant material is in paste form;
[0041] FIG. 2 is a schematic representation of a manufacturing process of a simulant material according to a first embodiment of the present invention where said simulant material is in solid form; and
[0042] FIGS. 3A-3E are samples of simulant material articles according to the present invention, formed in different shapes.
DETAILED DESCRIPTION OF THE INVENTION
[0043] Attention is first directed to FIG. 1 of the drawings illustrating a process for manufacturing simulant materials in accordance with the present invention. The manufacturing process utilizes a conventional chemical engineering system comprising a plurality of hoppers 10 , 12 and 14 for containing a plurality of powdered or granulated material, and a plurality of liquid containers 16 , 18 , 20 , 22 and 24 for containing different liquids, as will be exemplified hereinafter.
[0044] Each of the hoppers and containers is fitted with a controllable port P, typically governed by a controlled processing unit (not shown) for discharging precise amounts of material through said ports. Furthermore, each of the hoppers 10 , 12 and 14 is fitted with a shaker/vibrator or a screw-type feeder S to ensure proper flow of the solid particles (powder or granular).
[0045] Extending from each of the hoppers and containers there are ducts D extending towards a large blender 24 which in the present example is a sigma blade type blender operated by a motor M.
[0046] As disclosed hereinbefore, in accordance with one embodiment of the invention, the simulant material is in a paste/putty like form which may be obtained directly from the mixer 24 . Such paste-like material may then be removed from the mixer 24 and may either be collected into suitable containers or putty dispensing tubes, e.g. of the type used with putty dispensers 30 as in FIG. 3A , wherein upon squeezing a trigger 32 the paste/putty material 36 is dispensed and may be applied directly on any surface whereby it is likely to adhere owing to its pasty nature. Alternatively, the paste-like simulant material 36 may be injected into containers of different shapes to simulate different conditions.
[0047] In accordance with a second embodiment, the simulant material is formed into solid state and further attention is now directed also to FIG. 2 of the drawings illustrating further steps of the method for obtaining such solid simulant material. The paste/putty like stimulant material obtained after the mixing stage in mixer 24 is then withdrawn and transferred, e.g. by belt conveyor 40 , to a vacuum extruder generally designated at 44 . This stage of the process takes place under vacuum wherein the pasty material is extruded, whilst removing residual air and compressing the pasty material into any desired form. In the particular embodiment, the material is formed into a continuous flat strip of material 50 placed on a second conveyor belt 54 which transfers the material into a drier 58 wherein the simulant material is solidified and reaches its final stage as a solid, though pliable/foldable material collected in the form of a roll of material 62 , or flexible sheets obtainable at various thicknesses.
[0048] The following is an example of a method of obtaining a simulant explosive material. Hopper 10 comprises explosive material, e.g. RDX, hopper 12 comprises a powdered agent, e.g. silica, container 16 comprises a siliconic polymer, (e.g. PDMS—polydimethyl siloxsane), container 18 comprises a cross-linking agent, (e.g. tetra-ethyl silicate) and container 20 comprises an organo-metallic catalyst (e.g. tin dibutyl laurate). The above ingredients are obtained and introduced into the mixer 24 . In accordance with one particular embodiment the following volumetric ratio is used:
[0000]
RDX
17%;
Silica
30%;
PDMS
49.4%;
Tetra-ethyl silicate
3.5%;
Tin dibutyl laurate
0.1%.
[0049] The ingredients are mixed for approximately 1 hour to thereby obtain a homogenous paste-like material which is then transferred into the vacuum extruder 44 to compress the material under vacuum conditions, so as to remove residual air and obtain a pasty homogenous material, which is then polymerized and cross-linked within the oven 58 , e.g. by placing it overnight in a temperature of about 50° C.
[0050] However, if it is required to retain the simulant material in its paste-like form, then the cross-linking agent (tetra-ethyl silicate in the present example) and the catalyst (tin dibutyl laurate in the present example) are not fed into the mixture.
[0051] Having given the above example, it should be apparent to a person versed in the art that different parameters may be manipulated so as to obtain the simulant material at different levels of viscosity. Such parameters may be concentration of the additives or mixing speed and time at mixer 24 .
[0052] Amongst the additives which may be added into the mixture are, for example, color agents, odor agents, different drugs so as to impart the simulant material features also as a drug simulating material. The explosive material used for the mixture may be a single material or may be a cocktail of materials to thereby simulate several such materials. As an example, RDX may be used side by side with PETN.
[0053] Other additives which may be used are, for, example, fire retarding agents, metallic powder detectable by metal detectors (magnetometers), e.g. ferrum powder or tungsten powder, the latter being preferable as it has increased specific weight.
[0054] The hardened material obtained after the cross linking process at oven 58 may be processed in different forms. For example, it may be kept as a continuous sheet-like material ( FIG. 3B ). The material 64 may be cut by any suitable tool (scissors, knife, etc.) per demand. FIG. 3C illustrates a simulant material 66 cut in the shape of a sole simulating a sole-like article of the type commonly used by drug smugglers. In this case it is likely that the article is mixed also with drug simulating agents. In the embodiment of FIG. 3B the simulant material 68 is cut in the shape of a weapon, a pistol in the present example, and in this case it is likely that a metallic powder is embedded in the simulant material, to be detectable also by a magnetometer. FIG. 3A illustrates a simulant material 72 formed in the shape of a long rod, e.g. having a square cross-section, a cylindrical cross-section, a tubular cross-section, etc. to be used in different applications.
[0055] Whilst some embodiments have been described and illustrated with reference to some drawings, the artisan will appreciate that many variations are possible which do not depart from the general scope of the invention, mutatis, mutandis.
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Provided is a simulant material for simulating hazardous materials, including a quantity of at least one explosive material and at least one inert material. The simulant material is a non-explosive material and is in the form of a homogenous, flexible and non-particulated material. Also provided is a method for manufacturing such a simulant material.
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a cylindrical screen, and particularly, it relates to a cylindrical screen in which a mat formed on a surface of the screen is liable to be peeled off.
There is a screen apparatus in which round holes or slits are formed on an outer peripheral surface of a cylindrical screen and a stirring member (agitator) is provided outside the cylindrical screen, to thereby remove foreign substances from a papermaking material.
However, in the aforementioned screen apparatus, although a screen cleaning operation is made by the agitator, fibers are accumulated on the surface of the screen to form a mat on the entire surface of the screen, and the mat is difficult to be peeled off, resulting in deteriorating a performance of the screen.
An object of the invention is to provide a cylindrical screen which solves the aforementioned problem.
Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
To achieve the aforementioned object, the present invention provides a cylindrical screen, which comprises a cylindrical shape having a height larger than a diameter; a plurality of screen bars disposed in parallel to each other and spaced away with intervals therebetween; a plurality of slits in longitudinal shapes respectively formed between two of the screen bars adjacent to each other; a ring for stopping the screen bars; and a member having a width larger than a thickness of the ring and disposed in a direction transversely crossing a longitudinal direction of the screen bars, in which the member divides the slits in the longitudinal shapes in a middle thereof.
Also, the present invention provides a cylindrical screen, which comprises a cylindrical shape having a height larger than a diameter; a screen plate having an outer peripheral surface; and a plurality of slits formed on the outer peripheral surface of the screen plate. In the cylindrical screen, the plurality of slits is disposed with small intervals therebetween in a vertical direction, and provided with a large interval larger than the small interval in a middle portion of the cylindrical screen.
Further, the present invention provides a cylindrical screen, which comprises a cylindrical shape having a height larger than a diameter; a screen plate having an outer peripheral surface; and a plurality of round holes formed on the outer peripheral surface of the screen plate. In the cylindrical screen, the plurality of round holes is disposed with small intervals therebetween in a vertical direction, and provided with a large interval larger than the small interval in a middle portion of the cylindrical screen.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a screen apparatus, in which a cylindrical screen according to an embodiment of the invention is installed;
FIG. 2 is a schematic front view of the cylindrical screen of FIG. 1, shown partly in section;
FIG. 3 is a schematic cross sectional view taken along line 3 — 3 in FIG. 2;
FIG. 4 is a schematic front view of a cylindrical screen according to another embodiment of the invention which differs from the cylindrical screen in FIG. 2;
FIG. 5 is a schematic, partly sectional front view of a cylindrical screen according to another embodiment of the invention which differs from the cylindrical screen in FIG. 4;
FIG. 6 is a schematic, partly sectional front view of a cylindrical screen according to another embodiment of the invention which differs from the cylindrical screen in FIG. 5;
FIG. 7 is a schematic, partly sectional front view of a cylindrical screen according to another embodiment of the invention which differs from the cylindrical screen in FIG. 6; and
FIG. 8 is a schematic, partly sectional front view of a cylindrical screen according to another embodiment of the invention which differs from the cylindrical screen in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A cylindrical screen according to an embodiment of the invention will be explained with reference to the attached drawings.
In FIG. 1 through FIG. 3, reference numeral 1 denotes a screen in a cylindrical form, and more specifically, reference numeral 1 is a papermaking screen in a cylindrical form which separates foreign substances from a papermaking material.
In the cylindrical screen 1 , screen bars 2 are disposed in parallel with intervals therebetween, and a height H of the cylindrical screen 1 is larger than a diameter D thereof (D<H).
Then, screen bars 2 adjacent to each other form a slit S in a longitudinal form (an elongate space), and the screen bars 2 are engaged with and stopped by stopping portions formed at, for example, outer peripheries (alternatively, inner peripheries inside) of rings R.
Also, in the screen bars 2 , the slits S in the longitudinal form are cut in the middle by a member 3 having a width T larger than a thickness t of the ring R (T>t) and disposed in a direction transversely crossing the longitudinal direction of the screen bar 2 . The member 3 is formed into a concave portion which is concaved inwardly, and an opening portion of the concave portion of the member 3 faces an outside. At the same time, the member 3 is formed throughout an entire outer periphery of the cylindrical screen 1 .
Incidentally, in the cylindrical screen 1 , one end of each screen bar 2 at an upper side portion of the screen 1 is supported by a first end plate R 1 in a ring form, and the other end of each screen bar 2 at the upper side portion of the screen 1 is supported by the member 3 formed in the ring form. Also, in each of the screen bars 2 at a lower side portion of the screen, one end thereof is supported by the member 3 formed in the ring form, and the other end thereof is supported by a second end plate R 2 .
Reference numeral 4 denotes an agitator formed outside the cylindrical screen 1 , and by utilizing a change of pressure caused at front and rear sides of the agitator 4 by the rotation of the agitator 4 , the screen cleaning operation for the screen 1 is carried out.
Therefore, according to the embodiment, a papermaking material entered from a material inlet passage 5 is subjected to an agitating operation by the agitator 4 in a tank 6 , and good fibers are guided to an outside of the tank 6 through the longitudinal slits S and an outlet passage 7 . It is structured that the foreign substances can not pass through the longitudinal slits S, to thereby remove the foreign substances from the papermaking material.
In this case, the fibers are accumulated on the surface of the screen 1 such that a mat is formed on the screen 1 . In the screen bars 2 , since the longitudinal slits S are divided in the middle by the member 3 , which has the width T larger than the thickness t of the ring R in the direction transversely crossing the longitudinal direction of the screen bars 2 , the mat formed on the screen 1 is divided, so that the mat can be easily peeled off due to the agitating operation by the agitator 4 . Accordingly, the performance of the screen 1 is prevented from being deteriorated.
Incidentally, in the screen bars 2 of the aforementioned embodiment, single member 3 including the width T larger than the thickness t of the ring R is used in the direction transversely crossing the longitudinal direction of the screen bars 2 to thereby divide the longitudinal slits S in the middle. However, in the present invention, the number of the member 3 is not limited to one, and for example, as shown in FIG. 4, a plurality of the members 3 structured as described above can be used.
Also, although the agitator 4 is provided outside of the cylindrical screen 1 in the aforementioned embodiment, the present invention is not limited thereto, and the present invention can be applied to a case in which the agitator 4 is provided inside of the cylindrical screen 1 .
Further, as shown in FIG. 1 through FIG. 4, in case the member 3 is formed with the concave portion concaved toward an inner side of the screen 1 , foreign substances which can not pass through the screen 1 tend to be accumulated in the concave portion of the member 3 , so that the foreign substances in the papermaking material passing through the slits S are reduced by an amount of the foreign substances accumulated in the concave portion. Therefore, a screening effect by the screen 1 can be improved.
Also, although the screen bars 2 are disposed in parallel to each other with intervals therebetween to form the slit S in the cylindrical screen 1 of the aforementioned embodiment, the present invention is not limited to this embodiment. The present invention can be similarly applied to a cylindrical screen in which slits S are formed on an outer peripheral surface of a screen plate as shown in FIG. 5, and also can be applied to a cylindrical screen 1 in which round holes S′ are formed on the outer peripheral surface of the screen plate as shown in FIG. 6 .
In case of FIG. 5, a plurality of the slits S is disposed with intervals t therebetween in a vertical direction, and in the middle thereof, an interval T larger than the interval t (T>t) is provided.
Incidentally, in case of the round holes S′ shown in FIG. 6, a plurality of round holes S′ is disposed with intervals t therebetween in a vertical direction, and in the middle thereof, an interval T larger than the interval t (T>t) is provided.
Further, as same as in the aforementioned embodiment of FIGS. 1 through 4, as shown in FIG. 7 and FIG. 8, a portion of an outer peripheral surface of a screen plate at an interval T is formed into a concave portion 3 ′ concaved inwardly, and an opening portion of the concave portion 3 ′ faces the outside. At the same time, the concave portion 3 ′ is formed throughout an entire outer periphery of the cylindrical screen 1 .
Incidentally, as in the embodiment shown in FIGS. 1 through 4, the foreign substances which can not pass through the screen 1 tend to be accumulated also in this concave portion 3 ′, and the foreign substances in the papermaking material passing through the slits S or the round holes S′ are reduced by the amount of the foreign substances accumulated in the concave portion 3 ′, so that the screening effect by the screen 1 can be improved.
According to the cylindrical screen of a first aspect of the invention, in the screen bars, the longitudinal slits are divided in the middle by the member having the width larger than the thickness of the ring in the direction transversely crossing the longitudinal direction of the screen bars, the mat adhering to the outer peripheral surface of the screen is easily peeled off, so that the screening effect by the screen can be improved.
Also, according to the cylindrical screen of a second aspect of the invention, in addition to the effect of the first aspect of the invention, the foreign substances which can not pass through the screen tend to be accumulated in the concave portion of the member, so that the foreign substances in the papermaking material passing through the slits are reduced by the amount of the foreign substances accumulated in the concave portion. Accordingly, the screening effect by the screen can be improved.
Further, according to the cylindrical screen of a third aspect of the invention, a plurality of slits is disposed with the intervals t therebetween in the vertical direction, and at the same time, the interval T larger than the interval t (T>t) is provided in the middle. Accordingly, the mat formed on the screen plate is divided, and it becomes easier to peel off the mat due to the division of the mat, so that the screening effect by the screen can be improved.
Also, according to the cylindrical screen of a fourth aspect of the invention, since a plurality of round holes is disposed with intervals t therebetween in a vertical direction and the interval T larger than the interval t (T>t) is provided in the middle, the mat formed on the screen plate is divided, and it becomes easier to peel off the mat due to the division of the mat, so that the screening effect by the screen can be improved.
Furthermore, according to the cylindrical screen of a fifth aspect of the invention, in addition to the effect of the third aspect or the fourth aspect of the invention, the portion of the outer peripheral surface of the screen plate at the interval T is formed into a concave portion S′ concaved inwardly, and the foreign substances which can not pass through the screen tend to be accumulated in the concave portion S′. Thus, the foreign substances in the papermaking material passing through the slits or the round holes are reduced by the amount of the foreign substances accumulated in the concave portion S′, so that the screening effect by the screen can be improved.
While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative and the invention is limited only by the appended claims.
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In a cylindrical screen, a screen body has a height greater than its diameter, and is formed of a plurality of portions spaced apart from each other in a direction of the height. Each portion has slits laterally and vertically spaced apart from each other. At least one annular member is situated between two of the plurality of the portions of the screen body to be located radially inside an outer surface of the screen. The annular member has an annular concave formed in a middle thereof extending toward an inner side of the screen from the outer surface of the screen, and a width extending in the direction of the height. The width is greater than a distance of the slits vertically spaced apart from each other. Accordingly, a mat formed on the screen can be easily peeled off.
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This invention relates generally to industrial heat treat furnaces and more particularly to a retractable, refractory roller furnace hearth for use in the furnace.
The invention is particularly applicable to batch type, positive pressure industrial heat treat furnaces subjected to heavy workpiece loads at elevated temperatures and will be described with particular reference thereto. However, the invention may have broader application and could, conceivably, be applied to other heat treat furnaces.
BACKGROUND
In typical batch type industrial heat treat furnaces operated at positive pressures, workpieces are loaded into a wire mesh work tray which is moved into the furnace chamber for the heat treat process and thence out of the furnace chamber into a quench chamber or a vestibule. When the tray is loaded, it is quite heavy, often in excess of 1,000 lbs and movement of the loaded tray into and out of the furnace chamber can become difficult. It is thus conventional to imbed rollers into the refractory floor or hearth in the furnace chamber and use a drive chain arrangement to automatically pull or push the loaded work tray into and out of the furnace chamber. Such arrangements are conventionally referred to as roller rail hearths.
Batch type heat treating furnaces operated at positive pressures are general, all purpose type furnaces which are designed so that a wide configuration of different parts can be heat treated in accordance with any number of different heat treat processes. Such furnaces fundamentally require an integral box type furnace chamber which is soundly insulated in contrast to other types of furnaces which may have certain structural provisions for treating particular part configurations or applicability for only certain type of heat treat processes.
No matter what heat treat process is employed but particularly for high temperature processes such as carburizing, it is important from an economic (as well as possibly from a process) point of view to heat the work to its heat treat temperature as quickly as possible. In this direction, efforts have been made to produce higher and higher furnace heating rates with, for example, gas burners so as to reduce the time it takes to raise the temperature of the work to its heat treat temperature. At present, it is not uncommon, for example in a batch type carburizing process, to supply heat to the furnace chamber from the radiant tubes which are at temperatures of between 1950° and 2050° F. When the conventional roller hearth is subjected to such temperatures, the thermal stress induced in the roller support arrangement coupled with the heavy work loads easily cause permanent distortion of the roller support. To avoid such distortion, the furnace manufacturers have been forced to reduce the capacity of the furnace as a way to insure that the overall stress level on the roller supports does not exceed the elastic limit of the material.
Movable hearths are known in the furnace art. Conventional rotary hearths use doughnut shaped refractory beds which rotate within a fixed housing as the work deposited thereon is sequentially heated in a predetermined manner as it passes through several fixed stations within the hearth. Another movable hearth arrangement is car bottom furnaces which are conventionally used in steel mill applications, for annealing and tempering. In such arrangements, a cart rolling on a rail is actually rolled under a bottomless furnace enclosure which is then sealed to the cart to form the furnace enclosure. Such arrangements typically use sand seals to establish the furnace enclosure between the car bottom and the furnace walls which, while perfectly acceptable in steel mill applications are not adequate for the repeated loadings encountered in batch type industrial heat treat furnace arrangements.
Nevertheless, within the literature, variations on the car bottom approach, using sand seals, can be found in the art such as in U.S. Pat. No. 1,946,270 to Breaker and U.S. Pat. No. 2,869,856 to Greene both of which use a hydraulic ram to lift a hearth into the open bottom of a furnace chamber in an industrial furnace application. In addition, once the hearth is lowered, all the furnace temperatures are released rendering such devices uneconomical. A further variation on the car bottom furnace may be found in U.S. Pat. No. 4,421,481 to Holz et al in which cars are rolled into an enclosure end to end for the stated purpose of forming a hearth. Holz is relevant to the present invention only in the sense that some form of a movable hearth is thus disclosed.
SUMMARY OF THE INVENTION
It is thus a principal object of the present invention to provide a high capacity roller hearth for use in an industrial heating furnace which retains its load bearing capacity despite the fact that the heat treat furnace is operated at elevated temperatures.
This object along with other features of the present invention is achieved in a conventionally constructed batch type heat treat furnace which has an insulated furnace chamber, a door into the furnace chamber for entry and exit of the work, conventional heating means within the furnace chamber providing heat to the atmosphere within the chamber, conventional fan circulating means within the chamber circulating furnace atmosphere within the chamber and means to supply a furnace atmosphere and a heat treat atmosphere to the furnace chamber. A conventional work tray which preferably is a wire mesh construction so that furnace atmosphere can flow not only through the sides but the bottom of the tray is loaded with ferrous or metal workpieces and drawn by a conventional mechanism into and out of the furnace chamber where the loaded work tray rests on a retractable, refractory hearth. The hearth comprises a refractory base having a bottom surface, a top surface and a closed peripheral edge surface extending between the bottom and the top surfaces. A tile support mechanism which extends from the top surface of the refractory base, when acutated, supports the work tray when the furnace chamber is heat treating the work. A roller rail mechanism also extending from the top surface of the refractory base and including a plurality of rollers, when actuated, supports the work tray to permit movement of the tray into and out of the furnace chamber in a rolling, anti-friction bearing manner similar to that of conventional roller hearths. A hearth lift mechanism effects relative movement between the roller rail mechanism and the tile mechanism while the refractory base is maintained entirely within the furnace chamber so that the roller rail mechanism or the tile mechanism is alternately actuated to remove any loading of the roller rail mechanism when the furnace chamber is initially heated at the excessive temperatures. In fact, only at the end and the beginning of the heat treat cycles is the roller rail mechanism subjected to any mechanical loading at elevated temperature thus allowing the capacity of the heat treat furnace to be maintained at the same load level irrespective of the operating temperatures of the furnace. Thus, the temperature of the furnace chamber can always be maintained at elevated temperatures, notwithstanding the transfer of work into and out of the furnace chamber while the roller hearth is subjected to only brief loading at the elevated but not necessarily the peak temperature so as to maintain a constant high capacity furnace load rating.
In accordance with another feature of the invention, a sealing mechanism between the refractory base and the furnace chamber is provided. The sealing mechanism is actuated only when the hearth lift mechanism actuates the tile support mechanism at which time the furnace chamber is effectively sealed into a first and second enclosure with the first enclosure including the work tray and the top surface of the refractory base while the second enclosure includes the bottom surface of the refractory base. Since the second enclosure is not as thoroughly insulated as the first enclosure, furnace atmosphere which otherwise would escape to the lower temperature enclosure and deposit carbon when a carburizing process heat treat process was being effected within the furnace is thus prevented thereby improving the efficiency of the heat treat process and minimizing the use of the carbon bearing gas, i.e. methane.
In accordance with another feature related to this seal a fibrous rope member is disposed within a groove formed about the peripheral edge surface of the refractory base such that the rope member extends outwardly beyond the edge surface. A similar second rope member is similarly disposed within a groove formed within the furnace chamber but axially spaced from the first rope member such that when the hearth lift mechanism actuates the tile support mechanism the first rope member contacts the second fibrous rope member to provide a seal while also permitting thermal expansion of the refractory base member within the furnace chamber without incurring any binding therebetween. A simple seal which can be subjected to repeated loadings without failure thus results.
In accordance with yet another aspect of the invention, the roller rail mechanism includes a first and second roller rail guide, each guide supporting a plurality of rollers in a line extending from one end to the opposite end of the refractory base. A plurality of stationary post assemblies equally positioned along each roller guide are provided with one end of each post assembly secured to the guide and the opposite end of each post assembly secured to a fixed structural point within the furnace chamber such that each post assembly extends through the refractory base from the top surface to the bottom surface. A seal arrangement is provided between the stationary posts and the refractory base to prevent furnace atmosphere from escaping through the refractory base while there are also provided guides with each post assembly to maintain the centered attitude of the refractory base within the furnace enclosure while securely supporting the roller rail member against deformation at several points along the length thereof.
In accordance with another aspect of the invention, the refractory base member is lifted within the furnace chamber by at least one post member secured at one end to a structural member in turn secured to the bottom side of refractory base member and at its other end to a lift mechanism located outside of the furnace chamber with each post sealed in a stuffing box arrangement so that leakage of air into the enclosure does not occur as the post moves relative to the furnace chamber. The seal arrangement also functions as a guide for each post and preferably four spaced posts are utilized to insure a straight line axial lift motion of the refractory base member within the furnace enclosure. The guides on the lift posts in combination with the guide on the rail support posts insure the centered relationship of the hearth thus permitting the fibrous seal members to effectively seal the chamber into the first and second furnace enclosures as defined above.
In accordance with yet another feature of the invention the tile support mechanism includes at least a first and second plurality of ceramic tiles extending from the top surface of the refractory base a fixed distance therefrom such that when the tile support mechanism is actuated by the hearth lift mechanism, the tiles extend beyond the rollers for supporting the work tray. The first and second pluralities of tiles are arranged generally parallel to the roller rail guide with spaces provided therebetween for circulation of the atmosphere through the underside of the work tray to assure more efficient cooling of the workpieces therein. Additionally, a plurality of "H" shaped ceramic tile pieces are placed end to end to extend from one end to the other end of the refractory base member with one base of each "H" shaped tile embedded within the top surface of the refractory base to define an upstanding U-shaped member. The legs of the U-shaped member extend from the top surface of the refractory base a distance equal to that which the first and second pluralities of tiles extend. Contained within the bight portion of the "U" is the chain drive mechanism which conveys the work tray into and out of the furnace chamber. The U-shaped tiles in combination with the first and second plurality of tiles defines a totally ceramic, refractory, multi-point stable support for the work tray when the work is heated which permits circulation of the furnace atmosphere to the bottom of the work tray as well as the sides and the top thus efficiently heating and heat treating the workpieces within the work tray.
It is thus another object of the present invention to provide a retractable roller hearth which enhances the heat treat processes carried on by the heat treat furnace within which the hearth is disposed.
It is yet another object of the invention to provide an extremely stable retractable hearth for use in an industrial heat treat furnace which permits a simple seal to be used despite the distortion of the hearth and the axial movement thereof.
It is yet another object of the invention to provide a retractable furnace hearth which permits the flow of furnace atmosphere gases about the workpieces contained within the furnace chamber.
It is another object of the invention to provide a retractable roller hearth which has an insignificant down time for maintenance.
It is another object of the invention to provide a hearth which conserves the heat treat gases otherwise required to heat treat on a workpiece.
Yet another object of the invention is to provide a retractable roller hearth which can be used in furnaces which employ a high, initial preheat temperature.
Still another object of the invention is to provide a simple, inexpensive retractable furnace hearth.
DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which form a part hereof and wherein:
FIG. 1 is a general side view of an industrial heat treat furnace with the furnace casing broken away in the furnace chamber to show the retractable roller hearth of the present invention;
FIG. 2 is a top plan view of the retractable roller hearth;
FIG. 3 is a section split view of the hearth taken along lines 3--3 of FIG. 2 showing the hearth in a raised and lowered position;
FIG. 3a is an enlarged detail of the stuffing box shown in FIG. 3; and
FIG. 4 is a graph illustrating the effects of furnace temperature on an alloy roller hearth.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only and not for the purpose of limiting the same, FIG. 1 shows a conventional, multi-chambered, batch type industrial heat treat furnace 10. Furnace 10 includes the vestibule or charging chamber section 12, a furnace section 13 located behind vestibule 12, a quench tank 15 located beneath vestibule section 12 and a top cool section 16 located above vestibule section 12. A conventional elevator schematically illustrated at 18 is provided for moving the work vertically from the vestibule section 12 into quench tank 15, or if the heat treat processor calls for gas cooling, top cool section 16 is activated for cooling the work in a conventional manner. A sealed vestibule door 19 is provided for placing work into vestibule section or removing work therefrom and a conventional hydraulic cylinder actuated sealed furnace door 20 is provided for moving work from vestibule section 12 to furnace section 13 and visa versa. The work which typically comprises various piece parts are stacked in a work tray shown by phantom line 22 in FIG. 1. Work tray 22 is essentially a box of a wire mesh type construction so that the furnace atmosphere can be circulated completely about the entire surface of the workpieces within work tray 22. Work tray 22 is rigidized at its bottom (not shown) for engagement with a tray handler head (drawn in phantom) 24 of a chain drive mechanism which is also conventional in the art and not further described in detail herein. Work tray 22 rests on rollers 25 supported on a track which extends into vestibule and furnace sections 12, 13 so that work tray 22 can be rolled in an anti-friction bearing manner from vestibule section 12 to furnace section 13 and from furnace section 13 to vestibule section 12. Movement of work tray 22 from and to the various furnace sections is accomplished automatically after work tray 22 is placed in vestibule section 12 in accordance with the requirements of whatever the heat treat process calls for by means of chain drive mechanism and the automatic engagement and disengagement of tray handler head 24. Other conventional push-pull arrangements can be used in place of the chain drive mechanism illustrated.
Furnace section 13 essentially comprises a sealed, refractory enclosed furnace chamber 30. Generally speaking and is well known in the furnace art, structural members tied to a structural framework as shown at 31 support refractory sections such as indicated at 32 which are covered by a furnace skin 34 to define furnace chamber 30. Refractory sections 32, depending on the furnace construction and use can be cast refractories, ceramic, fire brick or a fibrous or felt type insulation secured to furnace skin 34 by being impaled on pin and washer arrangements. Extending into the furnace is a conventional axial bladed furnace fan 36 for circulation the furnace atmosphere within furnace chamber 30 throughout work tray 22 in a conventional manner. Also extending into furnace chamber 30 is a gas generator 37 which generates gases, either atmosphere, carrier or heat treat processing atmospheres all in a conventional manner and not further described in detail herein. Gas generator 37, however, is not essential to the workings of the present invention and could be replaced by a gas tube or tubes controlled by a microprocessor which function to emit furnace processing gases within furnace chamber 30 in a conventional manner. Also disposed within furnace chamber 30 is a conventional radiant tube 38 for supplying heat to furnace chamber 30 in a conventional manner. As is well known in the furnace art, the heat treat or furnace atmosphere must be carefully controlled and if electrical resistance heating elements are the source of heat for a positive pressure furnace of the type disclosed, the electric resistance heating elements are disposed within radiant tubes 38 to prevent corrosive attack or other degradation of the elements by the atmosphere. Preferably, however, gas fired burners 39 are desired as the source of heat for the positive pressure furnaces of the type illustrated herein both from an economic and output consideration basis. Radiant tubes 38 are necessary to separate or contain the products of combustion emanating from gas fired burners 39 from co-mingling with the furnace atmosphere in furnace chamber 30 (although various schemes have been employed in the past to permit highly efficient gas fired burners 39 to fire the products of combustion directly into furnace chamber 30 with appropriate sensors and microprocessors used to add the necessary heat treat gas elements to furnace chamber 30). The products of combustion from gas fired burners 39 exit radiant tubes 38 through an exhaust outlet (not shown) to a stack which may or may not include a heat exchanger to recover sensible heat generated in the process which may be used to preheat the combustion air for gas fired burners 39 or for other conventional purposes known in the art (not shown). Developments in gas fired burners in recent years have increased the heat output of such burners and this invention is specifically contemplated to be used with such high output burners. Today, such burners are capable of heating radiant tubes 38 to temperatures of 2100°-2200° F. and perhaps higher with ceramic tubes. From a heat treat processing time consideration, it is desirable to heat cold work to its heat treat temperature as quickly as possible. Thus it is desired that the radiant tubes be at a substantially higher temperature initially than that required by the heat treat cycle so that the work can be raised to the heat treat temperature as quickly as possible. When the work reaches its heat process temperature, appropriate burner controls (not shown) are then provided to cut back the firing rate of burners 39 to reduce the radiant tube temperature to the heat treat temperature whereat the heat treat cycle will take place. This is usually accomplished by simply locating thermocouples within the furnace or workpieces or by the use of optical temperature recording devices. This initial high heat scheme described is conventional and has been used with success in the reheating of slabs and billets by direct firing of gas burners in the steel mill furnace area. Heretofore, such initial high heat scheme has not been practiced in batch type industrial heat treat furnaces, or at least to the extent practiced herein at the temperatures noted, because of structural limitations of the furnace.
At the bottom of furnace chamber 30 is a retractable roller hearth 40. Referring now to FIGS. 1, 2 and 3, retractable roller hearth 40 includes an essentially solid one piece refractory base 43 which as best shown in FIG. 2 is rectangular in configuration and conform to the outline of furnace chamber 30. Refractory base 43 has a top surface 44, a bottom surface 45 and a peripherally extending edge surface 46. Structural angle members 48 positioned at the intersection bottom and edge surfaces 45, 46 box in and rigidize refractory base 43. Extending along a first longitudinal axis 50 (FIG. 2) are four equally spaced rail support post openings 51 extending from top surface 44 through bottom surface 45 of refractory base 43. Similarly extending along second longitudinal axis 52 are four similarly positioned rail support post openings 51. A rail support post arrangement 54 extends through each rail support post opening 51. As best shown in FIGS. 1 and 3, each rail spport post arrangement 44 includes an upper tubular member 55 with one end extending above top surface 44 and abutting against, at its opposite end, with a lower tubular member 56, which extends through bottom surface 45 of refractory base 43. The outside diameters of tubular members 55, 56 are equal with upper tubular member 55 having a significantly thicker wall section than lower tubular member 56. Attached to the exposed end of upper tubular member 55 is a laterally extending U-shaped roller rail guide 58. The upstanding legs of roller rail guide 58 cradle roller rail supports 59 which are parallel to first and second longitudinal axis 50, 52 as shown in FIGS. 2 and 3 and are arcuately configured at space locations to rotably support the trunnions 60 of rollers 25 positioned at equal increments along the length of roller rail supports 59. Placed underneath and generally about roller rail guide 58 and on top of top surface 44 of refractory base 43 is a one inch, eight pound ceramic blanket 61 which seals upper tubular member 55 within rail support post opening 51 preventing the flow of furnace atmosphere through rail support post opening 51. The bottom end of lower tubular member 56 is securely bolted as at 62 to an inverted, laterally extending channel member 63 (FIG. 1) which extends beyond refractory base 43 and is tied to structural framework 31 (not shown) of furnace section 13. The legs of inverted channel members 63 rests on the bottom furnace casing portion 64 of furnace skin 34 and in turn is supported by structural framework 31. Each channel member 36 supports two rail support post arrangements 54, there being four channel member 63 shown. At bottom surface 45 of refractory base 43, each rail support post opening 51 is enlarged to receive a metal ring shaped post guide member 66 which is pressed into rail support post opening 51 from bottom surface 45 of refractory base 43. When refractory base 43 is raised or lowered within furnace chamber 30, post guide member 66 insures that refractory base 43 moves only in a vertical direction and does not tilt or cock or assume any horizontal motion and this selfaligning feature will be important for reasons which will hereafter be explained. Furthermore, any tendency of rail support post arrangement 54 to cock within rail support post opening 51 will not result in a wear or an abrasion of refraction base 43. Satisfactory alignment results have been obtained using a 4 inch OD rail support post arrangement 54 within a 41/4 inch I.D. post guide member 66.
Referring still again to FIGS. 2 and 3, laterally disposed on the outside of roller rail supports 59 is a support ceramic tile 70, there being six such tiles illustrated, with each support tile 70 having a length of about 131/2 inches, a height of about 9 inches and a width of about 3 inches. As shown in FIG. 3, support tiles 7 extend above rollers 60 when refractory roller hearth 40 is raised and dropped below rollers 60 when refractory roller hearth 40 is lowered. Support tiles 70 are fitted loosely into recesses 71 formed in top surface 44 of refractory base 43 and the looseness of the fit between support tiles 7 and recesses 71 is taken up by Kaowool paper 72 packed therebetween thus permitting some attitudinal alignment of support tiles 70 when supporting the weight of work tray 22 without it causing an abrasion between support tiles 70 and refractory base 43. As best shown in FIG. 2, support ceramic tiles 70 are spaced from one another to permit the flow of furnace atmosphere therebetween from top surface 44 of refractory base 43 through the bottom of work tray 22.
Referring now to FIG. 3, positioned at the middle and extending from top surface 44 of refractory base 43 are a plurality of H-shaped guide support tiles 74 which are placed end to end to longitudinally extend in a continuous manner from one end to the other end of refractory base 43. (As used herein end to end means the longitudinal direction of roller support hearth 40 while side to side means the lateral direction of the hearth.) Each H-shaped tile is maintained in its position on top surface 44 of refractory base 43 by outside tiles 76 engaging the outside surfaces of the legs of the H-tiles 75 and are wedged into longitudinally extending recesses 77 formed within top surface 44. H-shaped tiles 75 have an upper bight portion 79 which forms a longitudinally extending channel from one end to the other end of refractory base 43 which guides tray handler head 24 and the chain when work tray 22 is moved into and out of furnace chamber 30. Thus when refractory base 43 is in its raised position, work tray 22 is supported along four longitudinally extending support lines defined by the two outer rows of support ceramic tiles 70 and the two upstanding legs of H tiles 75. As noted, tiles 70, 75 assume some relative movement with respect to top surface 44 to adjust to the loading of work tray 22 while still maintaining an even load transmitted to refractory base 43 of retractable roller hearth 40. Movement between raised and lowered positions of retractable roller hearth 40 is approximately 3 inches.
The lifting mechanism for retractable roller hearth 40 includes a scissors mechanism 80 which support four lift posts 82. While any mechanism could in theory be used to raise or lower lift posts 82, the scissors mechanism 80 is particularly advantageous in that because of the mechanical advantage obtained a smaller actuator need be employed to lift the posts than that which is otherwise required and, importantly, all lift posts 82 are uniformly raised or lowered the same discrete distance. However, other lift mechanisms can be employed. Each lift post 82 extends through bottom furnace casing section 64 and is secured at its end to a laterally extending structural box shaped member 65 in turn secured to opposite angle members 48 on bottom surface 45 of refractory base 43, there being two laterally extending box members 65 with each box member 65 supporting two lift posts 82. Angle members 48 in combination with box members 65 provide a rigid framework for refractory base 43 while the four lift posts 82 assure smooth raising and lowering of refractory base 43. An adjusting nut 85 between each lift post 82 and a tubular receiving housing 86 on scissors mechanism 80 provides the necessary adjustments to assure alignment of each lift post 82 with one another relative to refractory base 43. In addition, because each tubular housing 86 receives a bottom end 87 of lift post 82, there is established one guide on the scissors mechanism 80 which insures straight line motion of each list post 82.
A stuffing box arrangement 88 is used to provide a seal between furnace chamber 30 and lift posts 82 and is best shown in FIG. 3 and 3a to comprise a first guide plate 90 which is bolted in a sealed (Permatex) manner as shown at 91 to bottom furnace casing 64. First guide plate 90 includes an annular boss section 93 slightly greater in diameter than that of lift post 82. A second guide plate 94 has a tubular section 95 equal to that of boss section 93 and a flat annular base section 96 extending from tubular section 95. First and second guide plates 90, 94 are orientated so that tubular section 95 of second guide plate 94 faces boss section 93 of first guide plate 90 with a packing such as Fibrefax 98 compressed therebetween thus effecting a seal between first and second guide plates 90, 94 and lift post 82. A collar member 100 having a tubular section 101 fitting over boss section 93 of first guide plate 90 and a portion of tubular section 95 of second guide plate 94 has an annular flange section 102. Annular flange section 102, first guide plate 90 and base section 96 are secured together as shown by bolts 104 threaded into blind holes in first guide plate 90. Stuffing box arrangement 88 thus functions not only to seal furnace chamber 30 despite the motionof lifting post 82 into and out of furnace chamber 30, but the arrangement provides a guide which in combination with the guide established by tubular receiving housing 86 establishes two guide points to insure that the posts are moved in a vertically straight up and down motion thus insuring that refractory base 43 does not cock or tilt as retractable roller hearth 40 is raised or lowered.
Additionally, the fact that there are four separate lift posts 82, with each post aligned by two guides as noted, operated by a common scissor jack mechanism 80 and in combination with the aligning features of rail support post arrangement 54 results in a very accurately positioned retractable roller hearth. Specifically, the distance or spacing 112 between peripheral edge surface 46 of refractory base 43 and the similarly configured lower furnace refractory portion 105 of furnace chamber 30 surrounding peripheral edge surface 46 can be controlled to about 1/4" (one-fourth inch) without binding which, considering the weight of refractory base 43 and the thermal expansion of the refractory, is significant in the furnace art.
The alignment features of retractable roller hearth 40 permit a highly efficient, but simple sealing mechanism to be employed to divide furnace chamber into an upper furnace enclosure 107 and a lower furnace enclosure 108 when retractable roller hearth 46 is in the raised position. The sealing mechanism includes a continuous annular hearth groove 110 formed in peripheral edge surface 46 which circumscribes refractory base member 43. Packed within groove 110 (which is preferably square shaped) is a fibrous, rope seal 111 which extends into the space 112 between peripheral edge surface 46 and lower furnace refractory portion 105. Seal 111 in practice is a 11/2" square fibrous, ceramic rope such as that marketed as "Fibrefax". A similar annular refractory groove 114 is provided in lower furnace refractory portion 105 but spaced upwardly from annular hearth groove 110 a distance approximately equal to the hearth travel (i.e. about 3") and an identical chamber rope seal 115 is packed in refractory groove 114. The space or distance 112 is approximately 3/4" and each rope seal 111, 115 extends from opposite sides into space 112 about 1/2". When refractory base 43 is raised hearth rope seal 111 contacts refractory rope seal 115 to seal upper furnace enclosure 107 from lower furnace enclosure 108. Despite the fact that bottom furnace casing section 64 is sealed by a fibrous, blanket insulation (as shown by reference numeral 120), lower furnace enclosure 108 is at a lower temperature than upper furnace enclosure 107. When certain heat treat processes are carried out in furnace 10, notably carburizing, the lower temperature in lower furnace enclosure 108 will cause carbon to precipitate or be deposited thus reducing the efficiency of the process and resulting in unnecessary down time for furnace cleaning. By using the sealing arrangement disclosed, all the carbon potential of the furnace processing gases is deposited on the workpieces within work tray 22 resulting in a more efficient heat treat process from a gas consumption viewpoint as well as potentially faster processing times. As noted this is made possible by the built-in alignment features of the hearth which permits a simple rope seal to seal the entire peripheral edge surface of retractable, roller hearth 40 despite the lifting, the mass of the hearth and the work, and the thermal expansion or distortion which the hearth and furnace chamber 30 are exposed to.
The primary aspect of the invention can be appreciated by reference to FIG. 4. Multi-chambered industrial heat treat furnaces are principally designed as such so that the temperature of furnace chamber 30 is maintained at an elevated state during the charging and discharging stages although some temperature drop must occur. A normal heat treat cycle is generally about four hours in duration. If the conventional roller hearth must support the load during the entire cycle, the thermal stress over the four hour cycles shortens the life of the roller rails as shown by the dotted line. Thus to maintain the hearth life, the loading of the hearth (and thus the capacity of the furnace) was reduced. In accordance with the present invention the rollers are only loaded for about 1% of the heat treat cycle and only during the discharge or charging stages before the initial, high temperature heating stage of the cycle is actuated. During that high heating stage, i.e. in excess of 2,000° F., rollers 25 are not under load and the thermal stress induced by the high temperatures does not exceed the elastic limit. When the rollers are actuated, the furnace temperature may be at its lower value where higher work tray stresses can be tolerated and the loading time is short to obviate any adverse effects of fatigue or creep.
The invention has been described with reference to a preferred embodiment. Obviously, modifications and alterations will occur to those skilled in the art. For example, it is possible to keep the hearth stationary and move the rail posts by the scissors mechanism. While such a modification could obviate the seal mechanism of the hearth, it is not the preferred arrangement because the hearth would have to support the work tray below the track elevation line and there are occasions where the tray can be skewed within the furnace chamber or not pulled entirely within the chamber and in such instance "hang up". This cannot occur in the preferred embodiment. Yet another modification would be to provide deeper pockets within refractory base 43 for the rail support arrangement 54 to be withdrawn in and to provide such pockets with a cooling arrangement so that the rollers 60, etc. would not be even exposed to any of the initial high heat temperatures of furnace 10. This could be accomplished by extending support tiles 70 in a solid line and using a work tray 22 with a solid bottom. The support tiles 70 and H tile 75 and tray 22 would provide a passage for circulating a cooling fluid therein which would be thermocoupled controlled to prevent the temperature from rising beyond a fixed point, say 1850° F. However, this modification, while contemplated, does not form part of the preferred embodiment because, as demonstrated in FIG. 4, the thermal stress does not, within current initial, high heat schemes exceed the elastic limit of the alloy rollers. Furthermore, the contemplated modifications could adversely affect the processing time because furnace atmosphere cannot circulate beneath the work tray through the work, although conceivably other arrangement could be employed to overcome this disadvantage. It is my intention to include all such modifications and alterations insofar as they come within the scope of my invention.
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A retractable, roller hearth for use in an industrial heat treat furnace is disclosed whereby the alloy rollers are retracted from their load bearing position when the furnace heat treat processes are underway thus maintaining the rated load capacity of the furnace. A plurality of guided rail support posts and guided, sealed lift posts accurately assure straight line vertical motion of the refractory base enabling contact between fibrous rope seals to seal the hearth from the cooler, lower portions of the furnace when the hearth is in a raised position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a beneficiation process for upgrading mined oil shale prior to retorting for recovery of the oil.
2. Description of the Prior Art
Large deposits of oil shale are found in many locations throughout the world, and extensive efforts have been undertaken to develop oil shale as a source of hydrocarbon products. The term "oil shale" is widely used to refer to a layered sedimentary formation containing an organic material known as kerogen which may be decomposed by heating to produce gaseous and liquid hydrocarbon products. Such processing of the oil shale may be conducted in place in the deposit (in situ) or the oil shale may be mined by conventional mining methods and the oil shale ore processed by retorting on the surface. In such retorting, particles of mined oil shale are heated over a period of time to an appropriate temperature of yield gaseous and liquid hydrocarbon fractions. Two examples of such retorts and retorting processes are those described in U.S. Pat. Nos. 3,821,353, and 4,133,741 granted to Weichman and Knight et al. respectively.
Because of the high temperatures required in known retorts and retorting processes for obtaining hydrocarbon values from oil shale, and the resultant need for large amounts of energy to provide such heat, it is desirable to retort as little oil shale as possible to obtain each gallon of oil. To accomplish a reduction in the amount of heat required to retort oil shale, others have developed processes for the beneficiation of oil shale.
Such a process is described in U.S. Pat. No. 4,257,878 which was granted to Fishback et al. in which oil shale is beneficiated by increasing the oil content of the clay-bearing oil shale ore by subjecting the oil shale ore to an aqueous medium, agitating to disintegrate at least a portion of the clay, and separating the disintegrated clay from the remaining oil shale to yield an oil shale having a greater amount of recoverable hydrocarbon values per ton than the unprocessed oil shale ore.
Moudgil et al. disclosed in U.S. Pat. No. 4,169,045 a method for the separation of shale from run of mine (ROM) shale containing particles of shale and refuse, which comprised conditioning the ROM shale with a coupling agent capable of selectively coating the kerogen hydrocarbons in the particulate shale to the substantial exclusion of coating the non-hydrocarbonaceous refuse, which coupling agent was at least one carbolic acid, preferably containing from about five to about twenty-eight carbon atoms and a ketone. Combined with the coupling agent was a fluorescent dye in a quantity sufficient to make the coated particles of shale fluoresce upon excitation to a degree sufficient to distinguish the coated shale particles from the substantially non-coated refuse.
Fahlstrom teaches a method for treating shales in U.S. Pat. No. 4,176,042. Here, kerogen-containing shale is crushed and comminuted to a fineness sufficient to free kerogen and any sulphides present in said shale. To enable the shale to be finely-divided more readily, the crushed shale is subjected to a leaching treatment prior to final comminution thereof. Fahlstrom also taught the use of a density-separation process where a non-polar, water immiscible liquid was used. This liquid had a density of from about 1.3-1.5.
Rosar et al. via U.S. Pat. No. 3,973,734 disclosed a froth flotation method for separation of sodium compounds, principally nahcolite, dawsonite, trona, related authigenic sodium ores, and corresponding sodium compounds including sodium carbonate and sodium bicarbonate, from kerogen-type organics-containing rock, by use of sodium carbonate and/or sodium bicarbonate-containing brines having a basic pH ranging above about 7.0, preferably about 8.0-12.0, and recovering a sodium compound-rich fraction as a non-float portion and an organics-rich fraction as a float portion. Frothers, froth control agents and collection agents may be used separately or in combination. Single or multiple-stage flotation, with cleaning, conditioning, scavenging, reflotation, and combining of products might also be used. Feed ore end products may be screened to abrate the head or product assay. By this method, raw or retorted oil shale may be separated from sodium minerals and compounds obtained therein.
B. M. Moudgil and N. Arbiter have given a comprehensive overview regarding oil shale beneficiation in their article entitled "Oil Shale Beneficiation for Above Ground Retorting." This article appeared in Mining Engineering at pages 1336-38 (Sept. 1982).
Applicant in the present invention has determined that oil shale can be enriched and the amount of shale oil recovered can be optimized by controlling the size of the particles for retorting purposes.
Utilizing Applicant's invention results in lower raw oil shale processing costs and lower costs in retorting the oil shale. These lower costs result from energy savings during the processing and retorting of raw oil shale.
SUMMARY OF THE INVENTION
This invention is directed to a method for crushing and pulverizing raw oil shale to a small particle size including relatively smaller, oil lean particles and larger, oil rich particles; subsequently floating said larger particles in a non-polar liquid having a specific gravity which causes the oil rich particles to float and the oil lean particles to sink; and thereafter separately recovering the floating particles and the submerged particles from said liquid.
An embodiment of this invention is directed to a method for enriching raw oil shale or other similar oil containing materials by crushing and pulverizing raw oil shale into a small particle size including relatively smaller, oil lean particles of about 1/16 inch (0.16 cm) or less in diameter and larger, oil rich particles of about 3/8 inch (1.0 cm) or less in diameter; floating the rich oil particles of about 3/8 inch (1.0 cm) or less in diameter in a non-polar liquid having a specific gravity which causes the oil rich particles to float and the oil lean particles to sink; and separately recovering the floating particles and the submerged particles from said liquid.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A shows graphically the relationship between the specific gravity of the crushed shale and the particle size of the Colorado Green River shale.
FIG. 1B graphically depicts the relationship between the total organic carbon (wt. %) of the shale and the particle size of the Colorado Green River shale.
FIG. 1C represents graphically the relationship between the calculated oil yield in gallons per ton ("GPT") and the particle size of the Colorado Green River shale.
FIG. 2A shows graphically the variations between the specific gravity of Kentucky Sunbury shale and the particle size of the shale.
FIG. 2B is a graphic representation depicting the variation between the calculated oil yield ("GPT") of Kentucky Sunbury shale and the particle size of the shale.
FIG. 3 illustrates graphically the relationship between oil yield and particle size of Colorado Green River shale based upon data obtained from two series of tests, (A) and (B).
FIG. 4A shows graphically the cumulative weight percent of float products from heavy media separation tests as a function of initial shale grade.
FIG. 4B depicts graphically the cumulative oil yield of float products from heavy media separation tests as a function of initial shale grade.
FIG. 5 is a schematic representation of the preferred embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 5, raw shale of approximately 3 to 6 inches (7.6-15.2 cm) is introduced into the crusher (12) via line (10). Crushers which can be used in the process of this invention include ones described by Fisher in U.S. Pat. No. 2,587,609 and by Blythe described in U.S. Pat. No. 3,614,000. Both of these patents are hereby incorporated by reference in their entireties. After leaving the crusher (12), the shale is fed onto a screen (16) which sizes and grades the shale. Small, lean shale particles which are of a size less than about 1/16 inch (0.16 cm) are discarded via line (20). Shale which is larger than about 3/8 inch (1.0 cm) is removed from the screen (16) and transported via line (18) into the crusher (12) for further crushing and pulverizing. Larger shale particles which are of a size of about 3/8 inch to about 1/16 inch (1.0 cm-0.16 cm) are removed from the screen (16) and led by line (22) into the heavy media separator (24). This separator contains halogenated hydrocarbons having a specific gravity range of from about 1.6 to about 2.3, preferably about 2.0-2.1. Chlorinated and brominated hydrocarbons are preferred. The shale which floats on the heavy media liquid is removed from the heavy media separator (24) via line (26) to a rinser and dryer (28). Afterwards, the shale which is of a particle size of about 3/8 inch to about 1/16 inch (1.0 to 0.16 cm) is removed from the rinser and dryer (28) by line (32) and fed into an oil shale retort (34). A retort which can be used for this purpose is described in U.S. Pat. No. 3,960,702 which was issued to V. D. Allred and is hereby incorporated by reference in its entirety. The heavier lean particles which sank to the bottom of the heavy media separator (24) are removed therefrom via line (30) and discarded.
In an another embodiment of this invention, the small fines which are less than about 1/16 inch (1.0 cm) which have been obtained from line (20) as well as the heavier lean particles from line (30) may be pelletized and fed into the retort for the further reclamation of kerogen containing products.
In yet another embodiment of this invention the lean particles or small fines which are about 1/16 inch (1.0 cm) or less can be fed into a pulverizer then to a froth floatation process as described in U.S. Pat. No. 4,176,042 to Falstrom et al. for further reclamation of useful materials therefrom. The Falstrom et al. patent is hereby incorporated by reference in its entirety.
To demonstrate the beneficial results obtainable by this process, Colorado and Kentucky oil shales were initially crushed into a size of about 3 to 6 inches or 7.62 to 15.24 cm. Afterwards the shales were crushed in a Holmes crusher (Holmes model 201, size 7×6), followed by grinding in a Holmes pulverizer (Holmes model 500). The openings of the screen plates used in the Holmes crusher were about 3/8 inch or about 1.0 centimeters. Openings of the screen plates used in the pulverizer were 0.63 inches or about 0.16 centimeters. After crushing and grinding, the two shales were sieved into six size fractions each and tested for total organic carbon (TOC) and specific gravity (SG). These values were then plotted in FIGS. 1 and 2 along with calculated oil yields versus the size of the sieve openings.
FIGS. 1 and 2 show that with decreasing shale particle size, there is an increase in the specific gravity of the shale, but a decrease in the total organic carbon and oil content of the shale. The greater specific gravity in the smaller sized particles is due to the lower organic carbon content of the small size fractions. In the case of Colorado Green River shale with initial oil yield somewhere around 20 gallons per ton ("GPT"), FIG. 1C indicates that after crushing, pulverizing and grinding, the shale has been separated into relatively enriched larger size fractions and relatively depleted smaller size fractions. Kentucky Sunbury shale, whose initial grade is around 14 GPT, (FIG. 2B), after crushing, was separated into leaner, smaller size fractions and richer, larger size fractions.
Such a preferential grade separation with varying particle sizes can be attributed to the difference in the mechanical properties between organic and mineral particles. Organics have been known to be somewhat resilient. When crushed, organics probably tend to bend and deform but remain somewhat unsusceptible to breaking. Inorganics are comparatively more brittle and therefore, easier to break in all directions. As a result, when oil shales are crushed, more minerals wind up in the fine fractions which leave the coarse, large fractions relatively rich in organics.
Knowing that the efficiency of beneficiation by heavy media separation or the "sink-float" method increases with the grade of input shale, it is obviously advantageous to send shale of higher grade through the beneficiation circuit. Since there is a preferential grading of oil shales by size during crushing operations, lean shales can be upgraded by strategic crushing and screening to yield a higher grade fraction. The combination of these two steps indicate that a two-stage beneficiation process is advantageous. First the mine-run shales are separated by crushing and screening (size reduction) into a rich coarse fraction and a lean fine fraction. Then the rich coarse fraction is further upgraded by heavy media (sink-float) separation.
Of course, at some point it will become impossible to increase oil yield with increased particle size. At some point this rising trend will drop first and eventually flatten out at above certain particle size. It can be visualized that when shale particles become larger than the maximum dimensions of organics, the resilient property of organics in keeping them from entering fine fractions no longer plays an important and effective role. This implies that, the oil yield of a 3" sized shale might not be much different from that of a 1" sized shale from the same source. To demonstrate this point, data obtained from a different set of experiments can be used. Each of four batches of oil shale samples were screened into four size fractions, 11/2"×1", 1"×3/4", 3/4"×1/4" and 1/4"×28 mesh. Each size fraction was then analyzed for its oil yield in terms of its Fisher Assay. FIGS. 3A and B are plots of all these four sets of data. This data varied randomly and no clear trend was demonstrated. However, compared to the rather steep trend observed for the smaller particle size region in FIG. 3A, it is reasonable to conclude that the data over the larger sized region has an overall flatter appearance. Since the samples did not come from the same batch as these samples used in the first experiment, nor had they been prepared in the same manner, these two sets of data may not be compared directly on an absolute base. However, the trends are of significance here. FIG. 3B shows that the trend of the second data set is not inconsistent with our earlier prediction, that is, the rising trend of increasing oil content with increasing particle size would drop and flatten out. In other words, the organic enrichment becomes effective only when the shale particles are down to certain size range, probably somewhere below about 3/8-1/16 inch (1.0-0.16 cm).
The efficiency of oil shale beneficiation is related to the grade of input shale. This is evident when the test results of heavy media separation of oil shales of different grades are examined. The separating media (or heavy liquids) are preferably solvents of halogenated hydrocarbons that are combined to provide the desired specific gravity. The oil shale samples are immersed first in a bath of lower specific gravity to generate a float product and a sink product. This light bath has a specific gravity of about 1.6 to about 1.8 and is comprised of mixtures of halogenated hydrocarbons which include exemplary mixtures of carbon tetrabromide, carbon tetrachloride, and acetylene tetrabromide. The sink product is then immersed into the next heavier liquid bath to generate float and sink products. After rinsing and drying each float product, it is analyzed for its oil yield via a Fisher assay. FIG. 4A shows the relationship between shale grade in gallons per ton and the cumulative percent of float for each of the increasingly heavy media used. FIG. 4B depicts the relationship between shale grade and the cumulative oil yield of float. The trends seen in these two figures indicate that the higher the shale grade, the higher is the proportion of shale that floats or the higher is the cumulative oil yield of float. In other words, the efficiency of heavy media separation in upgrading oil shale increases with the initial shale grade. This is understandable since the richer is the shale grade the greater are the organic content and buoyancy. The slopes of the lines are greatest for those sink-float tests done at specific gravity of about 2.0 and 2.1. The largest increase in the efficiency of heavy media separation with increasing shale grade is manifested when a heavy media with specific gravity of about 2.0 or 2.1 is used.
From these test results it is shown that selecting an oil shale particle size of from about 1/16-3/8 inch (0.16-1.0 cm) minimizes the amount of energy required to obtain the optimum amount of oil from a given amount of oil shale without retorting unnecessarily the mineral portion of the oil shale.
Obviously, many other variations and modifications of the invention, as previously set forth, may be made without departing from the spirit and scope of this invention, as those skilled in the art will readily understand. Such variations and modifications are considered to be within the purview and scope of the appended claims.
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This invention discloses a method of enriching raw oil shale by crushing and pulverizing raw oil shale or similar oil bearing materials into smaller, lean oil particles and larger, oil rich particles; floating the larger, oil rich particles in a heavy media organic liquid which causes the oil rich lighter particles to float on the surface and causes the heavier, mineral containing particles to sink. The floating larger, oil rich particles thus obtained contain increased percentages of oil bearing constituents.
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TECHNICAL FIELD
[0001] The following description relates to a method of transceiving a contact verification signal in a wireless communication system.
BACKGROUND ART
[0002] A standard for a wireless local area network (WLAN) technology has been developed as IEEE (Institute of Electrical and Electronics Engineers) 802.11 standard. IEEE 802.11a or IEEE 802.11b uses an unlicensed band in 2.4 GHz or 5 GHz, IEEE 802.11b provides transmission speed of 11 Mbps and IEEE 802.11a provides transmission speed of 54 Mbps. IEEE 802.11g provides transmission speed of 54 Mbps in a manner of applying Orthogonal Frequency Division Multiplexing (OFDM) in 2.4 GHz. IEEE 802.11n provides transmission speed of 300 Mbps for 4 spatial streams in a manner of applying Multiple Input Multiple Output-OFDM (MIMO-OFDM). IEEE802.11n supports a channel bandwidth up to 40 MHz. In this case, IEEE802.11n provides transmission speed of 600 Mbps.
[0003] IEEE 802.11af standard is a standard set to regulate an operation of an unlicensed device in a TV whitespace (TVWS) band.
[0004] The TVWS is a frequency assigned to a broadcast TV and includes an Ultra High Frequency (UHF) band and a Very High Frequency (VHF). The TVWS means a frequency band permitted to an unlicensed device to use under a condition that the unlicensed device does not impede a communication of a licensed device operating in a corresponding frequency band. The licensed device can include a TV, a wireless microphone, and the like. The licensed device can be called an incumbent user or a primary user. And, in order to solve a coexistence problem between unlicensed devices using the TVWS, it may be necessary to have such a signaling protocol as a common beacon frame and the like, frequency sensing mechanism, and the like.
[0005] Although operations of all unlicensed devices are permitted on 512˜608 MHz and 614˜698 MHz except several special cases, a communication between fixed devices is only permitted on 54˜60 MHz, 76˜88 MHz, 174˜216 MHz, 470˜512 MHz. A fixed device indicates a device performing a signal transmission at a fixed position only. IEEE 802.11 TVWS terminal means an unlicensed device operating by using IEEE 802.11 MAC (media access control) and a physical layer (PHY) in a TVWS spectrum.
[0006] The unlicensed device wishing to use the TVWS should provide a protection function for a licensed device. Hence, the unlicensed device should check whether the licensed device occupies a corresponding band before starting a signal transmission in the TVWS.
[0007] To this end, the unlicensed can check whether the corresponding band is used by the licensed device in a manner of performing a spectrum sensing. A spectrum sensing mechanism includes an energy detection scheme, a feature detection scheme, and the like. If strength of a signal received from a specific channel is greater than a certain value or a DTV preamble is detected, the unlicensed device can judge that the specific channel is currently used by the licensed device. And, if it is judged that the licensed device currently uses a channel adjacent to the channel currently used, the unlicensed device should lower a transmit power.
[0008] And, the unlicensed device should obtain channel list information capable of being used by the unlicensed device in a corresponding area in a manner of accessing a database (DB) via the internet or a dedicated network. The DB is a database storing and managing information on the licensed device registered in the DB and a channel use information, which dynamically varies according to a geographical location of the corresponding licensed devices and hours of use.
[0009] In explaining the present specification, a white space band includes the aforementioned TVWS, by which the present invention may be non-limited. In the present specification, a terminology of white space band means a band preferentially permitting an operation of the licensed device and the band permitting an operation of the unlicensed device only when a protection for the licensed device is provided. And, a white space device means a device operating in the white space band. For instance, a device according to an IEEE 802.11 system may become an example of the white space device. In this case, the white space device may indicate the unlicensed device operating in the white space band using the IEEE 802.11 MAC (Medium Access Control) layer and the PHY (Physical) layer. In particular, a general AP according to 802.11 standard and/or an STA operating in the white space band may correspond to an example of the unlicensed device.
DISCLOSURE OF THE INVENTION
Technical Tasks
[0010] As mentioned in the foregoing description, since a channel available to the unlicensed device in the whitespace can dynamically vary according to a time, the unlicensed device should be able to check whether the available channel is valid.
[0011] After the information on the available channel is given to the unlicensed device, a process of checking whether a corresponding channel is still available for the unlicensed device to use can be performed as well. The process can be called a contact verification and a signal used for the process is called a contact verification signal (CVS).
[0012] Hence, a technical task of the present invention is to provide a method of efficiently constructing a CVS indicating the validity of an available channel for the unlicensed device in the white space band. And, another technical task of the present invention is to provide a method of efficiently constructing a message to request and respond for information on the channel available to the unlicensed device.
[0013] Technical tasks obtainable from the present invention are non-limited the above-mentioned technical task. And, other unmentioned technical tasks can be clearly understood from the following description by those having ordinary skill in the technical field to which the present invention pertains.
Technical Solution
[0014] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, according to one embodiment of the present invention, a method of receiving a verification signal, which is received by a first station (STA) from a second STA in a wireless communication system includes the steps of receiving information on a white space map (WSM) from the second STA before operating in a white space band, receiving a contact verification signal (CVS) frame including a map identifier (Map ID) of a currently valid WSM from the second STA, and comparing a value of the Map ID field included in the CVS frame with a Map ID possessed by the first STA, wherein the CVS frame further includes a field indicating a time interval of which the CVS frame is transmitted from the second STA and wherein the CVS frame is received on the every time interval of a CVS transmission.
[0015] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, according to a different embodiment of the present invention, a method of transmitting a verification signal, which is transmitted by a second station (STA) to a first STA in a wireless communication system includes the steps of transmitting information on a white space map (WSM) to the first STA before the first STA operates in a white space band and transmitting a contact verification signal (CVS) including a map identifier (Map ID) of a currently valid WSM to the first STA, wherein a value of the Map ID field included in the CVS frame and a Map ID possessed by the first STA are compared with each other in the first STA, wherein the CVS frame further includes a field indicating a time interval of which the CVS frame is transmitted from the second STA, and wherein the CVS frame is received on the every time interval of a CVS transmission.
[0016] In order to solve the aforementioned technical task, according to a different embodiment of the present invention, a first station (STA) device configured to receive a verification signal from a second station (STA) in a wireless communication system includes a transceiver configured to receive information on a white space map (WSM) from the second STA before operating in a white space band and configured to receive a contact verification signal (CVS) frame including a map identifier (Map ID) of a currently valid WSM from the second STA and a processor configured to compare a value of the Map ID field included in the CVS frame with a Map ID possessed by the first STA, wherein the CVS frame further includes a field indicating a time interval of which the CVS frame is transmitted from the second STA and wherein the CVS frame is received on the every time interval of a CVS transmission.
[0017] In order to solve the aforementioned technical task, according to a further different embodiment of the present invention, a second station (STA) device configured to transmit a verification signal to a first station (STA) in a wireless communication system includes a processor configured to determine a white space map (WSM) for the first STA and a transceiver configured to transmit information on the white space map (WSM) to the first STA before the first STA operates in a white space band and configured to transmit a contact verification signal (CVS) including a map identifier (Map ID) of a currently valid WSM to the first STA, wherein a value of the Map ID field included in the CVS frame and a Map ID possessed by the first STA are compared with each other in the first STA, wherein the CVS frame further includes a field indicating a time interval of which the CVS frame is transmitted from the second STA, and wherein the CVS frame is received on the every time interval of a CVS transmission.
[0018] In the embodiments according to the present invention, following description can be commonly applied.
[0019] The field indicating the time interval can include a variable indicating a CVS transmission time interval.
[0020] If the CVS frame is not received on the every time interval, the method can further include the step of transmitting a channel availability query (CAQ) to the second STA.
[0021] In this case, if an updated WSM is not received, the method can further include the step of terminating a radio transmission.
[0022] If the Map ID is identical to each other according to the comparison result, the method can further include the step of judging that the WSM is valid.
[0023] If the Map ID is different from each other according to the comparison result, the method can further include the step of judging that the WSM is not valid.
[0024] In this case, if it is judged that the WSM is not valid, the method can further include the step of transmitting a CAQ request frame to the second STA.
[0025] In this case, the method can further include the step of receiving a CAQ response frame including an updated WSM from the second STA.
[0026] The second STA may correspond to an STA, which has provided the WSM to the first STA.
[0027] The Map ID field included in the CVS frame can indicate whether the WSM is modified.
[0028] The CVS frame can include the Map ID of the WSM for multiple locations.
[0029] A variable indicating a CVS enablement for the first and the second STA can be set to true.
[0030] The above-mentioned general description for the present invention and the following details of the present invention may be exemplary and are provided for the additional description for the inventions in the appended claims.
Advantageous Effects
[0031] According to the present invention, a method of efficiently constructing a CVS indicating the validity of an available channel for the unlicensed device in the white space band and a method of efficiently constructing a message to request and respond for information on the channel available to the unlicensed device can be provided.
[0032] Effects obtainable from the present invention may be non-limited by the above mentioned effect. And, other unmentioned effects can be clearly understood from the following description by those having ordinary skill in the technical field to which the present invention pertains.
DESCRIPTION OF DRAWINGS
[0033] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0034] FIG. 1 is a diagram of one example of a configuration of a wireless local area network system;
[0035] FIG. 2 is a diagram of a different example of a configuration of a wireless local area network system;
[0036] FIG. 3 is a schematic diagram of an active scanning;
[0037] FIG. 4 is a schematic diagram of a passive scanning;
[0038] FIG. 5 is a diagram of an enabling process of an STA;
[0039] FIG. 6 is an exemplary diagram of a geographical region represented by multiple locations and vicinity information;
[0040] FIG. 7 is a diagram for an example of a format of a Mode I CAQ (channel availability query) frame;
[0041] FIG. 8 is a diagram of a format related to a CVS (contact verification signal);
[0042] FIG. 9 is a diagram for an example of a Mode I CAQ frame format for a channel list available in one or more locations;
[0043] FIG. 10 is a diagram of a CVS information element format for one or more available channel lists;
[0044] FIG. 11 is a flowchart indicating a Mode I CAQ process and a CVS transceiving process according to one example of the present invention;
[0045] FIG. 12 is a flowchart indicating a Mode I CAQ process and a CVS transceiving process according to a different example of the present invention;
[0046] FIG. 13 is a diagram for explaining a detail configuration of a processor of a wireless device according to one embodiment of the present invention.
BEST MODE
Mode for Invention
[0047] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. In the following detailed description of the invention includes details to help the full understanding of the present invention. Yet, it is apparent to those skilled in the art that the present invention can be implemented without these details.
[0048] Occasionally, to prevent the present invention from getting vaguer, structures and/or devices known to the public are skipped or can be represented as block diagrams centering on the core functions of the structures and/or devices. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0049] First of all, a general configuration of a wireless local area network is described with reference to FIG. 1 and FIG. 2 .
[0050] FIG. 1 is a diagram of one example of a configuration of a wireless local area network system.
[0051] As depicted in FIG. 1 , a wireless local area network includes at least one Basic Service Set (BSS). The BSS is a set of stations (STA) capable of communicating with each other by successfully performing synchronization.
[0052] The STA is a logical entity including a physical layer interface for a Medium Access Control (MAC) and wireless media. The STA includes an access point (AP) and a Non-AP STA (Non-AP station). A mobile terminal operated by a user corresponds to the Non-AP STA among the STAs. If it is simply called an STA, the STA may correspond to the Non-AP STA. The Non-AP STA can be called such a different name as a terminal, a Wireless Transmit/Receive Unit (WTRU), User Equipment (UE), a Mobile Station (MS), a Mobile Terminal, a Mobile Subscriber Unit, or the like.
[0053] And, the AP is an entity providing an STA associated to the AP with an access to a distribution system (DS) via the wireless media. The AP can be called a concentrated controller, a Base Station (BS), a Node-B, a Base Transceiver System (BTS), a site controller, or the like.
[0054] The BSS can be divided into an infrastructure BSS and an independent BSS (IBSS).
[0055] The BSS depicted in FIG. 1 corresponds to the IBSS. The IBSS means the BSS not including an AP. Since the IBSS does not include the AP, an access to the DS is not permitted to the IBSS. Thus, the IBSS forms a self-contained network.
[0056] FIG. 2 is a diagram of a different example of a configuration of a wireless local area network system.
[0057] The BSS depicted in FIG. 2 corresponds to the infrastructure BSS. The infrastructure BSS includes at least one STA and an AP. Although a principle of a communication between non-AP STAs is to perform the communication via the AP, if a link is directly established between the non-AP STAs, it is possible to directly communicate between the non-AP STAs.
[0058] As depicted in FIG. 2 , a plurality of infrastructure BSSs can be connected to each other via the DS. A plurality of the infrastructure BSSs connected through the DS is called an Extended Service Set (ESS). STAs included in the ESS can communicate with each other and a non-AP STA can move from one BSS to another BSS while seamlessly communicating in an identical ESS.
[0059] The DS is a mechanism connecting a plurality of APs to each other and the DS is not necessarily to be a network. If the DS is able to provide a prescribed distribution service, there is no limit on a form of the DS. For instance, the DS may correspond to such a wireless network as a mesh network or may correspond to a physical structure connecting APs to each other.
[0060] A spectrum not used by a licensed device is called a whitespace and the whitespace can be used by an unlicensed device. In order for an STA to operate in a whitespace spectrum, it is necessary to preferentially provide a protection scheme for the licensed device (incumbent user). In order for the STA or an AP to protect the licensed device, the STA or the AP should use a channel not used by the licensed device only. The channel capable of being used by the unlicensed device, since it is not used by the licensed device, is called an available channel. A most basic method for the STA or the AP to identify availability of a TV channel is a spectrum sensing and a method of finding out a TV channel schedule by accessing a database (DB). DB information includes the information on a schedule of a specific channel used by the licensed device in a specific location, and the like. Hence, in order to identify whether the TV channel is available, the STA or the AP should obtain the DB information based on location information of the STA or the AP in a manner of accessing the DB via the internet.
[0061] In order for an STA to access a network, the STA should find out a network eligible to participate. Before participating in a wireless network, the STA should identify a compatible network. A process of identifying a network existing in a specific area is called a scanning.
[0062] FIG. 3 is a schematic diagram of an active scanning.
[0063] An STA performing a scanning in the active scanning moves around channels, transmits a probe request frame and waits for a response for the probe request frame to investigate which AP is existing in the vicinity of the STA. A responder transmits a probe response frame to the STA, which transmitted the probe request frame, in response to the probe request frame. In this case, the responder corresponds to an STA lastly transmitted a beacon frame in the BSS of a channel, which is currently scanned. In the infrastructure BSS, since an AP transmits a beacon frame, the AP corresponds to the responder. On the contrary, in the IBSS, since STAs in the IBSS transmit the beacon frame in turn, the responder is not constant.
[0064] Referring to FIG. 3 , if a scanning STA 300 transmits a probe request frame 305 , a responder 1 310 of a BSS 1 and a responder 2 320 of a BSS 2 , which received the probe request frame, transmit a probe response frame 1 315 and a probe response frame 2 325 to the scanning STA 300 , respectively. Having received the probe response frame, the scanning STA 300 stores BSS-related information included in the received probe response frame, moves to a next channel, and performs a scanning with an identical method in the next channel.
[0065] FIG. 4 is a schematic diagram of a passive scanning.
[0066] An STA performing a scanning in a passive scanning waits for a beacon frame by moving around channels. The beacon frame is one of management frames in IEEE 802.11. The beacon frame informs an existence of a wireless network and is periodically transmitted to enable the STA performing the scanning to participate in the wireless network by finding out the wireless network. In the infrastructure BBS, an AP plays a role of periodically transmitting the beacon frame.
[0067] Having received the beacon frame, the STA performing the scanning stores the information on the BSS included in the beacon frame, moves to a different channel, and records beacon frame information in each channel.
[0068] Referring to FIG. 4 , a scanning STA 400 performing a channel scanning in a specific channel with a passive scanning scheme receives a beacon frame 1 415 transmitted by an AP 1 410 of a BSS 1 and a beacon frame 2 425 transmitted by an AP 2 420 of a BSS 2 . If the scanning STA does not receive a beacon frame 3 435 transmitted by an AP 3 430 of a BSS 3 , the scanning STA 400 stores information that 2 BSSs (BSS 1 and BSS 2 ) are detected in a measurement channel and moves to a different channel.
[0069] Compared the active scanning with the passive scanning, there exists a merit in that the active scanning has a less delay and less power consumption than the passive scanning.
[0070] In the following description, a process of enablement for an STA to operate in a whitespace band is explained.
[0071] The unlicensed device operating in the whitespace band can be classified into an enabling STA and a dependent STA. The enabling STA is an STA enabling the dependent STA, can transmit a signal without receiving an enabling signal, and can initiate a network.
[0072] The enabling STA provides a database (DB) with geo-location information and can obtain available channel information capable of being used in a corresponding geo-location from the DB. The enabling STA does not need to be a WLAN STA and may correspond to a logical entity capable of providing enabling-related services or may correspond to a network server.
[0073] The dependent STA is an STA capable of transmitting a signal in a manner of receiving an enabling signal only. The dependent STA is controlled by the enabling STA. The dependent STA should be enabled by the enabling STA and cannot be independently enabled.
[0074] FIG. 5 is a diagram of an example of an enabling process of an STA.
[0075] IEEE 802.11y is a standard constructed for the unlicensed device operating on 3.5 GHz. The standard describes an enabling process and the enabling process is called a dynamic STA enablement (DSE). A process of enabling the dependent STA by the enabling STA may follow a process similar to the dynamic STA enablement of IEEE 802.11y. Although the enabling process practically applied to the whitespace may not be same with the process of the DSE, it is basically identical in a point that the dependent STA can transmit a signal to a corresponding band/channel only after receiving an enabling signal.
[0076] As depicted in FIG. 5 , the enabling STA can transmit a beacon including an enabling signal or a probe response frame to the dependent STA [S 510 ]. A signal indicating that an enabling is available is called an enabling signal. In an example of FIG. 5 , the beacon including an enabling signal element or the probe response frame corresponds to the enabling signal. Having received and decoded the enabling signal, the dependent STA transmits an enablement request frame to the enabling STA using a channel received the corresponding signal [S 520 ] and receives an enablement response frame from the enabling STA [S 530 ].
[0077] Configuration of Available Channel Information
[0078] In order for not an incumbent user but the unlicensed device to operate in the whitespace band, the corresponding unlicensed device obtains information on a channel not interfering the incumbent user in a specific location, i.e., an available channel to protect the incumbent user and can operate according to the information. The information on the available channel may include an available channel list, which is a set of one or more available channels.
[0079] As mentioned in the foregoing description, the information on the available channel obtained by the enabling STA from the DB and/or the information on the available channel (or the available channel list) obtained by the dependent STA from the enabling STA can be provided in a form of a White Space Map (WSM). The available channel list (WSM) can be transmitted and received between the STAs according to the example depicted in FIG. 5 or can be provided via a Channel Availability Query (CAQ) request/response, which shall be described later, and the like.
[0080] In an available channel list obtaining mechanism of the STA in the WS, detail examples of the present invention for obtaining an available channel and a contact verification operation after the available channel is obtained are explained in the following description.
[0081] First of all, a process of obtaining an available channel list can be differently defined according to a type of the STA. The STA type currently defined includes 2 types. One is a device of a low power and the device capable of being carried by a person (personal/portable device (P/P STA)) and another one is a device of a high power and the device operating in a fixed position (fixed STA).
[0082] The fixed STA can transceives a signal in a specific position, which is fixed. In order for the fixed STA to transmit a signal in a corresponding position, the fixed STA should obtain available channel information in a manner of accessing a DB. In order to obtain the available channel information from the DB, a position of the fixed STA should be determined. To this end, such an equipment capable of checking a location as a GPS (global positioning system) may be installed in the fixed STA. Yet, the position of the fixed STA can be directly inputted by a person (professional installer). In case that the position of the fixed STA is directly inputted by the person, it is assumed that the position of the fixed STA does not change after the fixed STA is installed and the position of the fixed STA is inputted. If the position of the fixed STA changes (i.e., if the fixed STA is installed in a different position in a manner of being moved), a new position according to the change should be modified and registered. By doing so, location information of the fixed STA can be delivered to the DB and the fixed STA can obtain available channel information in a corresponding position from the DB.
[0083] The fixed STA may service a different fixed STA of the same kind or may service a P/P STA. When the fixed STA obtains the available channel information from the DB, the fixed STA should receive the available channel information of the fixed STA capable of being directly used by the fixed STA in a manner of delivering a device type of the fixed STA to the DB. Simultaneously, in order for the fixed STA to perform a service for the P/P STA, available channel information capable of being used by the P/P STA should be additionally received from the DB. Since a channel interval available to the fixed STA and the channel interval available to the P/P STA are different from each other and since maximum permissible transmit power and requirement for an adjacent channel for the fixed STA and the P/P STA are different from each other, an available channel list varies according to the type of each device. In particular, the fixed STA is permitted to transmit a signal on a frequency band of 512˜608 MHz, 614˜698 MHz, as well as 54˜60 MHz, 76˜88 MHz, 174˜216 MHz, and 470˜512 MHz. Yet, the P/P STA is not permitted to transmit a signal on a WS band of a different frequency band except the frequency band of 512˜608 MHz and 614˜698 MHz. And, the fixed STA can transmit a signal with a high power compared to the P/P STA. The maximum permissible transmit power of the fixed STA is 4 Watt (EIRP (Effective Isotropically Radiated Power)). On the other hand, the maximum permissible transmit power of the P/P STA is 100 mW (EIRP).
[0084] The P/P STA corresponds to the equipment capable of transceiving a signal in an unspecified position. A position of the P/P STA can change. In many cases, since the P/P STA is a portable device, it is difficult to predict the mobility of the P/P STA. The P/P STA can be divided into 2 types (Mode I STA and Mode II STA) according to whether the P/P STA has identification capability for the position of the P/P STA. The identification capability for a position means a geo-location determination capability and an access capability to the DB via an internet access.
[0085] The Mode II STA has a capability of the geo-location determination and internet access. After the information on an available channel in the position of the Mode II STA is obtained by directly accessing the DB, the Mode II STA can operate in the WS at a corresponding position. And, after the available channel information is obtained from the DB, the Mode II STA can transmit a signal indicating the Mode I STA to start a communication. Yet, the Mode I STA is not required to have a capability of checking a position of the Mode I STA or a capability of accessing the DB. Yet, the Mode I STA obtains the available channel information in a manner of being controlled by a different STA (the Mode II STA capable of accessing the DB and having valid channel information or a fixed STA) and can perform an operation in the WS.
[0086] Mode II Channel Availability Query (CAQ)
[0087] The Mode II STA registers location information of the Mode II STA by accessing the DB and should be able to obtain available WS channel list. A process of obtaining the available channel list obtained by the Mode II STA is called a Mode II channel availability query (Mode II CAQ) process.
[0088] After the Mode II STA has obtained the available channel information in a specific position via the CAQ process, if the position of the Mode II STA changes more than a prescribed distance (e.g., more than 100 meters) or previously obtained DB information is not valid anymore, the Mode II STA performs the CAQ process again.
[0089] Basically, the Mode II CAQ is the process of obtaining available channel information in a specific position. Hence, if location information changes as the Mode II STA moves more than a prescribed distance (e.g., more than 100 meters), an overhead, which is resulted from obtaining an available channel in a new position by mandatorily accessing the DB again, occurs. In order to reduce the overhead, it is able to apply a scheme of obtaining a channel available for the Mode II STA in multiple locations from the DB in advance. This sort of scheme can be very usefully utilized in case that the Mode II STA can predict a moving path or a moving area of the Mode II STA.
[0090] Specifically, the Mode II STA can perform the Mode II CAQ for one or more locations. Location information on one location among the one or more locations can be configured by a combination of the information (information on a latitude, information on a longitude, information on an altitude) specifying the one location and vicinity information. The vicinity information, for instance, can include radius information, which is based on the one location. As mentioned in the foregoing description, a combination of the location information on each of the one or more locations and the vicinity information can be determined and the location information on one or more locations can be configured by a set of the combinations.
[0091] FIG. 6 is an exemplary diagram of a geographical region represented by multiple locations and vicinity information.
[0092] Referring to an example of FIG. 6 ( a ), 3 different locations are determined on an anticipated moving path of the Mode II STA and a radius on each of the 3 locations is determined by a size of which the anticipated moving path is not straying from a union of the regions including each of the radiuses of the 3 locations. 3 points (P1, P2, and P3) are specified in the example of FIG. 6 ( a ) and the P1, the P2, and the P3 can be specified by a combination of latitude, longitude, and altitude (for instance, it can be represented as P1=(LAT1, LONG1, ALT1), P2=(LAT2, LONG2, ALT2), P3=(LAT3, LONG3, ALT3)). And, the vicinity information on the P 1, the P2, and the P3 can be configured by each of the radius informations (R1, R2, and R3). Hence, the location information on the 3 locations can be configured by (P1, R1), (P2, R2), (P3, R3). The Mode II STA can perform the channel availability query to the DB using the aforementioned location information.
[0093] Referring to an example of FIG. 6 ( b ), one location is determined on the anticipated moving path of the Mode II STA and 3 different radiuses capable of including the anticipated moving path can be determined from the one location. One location P1 on the anticipated moving path is specified in the example of FIG. 6 ( b ) and 3 different radiuses R1, R2, and R3 can be determined on the basis of the P1 as a center point. By doing so, the location information can be configured by (P1, R1), (P2, R2), (P3, R3). The Mode II STA can perform the channel availability query to the DB using the aforementioned location information.
[0094] The DB can calculate an available channel list for a region indicated by the location information (e.g., a combination of location and vicinity information) of which the Mode II STA has queried. If the Mode II STA queries multiple locations (e.g., multiple combinations of location and vicinity information), the DB calculates multiple available channel lists in a manner of combining the available channel list corresponding to each of the locations and may be then able to respond to the query of the Mode II STA for the multiple available channel lists.
[0095] By performing the Mode II CAQ process, the Mode II STA can obtain multiple channel informations available on the anticipated moving path in advance.
[0096] Mode I CAQ
[0097] Since the Mode I STA has no database access capability or geo-location determination capability, the Mode I STA cannot independently operate in a WS. The Mode I STA can perform a communication in the WS at last only when the Mode I STA receives a special signal (e.g., an enabling signal) from a different STA (e.g., a Mode II STA). It is necessary for the Mode I STA to obtain available channel information from the Mode II STA before the Mode I STA transmits a data. As mentioned in the foregoing description, a process of obtaining the available channel information obtained by the Mode I STA via the Mode II STA is called a Mode I channel availability query (CAQ) process.
[0098] FIG. 7 is a diagram for an example of a format of a Mode I CAQ (channel availability query) frame.
[0099] A Category field may have a value indicating a category (spectrum management, QoS (quality of service), a block ACK, a public action, and the like) to which a frame format is applied. In an example of a CAQ frame format, the Category field may have a value of a code (e.g., 4) indicating the public action.
[0100] A Public Action field may have a value indicating operations related to an intra-BSS communication, an inter-BSS communication, an unassociated-STA communication with an AP. In the example of the CAQ frame format, the Public Action field may have a value indicating a channel availability query.
[0101] Subsequently, if a Reason Result Code field value corresponds to 1, it means that the Mode I CAQ is requested (in particular, a channel availability list is requested) and if the Reason Result Code field value corresponds to 3, it means that a result of the available channel list is successful. If the Reason Result Code field value corresponds to 1, following fields (i.e., Map ID, Channel number, Maximum power level, and validity) of a Length field can be omitted. If the Reason Result Code field value is 3, it corresponds to a response for a request of the available channel list and includes a result of the available channel list.
[0102] The Length field may have a value indicating a length of the rest of frame fields and a unit of the Length field is octet (i.e., 8-bit unit). The following fields of the Length field may be omitted. Since the Channel number field, the Maximum power level field, and the validity field can be repeated, the value of the Length field is variable.
[0103] The Channel number field, the Maximum power level field, and the validity field mean available channel number, permitted maximum output power, and available validity time, respectively. In case of transmitting an available channel list consisted of one or more numbers (N (N≧1)) of channels, the Channel number field, the Maximum power level field, and the validity field can be repeated as many as the number (N) of available channels and a corresponding channel list may have a Map ID which is a unique number. In this case, repeating a field N times means that the field exists N times. For instance, repeating a field once means that the field exists one time only. If even a single available channel exists, a Map ID is provided for the corresponding available channel. In particular, the Map ID is provided for one available channel list (one available channel list consists of N numbers of available channel(s)). And, if an available channel list is updated, the Map ID increases by 1. If a channel list is updated after a maximum value (e.g., 2 8 −1) of the Map ID is provided, the Map ID may correspond to 0 and a next updated channel list can be provided with the Map ID increasing by 1.
[0104] Contact Verification Signal (CVS)
[0105] The Mode I STA should consistently check whether the Mode I STA exists within the coverage of the Mode II STA and whether an available channel obtained via the Mode I CAQ is valid even after an available channel list is obtained via the Mode I CAQ. This process is called contact verification and a signal transmitted to the Mode I STA by the Mode II STA for the contact verification is called a contact verification signal (CVS). In particular, the CVS is transmitted by an enabling STA (e.g., the Mode II STA) and the CVS is a signal transmitted to check whether dependent STAs (e.g., the Mode I STA) still exist in a reception range of the enabling STA and whether an available channel list is valid. And, the dependent STA should receive the CVS signal from the exact enabling STA, which has provided the available channel list (or WSM).
[0106] In order to configure the CVS including the aforementioned function, first of all, it is necessary to define a frame format for the CVS. The CVS can be defined as an information element (IE) in management frame body components. In general, the information element can include an Element ID field of one octet length, a Length field of one octet length, and a specific information field of variable length. For instance, a CVS IE format can be defined in a manner of including such contents as a following Table 1 in an element ID table of IEEE 802.11 standard.
[0000]
TABLE 1
Information element
Element ID
Length (in octets)
Extensible
Contact Verification Signal
<ANA>
variable
Yes
(see 8.4.2.af4)
[0107] Referring to Table 1, a unique element ID distinguished from a different element ID is provided for the CVS IE and the length of the CVS IE is variable and extensible.
[0108] And, the CVS can be defined as an STA capability for an STA to support transmission and reception of the CVS. To this end, an extended capabilities element can be defined and a bit indicating the content related to the CVS can be defined in a capabilities field of the extended capabilities element. For instance, CVS capability can be defined in a manner of including such contents as a following Table 2 in a capability field table of IEEE 802.11 standard.
[0000]
TABLE 2
Bit
Information
Notes
<ANA>
Contact
The STA sets the Contact Verification Signal
Verification
field to 1 when the MIB attribute
Signal
dot11ContactVerificationSignalActivated is true,
and set it to 0 otherwise. See 10.af2.3.
[0109] Referring to Table 2, contents related to the CVS can be indicated in a prescribed bit position of the capability field. For instance, among the Management Information Base (MIB) attributes, if a dot11ContactVerificationSignalActivated, which indicates CVS enabling, is true, the STA sets a prescribed bit value of the CVS field to 1, and otherwise, sets to 0.
[0110] FIG. 8 is a diagram of a format related to a CVS information element (IE).
[0111] FIG. 8 ( a ) is a diagram of an example of a CVS IE format. Referring to the example of FIG. 8 ( a ), an Element ID field is a field of one octet length and may have a value (e.g., a unique ID explained in relation to FIG. 1 ) indicating that a corresponding IE is a CVS IE. A Length field is a field of one octet length and may have a value indicating the length of the fields following the Length field. In the example of FIG. 8 ( a ), the value of the Length field can be set to 1. A Map ID field can be set to a number identifying a currently valid WSM (or an available channel list). Having received this kind of CVS IE, the dependent STA (or the Mode I STA) can judge whether the WSM used by the dependent STA is valid in a manner of comparing the Map ID of the WSM currently used by the dependent STA with the Map ID included in the CVS.
[0112] FIG. 8 ( b ) is a diagram of a different example of the CVS IE format. Referring to the example of FIG. 8 ( b ), the Element ID field, the Length field, and the Map ID field include content identical to the content described in the example of FIG. 8 ( a ). In the example of FIG. 8 ( b ), a Contact Verification Signal Delivery Interval field can be defined as a field of 2 octets length and can be set to a value indicating the time taken for transmitting a next CVS element by an enabling STA (e.g., the Mode II STA). For instance, after the present CVS is transmitted, if the next CVS is to be transmitted after N times of a DTIM (Delivery Traffic Indication Message Interval), a value of the CVS delivery interval field can be set to N.
[0113] FIG. 8 ( c ) is a diagram of an example of an action frame format related to the CVS. An action frame delivering a CVS IE can be defined as a public action frame. The public action frame is defined to additionally permit an inter-BSS communication and an unassociated-STA communication for an AP in an intra-BSS communication. Since the public action frame is distinguished according to a value of a public action field, the value of the public action field should be defined to define the public action frame for the CVS. For instance, a CVS-related action frame can be defined in a manner of including such contents as a following Table 3 in a Table indicating the value of the public action field of IEEE 802.11 standard.
[0000]
TABLE 3
Action field value
Description
<ANA>
Contact Verification Signal
[0114] In the Table 3, by defining the value of the public action field as a unique value for a CVS, it is able to distinguish the public action frame from a public action frame of a different purpose.
[0115] As mentioned in the foregoing description, the CVS frame defined as the public action frame is transmitted by an enabling STA and can be used to inform whether the available channel information from the DB is updated.
[0116] In the example of FIG. 8 ( c ), the Category field can be set to a value indicating a public action and the Public action field can indicate that the public action frame corresponds to the CVS frame in a manner of being set to a value identical to the value defined in the Table 3. Subsequently, the CVS IE field of FIG. 8 ( c ) can be configured by the content described in the CVS IE of FIG. 8 ( a ) or FIG. 8 ( b ). In particular, in case of such a format as the CVS IE format in FIG. 8 ( a ), a length of the CVS IE field of FIG. 8 ( c ) becomes 3 octets. In case of such a format as the CVS IE format in FIG. 8 ( b ), the length of the CVS IE field of FIG. 8 ( c ) becomes 5 octets.
[0117] Subsequently, a protected dual public action frame can be defined among the action frame formats. The protected dual public action frame is defined for specific information to be robustly communicated between STAs. The specific information is identical to the information delivered from an action frame, which is not robust. Since the protected dual public action frame is distinguished according to a value of the public action field defined for the protected dual public action frame, the value of the public action field should be defined to define the protected dual public action frame for a CVS. For instance, a protected public action frame for the CVS can be defined in a manner of including such contents as a following Table 4 in a Table indicating the value of the public action field defined for the protected dual public action frame of IEEE 802.11 standard.
[0000]
TABLE 4
Action field value
Description
<ANA>
Protected Contact Verification Signal
[0118] In the Table 4, by defining the value of the public action field by a unique value for a protected CVS, it is able to distinguish the protected dual public action frame from a protected dual public action frame of a different purpose. In this case, the protected CVS frame format can be identical to the CVS frame format of FIG. 8 ( c ). The protected CVS frame format can be used instead of the CVS frame in case that a management frame protection is negotiated.
[0119] In case that a CVS is defined as mentioned in the foregoing description, CVS-related content for an operation of a Mac sublayer management entity (MLME) in a regulatory domain (e.g., a licensed band) can be defined as follows.
[0120] A CVS frame can be transmitted by an enabling STA to check whether dependent STAs still exist in a reception range of the enabling STA and to verify whether an available channel list is valid. An STA supporting a CVS can advertise that the STA supporting the CVS has CVS-related capability in a manner of including the extended capability element (refer to the Table 2) in a beacon, an association request, a re-association request, an association response, a probe response frame, and the like.
[0121] An enabling STA of which the dot11ContactVerificationSignalActivated is set to true can transmit the protected dual CVS action frame (refer to the Table 4) to the dependent STAs of which the dot11ContactVerificationSignalActivated is set to true. In this case, the dependent STAs are the STAs to which the enabling STA has provided WSMs.
[0122] After receiving the WSMs, the dependent STA can receive a CVS from the enabling STA, which has provided the WSMs to the dependent STA, to check whether the dependent STA exists in the reception range of the enabling STA. The CVS includes a Map ID field indicating whether the WSM is modified (refer to FIG. 8 ( a ) or FIG. 8 ( b )). The dependent STA can compare the Map ID of the WSM of the dependent STA with the Map ID field of the CVS. If the Map IDs are identical to each other, the dependent STA can assume that the WSM is still valid. If the MAP IDs are different from each other, the dependent STA can recognize that the WSM of the dependent STA is not valid and it is necessary to transmit a CAQ.
[0123] The dependent STA can receive the CVS once on every dot11ContactVerificationSignalInterval. If the dependent STA fails to receive the CVS, the dependent STA can transmit the CAQ to the enabling STA. If an updated WSM is not obtained, the dependent STA can stop transmitting over the air.
[0124] In addition, a TVWS function, which corresponds to an example of a white space, can be defined as Table 5 to synchronize in implementing a protocol.
[0000]
TABLE 5
Item
Protocol Capability
References
Status
Support
*WS1
Fixed STA TVWS Operation
10.12.3,
CFaf: O
Yes, No, N/A
Annex D,
Annex E.2.4
*WS2
Master STA TVWS Operation
10.12.3,
CFaf: O
Yes, No, N/A
10.12.4,
Annex D,
Annex E.2.4
*WS3
Client STA TVWS Operation
10.12.5,
CFaf: O
Yes, No, N/A
Annex D,
Annex E.2.4
WS3.1
Dependent STA TVWS Behavior
10.12.5,
WS3: M
Yes, No, N/A
Annex D,
Annex E.2.4
WS4
White Space Map Announcement
8.4.2.af1,
CFaf: M
Yes, No, N/A
8.5.8.af1,
10.af2.2
WS5
Multi-band Operation
8.4.2.af2,
CFaf: O
Yes, No, N/A
10.af2.3
WS6
Channel Power Management
8.4.2.af1,
CFaf: M
Yes, No, N/A
Announcement
8.5.8.af2,
10.af1, Annex
E.2.4
WS9
Contact Verification Signal
8.4.2.af5,
CFaf: M
Yes, No, N/A
8.4.5.3,
8.5.8.af4,
10.af2.2
[0125] In particular, as shown in Table 5, in order to implement a protocol for a TVWS operation, CVS-related functions can be additionally defined. Related contents can be defined according to the contents described in the aforementioned Table 1 to Table 4, FIG. 8 , and the like.
[0126] A frequency band capable of being used in a wireless local area network system can be differently defined according to a country. To this end, country elements and operating classes can be defined. The operating classes can be defined by a set of channels capable of being used by a country. Regarding this, band-specific operating requirements can be defined. For instance, in order to support a CVS operation on a VWS band (54 MHz to 698 MHz) in the United States of America, an STA can set the dot11ContactVerificationSignalActivated of the MIB elements indicating a CVS enablement to true as depicted in table 6.
[0000]
TABLE 6
STAs shall have the following elements set to “true”
dot11LCIDSERequired,
dot11OperatingClassesRequired,
dot11SpectrumManagementRequired,
dot11MultiDomainCapabilityActivated,
dot11ChannelPowerManagementActivated-,
dot11ContactVerificationSignalActivated.
[0127] And, in case of encoding MAC and PHY MIB, it is able to add a new MIB variable indicating the CVS enablement, which is a dot11ContactVerificationSignalActivated as shown in Table 7.
[0000]
TABLE 7
Dot11StationConfigEntry::=
SEQUENCE {
dot11TVWSMapEnabled TruthValue, (472r1)
dot11TVWSMultiBandOperationEnabled TruthValue, (472r1)
dot11TVWSMapPeriod Unsigned32, (472r1)
dot11TVWSMapValidTime Integer, (472r1)
dot11RLSImplemented TruthValue, (737r3)
dot11RLSActivated TruthValue, (737r3)
dot11WhiteSpaceMapEnabled TruthValue, (790r2)
dot11ContactVerificationSignalActivated TruthValue,
dot11WhiteSpaceMapPeriod Unsigned32, (790r2)
dot11WhiteSpaceMapValidTime Integer, (790r2)
dot11ChannelPowerManagementActivated TruthValue (767r1)
}
[0128] And, in case of encoding the MAC and the PHY MIB, it is able to add a definition for the dot11ContactVerificationSignalActivated indicating the CVS enablement as depicted in Table 8.
[0000]
TABLE 8
dot11ContactVerificationSignalActivated OBJECT-TYPE
SYNTAX TruthValue
MAX-ACCESS read-write
STATUS current
DESCRIPTION
“This is a control variable.
It is written by an external management entity.
Changes take effect for the next MLME-START.request
primitive.
This attribute, when true, indicates that the system capability for Contact
Verification Signal is enabled. False indicates that the station has no
Contact Verification Signal so that the capability is present but is
disabled.”
DEFVAL { FALSE }
::= { dot11StationConfigEntry <ANA> }
[0129] And, in case of encoding the MAC and the PHY MIB, it is able to newly add a definition for a dot11 ContactVerificationInterval (or dot11WSMNotificationPeriod) related to a CVS transmission interval as shown in Table 9.
[0000]
TABLE 9
dot11ContactVerificationInterval OBJECT-TYPE
SYNTAX Unsigned32(1..255)
MAX-ACCESS read-write
STATUS current
DESCRIPTION
“This is a control variable.
It is written by an external management entity.
Changes take effect for the next MLME-START.request
primitive.
This attribute specifies the number of beacon internals
.”
DEFVAL { 60 }
::= { dot11StationConfigEntry <ANA> }
[0130] As mentioned in the foregoing description, after the dependent STA (e.g., the Mode I STA) received an available channel list (or WSM) from the enabling STA (e.g., the Mode II STA), the dependent STA (e.g., the Mode I STA) can consistently receive a CVS from the enabling STA (e.g., the Mode II STA) with a period less than a preset time interval (e.g., CVSTimeInterval). For instance, the CVSTimeInterval value can be set to 60 seconds. The Mode I STA should receive the CVS on every 60 seconds or with a period less than 60 seconds. The Mode I STA can judge that a corresponding channel list is continuously valid in a manner of consistently receiving the CVS, which corresponds to the Map ID of the currently possessed available channel list, with the set period. If the Mode I STA does not receive the CVS corresponding to the Map ID of the currently possessed available channel list for the CVSTimeInterval, the Mode I STA judges that the channel list corresponding to the Map ID is not valid anymore. In particular, the CVSTimeInterval can be represented as an expiration date of the available channel list. If the Mode I STA does not possess a valid available channel list, the Mode I STA should obtain an available channel list in a manner of performing the Mode I CAQ process again.
[0131] A case of not capable of receiving the CVS, which corresponds to the Map ID of the currently possessed available channel list, for the CVSTimeInterval by the Mode I STA may include a case of not capable of receiving the CVS itself (e.g., a case of getting out from the coverage of the Mode II STA by the Mode I STA) and a case that the Map ID of the CVS is not matched with the Map ID of the currently possessed available channel list although the CVS is received. In this case, the Mode I STA judges that the currently possessed available channel list is not valid anymore. The Mode I STA should obtain new available channel information corresponding to the Map ID included in the CVS in a manner of transmitting the Mode I CAQ again and receiving a Mode I CAQ response.
[0132] In case that the Mode II STA moves, the CVS and the Mode I CAQ can be used to inform the Mode I STA of an updated available channel list.
[0133] For instance, assume that the Map ID of the available channel list provided to the Mode I STA is k. Subsequently, if the Mode II STA moves more than a prescribed distance and if the location of the Mode II STA is modified, the Mode II STA can obtain an available channel list in a modified location again by accessing the DB. If the channel list newly obtained from the DB by the Mode II STA is different from the channel list of which the Mode II STA conventionally possessed, the Map ID of the newly obtained channel list can be set to k+1. By doing so, the Mode II STA can transmit the CVS to the Mode I STA in a manner of setting the Map ID value included in the CVS to k+1. Having received the CVS, the Mode I STA checks that k+1, which is the Map ID different from k of the Map ID of the available channel list possessed by the Mode I STA, is included in the CVS and can recognize that the available channel list is updated. Hence, the Mode I STA can transmit a Mode I CAQ request to the Mode II STA. The Mode II STA can transmit a Mode I CAQ response to the Mode I STA in response to the Mode I CAQ request. Values of a Map ID field, a Channel number field, a Maximum power level field, and a validity field included in the Mode I CAQ response are newly set to the value corresponding to a new available channel list.
[0134] Meanwhile, the Mode II STA can obtain a channel available for one or more locations from the DB via the Mode II CAQ. By doing so, if the location of the Mode II STA were modified in the future, the Mode II STA does not access the DB since the Mode II STA already obtained the channel list capable of being used in the modified location. Yet, a case that the Mode II STA does not access the DB in the modified location may correspond to a case that channel validity of a corresponding channel list is not expired for travel time or a case that an update does not occur in the DB for the travel time. If the channel validity is expired, the Mode II STA can access the DB to obtain new available channel information in the modified location. If DB update occurred, the DB can inform the Mode II STA of the change of the available channel information (for instance, the DB can inform the Mode II STA in a form of an announcement).
[0135] As mentioned earlier, in case that the Mode II STA has obtained the channel list available for one or more locations in advance, if the information of the available channel among the available channel list obtained in advance is modified due to a location change or the DB update, the modified available channel information should be reported to the Mod I STA. It's because the Mod I STA possesses the available channel list at the time of receiving a response for a Mode I CAQ request only. And, in terms of the Mode I STA, although whether the available channel list possessed by the Mode II STA is modified or not can be checked via whether the Map ID of the CVS is modified, since the CVS does not include the channel information, the Mode I STA should make a request for the modified channel list information to the Mode II STA again. Hence, having received the CVS of the modified Map ID, the Mode I STA can transmit the Mode I CAQ request to the Mode II STA.
[0136] Mode I CAQ for One or More Locations
[0137] The Mode II STA can inform the Mode I STA of a channel list capable of being used in one or more locations (in particular, multiple locations) at a time. A scheme for informing an available channel list to the Mode I STA by the Mode II STA includes a scheme of responding a CAQ in response to a CAQ request of the Mode I STA or a scheme of responding an unsolicited CAQ. The unsolicited CAQ response means a message of which the Mode II STA informs available channel information without the CAQ request of the Mode I STA.
[0138] FIG. 9 is a diagram for an example of a Mode I CAQ frame format used for delivering a channel list available in one or more locations. The Mode I CAQ frame format of FIG. 9 can be defined as a new frame format to which a Number of Locations field in the Mode I CAQ frame format of FIG. 7 is added and fields (the Map ID field, the Channel number field, the Maximum power level field, and the Validity field) corresponding to the channel list are repeated.
[0139] For clarity, explanation on the fields (Category, Public Action, and Reason Result Code) duplicated with FIG. 7 is omitted in the example of the Mode I CAQ frame format.
[0140] Number of locations field may have a value indicating the number (i.e., K (K≧1)) of locations to which the Mode II STA queries the DB. Since one available channel list is given to one location, the value (i.e., K) of the Number of locations field has a value identical to the number (the number of repeating of {one ‘Map ID’ and N number of ‘Channel number, Maximum power level, and Validity’ field}) of available channel list in the field following the Number of locations field.
[0141] The Length field may have a value indicating the length of the fields following the Length field. In the Mode I CAQ frame format in FIG. 9 , the Length field has a value of K*(N*3+1). Yet, the example shown in FIG. 9 is just an exemplary to explain the principle of the present invention. A form of a channel list repeating in a frame format, which is repeated to represent the channel list (or WSM) for multiple locations, can be variously defined.
[0142] For instance, in case of K=1 in the example of FIG. 9 , the Length field can be represented as the Length field includes information indicating the length (i.e., the length of the Map ID+the length of the Channel number field, the Maximum power level field, and the Validity field) of the channel list. For instance, if it is assumed that one channel list includes N number of channels, since the Channel number field, the Maximum power level field, and the Validity field are repeated N times (N*(1+1+1) and the length of the Map ID is 1, the Length field may have a value of N*3+1. In this case, a maximum value of the N is limited to the maximum value capable of being represented by the Map ID. In particular, in the example of FIG. 9 , the Mode I CAQ frame format in case of K=1 has a configuration practically identical to the aforementioned configuration of the Mode I CAQ frame format in FIG. 7 .
[0143] More extensively, in case of K>1 (i.e., K≧2), {one ‘Map ID’ and N number of ‘Channel number field, Maximum power level, and Validity field’} can be repeated K times after the Length field. Since the length of the Map ID field, the Channel number field, the Maximum power level field, and the Validity field is one octet, respectively, the Length field may have a value of K*(N*3+1).
[0144] The Map ID field is a unique number of each channel list. And, a value different from each other is given to a channel list different from each other. In particular, since one available channel list is provided in one location, a Map ID of a channel list in one location and the Map ID of the channel list in another location are provided with a value different from each other. And, in case that an available channel list is updated, the Map ID can be provided with a value different from the value of the Map ID previously used. For instance, the Map ID can be set to increase by 1 on every update of the available channel list. Yet, this is just an exemplary and may be non-limited to this. According to the example that the Map ID increases by 1 on every update of the available channel list, in case that a channel list is updated after a maximum value (e.g., 2 8 −1) of the Map ID is provided to the channel list, 1 is provided to a value of the Map ID for an updated channel list and the Map ID value increasing by 1 is provided to a channel list to be updated. In particular, the value of the Map ID field explained in FIG. 7 , which is the example of the Mode I CAQ frame format for an available channel list in one location, is a scheme for providing 0 after a maximum value (e.g., 2 8 −1). On the other hand, the value of the Map ID field explained in FIG. 9 , which is the example of the Mode I CAQ frame format for an available channel list in one or more locations, is a scheme for providing 1 after a maximum value (e.g., 2 8 −1) of the Map ID field. In the example of FIG. 9 , the Map ID field having a value of 0 can be set to be used to indicate whether a channel list is updated and may not be used as an identification number of the channel list.
[0145] As shown in the example of FIG. 9 , the Mode I CAQ for multiple locations can be used by a request of the Mode I STA or can be used by a decision of the Mode II STA, which knows a moving area of the Mode II STA and is capable of directly selecting an operation channel. In case of the former, the Mode I STA can transmit a Mode I CAQ request message to the Mode II STA before an operation is started and the Mode II STA can transmit a Mode I CAQ response message such as the example of FIG. 9 to the Mode I STA in response to the Mode I CAQ request message. In case of the latter, after obtaining an available channel list for multiple locations from the DB on a random timing point, the Mode II STA can transmit (transmit in a form of an unsolicited CAQ response or an announcement) the Mode I CAQ response message to the Mode I STA. The latter case can be generally used more than the former case, by which the present invention may be non-limited.
[0146] After obtaining available channel list for multiple locations from the DB and providing a Map ID different from each other to a channel list corresponding to each location, the Mode II STA can inform the Mode I STA of the corresponding channel lists at a time via the Mode I CAQ message such as the example of FIG. 9 . The Map ID of which the Mode II STA informs the Mode I STA can be identical to the identification number numbered by the DB according to an available channel list when the DB transmits the available channel list to the Mode II STA. Or, besides the identification number numbered by the DB, the Mode II STA can generate, provide, and manage a Map ID according to each available channel list. For instance, in case that the Mode II STA provides the Map ID to a plurality of available channel lists for multiple locations at a time, the Map ID can be sequentially numbered. This is because the Mode II STA intends to easily manage the Map ID in case the available channel list is updated by the DB. And, if the available channel list is updated in a state that the Map ID is all assigned up to the maximum value (e.g., 2 8 −1), a value of the Map ID field is sequentially assigned not from 0 but from 1. In this case, in order to prevent the channel list assigned as Map ID=1 from being handled as a channel list identical to the channel list of previously assigned as Map ID=1, the Mode II STA transmits a CVS configured by Map ID=0 to the Mode I STA. Hence, although the Map ID of the Mode I CAQ transmitted thereafter has a value identical to the previous Map ID, the Mode II STA can inform that it is a different channel list indicator. And, Map ID=0 can be used as a usage for indicating that a correlation between the channel list and the map ID is newly defined instead of being assigned to the available channel list. In particular, in case of reusing a conventional Map ID value in a manner of assigning the Map ID from 1 again since the Map ID is over the maximum value, the Mode II STA can transmit the CVS configured by Map ID=0 to inform the Mode I STA of a channel list modification.
[0147] And, for instance, multiple locations included in a CAQ request frame can be sequentially mapped to a plurality of available channel lists (WSM) included in a CAQ response frame. In particular, if the multiple locations included in the CAQ request are sequentially called a first location, a second location, . . . , a K location, the CAQ response can sequentially include an available channel list for the first location, an available channel list for the second location, . . . , an available channel list for the K location. Similar to this, an order of the Map ID included in a CVS frame can be mapped to the order (or the order of a plurality of available channel lists in the CAQ response frame) of the location information in the CAQ request frame as well.
[0148] FIG. 10 is a diagram of a CVS information element (IE) format for one or more available channel lists. A CVS format in FIG. 10 ( a ) is different from the CVS format in FIG. 8 ( a ) in that the Map ID field can be repeated. Since the rest of the fields are identical to the fields of the example of FIG. 8 , duplicated explanation is omitted. In the CVS format in FIG. 10 ( a ), it is not excluded a case that one Map ID field is included only. And, a CVS IE format in FIG. 10 ( b ) is an example of which a CVS delivery interval field is added to the CVS format in FIG. 10 ( a ).
[0149] The Mode II STA can provide the Map ID of one or more channel lists to the Mode I STA using the CVS format in FIG. 10 . The Mode I STA can judge that a corresponding channel list is continuously valid in a manner of consistently receiving a CVS, which corresponds to the Map ID of a currently possessed available channel list, with a period less than a preset time interval (e.g., CVSTimeInterval). And, in case that although the Mode I STA receives the CVS itself for the CVSTimeInterval but cannot receive a Map ID of a specific channel list in the received CVS for the CVSTimeInterval (e.g., 60 seconds), the Mode I STA can judge that the corresponding channel list is not valid anymore. If the Mode I STA cannot receive the CVS itself for the CVSTimeInterval, the information on the channel lists obtained via the Mode I CAQ becomes not valid anymore. In this case, the Mode I STA can perform the Mode I CAQ process again.
[0150] In particular, the CVSTimeInterval can be represented as an expiration date of the available channel list. Hence, in order to maintain one or more channel lists valid for the time more than the CVSTimeInterval, one or more Map IDs for one or more channel lists should be delivered to the Mode I STA in a manner of being included in the CVS. To this end, the CVS of the format depicted in FIG. 10 can be used.
[0151] Having received the CVS, the Mode I STA checks the Map IDs included in the corresponding CVS. And then, the Mode I STA judges the channel list(s) corresponding to the Map ID, which does not correspond to the Map ID included in the CVS among the channel lists of which the Mode I STA possessed in advance (i.e., the Mode I STA possesses a plurality of channel lists and a plurality of Map IDs corresponding to a plurality of the channel lists via a latest Mode I CAQ), as invalid. The Mode I STA can discard the channel list(s) or simply may not use the channel list(s).
[0152] The Mode II STA can deliver the information on a plurality of the available channel lists to the Mode I STA in advance via the Mode I CAQ response (a response for the Mode I CAQ request of the Mode I STA or an unsolicited response). The Mode II STA can inform the Mode I STA of whether the preliminarily delivered a plurality of the available channel lists are continuously valid using the CVS. In particular, it is able to represent that the Mode II STA renewals the expiration date of the channel list capable of being used by the Mode I STA on every CVSTimeInterval using the CVS.
[0153] In this case, each of the map IDs preliminarily provided in the process of the Mode I CAQ does not need to be mandatorily included in the CVS. In particular, although the Mode II STA should consistently transmit the CVS on every CVSTimeInterval (e.g., 60 seconds), only a Map ID of an available channel in one location can be included in the CVS. The Mode I STA can identify that the available channel list applied in a current location (and current timing point) corresponds to which one of a plurality of the available channel lists obtained via the Mode I CAQ.
[0154] And, the Map ID included in the CVS not always corresponds to the channel list currently capable of being used by the Mode I STA. Besides the channel list currently capable of being used by the Mode I STA, the Map ID for a different channel list except the currently available channel list among the channel lists previously transmitted to the Mode I STA can be consistently provided to the Mode I STA via the CVS as well. For instance, as shown in FIG. 6 ( b ), if an available channel in (P1, R2) is a subset of an available channel in (P1, R1), the operation as mentioned in the above can be performed. For instance, assume a case that a MAP ID of an available channel in (P1, R1) region is 1, 2, 3, the MAP ID of the available channel in (P1, R2) is 1, 2, and the MAP ID of the available channel in (P1, R3) is 1. In this case, if the Mode I STA is currently positioned at the (P1, R1) region, the CVS received by the Mode I STA includes the MAP ID=1, 2, and 3. The MAP ID 1 and 2 correspond to the available channel list in the (P1, R2) region as well. Similarly, among the MAP ID=1, 2, and 3, which are included in the CVS received by the Mode I STA positioned at the (P1, R1) region, the MAP ID=1 corresponds to the available channel list (i.e., a different channel list) in the (P1, R3) region as well.
[0155] As mentioned in the foregoing description, the CVS may include a currently available channel list and a plurality of Map ID fields corresponding to the different channel lists. In particular, including a Map ID in the CVS can be called a renewal of a channel list corresponding to the corresponding Map ID. By performing a renewal of the corresponding channel list using the CVS from a transmission timing of the channel list on every CVSTimeInterval, it is able to manage the corresponding channel list to be consistently valid. Or, among a plurality of the Map IDs corresponding to a plurality of the channel lists preliminarily provided to the Mode I STA, a Map ID not included in a previous CVS can be included in a later CVS. For instance, in case that the Mode I STA does not discard a channel list corresponding to the Map ID not included in the CVS and does not simply use the channel list, the Mode I STA can perform a renewal for the channel list, which is not used before receiving a latest CVS although the Mode I STA possesses the channel list. In this case, the Mode I STA may simply operate in a manner that the Mode I STA uses a channel list(s) corresponding to the Map ID(s) included in the latest CVS and does not use the channel list(s) corresponding to the Map ID(s) not included in the latest CVS.
[0156] Meanwhile, if a channel list is modified due to a movement of the Mode II STA, the Mode II STA can inform the Mode I STA of a modified available channel list (e.g., in a manner of an announcement) using the Mode I CAQ. Yet, if the modified available channel list is a subset of the available channel list prior to the modification and there exists a channel list coincident with the modified available channel list among the channel lists corresponding to the Map ID included in the CVS, the Mode II STA does not inform the Mode I STA of the modified available channel list via the Mode I CAQ but informs the Mode I STA of which channel is not valid anymore via the CVS. In this case, the Map ID of the channel list including the channel, which is not valid anymore, is not included in the CVS. Having received the aforementioned CVS, the Mode I STA judges that the channel list corresponding to the Map ID, which is not included in the CVS, is not valid anymore. And then, the Mode I STA does not use (or may discard the channel list) the channel list. In particular, in terms of the Mode I STA, the channel list capable of being used by the Mode I STA is a union of the channel list corresponding to the Map ID included in the lately received CVS.
[0157] For instance, the Mode I STA can obtain available channel information on multiple locations in advance using the Mode I CAQ message such as the example of FIG. 9 . If a location of the Mode I STA is modified, the Mode I STA can continuously check (i.e., tracking) whether a plurality of available channel lists for the multiple locations are valid in a manner of not using a new Mode I CAQ message in a modified location but receiving the CVS (e.g., the CVS of FIG. 10 ) only. If the channel list capable of being used by the Mode I STA is changed since the location of the Mode I STA and/or the Mode II STA is modified, the Mode II STA can transmit a Map ID of the modified channel list to the Mode I STA via the CVS (in this case, assume that the channel list corresponding to the corresponding Map ID is provided to the Mode I STA in advance using the Mode I CAQ).
[0158] Having received the CVS, the Mode I STA can check whether there exists a channel list corresponding to the Map ID received via the CVS among the available channel list in the multiple locations obtained in advance via the Mode I CAQ. If the Mode I STA possesses the available channel list corresponding to the Map ID included in the CVS, the Mode I STA can use the channel list currently used in a manner of replacing into a channel list corresponding to the Map ID included in the CVS. If the Mode I STA does not possess the available channel list corresponding to the Map ID included in the CVS or the Map ID of the CVS is set to 0, the Mode I STA can receive a new available channel list from the Mode II STA. The Mode I STA can obtain a new available channel list by receiving a Mode I CAQ response from the Mode II STA with/without a request. This Mode I CAQ process can be called an updated Map ID obtaining process or a Map ID reset process.
[0159] In case of the Mode I CAQ as a usage of updating a Map ID, if the Mode II STA receives a Mode I CAQ request message, the Mode II STA transmits an updated Map ID and available channel list information corresponding to the updated Map ID to the Mode I STA via a Mode I CAQ response message. Having received the Mode I CAQ response message, the Mode I STA can add the updated Map ID and the available channel list corresponding to the updated Map ID to the conventional valid available channel lists.
[0160] Meanwhile, after receiving the CVS of which the Map ID=0, the Map ID of the channel list newly received via the Mode I CAQ response may have a number identical to the Map ID of the conventional channel list. In this case, the conventional channel list can be replaced (or reset) in a manner of matching the newly obtained channel list with the corresponding Map ID.
[0161] In the foregoing description, the Mode I STA obtains an available channel list in one or more locations and corresponding Map ID in advance using the latest Mode I CAQ process and a method of informing the Mode I STA of validity of the obtained available channel list via the CVS is described.
[0162] Subsequently, a case of newly configuring the available channel list itself, which is obtained using the Mode I CAQ process, is explained. For instance, it is able to assume a case that the Mode II STA moves the available channel list to not a location of which the Mode II STA obtained the available channel list in advance but a new location or a case that the Mode II receives a notification from the DB notifying that the available channel list is updated. In this case, although the Mode II STA transmits CVS to the Mode I STA, since the Mode II STA cannot be sure the validity of the available channel list corresponding to the Map ID included in the CVS, it is necessary for the Mode II STA to have a process of obtaining the available channel list again. Hence, the Mode II STA can obtain a new available channel list (an available channel list in a modified location or an available channel list updated in the DB although there is no location change) by accessing the DB again.
[0163] If the available channel list newly obtained by the Mode II STA from the DB is not matched with the conventional available channel list, the Mode II STA can transmit the CVS including the updated Map ID to the Mode I STA. Since the Mode I STA does not have a channel list of the Map ID included in the CVS, the Mode I STA transmits a Mode I CAQ request message to the Mode II STA and can receive a Mode I CAQ response message including the information on the updated available channel list from the Mode II STA.
[0164] Or, if the available channel list newly obtained by the Mode II STA from the DB is matched with the conventional available channel list, the Mode II STA can transmit the CVS using the conventional Map ID as it is. Having received the CVS, the Mode I STA does not perform a Mode I CAQ request.
[0165] In the following description, a Mode I CAQ process for one or more locations according to the aforementioned example of the present invention and various examples to which a CVS transmission and reception process is applied are explained.
[0166] FIG. 11 is a flowchart indicating a Mode I CAQ process and a CVS transceiving process according to one example of the present invention. In the example of FIG. 11 , assume that the Mode I STA is positioned within the coverage of the Mode II STA and the Mode II STA is capable of exchanging information with an authorized DB via the internet and the like.
[0167] In the step S 1001 , the Mode I STA can transmit a CAQ Request 1 to the Mode II STA and this corresponds to a Mode I CAQ request.
[0168] In the step S 1002 , the Mode II STA can transmit an available channel list query for multiple locations to the authorized DB (e.g., DB). This corresponds to a Mode II CAQ request. For instance, the Mode II STA is positioned at a P1 in the example of FIG. 6 ( a ) and can query a channel list available in 2 locations (i.e., (P1, R1) and (P2, R2)) to the DB.
[0169] In the step S 1003 , the DB can deliver an available channel list for multiple locations to the Mode II STA in response to the query of the Mode II STA. this corresponds to a Mode II CAQ response. For instance, the available channel list provided by the DB to the Mode II STA assumes a case that the channel number of the channels capable of being used in (P1, R1) is {1, 2, and 3} and the channel number of the channels capable of being used in (P2, R2) is {3, 4, and 5}.
[0170] In the step S 1004 , the Mode II STA can transmit a channel list capable of being used by the Mode I STA among the available channel list for the multiple locations obtained from the DB to the Mode I STA. This corresponds to a Mode I CAQ response. For instance, the information included in the CAQ Response 1 can be summarized in Table 10 as follows.
[0000]
TABLE 10
CAQ response 1
Location
Map ID
Channel number
(P1, R1)
1
{1, 2, 3}
(P2, R2)
2
{3, 4, 5}
[0171] Meanwhile, although the step S 1002 may be initiated by the step S 1001 , the Mode II STA can transmit the available channel list query to the DB despite that the step S 1001 is not performed. And, if the Mode II STA already obtained the available channel list for the multiple locations from the DB, the Mode II STA can perform the Mode I CAQ response of the S 1004 in response to the Mode I CAQ request without performing the Mode II CAQ process of the S 1002 and the S 1003 . Or, the Mode II STA may deliver the available channel list for the multiple locations to the Mode I STA without performing the S 1001 (or, without performing the S 1001 , the S 1002 , and the S 1003 ). This corresponds to an unsolicited Mode I CAQ response. As mentioned in the foregoing description, the available channel list for the multiple locations can be transmitted to the Mode I STA in the step S 1004 in various situations.
[0172] In the step S 1005 , the Mode II STA can transmit a CVS (CVS 1 ) to the Mode I STA. The CVS 1 can include information where Map ID=1 only. Hence, the Mode I STA can determine a channel capable of being used by the Mode I STA where the channel number {1, 2, 3} corresponding to the map ID=1 is available in a current location and current timing point. By doing so, the Mode I STA can perform a WS communication.
[0173] In the step S 1006 , a geo-location change may occur due to a movement of the Mode II STA to a different location. For instance, assume that the Mode II STA stays in the (P1, R1) position before the step S 1006 and moves to a (P2, R2) position in the step S 1006 (more specifically, assume that the Mode II STA moves to the (P2, R2) position except a part overlapped with the (P1, R1) region). According to the location change, the available channel list may be modified. Since the Mode II STA has already obtained the available channel list in the (P2, R2) position in the step S 1003 , the Mode II STA does not need to query a new available channel list to the DB due to the location change of the step S 1006 .
[0174] In the step S 1007 , the Mode II STA can transmit a CVS (CVS 2 ) including a Map ID of an available channel list in a current location to the Mode I STA. The CVS 2 can include information where Map ID=2 only. Hence, the Mode I STA can determine a channel capable of being used by the Mode I STA where the channel number {3, 4, 5} corresponding to the map ID=2 is available in a current location and current timing point. By doing so, the Mode I STA can perform a WS communication.
[0175] While the Mode II STA is staying in the (P2, R2) region, update of the channel list, which is available in the (P2, R2) position, may occur. In the step S 1008 , the DB can transmit an updated available channel list to the Mode II STA. This corresponds to an unsolicited Mode II CAQ response. For instance, the updated available channel list received by the Mode II STA in the step S 1008 (e.g., channel number {3, 4, 6} in the position (P2, R2)) may be not matched with the available channel list (e.g., channel number {3, 4, 5} in the position (P2, R2)) previously obtained in the step S 1003 . In this case, the Mode II STA can assign a Map ID to the updated available channel list as shown in the following Table 11.
[0000]
TABLE 11
Location
Map ID
Channel number
(P2, R2)
3
{3, 4, 6}
[0176] In the step S 1009 , the Mode II STA can transmit a CVS (CVS 3 ) to the Mode I STA to inform that the available channel list is updated in the (P2, R2). The CVS 3 can include information where Map ID=3 only. In this case, the Mode I STA includes the available channel list where Map ID=1, which is included in the CAQ Response received in the step S 1004 , and the available channel list where the Map ID=2 only. Hence, when the Mode I STA checks the Map ID included in the received CVS 3 , since the Mode I STA does not have Map ID=3, the Mode I STA cannot determine an available channel list corresponding to the Map ID=3. Hence, the Mode I STA should obtain new available channel information.
[0177] In the step S 1010 , the Mode I STA can transmit a CAQ Request 2 to the Mode II STA. This corresponds to the Mode I CAQ request.
[0178] In the step S 1011 , the Mode II STA can transmit the CAQ response 2 to the Mode I STA. This corresponds to the Mode I CAQ response. In this case, information of a following Table 12 should be included in the CAQ response 2.
[0000]
TABLE 12
CAQ Response 2
Location
Map ID
Channel number
(P2, R2)
3
{3, 4, 6}
[0179] Meanwhile, explanation on the aforementioned FIG. 11 can be identically applied to the example of FIG. 6 ( b ). For instance, S 1001 to S 1005 and S 1007 to S 1011 can be identically applied to the example. It can be understood that the channel list is modified due to the movement of the Mode II STA from the (P1, R1) position to the (P1, R2) in the step S 1006 (in particular, the channel list is modified when the Mode II STA moves from the (P1, R2) region to the region except the (P1, R1) region).
[0180] FIG. 12 is a flowchart indicating a Mode I CAQ process and a CVS transceiving process according to a different example of the present invention. In the example of FIG. 12 , for a part of which a separate explanation does not exist, the explanation for the example of FIG. 11 can be applied as it is.
[0181] In the example of FIG. 12 , assume a case that the Mode II STA starts from P1 of the example of FIG. 6 ( b ) and moves in a manner of passing through (P1, R1) region, (P1, R2) region, and (P1, R3) region. In particular, an anticipated moving path of the Mode II STA is shown in FIG. 6 ( b ) and assume that the Mode II STA has already obtained a channel list available in the anticipated moving path (for instance, assume that the Mode II STA already obtained available channel lists from the DB).
[0182] In the step S 1101 , the Mode I STA can transmit a Mode 1 CAQ Request 1 (CAQ Request 1) to the Mode II STA. In the step S 1102 , the Mode II STA can transmit a Mode I CAQ response (CAQ Response 1) to the Mode I STA. For instance, a channel list available in each location including the anticipated moving path of the Mode II STA can be included in the CAQ Response 1 as shown in the following Table 13.
[0000]
TABLE 13
CAQ response 1
Location
Map ID
Channel number
(P1, R1)
1
{1, 2, 3}
(P1, R2)
2
{1, 2}
(P1, R3)
3
{1}
[0183] As shown in the Table 13, in case of the multiple locations are configured as depicted in FIG. 6 ( b ), an available channel in a wider region can be set to a subset of an available channel of a narrower region. For instance, when a channel available in wherever in the wider region is determined, since the region is wider, possibility of existence of an incumbent user or interference of a neighboring channel may increase. Yet, this is just an exemplary for the understanding of the present invention. The present embodiment can be applied to various cases where an available channel list in one location becomes a subset of an available channel list in a different location.
[0184] The step S 1102 can be performed in response to the step S 1101 or can be performed by an unsolicited form.
[0185] In the step S 1103 , the Mode II STA can transmit a CVS (CVS 1 ) to the Mode I STA. The CVS 1 can include Map ID=1, 2, and 3. Hence, the Mode I STA can determine a channel capable of being used by the Mode I STA where the channel number {1, 2, 3} corresponding to the Map ID=1, 2, and 3 is available in a current location and current timing point (e.g., for CVSTimeInterval). By doing so, the Mode I STA can perform a WS communication.
[0186] In the step S 1104 , a geo-location change occurs due to the movement of the Mode II STA moving to a (P1, R2) position (in particular, in case that the Mode II STA, which exists in the (P1, R1) region, moves to the (P1, R2) region in a manner of getting out an R1 radius) and an available channel list can be modified according to the movement of the Mode II STA. In the step S 1105 , the Mode II STA can transmit a CVS (CVS 2 ) to inform the Mode I STA of the change of the available channel list. The CVS 2 can include the Map ID=2 and 3. Hence, the Mode I STA can determine a channel capable of being used by the Mode I STA where the channel number {1, 2} corresponding to the Map ID=2 and 3 is available in a current location and current timing point (e.g., for CVSTimeInterval). By doing so, the Mode I STA can perform a WS communication. And, the Mode I STA simply does not use or can discard the channel number {3} not corresponding to the Map ID of the CVS.
[0187] In the step S 1106 , a geo-location change occurs due to the movement of the Mode II STA moving to a (P1, R3) position (in particular, in case that the Mode II STA, which exists in the (P1, R2) region, moves to the (P1, R3) region in a manner of getting out an R2 radius) and an available channel list can be modified according to the movement of the Mode II STA. In the step S 1107 , the Mode II STA can transmit a CVS (CVS 3 ) to inform the Mode I STA of the change of the available channel list. The CVS 3 can include the Map ID=3. Hence, the Mode I STA can determine a channel capable of being used by the Mode I STA where the channel number {1} corresponding to the Map ID=3 is available in a current location and current timing point (e.g., for CVSTimeInterval). By doing so, the Mode I STA can perform a WS communication. And, the Mode I STA simply does not use or can discard the channel number {2, 3} not corresponding to the Map ID of the CVS.
[0188] Meanwhile, While the Mode II STA is staying in the (P1, R3) region, update of the channel list, which is available in the (P1, R3) position, may occur. In the step S 1108 , the DB can transmit an updated available channel list to the Mode II STA. This corresponds to an unsolicited Mode II CAQ response. For instance, the updated available channel list received by the Mode II STA in the step S 1108 (e.g., channel number {4, 5} in the position (P1, R3)) may be not matched with the available channel list (e.g., channel number {1} in the position (P1, R3)) previously obtained. In this case, the Mode II STA can assign a Map ID to the updated available channel list as shown in the following Table 14.
[0000]
TABLE 14
Location
Map ID
Channel number
(P1, R3)
4
{4, 5}
[0189] In the step S 1109 , the Mode II STA can transmit an unsolicited Mode I CAQ response (CAQ Response 2) to the Mode I STA to inform that the available channel list is updated. In this case, information of a following Table 15 should be included in the CAQ Response 2.
[0000]
TABLE 15
CAQ Response 2
Location
Map ID
Channel number
(P3, R3)
4
{4, 5}
[0190] Meanwhile, explanation on the aforementioned FIG. 12 can be identically applied to the example of FIG. 6 ( a ). For instance, it can be understood that the channel list is modified due to the movement of the Mode II STA from the (P1, R1) position to the (P2, R2) in the step S 1104 (in particular, the channel list is modified when the Mode II STA moves from the (P2, R2) region to the region except the (P1, R1) region). In this case, the available channel information in (P2, R2) may correspond to a subset of the available channel information in (P1, R1). As mentioned earlier, a CVS scheme for informing the validity of the available channel in the R2 radius except the R1 radius can be used.
[0191] For the method of transceiving a CAQ request/response and a CVS according to one embodiment of the present invention explained in relation to FIG. 11 and FIG. 12 , each of the items explained by the various embodiments of the present invention can be independently applied or two or more embodiments can be implemented in a manner of being simultaneously applied. For clarity, duplicated content is omitted.
[0192] FIG. 13 is a block diagram of a wireless device configuration according to one embodiment of the present invention.
[0193] An AP 700 can include a processor 710 , a memory 720 , and a transceiver 730 . An STA 750 can include a processor 760 , a memory 770 , and a transceiver 780 . The transceiver 730 / 780 can transmit/receive a radio signal. For instance, the transceiver can implement a physical layer according to an IEEE 802 system. The processor 710 / 760 can implement a physical layer and/or a MAC layer according to an IEEE 802 system in a manner of being connected to the transceiver 730 / 760 .
[0194] The processor 710 of the AP 700 can be configured to determine WSM for the STA 750 . The transceiver 730 of the AP 700 can be configured to transmit information on the WSM to the STA 750 and configured to transmit a CVS frame including a Map ID of a currently valid WSM to the STA 750 after the WSM is transmitted. Meanwhile, the transceiver 780 of the STA 750 can be configured to receive the information on the WSM from the AP 700 and configured to receive a CVS frame including a Map ID of a currently valid WSM from the AP 700 after the WSM information is received. The processor 760 of the STA 750 can compare a value of the Map ID field included in the CVS frame with a Map ID possessed by the STA 750 . In this case, a field for indicating a time interval of which the CVS frame is transmitted is included in the CVS frame. The CVS frame can be transmitted on every corresponding transmission time interval. Besides, the processor 710 of the AP 700 can be configured to control the AP 700 to perform an operation according to various embodiments of the present invention related to the CAQ request/response and the CVS transmission and reception.
[0195] And, a module for implementing the operation of the AP and the STA according to the aforementioned various embodiments of the present invention is stored in the memory 720 / 770 and can be executed by the processor 710 / 760 . The memory 720 / 770 is included in the inside of the processor 710 / 760 or is installed in the external of the processor 710 / 760 . The memory can be connected to the processor 710 / 760 by a well-known means.
[0196] For the aforementioned detail configuration of the AP device and the STA device, each of the items explained by the various embodiments of the present invention can be independently applied or two or more embodiments can be implemented in a manner of being simultaneously applied. For clarity, duplicated content is omitted.
[0197] Embodiments of the present invention can be implemented using various means. For instance, embodiments of the present invention can be implemented using hardware, firmware, software and/or any combinations thereof.
[0198] In the implementation by hardware, a method according to each embodiment of the present invention can be implemented by at least one selected from the group consisting of ASICs (application specific integrated circuits), DSPs (digital signal processors), DSPDs (digital signal processing devices), PLDs (programmable logic devices), FPGAs (field programmable gate arrays), processor, controller, microcontroller, microprocessor and the like.
[0199] In case of the implementation by firmware or software, a method according to each embodiment of the present invention can be implemented by modules, procedures, and/or functions for performing the above-explained functions or operations. Software code is stored in a memory unit and is then drivable by a processor. The memory unit is provided within or outside the processor to exchange data with the processor through the various means known in public.
[0200] Detailed explanation on the preferred embodiment of the present invention disclosed as mentioned in the foregoing description is provided for those in the art to implement and execute the present invention. While the present invention has been described and illustrated herein with reference to the preferred embodiments thereof, it will be apparent to those skilled in the art that various modifications and variations can be made therein without departing from the spirit and scope of the invention. For instance, those skilled in the art can use each component described in the aforementioned embodiments in a manner of combining it with each other. Hence, the present invention may be non-limited to the aforementioned embodiments of the present invention and intends to provide a scope matched with principles and new characteristics disclosed in the present invention.
INDUSTRIAL APPLICABILITY
[0201] Although various embodiments of the present invention are described in a manner of mainly concerning IEEE 802.11 system, the embodiments can be applied to various mobile communication systems where a CAQ request/response and a CVS transmission/reception are performed in a whitespace band in the same manner.
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The present document related to a method and apparatus for transceiving a signal capable of verifying the validity of an available channel in a wireless communication system. According to the present invention, a scheme for transceiving available channel information, a scheme for requesting/responding to a channel validity inquiry, and a scheme for transceiving a contact verification signal are provided, and accordingly, a scheme for supporting the accurate and efficient operation of an unlicensed device while protecting a licensed device in a whitespace band is provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to ladder associated, detachable trays or shelves for supporting tools, paint cans, paint brushes and the like.
2. Description of the Prior Art
A common problem encountered in completing construction, building repairs or painting on a ladder is the absence of convenient support at the higher ladder elevations of tools, paint, paint brushes and the like within convenient reach of the workmen. A number of prior art inventions have addressed this problem by providing detachable trays for ladders.
In order to provide maximum utility and versatility the supporting structure for a ladder tray should be easily demountable, equally suited for mounting on the left or right hand side of a ladder, and possess means for adjusting the angle of the attached tray to compensate for changes in ladder attitude. Further economic and utilitarian advantages are realized by providing a demountable tray supporting structure having simply constructed mounting and adjusting means capable of inexpensive fabrication and easy operation. The means by which a tray support structure is attached to a ladder should be adaptable to fit all types and sizes of ladders commonly in use by means of simple adjustments.
Although numerous prior art ladder trays and ladder tray supporting structures have been developed to solve certain of the aforementioned problems, none have adequately solved all of the problems. As will become apparent from the discussion which follows, however, the present invention solves each of the aforementioned problems in a simple, inexpensive and expedient manner.
The following United States Patents constitute the most pertinent art known to Applicant.
U.S. Pat. No. 639,611
U.S. Pat. No. 1,087,603
U.S. Pat. No. 1,358,277
U.S. Pat. No. 2,837,306
U.S. Pat. No. 3,131,900
U.S. Pat. No. 3,495,683
U.S. Pat. No. 3,822,847
The aforementioned prior art patents show ladder trays and supporting structures of a nature only generally similar to that herein shown, lacking specific structural features of advantage, hereinafter further described and claimed.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a ladder tray supporting structure which can be readily attached to and removed from all types of ladders commonly in use.
It is another object to provide a ladder tray support of the aforementioned character which can be easily mounted on either the left or right-hand side of a ladder.
It is still another object to provide a ladder tray support which can be fabricated from sheet metal and commonly available fasteners and having no compound curves or other complex structural features which would necessitate the employment of expensive, complicated and time-consuming fabrication techniques.
A further object of the invention is to provide a ladder tray support which may be readily adjusted by the user to ensure that an attached tray can be made level regardless of changes in ladder attitude.
A still further object of the invention is to provide a ladder tray support with a structure which neither contacts nor impedes access to the ladder steps.
A still further object of the instant invention is to provide a ladder tray support of the aforementioned character which also provides a bracket for supporting and rigidifying an attached tray.
A still further object of this invention is to provide a ladder tray support which can be securely mounted to the side rails of aluminum, fiberglass, and other types of ladders without undue stress on or deformation of the ladder side rails.
In this regard, a pair of parallel plates is used to clamp the ladder tray support to a ladder side rail thus distributing the clamping force over the greatest possible surface area and avoiding deformation which may otherwise result particularly when used on aluminum or fiberglass ladders.
In summary, these and other objects are achieved by a ladder tray support comprising a pair of support plates dimensioned for clamping on opposite sides of a ladder side rail, a pair of studs carried by a first of the plates and projecting substantially perpendicularly thereto, the studs being spaced apart to straddle said side rail, the second of the plates having openings positioned for and slidably receiving the studs with the latter projecting therethrough to an exterior side of said second plate, manually engageable means mounting on the stud ends for clamping said plates together on said side rail, a third stud carried by the second plate and projecting substantially perpendicularly from said exterior side thereof, a tray support bracket having an opening for and receiving the third stud and providing a pivotal connection for relative rotational displacement of said bracket, manually engageable means on the third stud retaining said pivotal connection, and index means mounted on said second plate in bracket for locking said bracket and second plate in selected rotated positions.
The invention possesses other objects and features of advantage, some of which of the foregoing will be set forth in the following description of the preferred form of the invention which is illustrated in the drawings accompanying and forming part of this specification. It is to be understood, however, that variations in the showing made by the said drawings and description may be adopted within the scope of the invention as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a ladder tray support attachment constructed in accordance with the present invention and shown operatively assembled on a ladder.
FIG. 2 is a cross-sectional view taken substantially on the plane of line 2--2 of FIG. 1.
FIG. 3 is a cross-sectional view taken substantially on the plane of line 3--3 of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
The demountable ladder tray support of the present invention comprises, briefly, a pair of support plates 6 and 7 dimensioned for clamping on opposite sides of a ladder side rail 8; a pair of studs 11 and 12 carried by plate 6 and projecting substantially perpendicularly thereto with the studs spaced apart as seen in FIGS. 1 and 3 to straddle ladder rail 8; and plate 7 is formed with openings 13 and 14 for slidably receiving studs 11 and 12 with the ladder extending through plate 7 and projecting to the exterior side 16 thereof as seen in FIG. 1.
Manually engageable means, here in the form of wing nuts 17 and 18 are mounted on the outer ends of studs 11 and 12 for clamping plates 6 and 7 together on side rail 8. A third stud 21 is carried by plate 7 and projects substantially perpendicular from its exterior side 16 for support of a bracket 22 for supporting a tray 23 and having an opening 24 for receiving stud 21 and providing a pivotal connection for relative rotational displacement of the bracket. Manually engageable means, here wing nut 26, is threaded onto stud 21 for retaining the pivotal connection; and index means is mounted on plate 7 and bracket 22 for locking the bracket and plate in selected rotated position. As here shown, bracket 22 is formed with an end portion 27 having a side in face-to-face confronting relation to the exterior side 16 of plate 7 and the indexing means comprises a pin 28 carried by bracket portion 27 and a plurality of arcuately spaced openings 29 in plate 7 dimensioned and positioned for receiving pin 28. Adjustment of the bracket and attached tray may be quickly and easily effected by backing off wing nut 26 to permit separation of plate 7 and bracket end 27 to remove pin 28 from one of openings 29, rotation of the bracket on stud 21 to position pin 28 in registration with another of openings 29, and re-tightening wing nut 26.
Attachment of the mounting plates on opposite sides of a ladder side rail is facilitated by the mounting around one of the studs 11-12 of a helical spring 31 for constantly urging the plates apart when the wing nut on the other stud is backed off to open the clamp for mounting on the opposite sides of a ladder side rail. In the present showing, helical springs 31 and 32 are mounted on studs 11 and 12, although, as noted, one will suffice. At the same time, the aforementioned indexing means may be easily and readily adjusted for horizontal positioning of tray 23 depending upon the ladder attitude.
Bracket 22 is here formed of a rigid, elongated strip, such as sheet steel, having a normally upright end 27, a contiguous normally lateral portion 24 for spacing tray 23 at a convenient distance from the ladder side rail 8, a third normally upright portion 35 depending from portion 34 and in face-to-face contact with one side 38 of tray 23, and a fourth portion 39 contiguous to and extending laterally from portion 35 and which is positioned in underlying supporting relation to the bottom 41 of tray 23. Fastening of tray 23 to bracket 22 may be conveniently effected as here shown by bolts and nuts 42 and 43 secured through the side and bottom walls of the tray to bracket sides 35 and 39, respectively.
As is clearly seen in FIG. 1, the ladder tray support of the instant invention is of extremely simple design and construction, having no complicated compound curves, special fasteners, or other exotic hardware. All of the adjustments are conveniently grouped together on the outside of the ladder side rail 4. The middle wing nut 17 is loosened by the user when it is necessary to change the attitude of the tray 22. When the proper position of the tray is found the tray 22 and bracket 15 are rotated by the user to the closest detent position and the wing nut 17 is hand-tightened to lock the tray in the newly selected position.
Plates 6 and 7 serve to distribute the clamping force exerted by the tightening of wing nuts 17 and 18 over a large surface area of the side rail for thus preventing possible damage or deformation. The helical springs 31 and 32 prevent accidental loosening of wing nuts 17 and 18 by pressing plate 7 firmly against the nuts.
While the ladder tray support is shown in FIG. 3 to be mounted on the right-hand forward ladder side rail, it could just as easily be mounted on either of the four side rails shown in the FIGURE. The device may with equal facility be mounted on the side rail of an extension ladder at any convenient height thereon. Preferably, in any case, the device is mounted to rest on one of the ladder rungs. Of particular importance, from a safety standpoint, is the minimal intrusion of the ladder tray support structure into the interior portion of the ladder. The support plates 6 and 7 do not contact or impede access to the ladder steps nor do they interfere in any other significant manner with normal use of the ladder.
By providing studs 11 and 12 of ample length, the structure of the present invention can be adjusted by means of simple manually engageable wing nuts to fit the side rail of any ladder in common use. A further safety feature is afforded by the unique structure of the present invention in that an accidental loosening or failure to tighten wing nuts 11 and 12 will not normally cause the tray 22 to fall from the ladder. Since studs 6 and 7 straddle the front and back of the side rail 4 and plates 2 and 3 straddle the sides of the side rail, a failure to tighten the wing nuts 11 and 12 will merely allow the ladder tray support to slide down the side rail until it comes into contact with a ladder step, a feature not found in certain prior art devices.
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A demountable ladder tray support is disclosed which allows a tray for holding tools, paint brushes, paint and the like to be carried adjacent to the side rail of a ladder at any height desired by the user. The ladder tray support is mounted by means of a pair of clamping plates which are adjustable to accommodate mounting on ladder side rails of all dimensions. Pivotal mounting of a tray support bracket ensures that an attached tray may be leveled regardless of the attitude of the ladder side rail.
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SUMMARY OF THE INVENTION
The invention relates to a container for a small quantity, for instance a portion, of fluid material such as liquid, gas, paste or gel, wherein the container is adapted to reduce its volume through the exertion of external forces and the container is provided with a closure.
BACKGROUND OF THE INVENTION
Such containers are generally known, for instance in the form of tubs for condensed milk closed by means of aluminium foil.
Such prior art containers have the drawback that when the cover is removed there is a considerable chance of leakage and spillage.
From GB-A-1 114 691 is known a container for fluid material wherein the container is adapted to reduce its volume through the exertion of external forces.
This is a container which is costly in mass production.
BRIEF DESCRIPTION OF THE INVENTION
The object of the present invention is to provide a container which can be manufactured at lower cost.
This object is achieved in that the container comprises two walls which are each rigid at least on their edge and which are connected by a flexible wall.
These steps result in a simpler and therefore less expensive production process, for instance by using a moulding process for the rigid walls and possibly a part of the flexible walls, and subsequently applying a blow moulding or deep-draw process to form the flexible walls.
It will be apparent that the container is not only intended for liquids such as condensed milk or lemon squash but that it is also suitable for packaging gas, for instance gas as fuel for lighters, or for gel-like products such as mayonnaise, sauce for french fries, or for pastes such as glue.
The closure is preferably arranged on a discharge spout adjoining an edge.
This step has the advantage that the closure, which is usually formed by a removable or displaceable element, is formed together with a rigid wall or- if this latter is formed by a rigid edge-is formed together with a cover element arranged on the rigid edge.
According to another preferred step the discharge spout is provided with a closure to be removed manually from its position closing the discharge spout.
With this step the container is properly closed until shortly before use; the closure is not opened by external pressure on the container.
According to a preferred embodiment the edges of the rigid walls are each located substantially in a flat plane, which planes extend substantially parallel when a container is full. This embodiment combines a simple production process, as already known for instance in the case of condensed milk tubs, with the advantages of the invention. For this purpose the manufacturing process for the tubs has only to be adapted to the collapsibility of the side walls. This can be performed for instance by a blow moulding process.
Other attractive preferred embodiments are designated in the sub-claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be elucidated hereinbelow with reference to the annexed drawings, in which:
FIG. 1 shows a perspective view of a first embodiment of the present invention;
FIG. 2 shows a perspective view of a second preferred embodiment of the present invention;
FIG. 3 is a perspective view of the embodiment shown in FIG. 2 of the present invention, but then in collapsed situation;
FIG. 4 is a perspective view of a variant of the embodiment shown in FIG. 2;
FIG. 5 is a perspective view of the variant shown in FIG. 4 in collapsed situation; and
FIG. 6 shows a cross sectional view of a third embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The container 1 shown in FIG. 1 comprises a flat upper surface 2 and a lower surface not shown in the drawing. Both the upper surface 2 and the lower surface are sufficiently rigid for this application. The rigid upper surface 2 and the rigid lower surface are mutually connected on their edge by side walls 3 which allow of a large measure of flexibility. Side surfaces 3 are folded in concertina shape, wherein the folds 4 extend substantially parallel to the edges of the rigid surfaces.
Arranged on one edge of upper surface 2 is a spout 5 which is provided with an internal channel and which is adapted to guide the content of container 1 when the upper surface 2 is pressed in the direction toward the lower surface. The spout 5 is preferably provided with a closure (not shown in the drawing) which can be removed manually to dispense the fluid. This closure can be formed for instance by a thin wall which is formed simultaneously with forming of the spout and which can be removed for instance by means of a pull tab.
It is possible to manufacture such a container from many types of material. It will also be apparent that such a container can preferably be manufactured from plastic, and particularly from those plastics which can result in a rigid surface when sufficiently thick and which, when the wall thickness is sufficiently thin, ensure the flexibility of such a wall preferably embodied in a concertina configuration.
It is pointed out here that it may also be useful to provide the rigid walls with reinforcement ribs and the like. These can be embodied internally but also externally, wherein external placing of reinforcement ribs facilitates grasping of the container with the fingers.
It is noted that the dimensions of such a container are small; the dimensions are chosen such that in the case of foodstuffs it is suitable to contain a single portion.
In order to remove the full contents from the container, one of the two surfaces can be provided with an inward directed recess.
Although the foregoing embodiment relates to a container with rectangular rigid surfaces, it will be apparent that such rigid surfaces may also take other forms, for instance square, polygonal, round or oval.
It will also be apparent that it is not necessary for the rigid surfaces to be mutually parallel when the container is full; it is also possible to mutually connect these surfaces on one side by a hinge-like construction, which must of course be fluid-tight, and to move the surfaces toward each other in the manner of a bellows, whereby the content flows out through spout 5.
FIG. 2 shows an alternative embodiment of a container according to the invention. The container 6 depicted therein once again comprises a rigid upper surface 7 and a rigid lower surface 8, only an edge of which can be seen in the drawing. Both rigid surfaces 7,8 take a round form. Extending round the rigid surface 7 in the manner of a skirt is a flexible surface 9 which is connected on its outer edge to a flexible surface 10 likewise extending in the manner of a skirt from the rigid surface 8. The two surfaces 9,10 are mutually connected along an edge 11. Arranged along the edge is a spout 12 through which the content of the container can flow out when the rigid surfaces 7,8 are moved toward each other. The two flexible surfaces 9,10 are provided with radially extending folds 13 which provide the flexible surfaces 9,10 with the relevant flexibility.
FIG. 3 shows the collapsed form of the container shown in FIG. 2. The content of the container flows out through discharge aperture 14 of spout 12.
FIG. 4 shows a variant of the container depicted in FIG. 2; in the container shown in FIG. 4 the material from which the flexible walls 9,10 are manufactured is of a great flexibility such that they do not have to be provided with folds; collapsing of the surfaces 7,8 results in a deformation of the flexible surfaces 9,10 as shown in FIG. 5.
Finally, FIG. 6 shows a third embodiment which is formed by a plastic container 15 formed by a substantially flat base 16 and a substantially cylindrical wall 17. The wall 17 is provided with ribs extending parallel to the base 16, whereby the container is collapsible in the direction perpendicularly of the wall 16.
Such a container can be manufactured for instance by initially deep-drawing a sheet of material, for instance plastic or aluminium, and subsequently plastically deforming the thus created semi-manufacture in other manner by, in the case of plastic, blow moulding or suction into a relevant shape or by deforming by means of a mould is stamp. A pouring spout 18 is moulded on the wall 17. Pouring spout 18 is provided with a lip 19. In order to close the container a cover 20 is arranged which is manufactured for instance from aluminium foil or from plastic. Cover 20 is attached by means of a thermal adhesion process to the edge 21 of wall 17.
At the position of pouring spout 18 the cover 20 is adhered to the lip 19. In the present embodiment a seam 22 is present in cover 20; in other configurations this seam can be omitted. At the position of lip 19 the cover 20 is attached by means of a thermal adhesion process to lip 19 as well as to the side walls (not shown in the drawing) of pouring spout 18. All this results in a good, fluid-tight closure. The lip 19 is provided with a tearing perforation 23 which can be torn off during use so that the part of the cover 20 located to the right of seam 22 in the drawing can be folded upward and the fluid can be dispensed from the pouring spout by for instance pressing the base 16 and cover 20 of the container between thumb and forefinger. The seam 22 can be made thinner.
Further in this embodiment the base 16 takes an elevated form to enable complete emptying of the container.
It will be apparent that it is possible to vary in diverse ways from the embodiment shown here without falling outside the scope of protection of the claims.
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The invention relates to a container for a small quantity, for instance a portion, of fluid material such as liquid, gas, paste or gel, wherein the container is adapted to reduce its volume through the exertion of external forces and the container is provided with a closure, wherein the container comprises two walls (7, 8) which are each rigid at least on their edge and which are connected by a flexible wall (9, 10). The container is preferably provided with a closure which is breakable by internal pressure on the container.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an adhesive composition, particularly relates to a cyanoacrylate adhesive composition for wound or surgical incision closure and a method for making the same.
[0003] 2. The Prior Arts
[0004] For treatment of small wounds, in general, the anti-inflammatory and anti-microbial drugs are applied so that the wound is gradually closed and healed by natural tissue regrowth. The drugs used here are intended for preventing bacterial infection and easing the pain. However, when the wound is large and deep, rejoining adjacent skins around the wound by sutures is a suitable treatment method to promote prompt wounds healing. Compared to the suturing, the tissue adhesive is currently becoming more popular for wound closure because of its unique properties.
[0005] The so-called tissue adhesive is like a glue. When it is used for wound closure, the liquid adhesive is coated on the skin surface adjacent to the wound. Through a curing reaction, the tissue adhesive is solidified and the skins adjacent to the wound can be bonded together by the adhesive, so that the aforementioned wound closure is achieved. Due to the proliferation of epidermal tissue, the cured adhesive would slough off with epidermal cells after about 5-10 days. In some case, the tissue adhesive could be absorbed by the tissue after a period of time. In comparison with the disadvantages of longer operation time and pains associated with the traditional skin suture surgery, utilizing the tissue adhesive for wound closure has the benefits of easy to use, time saving, less pain, and better cosmetic results. As a result, it is the preferred option either for common wound treatment or being an auxiliary treatment for a deep wound. In addition, the tissue adhesive can also be employed to stop the bleeding in ulcer, as an adhesive between the tissue or binding implants to the tissues, etc.
[0006] A preferred tissue adhesive has the following characteristics: (1) having sufficient viscosity so that it can be retained on/near the wound and doesn't flow to unexpected location, and it can cure in a short period of time to close the wound promptly; (2) can bond to tissue in the presence of water and having sufficient binding strength, tensile strength and toughness; (3) having excellent biocompatibility, nontoxic and not causing immune responses; (4) being biodegradable; (5) can be used as a scaffold for cell or tissue growth and thus promote healing.
[0007] Available tissue adhesives can be divided into three main categories: (1) cyanoacrylate adhesives; (2) fibrin glues; and (3) crosslinked protein glues. Among those, fibrin glues are prepared from animal or human blood. Even though they possess good biocompatibility, there are risks of viral infection. Further, the binding force of fibrin glues is relatively weak with about 3-4 N/cm 2 , which is a disadvantage for tissue adhesive. As for the crosslinked protein glues, although they also have good biocompatibility and biodegradability, the risk of viral infection is the same as fibrin glues. Comparatively, cyanoacrylate adhesives can polymerize rapidly and bond wounds in a few minutes with excellent adhesive performance; thereby they have outstanding hemostasia performance and are able to treat large wounds.
[0008] Cyanoacrylate adhesives are generally applied in monomeric form for wound closure. The cyanoacrylate monomers normally start anionic polymerization in the presence of water on the skin surface forming the desired adhesive bond with the skin. However, the monomeric form of cyanoacrylate has a very low inherent viscosity which can result in the flow of the adhesive into undesirable areas or into the wound. Other than causing damage to the adjacent tissue, this may affect the wound healing as well. In order to obtain a cyanoacrylate adhesive composition with a higher viscosity, different thickening agents, e.g. polycyanoacrylate, have been added to the adhesive composition. Polycyanoacrylate is generally prepared by initiating polymerization of cyanoacrylate monomers with bicarbonate or the like as an accelerator/initiator. Then a cleaning or neutralization step with an acid is usually required to remove the excess bicarbonate or the like. However, residual accelerators in polycyanoacrylate would cause premature polymerization of the adhesive (containing cyanoacrylate monomers) when the polycyanoacrylate is added therein, and consequently resulting in reduction of bonding strength and the adhesive's performance for wound closure.
SUMMARY OF THE INVENTION
[0009] The present invention provides an improved method for making a cyanoacrylate adhesive. The thickening agent employed by the present invention has the characteristic that the accelerator used in the thickening agent can be easily removed. As such, the thickening agent, free of accelerators, can prevent premature polymerization of cyanoacrylate monomers. As a result, the adhesive can retain the bonding strength and its wound closure capability.
[0010] In an embodiment of the present invention, a method of making an adhesive composition is provided. The method comprises the steps of: (a) providing an adhesive substrate, the adhesive substrate comprises at least a first cyanoacrylate monomer; (b) providing a thickening agent, the thickening agent comprises at least a polycyanoacrylate, wherein the polycyanoacrylate is prepared by a method comprising the steps of: providing a second cyanoacrylate monomer; adding an aqueous solution of ammonium hydroxide or alcohol into the second cyanoacrylate monomer to initiate polymerization and forming a polymer of the second cyanoacrylate monomer; and heating and drying the polymer of the second cyanoacrylate monomer at 30° C.-100° C. to remove the ammonium hydroxide or the alcohol; and (c) mixing the thickening agent with the adhesive substrate.
[0011] In one aspect of the embodiment, the first cyanoacrylate monomer or the second cyanoacrylate monomer may be selected from, but not limited to, the group consisting of alkyl 2-cyanoacrylate, cycloalkyl-2-cyanoacrylate, fluoroalkyl-2-cyanoacrylate, fluorocycloalkyl-2-cyanoacrylate, alkoxyalkyl-2-cyanoacrylate, alkoxycycloalkyl-2-cyanoacrylate, fluoroalkoxyalkyl-2-cyanoacrylate, and mixtures of two or more thereof.
[0012] In a preferred aspect of the embodiment, the first cyanoacrylate monomer or the second cyanoacrylate monomer may be selected from, but not limited to, the group consisting of methyl 2-cyanoacrylate, ethyl 2-cyanoacrylate, n-propyl 2-cyanoacrylate, iso-propyl 2-cyanoacrylate, n-butyl 2-cyanoacrylate, iso-butyl 2-cyanoacrylate, hexyl 2-cyanoacrylate, n-octyl 2-cyanoacrylate, 2-octyl 2-cyanoacrylate, 2-methoxyethyl 2-cyanoacrylate, 2-ethoxyethyl 2-cyanoacrylate, 2-propoxyethyl 2-cyanoacrylate, and mixtures of two or more thereof.
[0013] In another embodiment, the method of making an adhesive composition wherein step (c) further comprises adding at least a plasticizer and then mixing. The plasticizer can be selected from, but not limited to, the group consisting of citric esters, glycerol esters, sebacic esters, fatty acid esters, cellulose esters, polyethylene glycol ethers and mixtures of two or more thereof. In a preferred aspect, the plasticizer may be selected, for example, from the group consisting of glycerol triacetate, glycerol tripropionate, glycerol tributyrate, tricaproin, trivalerin, tricaprin, tributyl 2-acetylcitrate, isobutyl myristate, ethyl myristate, ethyl stearate, methyl sebacate, ethyl sebacate, ethylcellulose, polyethylene glycol diethers, and mixtures thereof. Tributyl 2-acetylcitrate is particularly preferred.
[0014] In a further embodiment of the present invention, the thickening agent is about 0.5-25% by weight based on the total weight of the adhesive composition. In a preferred aspect, the thickening agent is about 1-10%, more preferable about 1-5%, by weight based on the total weight of the adhesive composition.
[0015] In yet another embodiment of the present invention, the aqueous solution of ammonium hydroxide is about 0.001-1% by weight, preferably about 0.001-0.1% by weight. In another aspect, the weight ratio of ammonium hydroxide to the second cyanoacrylate monomer is about 1:10000 to about 1:100, preferably about 1:10000 to about 1:500.
[0016] In a further aspect, the alcohol may be selected from the group consisting of methanol, ethanol, n-propanol, butanol, and mixtures thereof. Because alcohols of lower boiling points can be removed at relatively lower temperature, the alcohol is preferably selected from the group consisting of methanol, ethanol, n-propanol, and mixtures thereof.
[0017] In a further aspect, the alcohol is more preferably ethanol, and the ethanol solution can be about 0.1-1.5% by weight, preferably about 0.1-0.6% by weight. In another aspect, the weight ratio of the alcohol to the second cyanoacrylate monomer is about 1:5000 to about 1:100, preferably about 1:5000 to about 1:200.
[0018] In another embodiment, the method of making an adhesive composition further comprises the step of adding a colorant, a free radical stabilizer or an anionic stabilizer for desired color and product stability.
[0019] In another embodiment, the method of making an adhesive composition further comprises a step of sterilizing the mixture of the thickening agent and the adhesive substrate.
[0020] Since ammonium hydroxide and alcohol have relatively low boiling points, they can be readily removed by heating at low temperature when used as an accelerator/initiator for polymerization of cyanoacrylate monomers. As a consequence, the process of removing or neutralizing the accelerator/initiator by conventional means can be eliminated. The thickening agent prepared by the present invention wouldn't contain residual accelerators and would not induce premature polymerization when added into cyanoacrylate monomers. The resulting adhesive composition would retain excellent bonding strength with long shelf life.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The following description and examples illustrate a preferred embodiment of the present invention in detail. Those of skill in the art will recognize that there are numerous variations and modifications of this invention encompassed by its scope. Accordingly, the description of a preferred embodiment should not be deemed to limit the scope of the present invention.
[0022] For preparing the adhesive composition of the present invention, a thickening agent, i.e. the polymer of the second cyanoacrylate monomer, should be made first. And then the thickening agent, in an amount depending on the demand, is added into the adhesive substrate containing the first cyanoacrylate monomer. After mixing, the resulting adhesive composition with the desired viscosity can be achieved.
[0023] The first cyanoacrylate monomer or the second cyanoacrylate monomer may be selected from the group consisting of alkyl 2-cyanoacrylate, cycloalkyl-2-cyanoacrylate, fluoroalkyl- 2-cyanoacrylate, fluorocycloalkyl-2-cyanoacrylate, alkoxyalkyl-2-cyanoacrylate, alkoxycycloalkyl-2-cyanoacrylate, fluoroalkoxyalkyl-2-cyanoacrylate, and mixtures of two or more thereof. In order to obtain the optimum compatibility, e.g., dissolving the polymer of the second cyanoacrylate monomer well in the first cyanoacrylate monomer, the first cyanoacrylate monomer and the second cyanoacrylate monomer are prefer to, but not limited to, the same monomer.
[0024] Further, the thickening agent (i.e. the polymer of the second cyanoacrylate monomer) may be poly alkyl 2-cyanoacrylates, poly cycloalkyl-2-cyanoacrylates, poly fluoroalkyl-2-cyanoacrylates, poly fluorocycloalkyl-2-cyanoacrylates, poly alkoxyalkyl-2-cyanoacrylates, poly alkoxycycloalkyl-2-cyanoacrylates, or poly fluoroalkoxyalkyl-2-cyanoacrylates. The preferred weight average molecular weight of the polymers is from about 5,000 to about 4,000,000; more preferably from about 5,000 to about 1,000,000.
[0025] For the preparation of the thickening agent, an accelerator/initiator with a low boiling point, e.g., ammonium hydroxide, alcohol, but not limited to, can be added to start the polymerization. Utilizing the property of their relatively low boiling points, ammonium hydroxide or alcohol can evaporate or be easily removed in the following heating procedures. The alcohol can be selected from the group consisting of methanol, ethanol, n-propanol, butanol, and mixtures thereof. The alcohol having a lower boiling point such as methanol, ethanol, n-propanol or mixtures thereof is preferred.
[0026] The amount of thickening agent (polycyanoacrylate) intended to be added to the adhesive substrate (cyanoacrylate monomers) is dependent upon the molecular weight of the polymers and the desired viscosity for the adhesive composition. The thickening agent typically may be about 0.5-25% by weight based on the total weight of the adhesive composition, preferably about 1-10% by weight, more preferably about 1-5% by weight.
[0027] In addition, a plasticizer can also be added to the mixture of the first cyanoacrylate monomer and the thickening agent for desired viscosity and elasticity. The plasticizer may be selected from, but not limited to, the group consisting of citric esters, glycerol esters, sebacic esters, fatty acid esters, cellulose esters, polyethylene glycol ethers and mixtures of two or more thereof. Preferably, the plasticizer can be selected for example from the group consisting of glycerol triacetate, glycerol tripropionate, glycerol tributyrate, tricaproin, trivalerin, tricaprin, tributyl 2-acetylcitrate, isobutyl myristate, ethyl myristate, ethyl stearate, methyl sebacate, ethyl sebacate, ethylcellulose, polyethylene glycol diethers, and mixtures thereof. Tributyl 2-acetylcitrate is particularly more preferred.
EXAMPLE 1
Preparation of Thickening Agent A
[0028] For the preparation of the accelerator, 1800 ml of deionized water was first placed in a 2000 ml beaker, and then 0.7 g (0.04% by weight) of NH 4 OH (Showa Chemical Co., Lot. number 111024) was added with a pipette and mixed by stirring for about 5 minutes. Then the second cyanoacrylate monomer, 32 ml of n-butyl cyanoacrylate monomer (nBCA, Chemence Co.), was added into the NH 4 OH solution drop by drop and mixed by continuous stirring for about 0.5 hour.
[0029] The resulting nBCA polymer, namely Thickening Agent A, was decanted and dried in the vacuum oven at 65° C. for 8 hours. The molecular weight of nBCA polymer was measured with a gel permeation chromatography (GPC). Consequently, the molecular weight of nBCA polymer, i.e. Thickening Agent A, is 57,300.
EXAMPLE 2
Preparation of Adhesive A
[0030] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent A prepared as described in Example 1 was then added slowly into the flask. Then they were mixed at 100° C. for 60 minutes to form Adhesive A. The viscosity of the Adhesive A was measured with a capillary viscometer. The viscosity of the Adhesive A is 43 cP at 20° C.
EXAMPLE 3
Preparation of Adhesive B
[0031] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent A prepared as described in Example 1 was then added slowly into the flask. 15 g of tributyl 2-acetylcitrate (ATBC, SAFC, Lot number MKBG8107V) was also added slowly subsequently, and then all were mixed at 100° C. for 60 minutes to form Adhesive B. The viscosity of the Adhesive B was measured with a capillary viscometer. The viscosity of the Adhesive B is 39 cP at 20° C.
EXAMPLE 4
Preparation of Thickening Agent B
[0032] For the preparation of the accelerator, 1800 ml of deionized water was first placed in a 2000 ml beaker, and then 1 g (0.06% by weight) of NH 4 OH (Showa Chemical Co., Lot. number 111024) was added with a pipette and mixed by stirring for about 5 minutes. Afterwards the second cyanoacrylate monomer, 32 ml of n-butyl cyanoacrylate monomer (nBCA, Chemence Co.), was added into the NH 4 OH solution drop by drop and mixed by continuous stirring for about 0.5 hour.
[0033] The resulting nBCA polymer, namely Thickening Agent B, was decanted and dried in the vacuum oven at 65° C. for 8 hours. The molecular weight of nBCA polymer was measured with a gel permeation chromatography (GPC). Consequently, the molecular weight of nBCA polymer, i.e. Thickening Agent B is 41,200.
EXAMPLE 5
Preparation of Adhesive C
[0034] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent B prepared as described in Example 4 was then added slowly into the flask. After this, they were mixed at 100° C. for 60 minutes to form Adhesive C. The viscosity of the Adhesive C was measured with a capillary viscometer. The viscosity of the Adhesive C is 31 cP at 20° C.
EXAMPLE 6
Preparation of Adhesive D
[0035] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent B prepared as described in Example 4 was then added slowly into the flask. 15 g of tributyl 2-acetylcitrate was also added slowly subsequently, and then all were mixed at 100° C. for 60 minutes to form Adhesive D. The viscosity of the Adhesive D was measured with a capillary viscometer. The viscosity of the Adhesive D is 48 cP at 20° C.
EXAMPLE 7
Accelerated Aging Test to Check the Stability of Adhesive B
[0036] 0.8 ml of Adhesive B sample was placed in each aluminum tube and sealed. A total of 300 Adhesive B samples were prepared for the execution of the testing. Those Adhesive B samples were randomly separated into 5 groups (Group 1-5) consisting of 60 samples/each. Those samples were aged in an Environmental Chamber at 60° C. to simulate various aging time at 20° C. The results are shown in Table 1.
[0000]
TABLE 1
Group
1
2
3
4
5
Accelerated Aging
0
6
12
18
24
Equivalence (month)
Absolute Viscosity
39
42
48
52
55
(cP)
Wound Closure
9.2
8.7
8.7
8.3
8.1
Strength (N)
EXAMPLE 8
Wound Closure Strength Test of Adhesive B
[0037] After aging test (Example 7), the samples were tested for their wound closure strength according to ASTM F2458 wound closure strength test. In this test, a thin layer of adhesive sample was applied on a piece of porcine skin specimen with a cut in the middle to simulate wound. Then, the force to pull the wound apart was measured.
[0038] Sufficient Adhesive B was first applied uniformly on a 2.5 cm×1.0 cm area adjacent to the cut to bond 2 pieces of porcine skins together. 10 sets of specimens were prepared. They were then placed in a sealed plastic bag and conditioned in 30±1° C. for 1 hr±15 min. Once the adhesive was cured, the specimens were allowed to cool to room temperature and were clamped between the upper and lower jaws of a universal test machine. The specimens were tested at a crosshead speed of 250 mm/min until failure. Both failure mode and peak load were recorded. The results of the wound closure strength test are shown in Table 1.
[0039] As seen from Table 1, the viscosity of Adhesive B increased as time goes by, but the wound closure strength thereof reduced slightly and possesses 8.1N after 24 months' aging. Thus, the adhesive provided by the present invention can prevent cyanoacrylate monomer from premature polymerization and has a desirable viscosity for convenient application. In addition, it also maintains appropriate wound closure strength for a long period of time.
EXAMPLE 9
Preparation of Thickening Agent C
[0040] For preparation of the accelerator, 1800 ml of deionized water was first placed in a 2000 ml beaker, and then 5 g (0.3% by weight) ethanol (Echo Chemical Co.) was added and mixed by stifling for about 5 minutes. Afterwards the second cyanoacrylate monomer, 32 ml of n-butyl cyanoacrylate monomer (nBCA, Chemence Co.), was added into the ethanol solution drop by drop and mixed by continuous stirring for about 0.5 hour.
[0041] The resulting nBCA polymer, namely Thickening Agent C, was decanted and dried in the vacuum oven at 65° C. for 8 hours. The molecular weight of nBCA polymer was measured with a gel permeation chromatography (GPC). Consequently, the molecular weight of nBCA polymer, i.e. Thickening Agent C, is 64,300.
EXAMPLE 10
Preparation of Adhesive E
[0042] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent C prepared in Example 9 was then added slowly into the flask. After this, they were mixed at 100° C. for 60 minutes to form Adhesive E. The viscosity of the Adhesive E was measured with a capillary viscometer. The viscosity of the Adhesive E is 47 cP at 20° C.
EXAMPLE 11
Preparation of Adhesive F
[0043] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent C prepared in Example 9 was then added slowly into the flask. 15 g of tributyl 2-acetylcitrate (ATBC, SAFC, Lot number MKBG8107V) was also added slowly subsequently. Then they were mixed at 100° C. for 60 minutes to form Adhesive F. The viscosity of the Adhesive F was measured with a capillary viscometer. The viscosity of the Adhesive F is 43 cP at 20° C.
EXAMPLE 12
Preparation of Thickening Agent D
[0044] For preparation of the accelerator, 1800 ml of deionized water was first placed in a 2000 ml beaker, and then 1.8 g (0.1% by weight) sodium bicarbonate (Sigma-Aldrich Co.) was added with a pipette and mixed by stirring for about 3 minutes. Afterwards the second cyanoacrylate monomer, 32 ml of n-butyl cyanoacrylate monomer (nBCA, Chemence Co.), was added into the sodium bicarbonate solution drop by drop and mixed by continuous stirring for about 0.5 hour.
[0045] The resulting nBCA polymer was decanted and rinsed several times with deionized water and then decanted again. The bicarbonate therein was neutralized with 0.1N HCl and then nBCA polymer was rinsed again with deionized water. The resulting product was dried in the vacuum oven at 65° C. for 8 hours to form Thickening Agent D. The molecular weight of the Thickening Agent D is 43,100.
EXAMPLE 13
Preparation of Adhesive G
[0046] The first cyanoacrylate monomer, 285 g of 2-octyl cyanoacrylate monomer (2-OCA, the viscosity thereof is 6 cP at 20° C.), was poured into a 1 liter round bottom flask on a heater/mixer and stirred at 200 rpm. 15 g of Thickening Agent D prepared in Example 12 was then added slowly into the flask. 15 g of tributyl 2-acetylcitrate (ATBC, SAFC, Lot number MKBG8107V) was also added slowly subsequently; and then all were mixed at 100° C. for 60 minutes to form Adhesive G. The viscosity of the Adhesive G was measured with a capillary viscometer. The viscosity of the Adhesive G is 31 cP at 20° C.
EXAMPLE 14
Accelerated Aging Test to Check the Stability of Adhesive G
[0047] 0.8 ml of Adhesive G sample was placed in each aluminum tube and sealed. A total of 300 Adhesive G samples were prepared for the execution of the test. The Adhesive G samples were randomly separated into 5 groups (Group 6-10) consisting of 60 each. They were accelerately aged in an Environmental Chamber at 60° C. to simulate various aging time at 20° C. The results are shown in Table 2.
[0000]
TABLE 2
Group
6
7
8
9
10
Accelerated Aging
0
6
12
18
24
Equivalence (month)
Absolute Viscosity
35
48
68
80
150
(cP)
Wound Closure
9.6
8.9
7.5
6.1
4.2
Strength (N)
EXAMPLE 15
Wound Closure Strength Test of Adhesive G
[0048] After aging test (Example 14), the samples were tested for their wound closure strength according to ASTM F2458 wound closure strength test as described in Example 8.
[0049] Sufficient Adhesive G was first applied uniformly on a 2.5 cm×1.0 cm area adjacent to the cut to bond 2 pieces of porcine skins together. 10 sets of specimens were prepared. They were then placed in a sealed plastic bag and conditioned in 30±1° C. for 1 hr±15 min. Once the adhesive was cured, the specimens were allowed to cool to room temperature and were clamped between the upper and lower jaws of a universal test machine. The specimens were tested at a crosshead speed of 250 mm/min until failure. Both failure mode and peak load were recorded. The results of the wound closure strength test are shown in Table 2.
[0050] Referring to the results shown in Tables 1 and 2, the wound closure strength of Adhesive G has been reduced to 7.5N after 12 months' aging, and 4.2N after 24 months' aging. The adhesive thickened by polycyanoacrylate, which was prepared by conventional accelerators exhibits premature polymerization in a cyanoacrylate monomer adhesive due to its residual accelerators. Owing to this premature polymerization of adhesive substrate, either the wound bonding strength is reduced or the shelf life is shortened. However, with the thickening agent prepared by the ammonium hydroxide or alcohol provided by the present invention, the premature polymerization can be reduced and the adhesive having excellent properties can be used for various medical applications.
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The present invention provides a method for making an adhesive composition. An adhesive substrate comprising at least a first cyanoacrylate monomer is provided and then mixed with a thickening agent containing polycyanoacrylate prepared by polymerization of a second cyanoacrylate monomer initiated with an aqueous solution of ammonium hydroxide or alcohol. In light of low boiling point of ammonium hydroxide and alcohol, they can be easily removed by heating at low temperature. As such, conventional premature polymerization of adhesive substrate owing to addition of a thickening agent containing residual accelerators can be overall improved.
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REFERENCE TO RELATED APPLICATIONS
This application is a continuation and claims the benefit of U.S. application Ser. No. 13/246,597 filed Sep. 27, 2011, entitled “Push Connect Joint Assembly, System and Method”, now U.S. Pat. No. 8,398,122, issued on Mar. 19, 2013, which claims the benefit of U.S. provisional application Ser. No. 61/473,418, filed Apr. 8, 2011 and entitled “Piping Joint Assembly, System and Method”, and is a continuation-in-part of U.S. application Ser. No. 12/981,855, entitled “Piping Joint Assembly, System and Method”, now U.S. Pat. No. 8,210,576, issued on Jul. 3, 2012, the disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to fluid flow systems, and more particularly to a push-fit joint assembly, system and method that facilitates the repair and re-use of piping and tubing system parts without coining or threaded end caps.
BACKGROUND OF THE PRESENT INVENTION
Piping systems exist to facilitate the flow of fluids (e.g., liquid, gas (such as air) or plasma). For example, homes, schools, medical facilities, commercial buildings and other occupied structures generally require integrated piping systems so that water and/or other fluids can be circulated for a variety of uses. Liquids and/or gases such as cold and hot water, breathable air, glycol, compressed air, inert gases, cleaning chemicals, waste water, plant cooling water and paint and coatings are just some examples of the types of fluids and gases that can be deployed through piping systems. Tubing and piping types can include, for example, copper, stainless steel, CPVC (chlorinated polyvinyl chloride) and PEX (cross-linked polyethylene). For purposes of the present disclosure, the term “pipe” or “piping” will be understood to encompass one or more pipes, tubes, piping elements and/or tubing elements.
Piping connections are necessary to join various pieces of pipe and must be versatile in order to adapt to changes of pipe direction required in particular piping system implementations. For example, fittings and valves may be employed at the ends of open pieces of pipe that enable two pieces of pipe to fit together in a particular configuration. Among fitting types there are elbows, “tees”, couplings adapted for various purposes such as pipe size changes, ends, ball valves, stop valves, and partial angle connectors, for example.
In the past, pipe elements have been traditionally connected by welding and/or soldering them together using a torch. Soldering pipe fittings can be time-consuming, unsafe, and labor intensive. Soldering also requires employing numerous materials, such as copper pipes and fittings, emery cloths or pipe-cleaning brushes, flux, silver solder, a soldering torch and striker, a tubing cutter and safety glasses, for example. The process for soldering pipes can proceed by first preparing the pipe to be soldered, as the copper surface must be clean in order to form a good joint. The end of the pipe can be cleaned on the outside with emery cloth or a specially made wire brush. The inside of the fitting must be cleaned as well. Next, flux (a type of paste) can be applied to remove oxides and draw molten solder into the joint where the surfaces will be joined. The brush can be used to coat the inside of the fitting and the outside of the pipe with the flux. Next, the two pipes are pushed together firmly into place so that they “bottom out”—i.e., meet flush inside the fitting. The tip of the solder can be bent to the size of the pipe in order to avoid over-soldering. With the pipes and fitting in place, the torch is then ignited with the striker or by an auto-strike mechanism to initiate soldering. After heating for a few moments, if the copper surface is hot enough such that it melts when touched by the end of the solder, the solder can then be applied to the joint seam so that it runs around the joint and bonds the pipe and fitting together.
In recent years, push-fit technology has been employed with piping systems to reduce the dangers and time involved in soldering joints. Push-fit methods require minimal knowledge of pipe fittings and involve far fewer materials than soldering. For example, one may only need the pipes, quick-connect fittings, a chamfer/de-burring tool and tubing cutter in order to connect pipes using push-fit technology.
The steps involved in connecting piping systems using push-fit technology can be outlined as follows. First, the pipe is cut to the appropriate length and the end of the pipe is cleaned with the de-burring tool. Then the pipe and fitting are pushed together for connection. The fitting is provided with a fastening ring (also called a collet, grip ring or grab ring) having teeth that grip the pipe as it is inserted. The fastening ring device is employed to provide opposing energy, preventing the device from disconnection while creating a positive seal. Accordingly, no wrenches, clamping, gluing or soldering is involved. Push-fit and/or quick-connect technology for piping systems can be obtained, for example, through Quick Fitting, Inc. of East Providence, R.I., USA, suppliers of the CoPro® line of push fittings and related products. Also, such technology is described, for example, in U.S. Pat. No. 7,862,089, the disclosure of which is incorporated herein by reference in its entirety.
In past pipe coupling technology, the fastening ring is inserted into the fitting body along with a plastic grip ring support that typically fails under extensive tensile testing. Further, the coupling must then be either coin rolled, glued or receive a threaded cap member to retain the fastening ring inside the fitting body. In addition to the added steps for the manufacture and assembly of the coupling, the strength of the plumbing joint is determined by the retaining cap member. The additional steps and components add significant labor and manufacturing costs to the final product cost and reduce the overall production capability due to the extensive time required for proper assembly.
In addition to the above, when using a threaded retaining cap method, the process of cutting threads into the fitting body and the retaining cap elevates the cost of machining the fitting components. Further, the threaded end cap method requires mechanical assembly as well as the added cost and application of a thread sealant to the threads. In prior efforts that employ a coined retaining cap method, the process of coining the fitting body as the retaining cap significantly increases the cost of final assembly of the fitting. Additionally, the coining process permanently encapsulates the fastening ring inside the fitting, whereby the fastening ring cannot be removed without complete destruction of the ring and fitting.
Along with additional assembly steps and increased manufacturing costs, past pipe fittings and connection methods do not allow repair for various reasons. In some cases, this is because they are factory sealed, for example. In other cases, it is because the separation of the fitting from the pipe can damage or induce wear on the parts. For example, some push-to-connect fittings provide permanently fixed demounting rings for removing the fittings. The demounting rings can be depressed axially to lift the fastening ring teeth off of the surface of the inserted pipe, such that the pipe can then be withdrawn. This arrangement, however, can subject the fittings to tampering and shorter life. In addition, while fastening ring devices work effectively as an opposing retaining member, their functionality makes them nearly impossible to dismount, remove or detach for re-use. The fastening rings are thus permanently affixed unless they are cut and removed, which then destroys the fastening ring.
Whether connected by traditional soldering methods or with push-fit methods, past efforts have been specifically provided for the connection of like materials and lack the ability to connect two unlike materials, such as copper with CPVC, PEX or stainless steel, or any other combination of unlike materials. Past methods further invariably require the replacement of fittings and valves, and do not allow re-use of the fittings or valves in instances where only a small internal component needs to be repaired or replaced.
SUMMARY OF THE PRESENT INVENTION
The present invention provides, in part, a push fitting assembly package that facilitates the re-use of push fittings without damage to the fitting elements or the pipe. The present invention connects piping using no tools, clamps, solder or glues, while creating a leak-free seal at the connected joining area. Further, unlike prior methods, the present invention can join both like and unlike piping elements in any combination, and without coining or threading the elements into place.
The quick connection pipe joint assembly package provided as part of the present invention employs a one-piece retaining ring and pusher that, when removed, exposes the clamping, sealing and fastening mechanisms of the fitting. The retaining ring and pusher member (“release pusher” for purposes of this disclosure) moves axially and can push the fastening ring of the present invention in order to facilitate the release of a cylindrical object such as a piping element held within the fitting.
For purposes of the present disclosure, a fitting (also referred to as a body member) can encompass a valve member and other piping elements including, but not limited to: a coupling joint, an elbow joint, a tee joint, a stop end, a ball valve member, tubing and other objects having cylindrical openings. In one embodiment of the present invention, one or more sealing member gasket inserts (e.g., O-ring members) fits within a first radial housing element defined in the interior wall of the fitting. In addition, at each pipe receiving end of the fitting, a second radial housing element is machined into the interior wall to retain the edges of the fastening ring. The interior housing elements provide integrated support for the sealing members and fastening ring when opposing force is applied to piping elements that have been inserted into the fitting. In one embodiment, a flexible metal support snap ring gland member is employed to provide additional support for the fastening ring.
One aspect of the present invention provides a novel push fitting joint packaging arrangement comprising a split fastening ring and a split O-ring support member. The split fastening ring can include a first and a second circumferential end point that do not connect, wherein the first and second end points include facing edges, and wherein the facing edges extend substantially radially outwardly along respective radial axes of the ring. The split o-ring support member can include a first and a second circumferential end point that do not connect, wherein the first and second end points include facing edges, and wherein the facing edges are not aligned with respective radial axes of the support member. The present invention can further comprise a split spacer member between the split o-ring support member and the split fastening ring. The split spacer member can be a separate member from the fastening ring, or can be integrated with the split fastening ring so as to form a crown-like member.
In one aspect of the present invention, once the fastening ring is inserted into the fitting, the fastening ring does not require any additional method or device to retain it under opposing force. The integrated radial housing element provides for a more stable fastening ring connection with the ability to withstand significantly higher tensile pulling forces than the prior art. As a result, the stability of the quick fitting fastening connection is not determined or co-dependent on a plastic retainer, threaded end cap or machined coined retainer.
The release pusher provided as part of the present invention is primarily employed to facilitate the release of tubing, piping and other cylindrical objects inserted into a fitting. The release pusher is manually pushed into the fitting body and tapered edges of the release pusher generally or nearly abut the installed fastening ring. When it is desired to release an inserted pipe, for example, from the fitting, the release pusher can be forced in the direction of the fastening ring such that its angular surfaces depress the fastening ring teeth off of the surface of the inserted pipe, thereby allowing the pipe to be removed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded front perspective view of one embodiment of a piping joint assembly package in accordance with the present invention.
FIG. 2 is an exploded front perspective cross-sectional view of the piping joint assembly package of FIG. 1 .
FIG. 3 is a front cross-sectional view of a portion of the present invention according to FIG. 1 .
FIG. 4 is a detailed cross-sectional view of encircled portion 4 - 4 of FIG. 3 .
FIG. 5 is a cross-sectional view of one embodiment of the fitting of the present invention.
FIGS. 6 and 7 are detailed cross-sectional views of encircled portions 6 - 6 and 7 - 7 of FIG. 5 , respectively.
FIG. 8 is a cross-sectional view of one embodiment of the release pusher of the present invention.
FIG. 9 is a left side view of one embodiment of the fastening ring of the present invention.
FIG. 10 is a front view of the fastening ring of FIG. 9 .
FIG. 11 is a right side cross-sectional view of the fastening ring taken along line 11 - 11 of FIG. 10 .
FIG. 12 is an exploded front perspective view of an alternative embodiment of the piping joint assembly package of the present invention.
FIG. 13 is a front cross-sectional view of a portion of the present invention according to FIG. 12 .
FIG. 14 is a detailed cross-sectional view of encircled portion 14 - 14 of FIG. 13 .
FIG. 15 is a cross-sectional view of one embodiment of the fitting of the present invention.
FIG. 16 is a detailed cross-sectional view of encircled portions 16 - 16 of FIG. 15 .
FIG. 17 is a front view of the flexible support snap ring gland member of the present invention.
FIG. 18 is a right side cross-sectional view of the snap ring gland member taken along line 18 - 18 of FIG. 17 .
FIG. 19 is an exploded front perspective view of the piping joint assembly package of the present invention including one embodiment of a split grip ring assembly package.
FIG. 20 is an exploded front perspective cross-sectional view of the piping joint assembly package of FIG. 19 including one embodiment of a split grip ring assembly package.
FIG. 21 is a front cross-sectional view of a portion of the present invention according to FIG. 19 .
FIG. 22 is a detailed cross-sectional view of encircled portion 22 - 22 of FIG. 21 .
FIG. 23 is a cross-sectional view of one embodiment of the fitting of the present invention.
FIG. 24 is a cross-sectional view of one embodiment of the release pusher of the present invention.
FIG. 25 is a front view of the flexible sealing member support ring of the present invention.
FIG. 26 is a right side cross-sectional view of the sealing member support ring taken along line A-A of FIG. 25 .
FIG. 27 is a left side view of one embodiment of the fastening ring of the present invention.
FIG. 28 is a front view of the fastening ring of FIG. 27 .
FIG. 29 is a right side cross-sectional view of the fastening ring taken along line 28 - 28 of FIG. 28 .
FIG. 30 is a front view of one embodiment of the spacer member in accordance with the present invention.
FIG. 31 is a right side cross-sectional view of the spacer member of FIG. 30 taken along line AA-AA of FIG. 30 .
FIG. 32 is a perspective view of a spacer member and a fastening ring integrated into a single monolithic piece in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the push-fit piping joint assembly 10 as shown in FIGS. 1 and 2 , elements of the joint assembly as shown include: a fitting (i.e., fitting body member) 12 having an inner wall 13 and outer wall 15 , a fastening ring 18 , two substantially identical sealing members 14 , 16 (which can be optionally lubricated) and a release pusher 20 . The fastening ring and sealing members together provide one embodiment of a packing arrangement for the present invention, and each has an internal diameter that allows for smooth and snug engagement of a piping or tubing element external surface 24 . The fitting 12 is substantially hollow with a pipe receiving opening 100 therein. In one embodiment, the interior diameters of the fastening ring 18 (as measured to the teeth 19 and not the ring cylindrical base) and sealing members 14 , 16 are substantially the same, and the interior diameters of the fitting 12 and the release pusher 20 are substantially the same. Further, the interior diameters of the fastening ring 18 and sealing members 14 , 16 are slightly less than that of the fitting 12 and release pusher 20 so as to facilitate proper operation of the present invention. The release pusher 20 is substantially cylindrical and includes an external tip 21 at the fastening ring engaging end thereof.
In one embodiment, the fitting 12 can be forged CW617N brass, with full porting and full flow fitting, for example. The lubricant for the sealing members 14 , 16 can be a food grade lubricant, for example. It will be appreciated that the sealing members can comprise a flat ring or washer-type seal member in addition or as an alternative to a circular member of substantially circular cross-section. The fastening ring 18 can comprise a spring steel formulation, for example, that enables the fastening ring to be malformed during installation, while springing back into its originally manufactured position once installed. The fastening ring is capable of grabbing an inserted pipe's surface via two or more teeth 19 to ensure connections cannot be pulled apart. The fastening ring teeth are angled downward from the substantially cylindrical perimeter of the ring, toward the fitting and away from the cap, such that when the pipe is inserted, the teeth exert a pressure against the pipe to discourage the pipe from slipping or moving back out of the fitting. No wrenches, solder, welding, glue and/or twisting and turning the elements are required to form a connection. Specifically, the combination of the fastening ring, an O-ring support member and a fastening ring crown provide a push-fit piping assembly when inserted into any cylindrical pipe.
As shown in FIGS. 3 , 4 and 8 , for example, the release pusher 20 includes a radially outer ledge 26 , the external tip 21 and outer wall segments 25 , 27 . The release pusher can comprise an injection-molded plastic material or a metal material such as brass, for example. When pressure is applied on the back side 30 of the release pusher 20 , the external tip 21 can engage the inside surface 32 of the fastening ring teeth 19 as will be described in more detail below, and the ledge back wall 29 can removeably engage a retaining lip 34 extending radially inwardly of the fitting inner wall 13 at the axially outermost position of the fitting, as shown in FIG. 3 .
In one embodiment of the release pusher of the present invention, the outer wall segments 25 , 27 comprise a single linear segment from the radially outer ledge to the external tip. In another embodiment of the present invention, as shown in FIG. 8 , the first outer wall segment 25 extends linearly at a first angle C from the radially outer ledge 26 to an outer wall intermediate point 36 , and the second outer wall segment 27 extends linearly from the outer wall intermediate point 36 to the external tip 21 at a second angle D.
During removal, a tool such as a specially adapted wrench, for example, can be applied to the outer top surface of the release pusher so as to exert a pushing and lifting force that causes the release pusher outer ledge to disengage the retaining lip 34 . Once the release pusher is removed, the internal packing arrangement components are exposed for removal and/or replacement.
As shown in FIGS. 2 through 7 , the fitting 12 is formed with first 40 and second 42 radial housing elements. The first radial housing element 40 houses sealing members 14 , 16 , and the second radial housing element 42 houses the fastening ring 18 . The sealing members can be housed so as to substantially abut one another within the first radial housing element 40 . Further, the sealing members 14 , 16 are shown axially inward of the fastening ring 18 , when in position within the fitting 12 . In the embodiment shown in FIGS. 12 through 14 , the second radial housing element 42 also houses a support snap ring gland member 90 , described in more detail below.
The first radial housing element 40 is formed by a first housing back wall segment 44 , the fitting inner wall 13 and a housing separator segment 46 . The second radial housing element 42 is formed by the housing separator segment 46 , the fitting inner wall 13 and a second housing front wall segment 48 . The inner wall 13 is not labeled within the recesses of the housing elements 40 , 42 . As shown in FIG. 7 , the second housing front wall segment 48 has a top angled guiding surface 50 , which permits sliding engagement with the fastening ring circumferential base 52 (shown in FIG. 10 ) when the fastening ring 18 is either being inserted or removed. The top angled guiding surface 50 of the second housing front wall segment 48 extends from the fitting inner wall 13 at an axially outer position 53 thereof to a front wall segment tip 54 at an axially inner position 55 of the fitting inner wall 13 .
As shown in FIG. 6 , the housing separator segment 46 has a plateau surface 58 and a front wall 60 with a front tip 62 . The housing separator segment also includes a top angled backing surface 64 that extends from the front wall tip 62 to the plateau surface 58 . In one embodiment of the present invention, the distance E from the fitting inner wall 13 to the separator segment front tip 62 is approximately the same as the distance from the fitting inner wall 13 to the second housing front wall segment tip 54 . In another embodiment of the present invention, as shown in FIG. 5 , the distance E from the fitting inner wall 13 to the separator segment front tip 62 is less than the distance from the fitting inner wall 13 to the second housing front wall segment tip 54 . This distance E can be changed as necessary to facilitate engagement and movement of the fastening ring 18 within the second radial housing element, as desired. As shown in FIG. 7 , the top angled guiding surface 50 of the second housing front wall segment 48 can extend at an angle A measured from the fitting inner wall. Further, as shown in FIG. 6 , the top angled backing surface 64 can extend at an angle B measured from the fitting inner wall. In one embodiment of the present invention, angles A and B are substantially the same. In one embodiment of the present invention, angle B can range from approximately 9 degrees to approximately 52 degrees, and angle A can range from approximately 6.5 degrees to approximately 50 degrees. Further, in one embodiment of the present invention, angle B is greater than angle D of the release pusher 20 (see FIG. 8 ) so as to facilitate proper operation of the present invention as described below.
As shown in FIGS. 1 and 9 through 11 , the fastening ring 18 can be a split ring member having a circumferential base 52 and two circumferential end points 66 that do not connect. The fastening ring can further include fixture points 68 for handling and compressing the fastening ring. In one embodiment of the present invention, the fixture points 68 are provided at the split end so that a tool designed to hold the fastening ring at the fixture points can more easily handle and compress the fastening ring in order to assist with assembly or disassembly. For example, as shown in FIG. 10 , a first fixture point 68 can be included on the left edge of a first tooth that extends from the circumferential base 52 , such that the right edge of the first tooth is flush with the first circumferential end point 66 . A second fixture point 68 can be included on the right edge of a second tooth that extends from the circumferential base 52 , such that the left edge of the second tooth is flush with the second circumferential end point 66 . Once compressed, the fastening ring is easily insertable into the second radial housing element 42 of the fitting 12 by releasing the hold on the fixture points 68 , thereby allowing the fastening ring to expand such that the circumferential base engages the walls of the second radial housing element. The fastening can be removed from the second radial housing element in similar manner. No wrenches, solder, welding, glue and/or twisting and turning the elements are required to form or disengage a connection.
The fastening ring 18 includes a substantially cylindrical base 52 that has a plurality of bifurcated or square edged teeth 19 extending inwardly from and along the base of the ring 52 . As shown in FIG. 9 , the teeth 19 of the fastening ring 18 can extend at an angle F from the horizontal axis G, wherein F ranges from approximately 39 degrees to approximately 68 degrees. In one embodiment of the present invention, angle F is approximately 56 degrees. These angles are measured when the teeth are at rest position and are not stressed by the insertion of a pipe. In one embodiment, each tooth has a substantially squared off edge, comprising a left edge, a right edge and a bottom edge. The top edge of each tooth is integrally connected to the circumferential base 52 of the fastening ring 18 . The number of teeth can readily vary in number and size.
In operation, the fitting 12 of the present invention is provided and one or more sealing members 14 , 16 are inserted into the first radial housing element 40 , as shown in FIG. 3 . Next, the fastening ring 18 is inserted into the second radial housing element 42 , and release pusher 20 is snapped into engagement with the retaining lip 34 of the fitting 12 . When a pipe 70 is inserted, it travels through the release pusher 20 into the pipe receiving cavity 100 of the fitting 12 , engaging the fastening ring 18 and the one or more sealing members 14 , 16 . The sealing members provide a strong, leak-free seal and the fastening ring prohibits any inclination the pipe may have to slide out of position adjacent the pipe end point lip 71 (see FIG. 3 ) inside the pipe fitting 12 .
FIGS. 12-18 illustrate an alternative embodiment of the present invention. In this embodiment, the first radial housing element 40 of the fitting 12 is substantially the same as described above. Further, as shown in FIG. 12 , the fitting 12 , sealing members 14 , 16 , release pusher 20 and fastening ring 18 are similarly present. However, the second radial housing element 42 includes a front wall segment 72 that does not have a top angled guiding surface. Rather, the front wall segment 72 of the second radial housing element 42 extends radially outwardly and into the fitting inner wall 13 . As such, the second radial housing element 42 includes the inner wall surface 13 for engaging the circumferential base 52 of the fastening ring 18 , as well as a surface 74 for engaging the circumferential base 92 of a snap ring 90 . Surface 75 provides a guiding surface for the release pusher 20 as it is pushed axially inwardly of the fitting in order to depress the fastening ring teeth so as to allow removal of an inserted pipe member, for example. As shown in FIGS. 17 and 18 , the snap ring 90 includes a fastening ring-engaging surface 94 and a release pusher engaging surface 96 , and is positioned in place in the fitting when the release pusher 20 is snapped or popped into engagement with the retaining lip 34 of the fitting 12 . The snap ring 90 can comprise a spring steel formulation. Further, circumferential base 92 can extend from the horizontal axis H of the snap ring 90 at an angle I of between approximately 6.5 degrees and approximately 50 degrees. In a particular embodiment of the present invention, angle I is approximately 40 degrees.
While the fastening ring 18 is shown in FIG. 12 as being a split ring, the fastening ring in this embodiment of the present invention can also be an integral ring that is not split. As such, and given the lower profile of the front wall segment 72 of the second radial housing element 42 , the fastening ring can be more easily inserted into the second radial housing element without as much initial deformation as that associated with the embodiment of the present invention shown in FIGS. 1-5 , for example.
In the embodiment of the present invention with the snap ring 90 , the snap ring can be provided with a split similar to that provided in fastening ring 18 in FIG. 1 . After placing the fastening ring into the second radial housing element, the support snap ring gland 90 can be compressed with a tool using fixture points (not shown) similar to that shown for the fastening ring 18 of FIG. 10 , and then positioned within the second radial housing element 42 . The compression of the supporting snap ring gland is released, and the ring returns to its original manufactured size, thereby acting to retain the fastening ring in position. Next, the release pusher 20 can be pushed into place such that the ledge back wall 29 removably engages the lip member 34 of the fitting 12 .
An alternative embodiment of the push connect joint assembly 110 of the present invention is illustrated in FIGS. 19-31 . As shown in FIGS. 19 and 20 , elements of the joint assembly as shown include: a fitting (i.e., fitting body member) 112 having an inner wall 113 and outer wall 115 , a fastening ring 118 , two substantially identical sealing members 114 , 116 (which can be optionally lubricated), a sealing member support ring 117 , a spacer member 119 and a release pusher member (also referred to as a release pusher or a release push cap) 120 . The sealing member support ring and fastening ring together provide one embodiment of a packing arrangement for the present invention, and each has an internal diameter that allows for smooth and snug engagement of a piping or tubing element external surface 124 . The fitting 112 is substantially hollow with a pipe receiving opening 200 therein.
As shown in FIGS. 20 , 21 and 23 , the fitting 112 is formed with a first radial housing element 140 to house sealing members 114 and 116 and a second radial housing element 142 to house the sealing member support ring 117 , the fastening ring 118 and the spacer member 119 . The sealing members can be housed so as to substantially abut one another within the first radial housing element 140 . The sealing member support ring 117 , the fastening ring 118 and the spacer member 119 can be housed so as to substantially abut one another within the second radial housing element 142 . The sealing member support ring 117 and O-ring member 116 can abut one another when installed, or there can be a slight gap in between these members when installed.
The first radial housing element 140 is formed by a first housing back wall segment 144 and the fitting inner wall 113 . The second radial housing element 142 is formed by the housing separation point wall 146 , the fitting inner wall 113 and a housing front wall segment 148 . In one embodiment, the radius of the second radial housing element 142 is slightly larger than the radius of the first radial housing element 140 .
In one embodiment, the interior diameters of the sealing member support ring 117 , fastening ring 118 (as measured to the teeth 121 and not the ring cylindrical base), spacer member 119 and sealing members 114 , 116 are substantially the same, and the interior diameters of the fitting 112 and the release pusher 120 are substantially the same. Further, the interior diameters of the sealing member support ring 117 , fastening ring 118 , spacer member 119 and sealing members 114 , 116 are slightly less than that of the fitting 112 and release pusher 120 so as to facilitate proper operation of the present invention.
As shown in FIGS. 19 through 22 and 25 through 26 , the sealing member support ring or member 117 has a circumferential base 124 , a sealing member-engaging surface 127 and a fastening ring-engaging surface 126 . Further, circumferential base 124 can extend from the horizontal axis J of the sealing member support ring 117 at an angle K of between approximately 6.5 degrees and approximately 50 degrees. In a particular embodiment of the present invention, angle K is approximately 37 degrees. In one embodiment of the present invention, the sealing member support ring 117 includes a first circumferential end point 128 and a second circumferential end point 129 that do not connect and thereby form a slit 125 . Each of the first and second end points 128 , 129 includes a facing edge, and each facing edge is not aligned with the radial axes of the support member. For instance, line A-A in FIG. 28 shows radial axes of the support member 117 , and this line does not extend through or otherwise align with the facing edges of the end points 128 , 129 of the support ring member 117 . In an alternative embodiment, the end points 128 and 129 can include facing edges that are aligned with radial axes of the sealing member support ring 117 . The slit 125 allows the sealing member support ring 117 to be manually pinched and compressed. When compressed, one circumferential end point can overlap the second circumferential end point so that the sealing member support ring can be easily inserted into a fitting. The overlapping capability is facilitated by the facing edges of the end points 128 , 129 being unaligned with radial axes of the support member.
As shown in FIGS. 19 and 27 through 29 , the fastening ring 118 can be a split ring member having a circumferential base 132 and two circumferential end points 130 and 131 that do not connect. The gap formed between the non-connecting circumferential end points 130 , 131 allows for the fastening ring to be easily compressed for insertion into a fitting. As shown in FIG. 28 , the first 130 and second 131 end points include facing edges that extend substantially radially outwardly along respective radial axes of the ring. Line 28 - 28 illustrates different axes extending radially outwardly from the center axis of the fastening ring. The arrangement of the end points 130 , 131 and their facing edges as shown facilitates ease of operability while maintaining overall strength of the fastening ring 118 .
The fastening ring can further include fixture points for handling and compressing the fastening ring, as described above. In one embodiment of the present invention, the fixture points are provided at the split end so that a tool designed to hold the fastening ring at the fixture points can more easily handle and compress the fastening ring in order to assist with assembly or disassembly. Once compressed, the fastening ring is easily insertable into the second radial housing element 142 of the fitting 112 by releasing the compression hold on the fastening ring, thereby allowing the fastening ring to expand such that the circumferential base engages the walls of the second radial housing element. The fastening ring can be removed from the second radial housing element in reverse manner. In one embodiment of the present invention, the split fastening ring 118 has a diameter that exceeds the diameter of the split sealing member support ring 117 . No wrenches, solder, welding, glue and/or twisting and turning the elements are required to form or disengage a connection.
As further shown in FIGS. 19 and 27 through 29 , the fastening ring 118 includes a substantially cylindrical base 132 that has a plurality of bifurcated or square edged teeth 121 extending inwardly from and along the base of the ring 132 . As shown in FIG. 27 , the teeth 121 of the fastening ring 118 can extend at an angle M from the horizontal axis L, wherein M ranges from approximately 39 degrees to approximately 68 degrees. In one embodiment of the present invention, angle M is approximately 56 degrees. These angles are measured when the teeth are at rest position and are not stressed by the insertion of a pipe. In one embodiment, each tooth has a squared-off outer edge comprising a left edge, a right edge and a bottom edge. The top edge of each tooth is integrally connected to the circumferential base 132 of the fastening ring 118 . The number of teeth can readily vary in number and size.
As shown in FIGS. 19 and 30 through 32 , the packing arrangement may further include a spacer member 119 . The spacer member is substantially cylindrical in shape and includes a circumferential base 133 , a fastening ring-receiving end 137 , an exterior surface 138 , an interior surface 134 and a top end 139 . Furthermore, the spacer member can be a split ring member having a circumferential base 133 and two circumferential end points that do not connect, similar to that of the fastening ring 118 shown in FIG. 28 , for example. The gap formed between the non-connecting circumferential end points allows for the spacer member to be easily compressed for insertion into a fitting. As shown in FIGS. 21 and 22 , once inserted into the second radial housing member 142 , the exterior surface 138 of the spacer member 119 is flush with the fitting interior wall 113 and the fastening ring-receiving end 137 is flush with the circumferential base 132 of the fastening ring 118 . Furthermore, the top end 130 of the spacer member 119 is adjacent to and flush with the housing front wall segment 148 of the second radial housing element 142 (see FIG. 23 ). The spacer member 119 can comprise a spring steel formulation in one embodiment of the present invention. Further, the spacer member may be a separate piece as shown in FIG. 19 , or it may be integrated with the fastening ring such that these two elements form a single, monolithic piece 219 in the fitting packing arrangement, as shown in FIG. 32 . When the spacer member is integrated into the fastening ring 118 , it forms a fastening ring crown that operates similarly to the spacer member.
The release pusher 120 is substantially cylindrical and hollow and includes an external tip 122 at the fastening ring engaging end thereof, as shown in FIG. 24 . The release pusher 120 also includes a radially outer ledge segment 135 , a ledge back wall 136 , and a second outer wall segment 150 . The pusher can comprise an injection-molded plastic or a metal material such as brass, for example. When pressure is applied on the back side 151 of the release pusher 120 , the external tip 122 can engage the inside surface of the fastening ring teeth 121 and the ledge back wall 136 can removeably engage the housing front wall segment 148 , as shown in FIG. 22 . Once the release pusher 120 is inserted into the fitting 112 , the radially outer ledge segment 135 provides for flush engagement with the interior surface 134 of the spacer member 119 . The diameter of the release pusher 120 , as measure to the exterior surface of the radially outer ledge segment 135 , can be slightly less than the diameter of the spacer member 119 , as measured to the interior surface 134 , in one embodiment of the present invention.
In one embodiment of the release pusher of the present invention, the second outer wall segment 150 comprises a linear segment from the radially outer ledge segment 135 to the external tip 122 . As shown in FIG. 24 , the second outer wall segment 150 extends linearly at a first angle O from the horizontal axis P to the external tip 122 . The angle O ranges from approximately 8 degrees to approximately 73 degrees.
In operation, the fitting 112 of the present invention is provided and one or more sealing members 114 , 116 are inserted into the first radial housing element 140 , as shown in FIG. 21 . Next, the sealing member support ring 117 , the fastening ring 118 and the spacer member 119 are inserted into the second radial housing element 142 , and release pusher 120 is snapped into engagement with fitting 112 . When a pipe 70 is inserted, it travels through the release pusher 120 into the pipe receiving cavity 200 of the fitting 112 , engaging the fastening ring 118 and the one or more sealing members 114 , 116 . The sealing members provide a strong, leak-free seal and the combination of the sealing member support ring 117 , the fastening ring 118 and the spacer member 119 prohibits any inclination the pipe may have to slide out of position.
The angles described herein will be understood to be exemplary and provided as embodiments associated with proper working operation of the present invention. For example, the angles of the top surfaces of members 46 and 48 contribute to the stability of the present invention as well as the easy manipulation of its component parts. Further, it will be appreciated that, in one embodiment of the present invention, the members of the push connect joint assembly are formed through hydroforming processes.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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A push fitting joint packaging arrangement allows the re-use and repair of push-to-connect fittings and valves without damage to the fitting or valve elements or the pipe, and without coining, gluing or threaded engagement of parts. In one embodiment of the present invention, the arrangement comprises a split fastening ring and a split O-ring support member.
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FIELD OF THE INVENTION
This invention pertains to window assemblies in which one or more sash members are slidably mounted into a window frame. More particularly, this invention relates to a brake system for arresting or stopping the movement of a sash that is slidably mounted in a window frame.
BACKGROUND ART
Modern premium windows are designed to be tilted for cleaning. The window is usually configured to fix two points on the window sash to act as a hinge for tilting. Specifically, such windows have a frame which includes track liners, such as a sill liner and a head liner, and means, such as trucks, for enabling the sash to easily slide within the frame.
One of the problems of tilting windows is that once the window tilts out of the plane of the window frame, if the hinge points undesirably slide in the frame, the window may fall out on the homeowner. This problem has been solved by providing a brake for the hinge points, activated by the tilting action of the window. Prior art brakes for these windows are not as foolproof as desired. Typically, the brake involves a cam or other member which is expanded or pushed against the side or bottom of the track liner. This has been known to fail, giving rise to the possibility of a falling window.
Another problem with prior art brakes to be installed in track liners of windows is that in order for the brakes to provide sufficient stopping action when they are engaged, they are oftentimes configured to somewhat inhibit the easy slidability of the sash within the frame when the brakes are not engaged. Preferably, the brakes provide an excellent grip or braking action when engaged, and yet provide no inhibition to the slidability of the frame within the sash while the brake is not engaged.
Another desirable attribute of braking systems for tilting windows is that the system be designed so that the window cannot be tilted until the brake is completely engaged. Many prior art brake systems are designed so that the brake system is actuated by the movement of a lever or by the actual tilting action of the window itself. In such systems, the braking action begins immediately, but is not fully engaged or completed until the full tilting action of the window is completed, or until the full movement of the lever is completed. In such systems, the window can be tilted before the brake is completely engaged, thereby opening up the possibility of a window falling out of the frame.
There is a need for an improved brake system which provides for easy slidability when the brake is not engaged, provides a sure braking action which will not enable any sliding of the window when the brake is engaged, and provides a positive foolproof system which assures that the brake system is completely activated before the sash can be tilted out of the plane of the frame.
STATEMENT OF THE INVENTION
There has now been developed a brake system for a window assembly in which the brake is completely activated before the sash can be tilted out of the plane of the frame. The sash has a sash retainer including a bolt which engages the frame for locking the sash in the plane of the frame. Reciprocal movement of the bolt out of engagement with the frame frees the sash for tilting out of the plane of the frame. The sash retainer has a lock operable upon rotation of the bolt so that the bolt cannot be reciprocated to free the sash for tilting unless the bolt is rotated, and the rotation of the bolt actuates the brake. This prevents any tilting of the sash before the brake is completely actuated. This provides an excellent safety feature, especially when considering today's heavier, larger windows.
According to this invention, there is provided a window assembly comprising a frame, a sash mounted for sliding in the plane of the frame, the sash being mounted for tilting out of the plane of the frame, a brake for precluding sliding of the sash while the sash is being tilted, the brake being actuated by the rotation of a rotatable receiver, and a sash retainer for preventing the tilting of the sash prior to engagement of the brake. The sash retainer has a bolt mounted for reciprocal movement and is adapted to engage the receiver. The reciprocal movement of the bolt out of engagement with the receiver frees the sash for tilting out of the plane of the frame. The bolt and the receiver are connected so that rotation of the bolt causes rotation of the receiver and actuation of the brake. The sash retainer is adapted with a lock operable upon rotation of the bolt so that the bolt cannot be reciprocated out of engagement with the receiver unless the bolt is first rotated, causing actuation of the brake.
In a specific embodiment of the invention, there is a sash retainer both at the top and at the bottom of the sash.
In another specific embodiment of the invention, the lock comprises a flange mounted on the bolt, and the sash retainer has a recessed portion in which the flange is positioned while the brake is in the unactuated position so that the bolt cannot be reciprocated out of engagement with the receiver unless the bolt is first rotated to enable the flange to be removed from the recessed portion of the sash retainer.
In another specific embodiment of the invention, the bolt and the receiver are keyed so that rotation of the bolt causes rotation of the receiver and actuation of the brake.
In another embodiment of the invention, the lock comprises a sash retainer slot in which the bolt is mounted for reciprocal movement, the upper end of the bolt being keyed to match the upper end of the sash retainer slot so that the bolt cannot be reciprocated out of engagement with the receiver unless the bolt is first rotated to enable the keyed upper end of the bolt to fit into the keyed upper end of the sash retainer slot.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a horizontal double sliding window.
FIG. 2 is a schematic sectional view in elevation along lines 2--2 of the window of FIG. 1.
FIG. 3 is a plan view of the brakeplate and post as shown along lines 3--3 of FIG. 2.
FIG. 4 is a schematic view in elevation of the brake plate and post along lines 4--4 of FIG. 3.
FIG. 5 is a schematic view in elevation of the brake plate and post along lines 5--5 of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the window is generally comprised of frame 10 and sashes 12. It is to be understood that the invention can be used for windows other than the horizontal windows shown in FIG. 1, such as in vertically mounted double-hung windows.
FIG. 2 shows the sash being vertically separated from track liner 14. This is for purposes of illustration only, and it is to be understood that the sash is not vertically separated from the track liner in actual operation. The track liner is generally comprised of track liner sides 16 which define a concave space or pocket 18. In a horizontally mounted window, as illustrated in FIG. 1, the track liner is a sill liner at the bottom, and a headliner at the top. In vertically mounted windows, such as a double-hung window, the track liners would be jamb liners. Preferably, the track liner is molded plastic, such as vinyl or polyester.
Mounted for sliding movement within the track liner is base 20. The base can be any suitable member for sliding within the track liner, and is suitable for mounting various brake parts and actuators.
The track liner sides are adapted with opposed grooves 22 in which the brake plate 24 is slidably mounted. The grooves extend longitudinally along the length of the track liner. The grooves are defined in part by flanges 26 which extend from the track liner sides into the pocket. The brake plate can be of any suitable material, such as metal.
The invention is not limited to the brake system shown in the drawings and described in this specification. Any suitable brake system can be used with the invention.
The base is adapted with a pair of brake shoes 28 which also slide with the base as the base slides within the track liner. Upon actuation of the brakes, the brake plate and the brake shoes are urged toward each other, thereby compressing and gripping the flange in a braking action. The brake shoes can be any suitable member for applying a gripping action to the flange, and preferably have a knurled or otherwise gripping surface to provide good adhesion during a braking action.
The base is adapted with receiver 30 which is actuable to urge the brake shoes and brake plate toward each other to grip the flange in a braking action. Preferably, the receiver comprises a post such as post 32 which is mounted for rotation in the base. Also, preferably, the receiver is adapted with cam detent 34, and the brake plate is adapted with a biasing means, such as cam 36 to press the brake plate downwardly upon the rotation of the receiver. The downward movement of the brake plate engages the flange in a braking action with the brake shoes. The receiver can be any means for receiving the action of a window latch or sash retainer and engaging the brake in response.
As shown in the upper portion of FIG. 2, the sash is adapted with sash retainer 38 which generally provides a release system to enable the sash to be tilted out of the plane of the frame. The sash retainer is generally comprised of bolt 40 which is vertically moved to raise the bolt bottom 42 out of engagement with the receiver. The bolt is mounted for vertical movement within sash retainer slot 46. The receiver is adapted with any suitable means for receiving the bolt bottom, such as key slot 44. It should be understood that ideally there is a sash retainer and receiver in both the top and bottom of the sash.
The bolt bottom, as shown, has a generally rectangular configuration. The bolt bottom matches or is keyed to the key slot in the receiver. When the bolt is rotated 90 degrees, the engagement of the bolt bottom with the key slot causes the receiver to be likewise rotated. This, of course, engages the cam and urges the brake plate toward the brake shoe, thereby providing a braking action on the flange.
In order for the sash to be tilted out of the plane of the frame, the bolt must be raised vertically. In order to provide a failsafe feature of the brake system, the bolt is adapted with a lock, such as bolt flange 48 which rests in bolt flange cutout 50. The flange can be manually gripped to rotate the bolt 90 degrees in order to engage the cam and the brake. The bolt flange rests within the bolt flange cutout and cannot be raised vertically until the 90 degree rotation has occurred. This prevents the bolt from being raised vertically (and thereby enabling the sash to be tilted) without first having a rotation of the receiver and actuation of the brake. The flange is prevented from sliding up into the sash retainer slot unless the rotation has occurred.
Any suitable means for preventing the raising of the bolt prior to the rotation of the bolt can be employed. In an alternative method for ensuring rotation of bolt prior to raising the bolt, the upper end of the bolt 52 can be adapted with a key matching the upper end of the sash retainer slot 54, thereby preventing the raising of the bolt prior to the 90 degree rotation of the bolt in order to line up the keyed end of the bolt with the keyed upper end of the sash retainer slot.
As shown in FIG. 3, the brake plate has orifice 56 and is mounted on the post 32. The diameter of the orifice is sufficiently larger than the diameter of the post to enable the brake plate to float or move relative to the post and base when the brake plate is moving along the track liner. As shown in FIG. 4, the floating feature of the mounting of the brake plate enables the brake plate to tilt sideways, in a yaw movement as shown by arrows 58.
As shown in FIG. 5, the floating feature of the mounting of the brake plate results in a pitch movement, as shown by arrows 60. Also, the brake plate is sufficiently loosely mounted on the post so that the brake plate has a sufficient degree of vertical movement as shown by arrow 62.
It will be understood that various modifications can be made to this invention. Such, however, are considered to be within the scope and spirit of the invention.
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A window assembly for selectively enabling a sash to be tilted out of the plane of the frame includes a brake and a sash retainer, the sash retainer having a reciprocally mounted bolt which upon rotation actuates the brake, and a lock which prevents reciprocation of the bolt until the bolt is rotated and the brake is engaged.
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This application is a continuation-in-part of application Ser. No. 08/010,565, filed Jan. 28, 1993, now U.S. Pat. No. 5,360,654.
FIELD OF THE INVENTION
The invention relates to sorbent articles formed from microfibers and, optionally, staple fibers and particulate material. The articles are in the form of elongate bodies such as, for example, booms.
DESCRIPTION OF RELATED ART
A variety of materials, delivered in numerous configurations have been used for sorption of liquids. These materials include boom and pillow configurations consisting of a casing filled with particulate sorbent products such as clay, cellulose, chopped corn cobs, or chopped microfibrous materials as well as sheet materials formed from wood pulp fibers or blown microfibers. A casing can also be filled with sorbent sheet or roll good materials.
U.S. Pat. No. 4,497,712, (Cowling) describes an expendable pillow in the form of a container of highly permeable, surfactant coated fabric having at least one pocket partially filled with a granular absorbent material such as ground corn cobs. The pillow is described as being light weight, having an absorption capacity in excess of 500% and capable of floating on liquids.
U.S. Pat. No. 4,366,067, (Golding et al.) discloses bags or booms of porous material filled with an oil absorbent, particulate polyisocyanurate synthetic foam material which is used to enclose and absorb oil spilled on water or hard surfaces.
U.S. Pat. No. 4,659,478, (Stapelfeld, et al.) describes an oil absorbing member and method which includes an elongate tubular member filled with a highly absorbent particulate material of capillary nature having a wicking action such as ground corn cobs. The tubular member is closed at each end and can be arranged around a tool base as a continuous absorbing member.
U.S. Pat. No. 4,792,399, (Haney et al.) describes a liquid collecting and retaining device consisting of a tubular, triangular shaped casing of a material which is permeable to liquids, which is partially filled with a material that collects and retains liquids passing through the casing, and which is incapable of itself passing through the casing.
U.S. Pat. No. 4,965,129, (Bair et al.) discloses a sausage-shaped liquid-absorbing article which includes within a porous fabric, fine, fibrous particles of flashspun polyethylene, optionally particles of foamed organic polymer, and an effective amount of wetting agent. The article is capable of absorbing oils or aqueous liquids in amounts equal to at least six times the weight of the particles.
U.S. Pat. No. 4,902,544, (Kim et al.) describes a leak resistant absorbent article made from a tubular casing of liquid permeable fabric wherein the casing is loosely filled with a mixture of particles of a crosslinked hydrocolloid and particles of other liquid absorbing material such as saw dust, crushed corn cobs, cotton linters, wood pulp and the like.
U.S. Pat. No. 4,737,394, (Zafiroglu) discloses an oil-absorbing article comprised of an outer fabric which encloses fibrous oil absorbing particles such as flash-spun linear polyethylene. The porous fabric is a nonwoven fibrous polyolefin layer of polyethylene or polypropylene that is stitch-bonded with an elastic thread.
U.S. Pat. No. 3,739,913, (Bogosian) describes an elongate body of oil absorbing material and flotation material including longitudinal reinforcing means whereby a plurality of bodies can be disposed in end-to-end relationship for temporarily fencing oil spills on water for retention and absorption of the oil. The body contents comprise oil absorbing fibers which are natural or synthetic or combination thereof and may include a flotation material interspersed therewith to aid buoyancy of the body even after saturation of the fibers by oil. In addition to the above referenced patents, there are a number of commercially available spill containment and recovery articles. For example, 3M Company, St. Paul, Minn., sells a family of liquid sorbent articles designed to contain and recover liquid spills. These articles, which are based on sorbent microfibrous materials, include sheet goods for wiping and final cleanup operations, pillows of chopped microfibrous materials contained within a covering designed for intermediate quantity liquid recovery, and booms of chopped microfibrous materials contained within an elongate casing having a substantially circular cross-section, which are used to recover larger spills. These materials are described, for example, in 3M product bulletin "Maintenance Sorbents" N. 70-0704-0625-4(227.5) DPI.
None of these spill containment and absorbent recovery systems is completely universally satisfactory because of certain problems. Those products containing particulate sorbent materials such as clay, cellulose, foams, vermiculite or chopped corn cobs frequently have escape of dust particulates rendering cleanup inconvenient and messy. Also shifting or pocketing of particulate material within the casing often causes concentrating of the sorbent in some areas while creating voids of sorbents in other areas. When sorbent recovery systems of the type having sorbent particulate contained within a casing are compressed to extract sorbed fluids, the particulate material within the casing can shift and .pocket creating voids of sorbent in portions of the casing. This renders the sorbent article less useful for performing spill containment and recovery upon redeployment.
U.S. Pat. No. 4,357,379, (Sloan, et al.) discloses a modification of the meltblowing process to form a rod having a relatively dense, rigid skin in which the fiber portions are oriented primarily in a longitudinal direction with respect to the axis of the product, and a less dense core where the fiber portions are oriented primarily in the transverse direction with respect to the axis of the product. The products are made by melt blowing fibers and intercepting them by a fiber collecting and forming device which permits a relatively heavy build-up of fibers in a lip portion surrounding the central portion. The collecting device may be funnel shaped, trumpet shaped or in the form of continuous belts which are shaped such that in combination the form a cylindrical opening at their nip. The fibers in the lip portion being deposited while still in a thermoplastic state, thermally bond together. As fibers are continuously deposited on the collecting and forming device, the product thus formed is withdrawn at a rate synchronized with of fibers such that the aforesaid build-up is maintained, and such that the lip portion is folded back over the central portion by the collecting and forming device to form the rod as described. The fibrous product has sufficient rigidity and resiliency for use in filters, ink pen reservoirs, etc.
U.S. Pat. No. 3,933,557, (Pall) discloses a process for the continuous production of nonwoven webs in cylindrical or sheet form from thermoplastic fibers, spinning the fibers continuously from a melt onto a rotating mandrel and winding them up on the mandrel to form a generally spirally wound cylinder.
U.S. Pat. No. 4,594,202, (Pall et al.) describes a method of manufacturing cylindrical fibrous structures comprising the steps of: extruding synthetic, polymeric material from a fiberizing die and attenuating the extruded polymeric material to form microfibers by the application of one or more gas streams directed toward a rotating mandrel and a forming roll in operative relationship with the mandrel; cooling the synthetic, polymeric microfibers prior to their collection on the mandrel to a temperature below that at which they bond or fuse together, thereby substantially eliminating fiber-to-fiber bonding; and collecting the cooled microfibers on the mandrel as a nonwoven, synthetic fibrous mass while applying a force on the exterior surface of the collected microfibers by the forming roll; wherein the process variables are controlled to form a cylindrical fiber structure with at least the major portion of the fibrous mass having substantially constant void volume.
U.S. Pat. No. 4,973,503, (Hotchkiss) discloses microfiber tow or tube products wherein larger diameter, short fibers are mixed with microfibers. The mixture is formed by physically entangling microfibers (having an average diameter in the range of up to about 10 microns and being discontinuous) containing 10% to 90% of shorter fibers with the micro fibers being predominately aligned parallel to the axis of the tow and the mixture being bonded at contact points between microfibers and the shorter fibers. The method of making the mixed fiber tow or tube products includes the steps of forming a melt with thermoplastic material and extruding it through one or more series of orifices arranged in a rounded or spinneret configuration at the die tip. The extruded melt is contacted with a first stream of gas whereby it is formed into a network of physically entangled microfibers that are attenuated to microfiber size. A second gas stream is used having entrained larger diameter, short fibers, and the gas streams are merged to form a mixture of fibers. The mixture is collected as a tow or tube having the desired fiber orientation. Uses for such tows or tubes are described as including beauty coils, tampons, cigarette filters, bottle stuffers, and with additives, other products such as insulating caulk and the like.
U.S. Pat. No. 3,073,735, (Till et al.) discloses a method for producing filters wherein fibers from a plurality of fiber-forming means are suspended in a gas stream and deposited on a collecting surface. The fibers of each fiber-forming means differ in physical characteristics from those of the other means, e.g., one of the fibers may be preformed, such as staple textile fibers and the other fiber may be produced in situ by feeding a plastic fiber-forming composition from a reservoir to a spraying unit which comprises a spraying tube positioned in the center of a nozzle through which air is forced at a high velocity. The fibers are deposited on the collecting device in such intermingled relationship that there is a gradual gradation in fiber property along one dimension of the filter.
U.S. Pat. No. 4,604,313, (McFarland et al.) discloses selective layering of super absorbents in meltblown substrates. A meltblown material containing wood fiber is formed on a continuous foraminous belt. The belt carrying this layer then passes beneath at least one further source of meltblown fiber into which super absorbent is added along with wood fibers.
SUMMARY OF THE INVENTION
The present invention provides a microfibrous sorbent article comprising an elongate boom having a substantially oval cross-section, said boom being formed of multiple adjacent microfibers layers, said layers being bonded to each other by entanglement of fibers between adjacent layers and ion exchange, selectively absorbent, selectively reactive or catalytic particulate material.
The term "substantially oval cross-section" as used herein means the boom has a cross-section with a transverse aspect ratio at least 1.2 times that of the vertical aspect with at least one transverse surface being curved.
The present invention further provides a method of making a microfibrous sorbent article comprising
a) extruding molten thermoplastic fiber-forming polymer from multiple orifices in a fiber-forming die, said orifices being aligned along the face of the die;
b) attenuating the fibers in a stream of hot air;
c) collecting said fibers on a collector surface substantially parallel to said die face and moving transverse to said die face.
The term "substantially parallel" as used herein to describe the relation between the collector surface and the die means that one end of the collector surface is angled no more than about 60° from the die than the other end.
The articles, or booms, of the present invention are capable of rapid sorption of liquid and high liquid retention. The booms do not experience shifting, pocketing or compacting of sorbent material during storage, use or after reclamation of sorbed liquid. Incineration of used booms generally results in low ash generation. The booms are integral and handleable both before and after immersion in liquid because the collected fibers are extensively entangled within each layer as well as entangled between layers. The booms are flexible and conformable and can be shaped to fit a specific area, e.g., around the base of equipment. The articles of the invention may further contain sorbent particulate materials and bulking staple fiber.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of an apparatus useful in practicing the present invention.
FIG. 2 is a perspective view of a portion of the apparatus useful in practicing the present invention.
FIG. 3 is a perspective view of a microfibrous sorbent article of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
A representative apparatus useful for preparing the boom of the present invention is shown schematically in FIGS. 1 and 2. Except for the collector, 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 which is incorporated herein for reference.
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 liquefied fiber-forming material is advanced; die orifices 12 arranged in lines 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. Collector 14 uses a closed-loop belt 15, typically a finely perforated screen, but the belt can be of fabric, wire, film, rubber or combinations thereof. The plane of the collector surface is substantially parallel to the die face and moves transverse to the die face with the input side of the collector 28 being that which the microfibers initially contact and the output side 29 being that where the boom 31 is formed. Preferably, the distance between the die and the collector is about 0.2 to 0.7 m, more preferably about 0.3 to 0.5 m. The collector generally tracks at a rate of 2 to 40 m/min. Gas-withdrawal apparatus may be positioned behind the screen to assist in deposition of fibers-and removal of gas. Surfactant and/or quenching water spray may be applied to the web by optional spray bar 9. 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. Preferably, the die has at least about 10 orifices, more preferably at least about 100 orifices, most preferably at least about 500 orifices. Generally, the die has no more than about 2000 orifices.
As can be seen in FIG. 3, the boom 31 of the present invention is layered. When viewed in cross-section, the boom, formed from multiple layers 32, has a contribution of fiber from each die orifice. Such a structure provides a boom with the microfibers substantially uniformly distributed over the length of the boom. The booms of the invention generally have a diameter, i.e., the average of the transverse and vertical aspects, of about 50 mm to about 30 cm and are substantially continuous as formed but can be cut to desired lengths. The cross-sectional shape of the boom can be adjusted to some extent by trimming the sides 33 of the boom using any known trimming technique, e.g., score roll, hot wire, or water jet. Such trimming is also useful for aesthetic purposes. The amount trimmed can range up to about 20 weight percent, but is generally in the range of about 5 to 10 weight percent. The linear weight of the booms of the invention can range from about 25 to 600 g/m.
Microfibers useful in the invention may be formed from nearly any fiber-forming material. Melt blown microfibers are greatly preferred for booms of the invention, but solution blown microfibers in which the fiber forming material is made liquid by inclusion of a volatile solvent can also be used. U.S. Pat. No. 4,001,067, (Carey) describes useful apparatus and procedures for preparing a web of such fibers; however, in preparing booms of this invention fiber-forming material is generally extruded through a plurality of adjacent orifices rather than the single orifice shown in the patent. Representative polymers for forming melt-blown microfibers include polyolefins such as polypropylene and polyethylene, polyesters such as polyethylene terephthalate and polybutylene terephthalate, polyamides, polyurethane, polystyrene-polybutadiene-polystyrene block copolymers, and other polymers as known in the art. Useful polymers for forming microfibers from solution include polyvinyl chloride, acrylics, and acrylic copolymers, polystyrene, and polysulfone.
The effective average diameter of the carrier microfibers of the blown microfiber web is generally less than about 10 microns and more preferably about 5 to 10 microns. The effective fiber diameter is calculated according to the method set forth in Davies, C. N., "The Separation of Airborne Dust and Particles," Institution of Mechanical Engineers, London, Proceedings 1B, 1952. To form useful booms, the aspect ratio (ratio of length to diameter) of the microfibers should approach infinity, though blown microfibers are known to be discontinuous.
In preferred embodiments of the invention, the boom also contains crimped bulking fibers and/or sorbent or neutralizing particulate material. The sorbent particulate material can be in the form of microfiber microwebs or substantially solid particles which can be porous such as, for example, wood pulp fibers, modified starches, diatomaceous earth, silica gels, high-molecular weight acrylic polymers containing hydrophilic groups, alkylstyrene particles and activated carbon. Neutralizing sorbent particulate material can include sodium bicarbonate, calcium hydroxide, borax, potassium dihydrogen phosphate, disodium hydrogen phosphate and potassium hydrogen phthalate. The boom may also contain other materials such as mold retardant, e.g., calcium propionate, and other preservatives, bacteriostatic agents, e.g., ureaformaldehyde resins and n-butyl-2-cyanoacrylate.
When crimped bulking fibers are incorporated, they are introduced into the stream of blown microfibers in the illustrative apparatus shown in FIG. 1 through the use of a lickerin roll 16 disposed above the microfiber blowing apparatus. A web 17 of bulking fibers, typically a loose, nonwoven web provided as roll 22 such as prepared on a garnet machine or RANDO-WEBER, is propelled along a table 18 under a drive roll 27 where the leading edge engages against the lickerin roll 16. The lickerin roll turns in the direction of the arrow and picks off fibers from the leading edge of the web 17, separating the fibers from one another. The separated fibers are conveyed in an air stream through an inclined trough or duct 20 and into the stream of blown microfibers where they become mixed with the blown microfibers. The air stream is generated inherently by rotation of the lickerin roll, or that air stream may be augmented by use of an auxiliary fan or blower operating through a duct 21 as known in the art.
The crimped bulking fibers have a continuous wavy, curly or jagged character along their length. The number of crimps, i.e., complete waves or cycles, per unit length can vary rather widely but generally is in the range of about 1 to 10 crimps/cm, preferably at least 2 crimps/cm. The size of the crimped bulking fiber can also vary widely but generally is in the range of about 1 to 100 decitex, preferably about 3 to 40 decitex. The crimped bulking fibers should have, as a minimum, an average length sufficient to include at least one complete crimp and preferably at least three or four crimps. Generally, the crimped bulking fibers average about 2 to 15 centimeters in length, preferably about 2 to 10 centimeters in length.
The amount of crimped bulking fibers included in the boom of the present invention can range from 0 to 90 weight percent but preferably is in the range of about 5 to 50 weight percent. The addition of the crimped bulking fibers reduces the density or solidity of the boom and generally permits greater sorption capacity of liquids.
When the boom of the invention is to be used for sorption of aqueous liquid, particulate materials such as wood pulp fiber or sorbent particulate can be used. The preferred sorbent materials are generally substantially solid super sorbent particles which rapidly sorb large quantities of liquids and retain the liquid under pressure. Examples of such substantially solid supersorbent particles include, for example, water-insoluble modified starches, such as those described in U.S. Pat. No. 3,981,100, and high molecular weight acrylic polymers containing hydrophilic groups. A wide variety of commercially available water-insoluble, water-sorbing particles typically sorb 20 or more times their weight of water and preferably 100 or more times their weight of water. With such modified starches and acrylic polymers the amount of water sorbed generally decreases as impurities in the water, such as salts and ionic species, increase. Among sorbent particles useful for sorbing liquids other than water are alkylstyrene sorbent particles such as IMBIBER BEADS available from Dow Chemical Company which generally sorb about 5 to 10 times or more their weight of liquid.
The amount of sorbent particulate included in the boom of the present invention can range from 0 to 95 weight percent but preferably is in the range of about 10 to 70 weight percent. The sorbent particulate material may be introduced into the microfiber stream from hopper 23 through metering device 24 and ducts 21 and 20.
Microfiber microwebs may also be used as sorbent particles in the booms of the present invention. The microfiber microwebs have a relatively dense nucleus with numerous individual fibers and/or fiber bundles extending therefrom. The extended fibers and fiber bundles provide an anchoring means for the microfiber microwebs when they are incorporated into the boom. The nucleus of the microfiber microwebs is preferably in the range of about 0.05 to 4 mm, more preferably in the range of about 0.2 to 2 mm. The extending fibers and/or fiber bundles preferably extend beyond the nucleus to provide an overall diameter of about 0.07 to 10 mm, more preferably about 0.1 to 5 mm. Such microfiber microwebs are described in U.S. Pat. No. 4,813,948, (Insley) which is incorporated herein by reference.
The microfiber microwebs useful in the present invention can be prepared from source microfiber webs such as, for example, those disclosed in Wente, Van A., "Superfine Thermoplastic Fibers," Industrial Engineering Chemistry, vol. 48, pp. 1342-1346 and in Wente, Van A. et al., "Manufacture of Superfine Organic Fibers," Report No. 4364 of the Naval Research Laboratories, published May 25, 1954, or from microfiber webs containing particulate matter such as those disclosed, for example, in U.S. Pat. No. 3,971,373, (Braun), U.S. Pat. No. 4,100,324, (Anderson et al.), and U.S. Pat. No. 4,429,001, (Kolpin et al.), which references are incorporated herein as exemplifying preparation of source microfiber webs.
The microfiber microwebs are prepared by mechanically divellicating, or tearing apart, the source microfiber web. Divellication can be accomplished, for example, by subjecting the source microfiber web to a lickerin as shown in FIG. 1. Source microfiber web 25 is fed to lickerin 16 which has, protruding from the surface thereof, teeth 26. The teeth must be at a sufficiently low angle, e.g., preferably less than about 60°, more preferably less than about 40°, from the surface of the lickerin to produce the microwebs having a relatively dense nucleus with fibers and fiber bundles extending therefrom. The lickerin rotates, counter clockwise as depicted in FIG. 1, at a rate sufficient to divellicate source microfiber web 25 to form discrete microfiber microwebs. The source web is generally held in contact with the lickerin by means of a nose bar or delivery roll 27. An air stream provided through duct 21 serves to remove microfiber microwebs from the lickerin teeth. The microfiber microwebs can be collected for later incorporation into the nonwoven webs of the invention or the microfiber microwebs can be supplied directly from the lickerin into the base microfiber stream formed at die 10.
In addition to or in place of adding substantially solid sorbent particulate directly into the microfiber boom, microfiber source webs can be loaded with solid sorbent-type particulate materials and can be divellicated to provide microfiber microwebs which include useful amounts of solid particulate material. In the microfiber source web from which the microfiber microwebs are divellicated, sorbent particles can comprise at least about 5 g/m 2 for each 100 g/m 2 of microfiber, preferably as much as 150 g/m 2 for each 100 g/m 2 microfiber, and in some applications as much as 500 g/m 2 for each 100 g/m 2 microfiber.
The amount of microfiber microwebs included in the boom of the present invention can range from 0 to 90 weight percent but preferably is in the range of about 10 to 50 weight percent.
When crimped bulking fibers and/or sorbent particulate materials are fed into the base microfiber stream, the materials are mixed by the air turbulence present and then continue to the collector 14 where the fibers form a continuous boom. Under close examination, the microfibers and crimped bulking fibers and/or sorbent particulate material are found to be thoroughly mixed. For example, the web is free of clumps of crimped fibers, i.e., collections a centimeter or more in diameter of many crimped fibers, such as would be obtained if a chopped section or multi-ended tow of crimped filament were unseparated or if crimped fibers were balled together prior to introduction into a micro fiber stream.
The optional crimped bulking fibers and/or the sorbent particulate material can be selectively loaded into the boom of the present invention. If the crimped bulking fibers and/or the sorbent particulate material are to be loaded throughout the boom, the crimped bulking fibers and/or the sorbent particulate material are fed into the microfiber stream across the full width of the die. If the crimped bulking fibers and/or the sorbent particulate material are to be located predominantly in the interior portion of the boom, the crimped bulking fibers and/or the sorbent particulate material is fed into the microfiber stream in the central portion of the die. Preferably, the crimped bulking fibers and/or the sorbent particulate material are fed into about 20 to 90 percent, more preferably 50 to 75 percent, of the die width when loaded into the interior portion of the boom. In this type of structure where the crimped bulking fibers and/or the sorbent particulate material are selectively loaded into the interior portion of the boom, the outer portions of the boom, formed from only the blown microfibers, substantially eliminate any dusting out of sorbent particulate material. Similarly, by adding the crimped bulking fibers and/or the sorbent particulate material predominantly at one side of the die, booms can be constructed such that one side contains the crimped bulking fibers and/or the sorbent particulate material and the other side is substantially formed from the blown microfibers.
When the boom is to be used for vapor suppression, i.e., sorption of vapors or contaminants from the air, the particulate material is an adsorbent material of the type commonly used to remove the particular vapor or contaminant that could be released from the sorbed liquid. Typical particles for use in vapor suppression or purifying booms include, for example, activated carbon, alumina, sodium bicarbonate, chitosan, elemental iron and silver particles which remove a component from a fluid by adsorption or absorption, chemical reaction or amalgamation, as well as clay and clay treated with acidic solutions such as acetic acid or alkaline solutions such as aqueous sodium hydroxide. Chitosan is particularly useful for removing dyes from solution. Elemental iron is particularly useful for treatment of waste streams from photographic developing systems by reducing silver ions to elemental silver which deposit or plate out in the booms.
Additional types of particulate material which can be added to the booms in the same manner as the sorbent particulate include ion exchange resins and catalytic agents. The ion exchange materials may be cationic ion exchange particles such as sulfonated styrene-divinylbenzene particles, anionic ion exchange resins and chitosan. Catalytic agents include particulate materials such as hopcalite which can catalyze the conversion of a hazardous material and palladium-on-carbon which can catalyze a hydrogenation or hydrogenolysis reaction.
The particulate material may vary in size from about 5 to 3000 micrometers in average diameter. Preferably the particles are less than about 1500 micrometers in average diameter.
The amount of particulate included in the boom can range from 0 to 95 weight percent but preferably is in the range of about 10 to 70 weight percent. The particulate material may be introduced into the microfiber stream from hopper 23 through metering device 24 and ducts 21 and 20.
The following examples further illustrate this invention, but the particular materials and amounts thereof in these examples, as well as the conditions and details, should not be construed to unduly limit this invention. In the examples all parts and percentages are by weight unless otherwise specified. All booms were prepared using equipment similar to that depicted in FIGS. 1 and 2 unless otherwise indicated.
Boom Size
The size of the booms were measured with the width being measured parallel to the collection surface and the height being measured perpendicular to the collection surface at the midpoint of the boom.
Tensile Strength
A boom sample is placed in an INSTRON tensile tester Model 1123, available from Instron Corporation, having jaw spacing of 25.4 cm and jaw faces 7.62 cm wide. The sample is tested at a crosshead speed of 20 cm/min. The peak tensile is recorded in N/boom.
Fabric Stiffness
Fabric stiffness was determined using ASTM Test Method D1388-64 and is reported as bend length.
Solidity
Solidity is determined using the formula [(1-b)c -1 +ba -1 +d] -1 x [(1-b)c+ab] -1 ×100 wherein a is the particle density, b is the particle weight fraction, c is the density of the polypropylene and d is the volumetric sorbency.
Instantaneous Sorption
A sample of boom approximately 8 cm long was weighed, then placed in a bath of 30 volume percent aqueous isopropyl alcohol solution and allowed to saturate 10 minutes. The weight of solution sorbed per unit weight of sorbent is reported as instantaneous sorption (g/g).
Volumetric Sorbency
Volumetric sorbency is calculated as the instantaneous sorption divided by the test fluid density.
Centrifugal Retention
A sample of boom approximately 8 cm long was weighed, then placed in a centrifuge cup having a support perforated with holes 3 mm in diameter, the support being raised 6 cm from the bottom of the cup holder to provide a receiver into which centrifuged liquid could drain. The sample and cup were placed in a bath of 30 volume percent aqueous isopropyl alcohol solution and allowed to saturate for 10 minutes, then removed and placed in a centrifuge. The sample was subjected to a centrifugal force of 150 gravities (1000 rpm, 15 cm rotating radius) for 5 minutes, then weighed. The centrifugal retention value is calculated as the weight of solution remaining in the boom sample per unit weight of sorbent.
Volumetric Retention
Volumetric retention is calculated as the centrifugal retention divided by the test fluid density.
Oil Sorbency Test
Modified ASTM Test Method F726 9.1.3 was used to determine oil sorbency. A 12 inch (30.5 cm) long boom sample is weighed and placed in a 61 cm×91 cm tray containing a drain screen in the bottom. Light mineral oil having a viscosity of 50-60 SUS at 38° C. is added to the tray to a depth of at least 50 mm. The sample is allowed to submerge and the time to full saturation, by visual observation, is recorded. The sample is then left undisturbed for an additional period of time equal to at least 20% of the elapsed time to saturation. After the additional time, the sample is removed from the tray using the drain screen and is allowed to drain for 30 seconds. The boom sample is again weighed and the amount of oil remaining in the sample is determined. The oil sorption is the amount of oil remaining in the sample per dry sample weight (g/g). Preferably the oil sorbency is at least about 5 g/g, more preferably 10 g/g.
Fluid Recovery
Fluid recovery was determined generally using ASTM Test Method F726 10.3. A boom sample is weighed (WDRY), saturated, drained and reweighed (WSAT) as in the Oil Sorbency Test and the amount of oil sorbed is calculated. The sample is then placed in a roller type wringer (Model 76-3 from Lake City Industries, Inc.) and the mineral oil is extracted from the sample using 1.4 kg/cm 2 pressure supplied to the roller surface by a pressure regulated cylinder adapted to the wringer. The extracted sample is then weighed (WEXT). The percent recovery is then calculated using the equation: 1-[(WEXT-WDRY)/(WSAT-WDRY)].
Vapor Sorption--Carbon Tetrachloride
A boom sample, preconditioned at 100° C. for 4 hours, was weighed and placed in a sealed desiccator on a porous ceramic plate positioned about 2 cm above 1 L carbon tetrachloride. After 24 hours, the boom was removed from the desiccator and weighed. The boom was reweighed at selected time intervals. Add-on weights were calculated in grams of carbon tetrachloride per gram of boom.
Acid Neutralization
A boom sample was weighed and saturated with excess hydrochloric acid. Titration was then performed with potassium hydroxide solution to determine the excess acid. The result is reported in MEQ base/g sample.
Ion Exchange Capacity
A 0.45 micron Millex™ filter unit, available from Millipore Corp., was attached to the tip of a 20 cm 3 disposable plastic syringe from which the plunger was removed. A circular boom sample was obtained using a die such that the sample fit into the syringe barrel. The sample was weighed in the syringe, then washed with 2×10 mL ultrapure water. The wash liquid was collected and weighed. A 10 mL aliquot of aqueous calcium chloride solution, containing 466.7 ppm calcium as measured by inductively coupled plasma atomic emission spectroscopy (ICP) was passed through the sample, followed by 2×10 mL ultrapure water. The latter three aqueous effluents were collected together and weighed.
The above test was repeated except the initial two washes were conducted with 2×10 mL of 0.1N aqueous hydrochloric acid.
ICP spectroscopic analysis of the collected effluents was carried out using an ARL 3580 instrument, available from Applied Research Laboratories, using both 317 nm and 393 nm wavelength measurements to capture both low and high concentration values.
EXAMPLES 1-8
In Examples 1-3, booms were prepared using polypropylene (FINA 7OMF, available from Fina Oil and Chemical Co.) melt blown microfibers having an average effective diameter of 8 microns. In Examples 4-6, booms were prepared containing 88.5 weight percent polypropylene (FINA 70MF) melt blown microfibers having an average effective diameter of 8 microns and 11.5 weight percent microfiber microwebs. In Example 7, the boom was prepared as in Examples 4-6 except that the boom contained 18 weight percent polypropylene melt blown microfibers and 82 weight percent microfiber microwebs. In Example 8, the boom was prepared as in Examples 4-6 except the boom contained 21 weight percent polypropylene melt blown microfibers, 55 weight percent micro fiber microwebs, and 24 weight percent 15 denier polyester staple fiber (Type 431, 15 denier, 3 crimps/cm, available from Eastman Chemical Products, Inc.).
Each boom was prepared on equipment similar to that shown in FIG. 1. The extrusion rate, per unit length of die, was 0.42 kg/hr/cm; the collector was 0.33 m from the die in Examples 1-6 and, in Examples 7-8, the input side of the collector was 0.33 m from the die and the output side of the collector was 0.41 m from the die. The microfiber microwebs were prepared from a source web which weighed 410 g/m 2 , had a solidity of 6.3% and was prepared from polypropylene (FINA 70MF) melt blown microfiber having an average diameter of about 8 microns. The lickerin was operated at a speed of 2650 rpm and had 6.2 teeth/cm 2 .
The meltblown microfiber was treated with 10.3 weight percent nonionic surfactant, (TRITON X-100, available from Union Carbide Corp.) and 0.5 weight percent gray pigment (#1607-052-15M Gray, available from Spectrum Colors, Inc.), each based on the weight of the base microfiber web, as described in U.S. Pat. No. 4,933,299, which is incorporated herein by reference.
The lineal weight of each boom was measured. The oil sorbency, tensile strength and stiffness were determined. The results are set forth in Table 1.
TABLE 1______________________________________ Lineal Oil Tensile StiffnessEx. Height Width Weight Sorbency Strength (cm bendNo. (cm) (cm) (g/m) (g/g) (N/boom) length)______________________________________1 1.3 21 90 13.4 108 9.82 2.0 22 167 10.0 147 13.73 2.9 22 286 9.4 255 19.84 1.7 17 80 13.6 78 7.75 2.3 17 156 11.3 118 10.06 3.5 17 324 10.1 245 18.77 2.7 11 80 14.4 49 10.48 5.0 10 93 24 39 11.4______________________________________
As can be seen from the data in Table 1, Examples 1-3 which contain only meltblown microfibers and 4-6 which contain meltblown microfiber base webs and microfiber microwebs demonstrate that as the lineal weight increases, the sorbency decreases while the tensile increases. Example 8 also demonstrates the effect of adding staple fiber content to significantly increase sorbency. In comparing Examples 1-3 with Examples 4-6, it can be seen that the addition of the microfiber microwebs to the base web increases boom flexibility.
EXAMPLES 9-12
In Examples 9-12, booms were prepared using equipment similar to that shown in FIG. 1 and various melt blown microfiber base webs, 15 denier polyester staple fiber (Eastman Type 431) and microfiber microwebs prepared as in Examples 4-8. The description of microfiber base web components and the amounts of each component are set forth in Table 2. The extrusion rate per unit length of die was 0.18 kg/hr/cm and the distance from the die to the collector was 0.46 m. The transverse collection speeds were 3.2, 2.6, 2.6 and 3.2 m/min for Examples 9-12 respectively.
The lineal weight was determined for each boom. Each boom was tested for oil sorbency and stiffness as in Examples 1-8. The tensile strength of each boom was determined as in Examples 1-8 except the jaw spacing was 12.7 cm in Examples 9 and 11 and 5.1 cm in Examples 10 and 12. The results are set forth in Table 3.
TABLE 2______________________________________ StapleMicrofiber Base Microfiber Fiber MicrofiberEx. Web Base Content MicrowebNo. Component Content (%) (%) Content (%)______________________________________ 9 CELANEX 46.1 10.8 43.12002-2.sup.110 KRATON 37.8 12.2 49.0G1657X.sup.211 25% FINA 39.9 12.0 48.13860.sup.3 /75% KRATONG1657X12 MORTON 46.2 10.8 43.0PS440-220.sup.4______________________________________ .sup.1 Polybutylene terephthalate available from Hoechst Celanese Corp. .sup.2 Polystyrene-polybutadiene-polystyrene block copolymer available from Shell Corp. .sup.3 Polypropylene available from Fina Oil and Chemical Company. .sup.4 Polyurethane available from Morton International.
TABLE 3______________________________________ Lineal Oil Tensile StiffnessEx. Height Width Weight Sorbency Strength (cm bendNo. (cm) (cm) (g/m) (g/g) (N/boom) length)______________________________________ 9 3.5 9 78.4 25.5 98 4.210 3.5 14 93.1 10.9 29 7.611 2.8 17 90.6 19.6 59 6.312 2.2 14.5 78.1 17.3 206 7.8______________________________________
As can be seen from the data in Table 3, various classes of materials can be extruded for the base microfiber to form a self supporting boom with high sorbency and a range of tensile strength.
EXAMPLE 13
A source web was prepared of polypropylene (FINA Grade 70 MF) microfibers having an effective fiber diameter of 8 microns. The web had a basis weight of 410 g/m 2 and a solidity of 6.3%. The web was chopped using a Model #20 hammer mill (available from C.S. Bell Company) to form sorbent particles. The sorbent particles were blended with polyester staple fiber (Eastman Type 431) at a ratio of sorbent particles to staple fiber of 80 to 20 weight percent. This blend was then fed into a polypropylene (FINA Grade 70 MF) melt blown microfiber web having an effective fiber diameter of 8 microns using the same method for feeding in the polyester staple fiber as in Examples 1-8, except the blend was fed into the microfiber stream only at the center 75% of the die and the extrusion rate was 0.42 kg/hr/cm. Surfactant (10.3 weight percent TRITON X-100) and 0.5 weight percent gray pigment (#1607-052-15M Gray, available from Spectrum Colors) based on the weight of the microfiber base web were added at the die as disclosed in U.S. Pat. No. 4,933,299. The product was collected using a transverse collection speed of 25.8 m/min and a collection distance of 0.33 m on the input side and 0.41 m on the output side. The resultant boom had a lineal weight of 68 g/m and contained 42.9 weight percent microfiber base web, 11.4 weight percent staple fiber and 45.7 weight percent sorbent microweb particles. The boom was layered with the outer portions being substantially all microfiber structure and the center portion being a microfiber/staple fiber/microweb blend.
The boom produced had a sorbency in light mineral oil of 24.3 g/g, a tensile strength of 85 N/boom and a bend length of 10.3 cm.
EXAMPLE 14
A source web was prepared of polypropylene (FINA Grade 70 MF) microfibers having an effective fiber diameter of 8 microns. The web had a basis weight of 410 g/m 2 and a solidity of 6.3%. The web was divellicated using a lickerin having 6.2 teeth/cm 2 at a speed of 2650 rpm to form sorbent microweb particles. Sorbent microweb particles were fed into a base microfiber web formed of two microfiber materials. Materials of the base web were generated by two separate dies, the outputs from which were made to converge before the inclusion of microweb particles and collection. The streams from the two dies intersected at an angle of approximately 60 degrees. The material produced from one die was a highly crystalline, oriented polypropylene. The degree of crystalline orientation was achieved by attenuating the fiber in an air chamber place directly in front of the microfiber die as taught in Meyer et al (No. 4,988,560). The second microfiber stream was composed of polybutylene. The combined base microfiber web was 50% PP (Fina 70 MF) and 50% PB (Shell 8510). The product was collected using a transverse collection speed of 0.77 m/min with a collection distance of 0.25 m on the input side and 0.35 m on the output side. The resultant boom had a lineal weight of 197 g/m and contained 50 weight percent microfiber base web and 50 weight percent sorbent microweb particles.
The boom produced had a sorbency in light mineral oil of 11 g/g and had a tensile strength of 1112 N/boom.
EXAMPLE 15
Sorbent particulate microwebs were prepared as in Example 1. The microwebs and polyester staple fiber (Eastman Type 431) were fed into a microfiber base web using equipment similar to that shown in FIG. 1. The microfiber base web was formed from a coextruded blend of 48 weight percent polypropylene (FINA 70 MF) and 52 weight percent polyethylene (ASPUN 6806, available from Dow Chemical Company) at an extrusion rate of 0.98 kg/hr/cm and had an effective fiber diameter of 8 microns. The product was collected at a collector speed of 23 m/min and a distance of 0.33 m on the input side and 0.41 m on the output side. The boom contained 46.8 weight percent microfiber base web, 9.3 weight percent staple fiber and 43.9 weight percent microwebs and had a height of 5 cm and a width of 11 cm. The boom had a sorbency of 22.1 g/g, a lineal weight of 160 g/m, a tensile strength of 39 N/boom and a bend length of 6.9 cm.
EXAMPLE 16
Sorbent particulate microwebs were prepared as in Example 15. The microwebs and polyester staple fiber (Eastman Type 431) were fed into a microfiber base web using equipment similar to that shown in FIG. 1. The microfiber base web was formed from a coextruded blend of 48 weight percent polypropylene (FINA 70 MF) and 52 weight percent polybutylene (Type 8510, available from Shell Company) at an extrusion rate of 0.98 kg/hr/cm and had an effective fiber diameter of 8 microns. The product was collected at a collector speed of 30.3 m/min and a distance of 0.33 m on the input side and 0.41 m on the output side. The boom contained 46.8 weight percent microfiber base web, 9.3 weight percent staple fiber and 43.9 weight percent microwebs. The boom had a lineal weight of 122.7 g/m, a height of 4.2 cm and a width of 17 cm. The boom had a sorbency of 21.4 g/g, a tensile strength of 98 N/boom and a bend length of 26.6 cm.
EXAMPLE 17 AND COMPARATIVE EXAMPLE C1
In Example 17, a source web was prepared of 18.6 weight percent polypropylene (FINA Grade 70 MF) microfibers having an effective fiber diameter of 8 microns and 81.4 weight percent activated coconut carbon (Type RFM-C, available from Calgon Carbon Corp.). The web had a basis weight of 333 g/m 2 and a solidity of 21%. The web was divellicated using a lickerin having 6.2 teeth/cm 2 at a speed of 2650 rpm to form sorbent particles. The sorbent particles were blended with polyester staple fiber (Eastman Type 431) and fed into a polypropylene (FINA 70 MF) base web at the center 50% of the die using equipment similar to that shown in FIG. 1 and collected on the transverse collector. The base web fibers had an effective fiber diameter of 8 microns. Surfactant and pigment were added as in Example 13. The extrusion rate was 0.42 kg/hr/cm die width, the collector speed was 40.3 m/min and the collector was 0.33 m at the input side of the collector and 0.41 m at the output side of the collector from the die. The boom formed had a lineal weight of 36 g/m and contained 51.4 weight percent microfiber base web, 10.3 weight percent staple fiber and 38.3 weight percent sorbent particulate carbon-loaded microwebs. The boom had a tensile strength of 45 N/boom.
In Comparative Example C1, a boom was prepared as in Example 17 except the microwebs contained no carbon. The composition of the boom was 42.6 weight percent microfiber base web, 4.1 weight percent polyester staple fiber and 53.3 weight percent microweb sorbent particulate.
Each prepared boom was tested for carbon tetrachloride (CCl 4 ) vapor sorption. The total amount for a given time is set forth in Table 4.
TABLE 4______________________________________Total CCl.sub.4 Vapor Sorption (g/g)Time (min) Example 17 Comparative Example 1______________________________________ 0 0.35 0.34 1 0.24 0.25 2 0.20 0.193.5 0.17 0.15 5 0.16 0.127.5 0.15 0.0910 0.14 0.0715 0.13 0.0520 0.13 0.0525 0.12 0.0430 0.12 0.0440 0.11 0.0350 0.11 0.0360 0.10 0.0390 0.09 0.02120 0.08 0.02180 0.07 0.02270 0.06 0.0120 hrs 0.04 0.01______________________________________
As can be seen from the data in Table 4, the boom containing the activated carbon in the microweb particulate retained a greater amount of carbon tetrachloride for a longer period of time than did the boom containing no carbon.
EXAMPLE 18 AND COMPARATIVE EXAMPLE C2
In Example 18, a source web was prepared containing 20 weight percent polypropylene (FINA Grade 70 MF) microfibers having an effective fiber diameter of 8 microns and 80 weight percent sodium bicarbonate powder (Grade No. 1, available from Church & Dwight Co., Inc). The web had a basis weight of 910 g/m 2 and a solidity of 4.5%. The web was divellicated using a lickerin having 6.2 teeth/cm 2 at a speed of 2650 rpm to form sorbent particles. The sorbent particles were blended with polyester staple fiber (Eastman Type 431) and fed into a polypropylene (FINA 70 MF) base web at the center 50% of the die using equipment similar to that shown in FIG. 1 and collected on the transverse collector. The base web had an effective fiber diameter of 8 microns. Surfactant and pigment were added as in Example 13. The extrusion rate was 0.42 kg/hr/cm die width, the collector speed was 17.8 m/min and the collector was 0.33 m at the input side of the collector and 0.41 m at the output side of the collector from the die. The boom formed had a lineal weight of 92.5 g/m and contained 45.9 weight percent microfiber base web, 9.2 weight percent staple fiber and 44.9 weight percent sorbent particulate sodium bicarbonate-loaded microwebs. The boom had a tensile strength of 85 N/boom.
In Comparative Example C2, a boom was prepared as in Example 18 except the microwebs contained no sodium bicarbonate. The composition of the boom was 42.6 weight percent microfiber base web, 4.1 weight percent polyester staple fiber and 53.3 weight percent microweb sorbent particulate. The tensile strength of the boom was 77 N/boom.
Each prepared boom was tested for sorption of hydrochloric acid. The boom of Example 18 had meq base/g of 3.41 and the boom of Comparative Example C2 had meq base/g of 0.13.
EXAMPLE 19
A source web was prepared of polypropylene (FINA Grade 70 MF) microfibers having an effective fiber diameter of 8 microns. The web had a basis weight of 410 g/m 2 and a solidity of 6.3%. Synthetic super sorbent particulate (39.5 weight percent J-550, available from Grain Processing Corp.) was loaded onto the source web. The web was divellicated using a lickerin having 6.2 teeth/cm 2 at a speed of 2650 rpm to form sorbent microweb particles. The sorbent microweb particles and the synthetic super sorbent particles were blended with polyester staple fiber (Eastman Type 431). This blend was then fed into a polypropylene (FINA Grade 70 MF) melt blown microfiber base web having an effective fiber diameter of 8 microns at the center 50% of the die. Surfactant and pigment were used as in Example 13. The extrusion rate was 0.42 kg/hr/cm. The product was collected using a transverse collection speed of 36.9 m/min with and collection distance of 0.33 m on the input side and 0.41 m on the output side. The resultant boom had a lineal weight of 70.5 g/m and contained 29.1 weight percent microfiber base web, 5.8 weight percent staple fiber, 25.6 weight percent sorbent microweb particles and 39.5 weight percent super sorbent particles. The boom produced had a sorbency in water of 76 g/g and a tensile strength of 53 N/boom.
EXAMPLE 20 AND COMPARATIVE EXAMPLES C3-C6
For Example 20, a source web was prepared of polypropylene (FINA Grade 70 MF) microfibers having an effective fiber diameter of 8 microns. The web had a basis weight of 410 g/m 2 and a solidity of 6.3%. The web was divellicated using a lickerin having 6.2 teeth/cm 2 at a speed of 2650 rpm to form sorbent microweb particles. The sorbent microweb particles were blended with polyester staple fiber (Eastman Type 431) at a ratio of sorbent particles to staple fiber of 87.8 to 12.2 weight percent. This blend was then fed into a polypropylene (FINA Grade 70 MF) melt blown microfiber web having an effective fiber diameter of 8 microns using the same method for feeding in the polyester staple fiber as in Examples 1-8, except the blend was fed into the microfiber stream only at the center 75% of the die and the extrusion rate was 0.42 kg/hr/cm. Surfactant (10.3 weight percent TRITON X-100) and 0.5 weight percent gray pigment (#1607-052-15M Gray, available from Spectrum Colors) based on the weight of the microfiber base web were added at the die as disclosed in U.S. Pat. No. 4,933,299. The product was collected using a transverse collection speed of 20 m/min and with collection distance of 0.33 m on the input side and 0.41 m on the output side with the edges being trimmed. The resultant boom had a lineal weight of 79 g/m, a height of 3.8 cm, a width of 7.6 cm and contained 46.9 weight percent microfiber base web, 6.5 weight percent staple fiber and 46.6 weight percent sorbent microweb particles. The boom was layered with the outer portions being substantially all microfiber structure and the center portion being a microfiber/staple fiber/microweb blend.
The boom produced had a sorbency in light mineral oil of 21.2 g/g, a sorbency in water of 24.3 g/g, a tensile strength of 69 N/boom, and a bend length of 9.6 cm.
For Comparative Example 3, a microfiber web containing 10% staple fiber was chopped and placed in a tubular sleeve which was then closed at each end.
For Comparative Examples 4-6, tubular sleeves filled with ground corn cobs and closed at each end to form booms were used.
The lineal weight of each boom was determined and the booms were tested for sorbency in light mineral oil and for fluid recovery. The results are set forth in Table 5.
TABLE 5______________________________________Example Lineal Weight Sorbency (g/g)______________________________________ Recovery (%)20 79 21.2 87.1C3 344 9.0 0C4 180 6.9 0C5 430 3.3 0C6 374 4.9 0______________________________________
As can be seen from the data in Table 5, the boom of Example 20 had superior sorbency over the comparative booms. Excellent recovery was achieved with the boom of Example 20. No recovery was achieved with the comparative booms because in each case the sorbent material shifted to the end of the tubular sleeve causing the sleeve to tear and allowing spillage of the sorbent material.
EXAMPLES 21 AND 22
In Examples 21 and 22, booms were prepared as in Examples 1-8 with an extrusion rate of 0.42 kg/hr/cm. In Example 21, the collector was 0.3 m from the die and in Example 22 the collector was 0.38 m from the die. Each boom contained 45 weight percent melt blown microfiber base web, 46 weight percent microfiber microwebs and 9 weight percent polyester staple fiber. The lineal weight, sorbency ratio, tensile strength and height were determined and are reported in Table 6.
TABLE 6______________________________________ TensileLineal Sorbency StrengthExample Weight (g/g) Ratio (g/g) (N/boom) Height (cm)______________________________________21 87 23.8 76 5.022 75 30.0 73 4.7______________________________________
As can be seen from the data in Table 6, the greater distance of the collector from the die in Example 22 over that in Example 21, increased lineal weight and sorbency ratio and decreased tensile strength and height.
EXAMPLE 23
A boom was prepared as in Examples 1-8 containing 19 weight percent carrier web of polypropylene (Exxon™ 3495G, available from Exxon Corp.) melt blown microfibers having an effective fiber diameter of 20 micrometers and 81 weight percent Absencts® hydrophobic molecular sieve particles (available from UOP Corp., Tarrytown, N.Y.) having a density of 1.8 g/ml. The basis weight of the carrier web was 200 g/m 2 . The extrusion rate, per unit length of die, for the carrier web, was 0.12 Kg/hr/cm; the collector was 0.53 m from the die and the collection speed was 131 cm/min. Particles were fed into the boom at the rate of 0.5 Kg/hr/cm. The resultant boom had a lineal weight of 206 g/m. When the edges were trimmed in the lineal direction, the boom had an essentially oval-shaped cross-section, measuring 2.5 cm by 5 cm. The basis weight, solidity, tensile strength, instantaneous sorbency, centrifugal retention, volumetric sorbency, and volumetric retention of the boom was determined. The results are set forth in Table 7.
A sample of the boom weighing 2.124 g was placed in a closed desiccator on a porous ceramic plate positioned about 2 cm above 1 L of chloroform such that the free space was saturated with chloroform fumes. The boom sample was exposed to chloroform fumes for 45 min. The sample took up 0.429 g of chloroform, a 20.6% weight increase. A 1.902 g portion of the Absencts.sup. molecular sieve particles was placed in the desiccator for 45 min. The sample took up 0.463 g of chloroform, a 24.3% weight increase, demonstrating that inclusion of the particles in the boom does not significantly reduce sorption.
EXAMPLE 24
In a Ross® planary mixer, 67 parts by weight alumina particles of approximately 0.06 mm diameter were dampened slightly with water, then mixed with 8 parts by weight powdered epoxy resin (Scotchcast™ XC6143, available from 3M, St. Paul, Minn.) and heated with stirring to 150° C. for one hour. After cooling, the agglomerated particles were broken up using a laboratory roller mill. Chitosan malate powder (25 parts by weight, available from Protan, Inc., Raymond, Wash.) was added and the mixture was stirred and reheated to 150° C. for sixteen hours to crosslink the epoxy resin. Free chitosan malate was removed by screening, after cooling. The chitosan malate-coated alumina particles were then washed with 1M aqueous NaCl solution followed by 1M aqueous NaOH solution, at room temperature. The resulting particles were screened to size (0.09-0.15 mm) and air-dried.
A boom was prepared as in Examples 1-8 containing 24 weight percent carrier web of polypropylene (EXXON 3495G) melt blown microfibers having an effective fiber diameter of 20 micrometer and 76 weight percent of the alumina-immobilized chitosan malate having a density of 0.9 g/ml. The basis weight of the web was 200 g/m 2 . The extrusion rate, per unit length of die, for the carrier web, was 0.12 Kg/hr/cm, the collector was 0.53 m from the die, and the collection speed was 131 cm/min. Particles were fed into the boom at the rate of 0.56 Kg/hr/cm. The resultant boom had a lineal weight of 168 g/m. When the edges were trimmed in the lineal direction, the boom had an essentially flat, rectangular-shaped cross-section, measuring 1 cm thick and 6.5 cm wide. The basis weight, solidity, tensile strength, instantaneous sorbency, centrifugal retention, volumetric sorbency, and volumetric retention of the boom was determined. The results are set forth in Table 7.
EXAMPLE 25
A boom was prepared containing 9 weight percent carrier web of polypropylene (EXXON 3495G) melt blown microfibers having an effective fiber diameter of 20 micrometers and 91 weight percent sulfonated styrene-divinylbenzene copolymeric ion exchange resin (Catalog No. C-100E, from Purolite Corp., Bala Cynwyd, Pa.). Resin particles were 0.3-1.18 mm in diameter and had a density of 1.3 g/ml. The basis weight of the carrier web was 200 g/m 2 . The extrusion rate, per unit length of die, for the carrier web, was 0.12 Kg/hr/cm; the collector was 0.53 m from the die, and the collection speed was 131 cm/min. Particles were loaded into the boom at the rate of 1.21 Kg/hr/cm. The resultant boom had a lineal weight of 431 g/m. When the edges were trimmed in the lineal direction, the boom had an essentially oval-shaped cross-section, measuring 3.5 cm thick by 5.5 cm wide. The basis weight, solidity, tensile strength, instantaneous sorbency, centrifugal retention, volumetric sorbency, and volumetric retention of the boom was determined. The results are set forth in Table 7.
EXAMPLE 26
A boom was prepared containing 8 weight percent carrier web of polypropylene (EXXON 3495G) melt blown microfibers having an effective fiber diameter of 20 micrometers and 92 weight percent of sulfonated styrene-divinylbenzene copolymeric ion exchange resin (HCR-S Fine Mesh resin, from Dow Chemical Co.). Resin particles were 0.25-0.7 mm diameter and has a density of 1.3 g/ml. The web had a basis weight of 200 g/m 2 . The extrusion rate, per unit length of die, for the carrier web, was 0.12 Kg/hr/cm; the collector was 0.53 m from the die, and the collection speed was 131 cm/min. Particles were loaded into the boom at the rate of 1.5 Kg/hr/cm. The resultant boom had a lineal weight of 526 g/m. When the edges were trimmed in the lineal direction, the boom had an essentially oval-shaped cross-section, measuring 3.2 cm thick and 5.5 cm wide. The basis weight, solidity, tensile strength, instantaneous sorbency, centrifugal retention, volumetric sorbency, and volumetric retention of the boom was determined. The results are set forth in able 7.
TABLE 7__________________________________________________________________________ Tensile Instant. Centrif. Volumetric Volumetric Weight Solidity Strength Sorbency Retention Sorbency RetentionEx. (g/m) (%) (N/boom) (g/g) (g/g) (ml/g) (ml/g)__________________________________________________________________________23 206 11 44 4.0 0.48 5.1 0.6124 168 22 93 3.1 0.36 3.9 0.4625 431 19 40 2.7 0.55 3.4 0.7026 526 18 43 2.8 0.67 3.5 0.85__________________________________________________________________________
EXAMPLES 27-29 AND COMPARATIVE EXAMPLE C7
In Examples 27-29, booms were prepared as in Examples 24-26, respectively. In Comparative Example C7, a boom was prepared as in Example 27 except no particulate was added. Two samples of each boom were tested for ion exchange capacity. The results are set forth in Table 8.
TABLE 8______________________________________ Micrograms Ca/grams of Micrograms Ca/grams ofExample sample (water washed) sample (acid washed)______________________________________C7 262 207 60 7127 2891 60 2496 6028 2174 2149 2644 205629 2809 2110 1508 2839______________________________________
Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention and this invention should not be restricted to that set forth herein for illustrative purposes.
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A microfibrous sorbent article is provided. The microfibrous sorbent article comprises an elongate boom having a substantially oval cross-section. The boom is formed of multiple adjacent microfibers layers, the layers being bonded to each other by entanglement of fibers between adjacent layers. The boom further contains ion exchange resin, selectively absorbent particulate material, catalytic agent or selectively reactive particulate material.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of co-pending application Ser. No. 11/702,810, entitled Single Phase Fluid Sampling Apparatus and Method for Use of Same, filed on Feb. 6, 2007, which is a continuation-in-part application of co-pending application Ser. No. 11/438,764, entitled Single Phase Fluid Sampling Apparatus and Method for Use of Same, filed on May 23, 2006, which is a continuation-in-part application of application Ser. No. 11/268,311, entitled Single Phase Fluid Sampler Systems and Associated Methods, filed on Nov. 7, 2005, now U.S. Pat. No. 7,197,923 B1, issued Apr. 3, 2007.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates, in general, to testing and evaluation of subterranean formation fluids and, in particular to, a single phase fluid sampling apparatus for obtaining multiple fluid samples and maintaining the samples near reservoir pressure via a common pressure source during retrieval from the wellbore and storage on the surface.
BACKGROUND OF THE INVENTION
[0003] Without limiting the scope of the present invention, its background is described with reference to testing hydrocarbon formations, as an example.
[0004] It is well known in the subterranean well drilling and completion art to perform tests on formations intersected by a wellbore. Such tests are typically performed in order to determine geological or other physical properties of the formation and fluids contained therein. For example, parameters such as permeability, porosity, fluid resistivity, temperature, pressure and bubble point may be determined. These and other characteristics of the formation and fluid contained therein may be determined by performing tests on the formation before the well is completed.
[0005] One type of testing procedure that is commonly performed is to obtain a fluid sample from the formation to, among other things, determine the composition of the formation fluids. In this procedure, it is important to obtain a sample of the formation fluid that is representative of the fluids as they exist in the formation. In a typical sampling procedure, a sample of the formation fluids may be obtained by lowering a sampling tool having a sampling chamber into the wellbore on a conveyance such as a wireline, slick line, coiled tubing, jointed tubing or the like. When the sampling tool reaches the desired depth, one or more ports are opened to allow collection of the formation fluids. The ports may be actuated in variety of ways such as by electrical, hydraulic or mechanical methods. Once the ports are opened, formation fluids travel through the ports and a sample of the formation fluids is collected within the sampling chamber of the sampling tool. After the sample has been collected, the sampling tool may be withdrawn from the wellbore so that the formation fluid sample may be analyzed.
[0006] It has been found, however, that as the fluid sample is retrieved to the surface, the temperature of the fluid sample decreases causing shrinkage of the fluid sample and a reduction in the pressure of the fluid sample. These changes can cause the fluid sample to approach or reach saturation pressure creating the possibility of asphaltene deposition and flashing of entrained gasses present in the fluid sample. Once such a process occurs, the resulting fluid sample is no longer representative of the fluids present in the formation. Therefore, a need has arisen for an apparatus and method for obtaining a fluid sample from a formation without degradation of the sample during retrieval of the sampling tool from the wellbore. A need has also arisen for such an apparatus and method that are capable of maintaining the integrity of the fluid sample during storage on the surface.
SUMMARY OF THE INVENTION
[0007] The present invention disclosed herein provides a single phase fluid sampling apparatus and a method for obtaining fluid samples from a formation without the occurrence of phase change degradation of the fluid samples during the collection of the fluid samples or retrieval of the sampling apparatus from the wellbore. In addition, the sampling apparatus and method of the present invention are capable of maintaining the integrity of the fluid samples during storage on the surface.
[0008] In one aspect, the present invention is directed to an apparatus for obtaining a plurality of fluid samples in a subterranean well that includes a carrier, a plurality of sampling chambers and a pressure source. In one embodiment, the pressure source is selectively in fluid communication with at least two sampling chambers thereby serving as a common pressure source to pressurize fluid samples obtained in the at least two sampling chambers. In another embodiment, the carrier has a longitudinally extending internal fluid passageway forming a smooth bore and a plurality of externally disposed chamber receiving slots. Each of the sampling chambers is positioned in one of the chamber receiving slots of the carrier. The pressure source is selectively in fluid communication with each of the sampling chambers such that the pressure source is operable to pressurize each of the sampling chambers after the fluid samples are obtained.
[0009] In another aspect, the present invention is directed to a method for obtaining a plurality of fluid samples in a subterranean well. The method includes the steps of positioning a fluid sampler in the well, obtaining a fluid sample in each of a plurality of sampling chambers of the fluid sampler and pressurizing each of the fluid samples using a pressure source of the fluid sampler that is in fluid communication with each of the sampling chambers.
[0010] In a further aspect, the present invention is directed to an apparatus for obtaining a fluid sample in a subterranean well. The apparatus includes a housing having a sample chamber defined therein. The sample chamber is selectively in fluid communication with the exterior of the housing and is operable to receive the fluid sample therefrom. A debris trap piston is slidably disposed within the housing. The debris trap piston includes a debris chamber and, responsive to the fluid sample entering the sample chamber, the debris trap piston receives a first portion of the fluid sample in the debris chamber then displaces relative to the housing to expand the sample chamber.
[0011] In one embodiment, the debris trap piston includes a passageway having a cross sectional area that is smaller than the cross sectional area of the debris chamber. In this embodiment, the first portion of the fluid sample passes from the sample chamber through the passageway to enter the debris chamber. Also in this embodiment, the first portion of the fluid sample is retained in the debris chamber due to pressure from the sample chamber applied to the debris chamber through the passageway. Alternatively or additionally, a check valve may be disposed in an inlet portion of the debris trap piston to retain the first portion of the fluid sample in the debris chamber.
[0012] In another embodiment, the debris trap piston may include a first piston section and a second piston section that is slidable relative to the first piston section such that the debris chamber is expandable responsive to the fluid sample entering the debris chamber. In this embodiment, as engagement device may be disposed between the first piston section and the second piston section to prevent additional movement of the first piston section relative to the second piston section after expanding the debris chamber to a preselected volume.
[0013] In an additional aspect, the present invention is directed to a method for obtaining a fluid sample in a subterranean well. The method includes the steps of disposing a sampling chamber within the subterranean well, actuating the sampling chamber such that a sample chamber within the sampling chamber is in fluid communication with the exterior of the sampling chamber, receiving a first portion of the fluid sample in a debris chamber of a debris trap piston slidably disposed within the sampling chamber, displacing the debris trap piston within the sampling chamber to expand the sample chamber and receiving the remainder of the fluid sample in the sample chamber.
[0014] The method may also include passing the first portion of the fluid sample through the sample chamber and through a passageway of the debris trap piston before entering the debris chamber and retaining the first portion of the fluid sample in the debris chamber by applying pressure from the sample chamber to the debris chamber through the passageway. Additionally or alternatively, a check valve disposed in an inlet portion of the debris trap piston may be used to retain the first portion of the fluid sample in the debris chamber.
[0015] In certain embodiments, the method may include expanding the debris chamber responsive to the fluid sample entering the debris chamber by sliding a first piston section relative to a second piston section and preventing additional movement of the first piston section relative to the second piston section after expanding the debris chamber to a preselected volume.
[0016] In yet another aspect, the present invention is directed to a downhole tool including a housing having a longitudinal passageway. A piston, including a piercing assembly, is disposed within the longitudinal passageway. A valving assembly is also disposed within the longitudinal passageway. The valving assembly includes a rupture disk that is initially operable to maintain a differential pressure thereacross. The valving assembly is actuated by longitudinally displacing the piston relative to the valving assembly such that at least a portion of the piercing assembly travels through the rupture disk, thereby allowing fluid flow therethrough.
[0017] In one embodiment, the piercing assembly includes a piercing assembly body and a needle that is held within the piercing assembly body by compression. In this embodiment, the needle has a sharp point that travels through the rupture disk. In addition, the needle may have a smooth outer surface, a fluted outer surface, a channeled outer surface or a knurled outer surface. In certain embodiments, the valving assembly may include a check valve that allows fluid flow in a first direction and prevents fluid flow in a second direction through the valving assembly once the valving assembly is actuated by the piercing assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a more complete understanding of the present invention, including its features and advantages, reference is now made to the detailed description of the invention, taken in conjunction with the accompanying drawings in which like numerals identify like parts and in which:
[0019] FIG. 1 is a schematic illustration of a fluid sampler system embodying principles of the present invention;
[0020] FIGS. 2A-H are cross-sectional views of successive axial portions of one embodiment of a sampling section of a sampler embodying principles of the present invention;
[0021] FIGS. 3A-E are cross-sectional views of successive axial portions of actuator, carrier and pressure source sections of a sampler embodying principles of the present invention;
[0022] FIG. 4 is a cross-sectional view of the pressure source section of FIG. 3C taken along line 4 - 4 ;
[0023] FIG. 5 is a cross-sectional view of the actuator section of FIG. 3A taken along line 5 - 5 ;
[0024] FIG. 6 is a schematic view of an alternate actuating method for a sampler embodying principles of the present invention;
[0025] FIG. 7 is a schematic illustration of an alternate embodiment of a fluid sampler embodying principles of the present invention;
[0026] FIG. 8 is a cross-sectional view of the fluid sampler of FIG. 7 taken along line 8 - 8 ; and
[0027] FIGS. 9A-G are cross-sectional views of successive axial portions of another embodiment of a sampling section of a sampler embodying principles of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention, and do not delimit the scope of the invention.
[0029] Referring initially to FIG. 1 , therein is representatively illustrated a fluid sampler system 10 and associated methods which embody principles of the present invention. A tubular string 12 , such as a drill stem test string, is positioned in a wellbore 14 . An internal flow passage 16 extends longitudinally through tubular string 12 .
[0030] A fluid sampler 18 is interconnected in tubular string 12 . Also, preferably included in tubular string 12 are a circulating valve 20 , a tester valve 22 and a choke 24 . Circulating valve 20 , tester valve 22 and choke 24 may be of conventional design. It should be noted, however, by those skilled in the art that it is not necessary for tubular string 12 to include the specific combination or arrangement of equipment described herein. It is also not necessary for sampler 18 to be included in tubular string 12 since, for example, sampler 18 could instead be conveyed through flow passage 16 using a wireline, slickline, coiled tubing, downhole robot or the like. Although wellbore 14 is depicted as being cased and cemented, it could alternatively be uncased or open hole.
[0031] In a formation testing operation, tester valve 22 is used to selectively permit and prevent flow through passage 16 . Circulating valve 20 is used to selectively permit and prevent flow between passage 16 and an annulus 26 formed radially between tubular string 12 and wellbore 14 . Choke 24 is used to selectively restrict flow through tubular string 12 . Each of valves 20 , 22 and choke 24 may be operated by manipulating pressure in annulus 26 from the surface, or any of them could be operated by other methods if desired.
[0032] Choke 24 may be actuated to restrict flow through passage 16 to minimize wellbore storage effects due to the large volume in tubular string 12 above sampler 18 . When choke 24 restricts flow through passage 16 , a pressure differential is created in passage 16 , thereby maintaining pressure in passage 16 at sampler 18 and reducing the drawdown effect of opening tester valve 22 . In this manner, by restricting flow through choke 24 at the time a fluid sample is taken in sampler 18 , the fluid sample may be prevented from going below its bubble point, i.e., the pressure below which a gas phase begins to form in a fluid phase. Circulating valve 20 permits hydrocarbons in tubular string 12 to be circulated out prior to retrieving tubular string 12 . As described more fully below, circulating valve 20 also allows increased weight fluid to be circulated into wellbore 14 .
[0033] Even though FIG. 1 depicts a vertical well, it should be noted by one skilled in the art that the fluid sampler of the present invention is equally well-suited for use in deviated wells, inclined wells or horizontal wells. As such, the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.
[0034] Referring now to FIGS. 2A-2H and 3 A- 3 E, a fluid sampler including an exemplary fluid sampling chamber and an exemplary carrier having a pressure source coupled thereto for use in obtaining a plurality of fluid samples that embodies principles of the present invention is representatively illustrated and generally designated 100 . Fluid sampler 100 includes a plurality of the sampling chambers such sampling chamber 102 as depicted in FIG. 2 . Each of the sampling chambers 102 is coupled to a carrier 104 that also includes an actuator 106 and a pressure source 108 as depicted in FIG. 3 .
[0035] As described more fully below, a passage 110 in an upper portion of sampling chamber 102 (see FIG. 2A ) is placed in communication with a longitudinally extending internal fluid passageway 112 formed completely through fluid sampler 100 (see FIG. 3 ) when the fluid sampling operation is initiated using actuator 106 . Passage 112 becomes a portion of passage 16 in tubular string 12 (see FIG. 1 ) when fluid sampler 100 is interconnected in tubular string 12 . As such, internal fluid passageway 112 provides a smooth bore through fluid sampler 100 . Passage 110 in the upper portion of sampling chamber 102 is in communication with a sample chamber 114 via a check valve 116 . Check valve 116 permits fluid to flow from passage 110 into sample chamber 114 , but prevents fluid from escaping from sample chamber 114 to passage 110 .
[0036] A debris trap piston 118 separates sample chamber 114 from a meter fluid chamber 120 . When a fluid sample is received in sample chamber 114 , piston 118 is displaced downwardly. Prior to such downward displacement of piston 118 , however, piston section 122 is displaced downwardly relative to piston section 124 . In the illustrated embodiment, as fluid flows into sample chamber 114 , an optional check valve 128 permits the fluid to flow into debris chamber 126 . The resulting pressure differential across piston section 122 causes piston section 122 to displace downward, thereby expanding debris chamber 126 .
[0037] Eventually, piston section 122 will displace downward sufficiently far for a snap ring, C-ring, spring-loaded lugs, dogs or other type of engagement device 130 to engage a recess 132 formed on piston section 124 . Once engagement device 130 has engaged recess 132 , piston sections 122 , 124 displace downwardly together to expand sample chamber 114 . The fluid received in debris chamber 126 is prevented from escaping back into sample chamber 114 by check valve 128 in embodiments that include check valve 128 . In this manner, the fluid initially received into sample chamber 114 is trapped in debris chamber 126 . This initially received fluid is typically laden with debris, or is a type of fluid (such as mud) which it is not desired to sample. Debris chamber 126 thus permits this initially received fluid to be isolated from the fluid sample later received in sample chamber 114 .
[0038] Meter fluid chamber 120 initially contains a metering fluid, such as a hydraulic fluid, silicone oil or the like. A flow restrictor 134 and a check valve 136 control flow between chamber 120 and an atmospheric chamber 138 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A collapsible piston assembly 140 in chamber 138 includes a prong 142 which initially maintains another check valve 144 off seat, so that flow in both directions is permitted through check valve 144 between chambers 120 , 138 . When elevated pressure is applied to chamber 138 , however, as described more fully below, piston assembly 140 collapses axially, and prong 142 will no longer maintain check valve 144 off seat, thereby preventing flow from chamber 120 to chamber 138 .
[0039] A floating piston 146 separates chamber 138 from another atmospheric chamber 148 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A spacer 150 is attached to piston 146 and limits downward displacement of piston 146 . Spacer 150 is also used to contact a stem 152 of a valve 154 to open valve 154 . Valve 154 initially prevents communication between chamber 148 and a passage 156 in a lower portion of sampling chamber 102 . In addition, a check valve 158 permits fluid flow from passage 156 to chamber 148 , but prevents fluid flow from chamber 148 to passage 156 .
[0040] As mentioned above, one or more of the sampling chambers 102 and preferably nine of sampling chambers 102 are installed within exteriorly disposed chamber receiving slots 159 that circumscribe internal fluid passageway 112 of carrier 104 . A seal bore 160 (see FIG. 3B ) is provided in carrier 104 for receiving the upper portion of sampling chamber 102 and another seal bore 162 (see FIG. 3C ) is provided for receiving the lower portion of sampling chamber 102 . In this manner, passage 110 in the upper portion of sampling chamber 102 is placed in sealed communication with a passage 164 in carrier 104 , and passage 156 in the lower portion of sampling chamber 102 is placed in sealed communication with a passage 166 in carrier 104 .
[0041] In addition to the nine sampling chambers 102 installed within carrier 104 , a pressure and temperature gauge/recorder (not shown) of the type known to those skilled in the art can also be received in carrier 104 in a similar manner. For example, seal bores 168 , 170 in carrier 104 may be for providing communication between the gauge/recorder and internal fluid passageway 112 . Note that, although seal bore 170 depicted in FIG. 3C is in communication with passage 172 , preferably if seal bore 170 is used to accommodate a gauge/recorder, then a plug is used to isolate the gauge/recorder from passage 172 . Passage 172 is, however, in communication with passage 166 and the lower portion of each sampling chamber 102 installed in a seal bore 162 and thus servers as a manifold for fluid sampler 100 . If a sampling chamber 102 or gauge/recorder is not installed in one or more of the seal bores 160 , 162 , 168 , 170 then a plug will be installed to prevent flow therethrough.
[0042] Passage 172 is in communication with chamber 174 of pressure source 108 . Chamber 174 is in communication with chamber 176 of pressure source 108 via a passage 178 . Chambers 174 , 176 initially contain a pressurized fluid, such as a compressed gas or liquid. Preferably, compressed nitrogen at between about 7,000 psi and 12,000 psi is used to precharge chambers 174 , 176 , but other fluids or combinations of fluids and/or other pressures both higher and lower could be used, if desired. Even though FIG. 3 depicts pressure source 108 as having two compressed fluid chambers 174 , 176 , it should be understood by those skilled in the art that pressure source 108 could have any number of chambers both higher and lower than two that are in communication with one another to provide the required pressure source. As best seen in FIG. 4 , a cross-sectional view of pressure source 108 is illustrated, showing a fill valve 180 and a passage 182 extending from fill valve 180 to chamber 174 for supplying the pressurized fluid to chambers 174 , 176 at the surface prior to running fluid sampler 100 downhole.
[0043] As best seen in FIGS. 3A and 5 , actuator 106 includes multiple valves 184 , 186 , 188 and respective multiple rupture disks 190 , 192 , 194 to provide for separate actuation of multiple groups of sampling chambers 102 . In the illustrated embodiment, nine sampling chambers 102 may be used, and these are divided up into three groups of three sampling chambers each. Each group of sampling chambers can be referred to as a sampling chamber assembly. Thus, a valve 184 , 186 , 188 and a respective rupture disk 190 , 192 , 194 are used to actuate a group of three sampling chambers 102 . For clarity, operation of actuator 106 with respect to only one of the valves 184 , 186 , 188 and its respective one of the rupture disks 190 , 192 , 194 is described below. Operation of actuator 106 with respect to the other valves and rupture disks is similar to that described below.
[0044] Valve 184 initially isolates passage 164 , which is in communication with passages 110 in three of the sampling chambers 102 via passage 196 , from internal fluid passage 112 of fluid sampler 100 . This isolates sample chamber 114 in each of the three sampling chambers 102 from passage 112 . When it is desired to receive a fluid sample into each of the sample chambers 114 of the three sampling chambers 102 , pressure in annulus 26 is increased a sufficient amount to rupture the disk 190 . This permits pressure in annulus 26 to shift valve 184 upward, thereby opening valve 184 and permitting communication between passage 112 and passages 196 , 164 .
[0045] Fluid from passage 112 then enters passage 110 in the upper portion of each of the three sampling chambers 102 . For clarity, the operation of only one of the sampling chambers 102 after receipt of a fluid sample therein is described below. The fluid flows from passage 110 through check valve 116 to sample chamber 114 . An initial volume of the fluid is trapped in debris chamber 126 of piston 118 as described above. Downward displacement of the piston section 122 , and then the combined piston sections 122 , 124 , is slowed by the metering fluid in chamber 120 flowing through restrictor 134 . This prevents pressure in the fluid sample received in sample chamber 114 from dropping below its bubble point.
[0046] As piston 118 displaces downward, the metering fluid in chamber 120 flows through restrictor 134 into chamber 138 . At this point, prong 142 maintains check valve 144 off seat. The metering fluid received in chamber 138 causes piston 146 to displace downward. Eventually, spacer 150 contacts stem 152 of valve 154 which opens valve 154 . Opening of valve 154 permits pressure in pressure source 108 to be applied to chamber 148 . Pressurization of chamber 148 also results in pressure being applied to chambers 138 , 120 and thus to sample chamber 114 . This is due to the fact that passage 156 is in communication with passages 166 , 172 (see FIG. 3C ) and, thus, is in communication with the pressurized fluid from pressure source 108 .
[0047] When the pressure from pressure source 108 is applied to chamber 138 , piston assembly 140 collapses and prong 142 no longer maintains check valve 144 off seat. Check valve 144 then prevents pressure from escaping from chamber 120 and sample chamber 114 . Check valve 116 also prevents escape of pressure from sample chamber 114 . In this manner, the fluid sample received in sample chamber 114 is pressurized.
[0048] In the illustrated embodiment of fluid sampler 100 , multiple sampling chambers 102 are actuated by rupturing disk 190 , since valve 184 is used to provide selective communication between passage 112 and passages 110 in the upper portions of multiple sampling chambers 102 . Thus, multiple sampling chambers 102 simultaneously receive fluid samples therein from passage 112 .
[0049] In a similar manner, when rupture disk 192 is ruptured, an additional group of multiple sampling chambers 102 will receive fluid samples therein, and when the rupture disk 194 is ruptured a further group of multiple sampling chambers 102 will receive fluid samples therein. Rupture disks 184 , 186 , 188 may be selected so that they are ruptured sequentially at different pressures in annulus 26 or they may be selected so that they are ruptured simultaneously, at the same pressure in annulus 26 .
[0050] Another important feature of fluid sampler 100 is that the multiple sampling chambers 102 , nine in the illustrated example, share the same pressure source 108 . That is, pressure source 108 is in communication with each of the multiple sampling chambers 102 . This feature provides enhanced convenience, speed, economy and safety in the fluid sampling operation. In addition to sharing a common pressure source downhole, the multiple sampling chambers 102 of fluid sampler 100 can also share a common pressure source on the surface. Specifically, once all the samples are obtained and pressurized downhole, fluid sampler 100 is retrieved to the surface. Even though certain cooling of the samples will take place, the common pressure source maintains the samples at a suitable pressure to prevent any phase change degradation. Once on the surface, the sample may remain in the multiple sampling chambers 102 for a considerable time during which temperature conditions may fluctuate. Accordingly, a surface pressure source, such a compressor or a pump, may be used to supercharge the sampling chambers 102 . This supercharging process allows multiple sampling chambers 102 to be further pressurized at the same time with sampling chambers 102 remaining in carrier 104 or after sampling chambers 102 have been removed from carrier 104 .
[0051] Note that, although actuator 106 is described above as being configured to permit separate actuation of three groups of sampling chambers 102 , with each group including three of the sampling chambers 102 , it will be appreciated that any number of sampling chambers 102 may be used, sampling chambers 102 may be included in any number of groups (including one), each group could include any number of sampling chambers 102 (including one), different groups can include different numbers of sampling chambers 102 and it is not necessary for sampling chambers 102 to be separately grouped at all.
[0052] Referring now to FIG. 6 , an alternate actuating method for fluid sampler 100 is representatively and schematically illustrated. Instead of using increased pressure in annulus 26 to actuate valves 184 , 186 , 188 , a control module 198 included in fluid sampler 100 may be used to actuate valves 184 , 186 , 188 . For example, a telemetry receiver 199 may be connected to control module 198 . Receiver 199 may be any type of telemetry receiver, such as a receiver capable of receiving acoustic signals, pressure pulse signals, electromagnetic signals, mechanical signals or the like. As such, any type of telemetry may be used to transmit signals to receiver 199 .
[0053] When control module 198 determines that an appropriate signal has been received by receiver 199 , control module 198 causes a selected one or more of valves 184 , 186 , 188 to open, thereby causing a plurality of fluid samples to be taken in fluid sampler 100 . Valves 184 , 186 , 188 may be configured to open in response to application or release of electrical current, fluid pressure, biasing force, temperature or the like.
[0054] Referring now to FIGS. 7 and 8 , an alternate embodiment of a fluid sampler for use in obtaining a plurality of fluid samples that embodies principles of the present invention is representatively illustrated and generally designated 200 . Fluid sampler 200 includes an upper connector 202 for coupling fluid sampler 200 to other well tools in the sampler string. Fluid sampler 200 also includes an actuator 204 that operates in a manner similar to actuator 106 described above. Below actuator 204 is a carrier 206 that is of similar construction as carrier 104 described above. Fluid sampler 200 further includes a manifold 208 for distributing fluid pressure. Below manifold 208 is a lower connector 210 for coupling fluid sampler 200 to other well tools in the sampler string.
[0055] Fluid sampler 200 has a longitudinally extending internal fluid passageway 212 formed completely through fluid sampler 200 . Passageway 212 becomes a portion of passage 16 in tubular string 12 (see FIG. 1 ) when fluid sampler 200 is interconnected in tubular string 12 . In the illustrated embodiment, carrier 206 has ten exteriorly disposed chamber receiving slots that circumscribe internal fluid passageway 212 . As mentioned above, a pressure and temperature gauge/recorder (not shown) of the type known to those skilled in the art can be received in carrier 206 within one of the chamber receiving slots such as slot 214 . The remainder of the slots are used to receive sampling chambers and pressure source chambers.
[0056] In the illustrated embodiment, sampling chambers 216 , 218 , 220 , 222 , 224 , 226 are respectively received within slots 228 , 230 , 232 , 234 , 236 , 238 . Sampling chambers 216 , 218 , 220 , 222 , 224 , 226 are of a construction and operate in the manner described above with reference to sampling chamber 102 . Pressure source chambers 240 , 242 , 244 are respectively received within slots 246 , 248 , 250 in a manner similar to that described above with reference to sampling chamber 102 . Pressure source chambers 240 , 242 , 244 initially contain a pressurized fluid, such as a compressed gas or liquid. Preferably, compressed nitrogen at between about 10,000 psi and 20,000 psi is used to precharge chambers 240 , 242 , 244 , but other fluids or combinations of fluids and/or other pressures both higher and lower could be used, if desired.
[0057] Actuator 204 includes three valves that operate in a manner similar to valves 184 , 186 , 188 of actuator 106 . Actuator 204 has three rupture disks, one associated with each valve in a manner similar to rupture disks 190 , 192 , 194 of actuator 106 and one of which is pictured and denoted as rupture disk 252 . As described above, each of the rupture disks provides for separate actuation of a group of sampling chambers. In the illustrated embodiment, six sampling chambers are used, and these are divided up into three groups of two sampling chambers each. Associated with each group of two sampling chambers is one pressure source chamber. Specifically, rupture disk 252 is associated with sampling chambers 216 , 218 which are also associated with pressure source chamber 240 via manifold 208 . In a like manner, the second rupture disk is associated with sampling chambers 220 , 222 which are also associated with pressure source chamber 242 via manifold 208 . In addition, the third rupture disk is associated with sampling chambers 224 , 226 which are also associated with pressure source chamber 244 via manifold 208 . In the illustrated embodiment, each rupture disk, valve, pair of sampling chambers, pressure source chamber and manifold section can be referred to as a sampling chamber assembly. Each of the three sampling chamber assemblies operates independently of the other two sampling chamber assemblies. For clarity, the operation of one sampling chamber assembly is described below. Operation of the other two sampling chamber assemblies is similar to that described below.
[0058] The valve associated with rupture disk 252 initially isolates the sample chambers of sampling chambers 216 , 218 from internal fluid passageway 212 of fluid sampler 200 . When it is desired to receive a fluid sample into each of the sample chambers of sampling chambers 216 , 218 , pressure in annulus 26 is increased a sufficient amount to rupture the disk 252 . This permits pressure in annulus 26 to shift the associated valve upward in a manner described above, thereby opening the valve and permitting communication between passageway 212 and the sample chambers of sampling chambers 216 , 218 .
[0059] As described above, fluid from passageway 212 enters a passage in the upper portion of each of the sampling chambers 216 , 218 and passes through an optional check valve to the sample chambers. An initial volume of the fluid is trapped in a debris chamber as described above. Downward displacement of the debris piston is slowed by the metering fluid in another chamber flowing through a restrictor. This prevents pressure in the fluid sample received in the sample chambers from dropping below its bubble point.
[0060] As the debris piston displaces downward, the metering fluid flows through the restrictor into a lower chamber causing a piston to displace downward. Eventually, a spacer contacts a stem of a lower valve which opens the valve and permits pressure from pressure source chamber 240 to be applied to the lower chamber via manifold 208 . Pressurization of the lower chamber also results in pressure being applied to the sample chambers of sampling chambers 216 , 218 .
[0061] As described above, when the pressure from pressure source chamber 240 is applied to the lower chamber, a piston assembly collapses and a prong no longer maintains a check valve off seat, which prevents pressure from escaping from the sample chambers. The upper check valve also prevents escape of pressure from the sample chamber. In this manner, the fluid samples received in the sample chambers are pressurized.
[0062] In the illustrated embodiment of fluid sampler 200 , two sampling chambers 216 , 218 are actuated by rupturing disk 252 , since the valve associated therewith is used to provide selective communication between passageway 212 the sample chambers of sampling chambers 216 , 218 . Thus, both sampling chambers 216 , 218 simultaneously receive fluid samples therein from passageway 212 .
[0063] In a similar manner, when the other rupture disks are ruptured, additional groups of two sampling chambers (sampling chambers 220 , 222 and sampling chambers 224 , 226 ) will receive fluid samples therein and the fluid samples obtained therein will be pressurize by pressure sources 242 , 244 , respectively. The rupture disks may be selected so that they are ruptured sequentially at different pressures in annulus 26 or they may be selected so that they are ruptured simultaneously, at the same pressure in annulus 26 .
[0064] One of the important features of fluid sampler 200 is that the multiple sampling chambers, two in the illustrated example, share a common pressure source. That is, each pressure source is in communication with multiple sampling chambers. This feature provides enhanced convenience, speed, economy and safety in the fluid sampling operation. In addition to sharing a common pressure source downhole, multiple sampling chambers of fluid sampler 200 can also share a common pressure source on the surface. Specifically, once all the samples are obtained and pressurized downhole, fluid sampler 200 is retrieved to the surface. Even though certain cooling of the samples will take place, the common pressure source maintains the samples at a suitable pressure to prevent any phase change degradation. Once on the surface, the samples may remain in the multiple sampling chambers for a considerable time during which temperature conditions may fluctuate. Accordingly, a surface pressure source, such a compressor or a pump, may be used to supercharge the sampling chambers. This supercharging process allows multiple sampling chambers to be further pressurized at the same time with the sampling chambers remaining in carrier 206 or after sampling chambers have been removed from carrier 206 .
[0065] It should be understood by those skilled in the art that even though fluid sampler 200 has been described as having one pressure source chamber in communication with two sampling chambers via manifold 208 , other numbers of pressure source chambers may be in communication with other numbers of sampling chambers with departing from the principles of the present invention. For example, in certain embodiments, one pressure source chamber could communicate pressure to three, four or more sampling chambers. Likewise, two or more pressure source chambers could act as a common pressure source to a single sampling chamber or to a plurality of sampling chambers. Each of these embodiments may be enabled by making the appropriate adjustments to manifold 208 such that the desired pressure source chambers and the desired sampling chambers are properly communicated to one another.
[0066] Referring now to FIGS. 9A-9G and with reference to FIGS. 3A-3E , an alternate fluid sampling chamber for use in a fluid sampler including an exemplary carrier having a pressure source coupled thereto for use in obtaining a plurality of fluid samples that embodies principles of the present invention is representatively illustrated and generally designated 300 . Each of the sampling chambers 300 is coupled to a carrier 104 that also includes an actuator 106 and a pressure source 108 as depicted in FIG. 3 .
[0067] As described more fully below, a passage 310 in an upper portion of sampling chamber 300 (see FIG. 9A ) is placed in communication with a longitudinally extending internal fluid passageway 112 formed completely through the fluid sampler (see FIG. 3 ) when the fluid sampling operation is initiated using actuator 106 . Passage 112 becomes a portion of passage 16 in tubular string 12 (see FIG. 1 ) when the fluid sampler is interconnected in tubular string 12 . As such, internal fluid passageway 112 provides a smooth bore through the fluid sampler. Passage 310 in the upper portion of sampling chamber 300 is in communication with a sample chamber 314 via a check valve 316 . Check valve 316 permits fluid to flow from passage 310 into sample chamber 314 , but prevents fluid from escaping from sample chamber 314 to passage 310 .
[0068] A debris trap piston 318 is disposed within housing 302 and separates sample chamber 314 from a meter fluid chamber 320 . When a fluid sample is received in sample chamber 314 , debris trap piston 318 is displaced downwardly relative to housing 302 to expand sample chamber 314 . Prior to such downward displacement of debris trap piston 318 , however, fluid flows through sample chamber 314 and passageway 322 of piston 318 into debris chamber 326 of debris trap piston 318 . The fluid received in debris chamber 326 is prevented from escaping back into sample chamber 314 due to the relative cross sectional areas of passageway 322 and debris chamber 326 as well as the pressure maintained on debris chamber 326 from sample chamber 314 via passageway 322 . An optional check valve (not pictured) may be disposed within passageway 322 if desired. Such a check valve would operate in the manner described above with reference to check valve 128 in FIG. 2B . In this manner, the fluid initially received into sample chamber 314 is trapped in debris chamber 326 . Debris chamber 326 thus permits this initially received fluid to be isolated from the fluid sample later received in sample chamber 314 . Debris trap piston 318 includes a magnetic locator 324 used as a reference to determine the level of displacement of debris trap piston 318 and thus the volume within sample chamber 314 after a sample has been obtained.
[0069] Meter fluid chamber 320 initially contains a metering fluid, such as a hydraulic fluid, silicone oil or the like. A flow restrictor 334 and a check valve 336 control flow between chamber 320 and an atmospheric chamber 338 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. A collapsible piston assembly 340 includes a prong 342 which initially maintains check valve 344 off seat, so that flow in both directions is permitted through check valve 344 between chambers 320 , 338 . When elevated pressure is applied to chamber 338 , however, as described more fully below, piston assembly 340 collapses axially, and prong 342 will no longer maintain check valve 344 off seat, thereby preventing flow from chamber 320 to chamber 338 .
[0070] A piston 346 disposed within housing 302 separates chamber 338 from a longitudinally extending atmospheric chamber 348 that initially contains a gas at a relatively low pressure such as air at atmospheric pressure. Piston 346 includes a magnetic locator 347 used as a reference to determine the level of displacement of piston 346 and thus the volume within chamber 338 after a sample has been obtained. Piston 346 included a piercing assembly 350 at its lower end. In the illustrated embodiment, piercing assembly 350 is threadably coupled to piston 346 which creates a compression connection between a piercing assembly body 352 and a needle 354 . Alternatively, needle 354 may be coupled to piercing assembly body 352 via threading, welding, friction or other suitable technique. Needle 354 has a sharp point at its lower end and may have a smooth outer surface or may have an outer surface that is fluted, channeled, knurled or otherwise irregular. As discussed more fully below, needle 354 is used to actuate the pressure delivery subsystem of the fluid sampler when piston 346 is sufficiently displaced relative to housing 302 .
[0071] Below atmospheric chamber 348 and disposed within the longitudinal passageway of housing 302 is a valving assembly 356 . Valving assembly 356 includes a pressure disk holder 358 that receives a pressure disk therein that is depicted as rupture disk 360 , however, other types of pressure disks that provide a seal, such as a metal-to-metal seal, with pressure disk holder 358 could also be used including a pressure membrane or other piercable member. Rupture disk 360 is held within pressure disk holder 358 by hold down ring 362 and gland 364 that is threadably coupled to pressure disk holder 358 . Valving assembly 356 also includes a check valve 366 . Valving assembly 356 initially prevents communication between chamber 348 and a passage 380 in a lower portion of sampling chamber 300 . After actuation the pressure delivery subsystem by needle 354 , check valve 366 permits fluid flow from passage 380 to chamber 348 , but prevents fluid flow from chamber 348 to passage 380 .
[0072] As mentioned above, one or more of the sampling chambers 300 and preferably nine of sampling chambers 300 are installed within exteriorly disposed chamber receiving slots 159 that circumscribe internal fluid passageway 112 of carrier 104 . A seal bore 160 (see FIG. 3B ) is provided in carrier 104 for receiving the upper portion of sampling chamber 300 and another seal bore 162 (see FIG. 3C ) is provided for receiving the lower portion of sampling chamber 300 . In this manner, passage 310 in the upper portion of sampling chamber 300 is placed in sealed communication with a passage 164 in carrier 104 , and passage 380 in the lower portion of sampling chamber 300 is placed in sealed communication with a passage 166 in carrier 104 .
[0073] As described above, once the fluid sampler is in its operable configuration and is located at the desired position within the wellbore, a fluid sample can be obtained into one or more of the sample chambers 314 by operating actuator 106 . Fluid from passage 112 then enters passage 310 in the upper portion of each of the desired sampling chambers 300 . For clarity, the operation of only one of the sampling chambers 300 after receipt of a fluid sample therein is described below. The fluid flows from passage 310 through check valve 316 to sample chamber 314 . It is noted that check valve 316 may include a restrictor pin 368 to prevent excessive travel of ball member 370 and over compression or recoil of spiral wound compression spring 372 . An initial volume of the fluid is trapped in debris chamber 326 of piston 318 as described above. Downward displacement of piston 318 is slowed by the metering fluid in chamber 320 flowing through restrictor 334 . This prevents pressure in the fluid sample received in sample chamber 314 from dropping below its bubble point.
[0074] As piston 318 displaces downward, the metering fluid in chamber 320 flows through restrictor 334 into chamber 338 . At this point, prong 342 maintains check valve 344 off seat. The metering fluid received in chamber 338 causes piston 346 to displace downwardly. Eventually, needle 354 pierces rupture disk 360 which actuates valving assembly 356 . Actuation of valving assembly 356 permits pressure from pressure source 108 to be applied to chamber 348 . Specifically, once rupture disk 360 is pierced, the pressure from pressure source 108 passes through valving assembly 356 including moving check valve 366 off seat. In the illustrated embodiment, a restrictor pin 374 prevents excessive travel of check valve 366 and over compression or recoil of spiral wound compression spring 376 . Pressurization of chamber 348 also results in pressure being applied to chambers 338 , 320 and thus to sample chamber 314 .
[0075] When the pressure from pressure source 108 is applied to chamber 338 , pins 378 are sheared allowing piston assembly 340 to collapse such that prong 342 no longer maintains check valve 344 off seat. Check valve 344 then prevents pressure from escaping from chamber 320 and sample chamber 314 . Check valve 316 also prevents escape of pressure from sample chamber 314 . In this manner, the fluid sample received in sample chamber 314 is pressurized.
[0076] While this invention has been described with a reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is, therefore, intended that the appended claims encompass any such modifications or embodiments.
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An apparatus ( 300 ) for obtaining a fluid sample in a subterranean well includes a housing ( 302 ) having a sample chamber ( 314 ) defined therein. The sample chamber ( 314 ) is selectively in fluid communication with the exterior of the housing ( 302 ) and is operable to receive the fluid sample therefrom. A debris trap piston ( 318 ) is slidably disposed within the housing ( 302 ). The debris trap piston ( 318 ) includes a debris chamber ( 326 ). Responsive to the fluid sample entering the sample chamber ( 314 ), the debris trap piston ( 318 ) receives a first portion of the fluid sample in the debris chamber ( 326 ) then displaces relative to the housing ( 302 ) to expand the sample chamber ( 314 ).
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CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority from U.S. Provisional Application Ser. No. 61/947,850 filed Mar. 4, 2014, the disclosure of which is incorporated herein as if set forth in its entirety.
FIELD
[0002] Provided herein are processes for the preparation of an apoptosis-inducing agent, and chemical intermediates thereof. Also provided herein are novel chemical intermediates related to the processes provided herein.
BACKGROUND
[0003] 4-(4-{[2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-en-1-yl]methyl}piperazin-1-yl)-N-({3-nitro-4-[(tetrahydro-2H-pyran-4-ylmethyl)amino]phenyl}sulfonyl)-2-(H-pyrrolo[2,3-b]pyridin-5-yloxy)benzamide (hereafter, “Compound 1”) and 4-(4-{[2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-en-1-yl]methyl}piperazin-1-yl)-N-({3-nitro-4-[(1R,4R)-([4-hydroxy-4-methylcyclohexyl]methyl)amino]phenyl}sulfonyl)-2-(1H-pyrrolo[2,3-b]pyridin-5-yloxy)benzamide (hereafter, “Compound 2”) are each potent and selective Bcl-2 inhibitors having, inter alia, antitumor activity as apoptosis-inducing agents.
[0004] Compound 1 has the formula:
[0000]
[0005] Compound 2 has the formula:
[0000]
[0006] Compound 1 is currently the subject of ongoing clinical trials for the treatment of chronic lymphocytic leukemia. U.S. Patent Publication No. 2010/0305122 describes Compound 1, Compound 2, and other compounds which exhibit potent binding to a Bcl-2 family protein, and pharmaceutically acceptable salts thereof. U.S. Patent Publication Nos. 2012/0108590 and 2012/0277210 describe pharmaceutical compositions comprising such compounds, and methods for the treatment of neoplastic, immune or autoimmune diseases comprising these compounds. U.S. Patent Publication No. 2012/0129853 describes methods for the treatment of systemic lupus erythematosus, lupus nephritis or Sjogren's Syndrome comprising these compounds. U.S. Patent Publication No. 2012/0157470 describes pharmaceutically acceptable salts and crystalline forms of Compound 1. The disclosures of U.S. 2010/0305122; 2012/0108590; 2012/0129853; 2012/0157470 and 2012/0277210 are hereby incorporated by reference herein in their entireties.
SUMMARY
[0007] Provided herein are processes for the preparation of compounds of formula A1:
[0000]
[0000] wherein R 2 is selected from
[0000]
[0008] Also provided herein are compounds of the formulae:
[0000]
[0000] wherein R is C 1 to C 12 alkyl; and processes for their preparation.
DETAILED DESCRIPTION
[0009] Provided herein is a process for the preparation of compounds of formula A1:
[0000]
[0000] wherein R 2 is selected from
[0000]
[0000] which comprises:
[0010] (a) combining a compound of formula (K):
[0000]
[0011] wherein R is C 1 to C 12 alkyl,
[0000] with a tert-butoxide salt, an aprotic organic solvent, and water to provide a compound of formula (L):
[0000]
[0000] and
[0012] (b″) combining the compound of formula (L) with 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDAC), 4-dimethylaminopyridine (DMAP), an organic solvent, and either a compound of formula (N), to provide a compound of formula (A1) wherein R 2 is
[0000]
[0000]
[0000] or a compound of formula (P), to provide a compound of formula (A1) wherein R 2 is
[0000]
[0000]
[0000] thereby providing a compound of formula (A1).
[0013] In one embodiment, R 2 is
[0000]
[0014] In another embodiment, R 2 is
[0000]
[0015] In some embodiments, R is C 1 to C 6 alkyl. In some embodiments, R is C 1 to C 4 alkyl. In some embodiments, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl. In some embodiments, R is tert-butyl.
[0016] In one embodiment, the process provided herein further comprises:
[0017] (c″) combining a compound of formula (M):
[0000]
[0000] with a tertiary amine base, an organic solvent, and either (tetrahydro-2H-pyran-4-yl)methanamine or a salt thereof, to provide the compound of formula (N), or (1R,4R)-4-(aminomethyl)-1-methylcyclohexanol or a salt thereof, to provide the compound of formula (P).
[0018] In one embodiment, the (1R,4R)-4-(aminomethyl)-1-methylcyclohexanol salt of step (c″) is the p-toluenesulfonic acid salt.
[0019] In another embodiment, the process provided herein further comprises:
[0020] (d) combining a compound of formula (D):
[0000]
[0021] wherein R is C 1 to C 12 alkyl,
[0000] with a compound of formula (I):
[0000]
[0000] a source of palladium, a tert-butoxide salt, and a phosphine ligand in an aprotic organic solvent to provide the compound of formula (K).
[0022] In some embodiments, the phosphine ligand is a compound of formula (J):
[0000]
[0023] In other embodiments, the phosphine ligand is selected from:
[0000]
[0024] In another embodiment, the process provided herein further comprises:
[0025] (e) combining a compound of formula (B) with a compound of formula (C):
[0000]
wherein R is C 1 to C 12 alkyl,
and a tert-butoxide salt in an organic solvent to provide the compound of formula (D).
[0027] In another embodiment, the process provided herein further comprises:
[0028] (f) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent;
[0029] wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I; and
[0030] (g) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (f), to provide the compound of formula (C).
[0031] In another embodiment, the process provided herein further comprises:
[0032] (h) combining a compound of formula (E):
[0000]
[0000] with DMF and POCl 3 to provide a compound of formula (F):
[0000]
[0033] (i) combining the compound of formula (F) with a source of palladium and 4-chlorophenylboronic acid in an organic solvent to provide a compound of formula (G):
[0000]
[0034] (j) combining the compound of formula (G) with BOC-piperazine and sodium triacetoxyborohydride in an organic solvent to provide a compound of formula (H):
[0000]
[0000] and
[0035] (k) combining the compound of formula (H) with hydrochloric acid to provide the compound of formula (I).
[0036] In one embodiment, the process comprises step (a), step (b″), step (c″) and step (d). In one embodiment, the process comprises step (a), step (b″), step (c″), step (d) and step (e). In one embodiment, the process comprises step (a), step (b″), step (c″), step (d), step (e), step (f) and step (g). In another embodiment the process comprises step (a), step (b″), step (c″), step (d), step (e), step (f), step (g), step (h), step (i), step (j) and step (k).
[0037] In one embodiment, the process comprises steps (a), (b″) and (d). In another embodiment, the process comprises steps (a), (b″), (d) and (e). In another embodiment, the process comprises steps (a), (b″), (d), (h), (i), (j) and (k). In another embodiment, the process comprises steps (a), (b″), (c″), (d), (h), (i), (j) and (k). In another embodiment, the process comprises steps (a), (b″), (d), (f), (g), (h), (i), (j) and (k). In another embodiment, the process comprises steps (a), (b″), (d), (e), (f), (g), (h), (i), (j) and (k).
[0038] Also provided herein is a process for the preparation of Compound 1 of the formula:
[0000]
[0000] which comprises:
[0039] (a) combining a compound of formula (K):
[0000]
[0040] wherein R is C 1 to C 12 alkyl,
[0000] with a tert-butoxide salt, an aprotic organic solvent, and water to provide a compound of formula (L):
[0000]
[0041] (b) combining the compound of formula (L) with a compound of formula (N):
[0000]
[0000] and
1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDAC), 4-dimethylaminopyridine (DMAP), and an organic solvent to provide the compound of formula (1).
[0042] In some embodiments, R is C 1 to C 6 alkyl. In some embodiments, R is C 1 to C 4 alkyl. In some embodiments, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl. In some embodiments, R is tert-butyl.
[0043] In one embodiment, the process for the preparation of Compound 1 further comprises:
[0044] (c) combining a compound of formula (M):
[0000]
[0000] with (tetrahydro-2H-pyran-4-yl)methanamine, a tertiary amine base, and an organic solvent to provide the compound of formula (N).
[0045] In another embodiment, the process for the preparation of Compound 1 further comprises:
[0046] (d) combining a compound of formula (D):
[0000]
[0047] wherein R is C 1 to C 12 alkyl,
[0000] with a compound of formula (I):
[0000]
[0000] a source of palladium, a tert-butoxide salt, and a phosphine ligand in an aprotic organic solvent to provide the compound of formula (K).
[0048] In some embodiments, the phosphine ligand is a compound of formula (J):
[0000]
[0049] In other embodiments, the phosphine ligand is selected from:
[0000]
[0050] In another embodiment, the process for the preparation of Compound 1 further comprises:
[0051] (e) combining a compound of formula (B) with a compound of formula (C):
[0000]
wherein R is C 1 to C 12 alkyl,
and a tert-butoxide salt in an organic solvent to provide the compound of formula (D).
[0053] In another embodiment, the process for the preparation of Compound 1 further comprises:
[0054] (f) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent;
[0055] wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I; and
[0056] (g) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (f), to provide the compound of formula (C).
[0057] In another embodiment, the process for the preparation of Compound 1 further comprises:
[0058] (h) combining a compound of formula (E):
[0000]
[0000] with DMF and POCl 3 to provide a compound of formula (F):
[0000]
[0059] (i) combining the compound of formula (F) with a source of palladium and 4-chlorophenylboronic acid in an organic solvent to provide a compound of formula (G):
[0000]
[0060] (j) combining the compound of formula (G) with BOC-piperazine and sodium triacetoxyborohydride in an organic solvent to provide a compound of formula (H):
[0000]
[0000] and
[0061] (k) combining the compound of formula (H) with hydrochloric acid to provide the compound of formula (I).
[0062] In one embodiment, the process for the preparation of Compound 1 comprises steps (a) through (d). In one embodiment, the process for the preparation of Compound 1 comprises steps (a) through (e). In another embodiment, the process for the preparation of Compound 1 comprises steps (a) through (g). In another embodiment, the process for the preparation of Compound 1 comprises steps (a) through (k).
[0063] In one embodiment, the process for the preparation of Compound 1 comprises steps (a), (b) and (d). In another embodiment, the process for the preparation of Compound 1 comprises steps (a), (b), (d) and (e). In another embodiment, the process for the preparation of Compound 1 comprises steps (a), (b), (d), (h), (i), (j) and (k). In another embodiment, the process for the preparation of Compound 1 comprises steps (a), (b), (c), (d), (h), (i), (j) and (k). In another embodiment, the process for the preparation of Compound 1 comprises steps (a), (b), (d), (f), (g), (h), (i), (j) and (k). In another embodiment, the process for the preparation of Compound 1 comprises steps (a), (b), (d), (e), (f), (g), (h), (i), (j) and (k).
[0064] Also provided herein is a process for the preparation of Compound 2 of the formula:
[0000]
[0000] which comprises:
[0065] (a) combining a compound of formula (K):
[0000]
[0066] wherein R is C 1 to C 12 alkyl,
[0000] with a tert-butoxide salt, an aprotic organic solvent, and water to provide a compound of formula (L):
[0000]
[0067] (b′) combining the compound of formula (L) with a compound of formula (P):
[0000]
[0000] 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDAC), 4-dimethylaminopyridine (DMAP), and an organic solvent to provide the compound of formula (2).
[0068] In some embodiments, R is C 1 to C 6 alkyl. In some embodiments, R is C 1 to C 4 alkyl. In some embodiments, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl. In some embodiments, R is tert-butyl.
[0069] In one embodiment, the process for the preparation of Compound 2 further comprises:
[0070] (c′) combining a compound of formula (M):
[0000]
[0000] with (1R,4R)-4-(aminomethyl)-1-methylcyclohexanol or a salt thereof, a tertiary amine base, and an organic solvent to provide the compound of formula (P).
[0071] In one embodiment, the (1R,4R)-4-(aminomethyl)-1-methylcyclohexanol salt of step (c′) is the p-toluenesulfonic acid salt.
[0072] In some embodiments, the method for the preparation of Compound 2 further comprises step (d) as described above for the preparation of Compound 1.
[0073] In some embodiments, the method for the preparation of Compound 2 further comprises step (e) as described above for the preparation of Compound 1.
[0074] In some embodiments, the method for the preparation of Compound 2 further comprises step (f) and step (g) as described above for the preparation of Compound 1.
[0075] In some embodiments, the method for the preparation of Compound 2 further comprises step (h), step (i), step (j) and step (k) as described above for the preparation of Compound 1.
[0076] In one embodiment, the process for the preparation of Compound 2 comprises step (a), step (b′), step (c′) and step (d). In one embodiment, the process for the preparation of Compound 2 comprises step (a), step (b′), step (c′), step (d) and step (e). In one embodiment, the process for the preparation of Compound 2 comprises step (a), step (b′), step (c′), step (d), step (e), step (f) and step (g). In another embodiment the process for the preparation of Compound 2 comprises step (a), step (b′), step (c′), step (d), step (e), step (f), step (g), step (h), step (i), step (j) and step (k).
[0077] In one embodiment, the process for the preparation of Compound 2 comprises steps (a), (b′) and (d). In another embodiment, the process for the preparation of Compound 2 comprises steps (a), (b′), (d) and (e). In another embodiment, the process for the preparation of Compound 2 comprises steps (a), (b′), (d), (h), (i), (j) and (k). In another embodiment, the process for the preparation of Compound 2 comprises steps (a), (b′), (c′), (d), (h), (i), (j) and (k). In another embodiment, the process for the preparation of Compound 2 comprises steps (a), (b′), (d), (f), (g), (h), (i), (j) and (k). In another embodiment, the process for the preparation of Compound 2 comprises steps (a), (b′), (d), (e), (f), (g), (h), (i), (j) and (k).
[0078] In some embodiments, in step (a) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide. In some embodiments, in step (a) the tert-butoxide salt is sodium tert-butoxide. In some embodiments, in step (a) the tert-butoxide salt is potassium tert-butoxide.
[0079] In some embodiments, in step (a) the aprotic organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (a) the aprotic organic solvent is 2-methyltetrahydrofuran.
[0080] In some embodiments, in step (b), step (b′) and/or step (b″) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (b), step (b′) and/or step (b″) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (b), step (b′) and/or step (b″) the organic solvent is dichloromethane.
[0081] In some embodiments, in step (c), step (c′) and/or step (c″) the tertiary amine base is N,N-diisopropylethylamine.
[0082] In some embodiments, in step (c), step (c′) and/or step (c″) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (c), step (c′) and/or step (c″) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (c), step (c′) and/or step (c″) the organic solvent is acetonitrile.
[0083] In some embodiments, in step (d) the compound of formula (I) is first combined with a base prior to the combining of step (d). In some embodiments, the base is an inorganic base. In some embodiments, the base is an organic base. In some embodiments, the base is selected from the group consisting of K 3 PO 4 , Na 3 PO 4 , NaOH, KOH, K 2 CO 3 or Na 2 CO 3 . In some embodiments, the base is K 3 PO 4 . In some embodiments, in step (d) the compound of formula (I) is first combined with a base in one or more solvents prior to the combining of step (d).
[0084] In some embodiments, in step (d) the source of palladium is Pd 2 dba 3 or [(cinnamyl)PdCl] 2 . In some embodiments, in step (d) the source of palladium is Pd 2 dba 3 .
[0085] In some embodiments, in step (d) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide.
[0086] In some embodiments, in step (d) the tert-butoxide salt is anhydrous. In some embodiments, in step (d) the tert-butoxide salt is anhydrous sodium tert-butoxide.
[0087] In some embodiments, in step (d) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (d) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (d) the aprotic organic solvent is a mixture of THF and toluene.
[0088] In some embodiments, step (d) further comprises the following steps:
(1) combining the tert-butoxide salt with the compound of formula (I) in an aprotic organic solvent; (2) combining the source of palladium, the compound of formula (J), and the compound of formula (D) in an aprotic organic solvent; and (3) adding the mixture of step (1) to the mixture of step (2).
[0092] In some embodiments, in step (d) the mixture resulting from step (2) is filtered prior to step (3).
[0093] In some embodiments, step (d) is carried out under an atmosphere of nitrogen or argon.
[0094] In some embodiments, in step (d) a catalytic amount of the source of palladium is used relative to the amount of compound (I). In some embodiments, the source of palladium is Pd 2 dba 3 and the catalytic amount of Pd 2 dba 3 is from about 0.5 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of Pd 2 dba 3 is about 0.75 mole percent.
[0095] In some embodiments, in step (d) a catalytic amount of the compound of formula (J) is used relative to the amount of compound (I). In some embodiments, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 5 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 2 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is about 1 mole percent or about 2 mole percent.
[0096] In some embodiments, in step (e) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide. In some embodiments, in step (e) the tert-butoxide salt is sodium tert-butoxide. In some embodiments, in step (e) the tert-butoxide salt is potassium tert-butoxide.
[0097] In some embodiments, in step (e) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (e) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (e) the organic solvent is DMF.
[0098] In some embodiments, in step (f), R 1 is C 1 to C 4 alkyl. In some embodiments, R 1 is isopropyl.
[0099] In some embodiments, in step (f), R is methyl and the C 1 to C 12 alkyl chloroformate is methyl chloroformate. In some embodiments, R is ethyl and the C 1 to C 12 alkyl chloroformate is ethyl chloroformate. In some embodiments, R is tert-butyl and the di-(C 1 to C 12 alkyl)dicarbonate is di-tert-butyl dicarbonate.
[0100] In some embodiments, in step (f) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (f) the aprotic organic solvent is THF.
[0101] In some embodiments, in step (i) the source of palladium is Pd(OAc) 2 .
[0102] In some embodiments, in step (i) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (i) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (i) the organic solvent is acetonitrile.
[0103] In some embodiments, step (i) comprises combining tetrabutylammonium bromide with the compound of formula (F), a source of palladium and 4-chlorophenylboronic acid in the organic solvent.
[0104] In some embodiments, in step (j) the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (j) the organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (j), the organic solvent is a mixture of THF and toluene. In some embodiments, the mixture of THF and toluene is about 1:1 by volume.
[0105] In some embodiments, step (j) further comprises producing the compound of formula (H) as a crystalline solid. In some embodiments, step (j) further comprises:
[0106] (1) adding an aqueous solution to the mixture of step (j) to produce an aqueous and an organic phase;
[0107] (2) separating the organic phase from the mixture of step (1);
[0108] (3) concentrating the organic phase; and
[0109] (4) adding an organic solvent to the mixture of step (3) to produce the compound of formula (H) as a crystalline solid.
[0110] In some embodiments of step (4) of step (j), the organic solvent is acetonitrile. In some embodiments of step (4) of step (j), the organic solvent is acetonitrile and the mixture is heated to about 80° C.
[0111] In some embodiments, step (4) of step (j) further comprises cooling the mixture to about 10° C. to about −10° C. In some embodiments, step (4) of step (j) further comprises cooling the mixture to about −10° C., and isolating the compound of formula (H) as a crystalline solid by filtering the mixture.
[0112] In some embodiments, the combining of step (k) is in an organic solvent. In some embodiments, the organic solvent is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the organic solvent is isopropanol.
[0113] In some embodiments, step (k) further comprises producing the compound of formula (I) as a crystalline solid. In some embodiments, the combining of step (k) is in an organic solvent, and step (k) further comprises isolating the compound of formula (I) as a crystalline solid by filtering the mixture.
[0114] In some embodiments, the combining of step (k) is in an organic solvent, and step (k) further comprises cooling the mixture to about 10° C. to about −10° C. to produce the compound of formula (I) as a crystalline solid.
[0115] In some embodiments, the combining of step (k) is in isopropanol, and step (k) further comprises cooling the mixture to about 10° C. to about −10° C. to produce the compound of formula (I) as a crystalline solid. In some embodiments, the combining of step (k) is in isopropanol, and step (k) further comprises cooling the mixture to about −5° C. to produce the compound of formula (I) as a crystalline solid, and isolating the compound of formula (I) as a crystalline solid by filtering the mixture.
[0116] Also provided herein is a process of preparing a compound of formula (C):
[0000]
wherein R is C 1 to C 12 alkyl,
which comprises
[0118] (a) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent; wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I; and
[0119] (b) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (a), to provide the compound of formula (C).
[0120] In some embodiments, R is C 1 to C 6 alkyl. In some embodiments, R is C 1 to C 4 alkyl. In some embodiments, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl. In some embodiments, R is tert-butyl.
[0121] In some embodiments, R 1 is C 1 to C 4 alkyl. In some embodiments, R 1 is isopropyl.
[0122] In some embodiments of the process of preparing a compound of formula (C), the organic solvent of step (a) is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments the organic solvent of step (a) is THF.
[0123] In one embodiment, R is C 1 to C 6 alkyl.
[0124] In one embodiment, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl.
[0125] In one embodiment, R is selected from the group consisting of methyl, ethyl, n-propyl, isopropyl, n-butyl, tert-butyl, iso-butyl and neo-butyl; and R 1 is isopropyl.
[0126] In one embodiment, R is tert-butyl and R 1 is isopropyl.
[0127] In some embodiments of the process of preparing a compound of formula (C), in step (b), R is methyl and the C 1 to C 12 alkyl chloroformate is methyl chloroformate. In some embodiments, R is ethyl and the C 1 to C 12 alkyl chloroformate is ethyl chloroformate. In some embodiments, R is tert-butyl and the di-(C 1 to C 12 alkyl)dicarbonate is di-tert-butyl dicarbonate.
[0128] Also provided herein is a process for the preparation of a compound of formula (D):
[0000]
[0129] wherein R is C 1 to C 12 alkyl,
[0000] which comprises:
[0130] (x) combining a compound of formula (B):
[0000]
[0000] with a compound of formula (C):
[0000]
[0000] and a tert-butoxide salt in an organic solvent to provide the compound of formula (D).
[0131] In one embodiment, R is tert-butyl.
[0132] In some embodiments, the process of preparing the compound of formula (D) further comprises steps (x′) and (x″):
[0133] (x′) combining a compound of formula (A):
[0000]
[0000] with R 1 MgX in an aprotic organic solvent; wherein R 1 is C 1 to C 6 alkyl; and X is Cl, Br or I;
[0134] (x″) combining a C 1 to C 12 alkyl chloroformate or a di-(C 1 to C 12 alkyl)dicarbonate with the product of step (x′), to provide the compound of formula (C).
[0135] In some embodiments, in step (x) the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide.
[0136] In some embodiments, the organic solvent of step (x) is selected from the group consisting of pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, THF, DMF, HMPA, NMP, nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, MTBE, benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the organic solvent of step (x) is DMF.
[0137] In some embodiments, in step (x′), R 1 is a C 1 to C 4 alkyl. In some embodiments, R 1 is isopropyl.
[0138] In some embodiments, in step (x″), the C 1 to C 12 alkyl chloroformate is methyl chloroformate. In some embodiments, the C 1 to C 12 alkyl chloroformate is ethyl chloroformate.
[0139] In some embodiments, the di-(C 1 to C 12 alkyl)dicarbonate is di-tert-butyl dicarbonate.
[0140] In some embodiments, in step (x′) the aprotic organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, in step (x′) the aprotic organic solvent is THF.
[0141] Also provided herein is a compound of the formula (3):
[0000]
[0142] In one embodiment, the compound of the formula (3) is prepared by the following steps:
[0143] (y) combining a compound of formula (B):
[0000]
[0000] with a compound of formula (C):
[0000]
[0000] wherein R is tert-butyl,
and a tert-butoxide salt in an organic solvent to provide the compound of formula (D):
[0000]
[0000] wherein R is tert-butyl; and
[0144] (z) combining the compound of formula (D), wherein R is tert-butyl;
[0000] with a compound of formula (I):
[0000]
[0000] a source of palladium, a tert-butoxide salt, and a phosphine ligand in an aprotic organic solvent.
[0145] In one embodiment, the phosphine ligand of step (z) is a compound of formula (J):
[0000]
[0146] In other embodiments, the phosphine ligand is selected from:
[0000]
[0147] In one embodiment, in step (z) the source of palladium is Pd 2 dba 3 .
[0148] In some embodiments, in step (z) the aprotic organic solvent is selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the aprotic organic solvent is a mixture of THF and toluene.
[0149] In some embodiments, in step (z), the tert-butoxide salt is selected from the group consisting of sodium tert-butoxide and potassium tert-butoxide.
[0150] In some embodiments, in step (z) the tert-butoxide salt is anhydrous sodium tert-butoxide or anhydrous potassium tert-butoxide.
[0151] In some embodiments, step (z) further comprises the following steps:
(1) combining the tert-butoxide salt with the compound of formula (I) in an aprotic organic solvent; (2) combining the source of palladium, the compound of formula (J), and the compound of formula (D) in an aprotic organic solvent; and (3) adding the mixture of step (1) to the mixture of step (2).
[0155] In some embodiments, in step (z) the mixture resulting from step (2) is filtered prior to step (3).
[0156] In some embodiments, step (z) is carried out under an atmosphere of nitrogen or argon.
[0157] In some embodiments, in step (z) a catalytic amount of the source of palladium is used relative to the amount of compound (I). In some embodiments, the source of palladium is Pd 2 dba 3 and the catalytic amount of Pd 2 dba 3 is from about 0.5 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of Pd 2 dba 3 is about 0.75 mole percent.
[0158] In some embodiments, when the phosphine ligand of step (z) is a compound for formula (J), a catalytic amount of the compound of formula (J) is used relative to the amount of compound (I). In some embodiments, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 5 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 2 mole percent to about 4 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is from about 1 mole percent to about 2 mole percent. In one embodiment, the catalytic amount of the compound of formula (J) is about 1 mole percent or about 2 mole percent.
[0159] In another embodiment, provided herein are compounds of the formulae:
[0000]
[0160] In some embodiments, the processes described herein are improved methods for commercial chemical manufacturing of Compound 1 or Compound 2. Without being bound to a particular theory or mechanism of action, the processes described herein significantly improve the overall efficiency and product yield of Compound 1 or Compound 2. Previous processes (e.g., U.S. Patent Publication Nos. 2010/0305122 and 2012/0157470, and International Patent Publication Nos. WO 2011/15096 and WO 2012/071336) were found to lack feasibility for production of Compound 1 on a commercial scale. Thus, the processes provided herein represent improved methods for the synthesis of compounds in quantities required for clinical and/or commercial development. Improvements relative to these previous processes include, but are not limited to, overall yield of Compound 1 or Compound 2, overall process efficiency and economics, mild reaction conditions, practical isolation/purification procedures, and viability for commercialization.
[0161] The improved process provided herein involves a selective nucleophilic aromatic substitution reaction (“SnAr reaction”) of compounds (B) and (C), which can be carried out under milder conditions with a shorter reaction time when compared to previously described processes as found, for example, in U.S. Patent Publication Nos. 2010/0305122 and 2012/0157470, and International Patent Publication Nos. WO 2011/15096 and WO 2012/071336. Without being limited by theory, the improved SnAr reaction of compound (B) and (C) does not generate regioisomeric side products which necessitate further purification to remove the side products, as was the case in previously described processes. The SnAr reaction in the previous process also requires a longer reaction time and harsh reaction conditions which result in a low overall yield relative to the processes described herein. Furthermore, the previous processes also require tedious purification of the intermediates which is impracticable on a large, commercial scale process. The processes described herein are more convergent than prior processes, resulting in a highly efficient cross-coupling reaction of compound (D) and the free base of compound (I) in high yield. In some embodiments, the processes described herein utilize crystalline solid intermediates (H) and (I), which allow efficient purification by crystallization to remove impurities—advantages not available in previously described processes.
[0162] The following schemes illustrate one or more embodiments of the process provided herein. In some embodiments, the compound of formula (D) is prepared from compound (B) and compound (C) as shown in Scheme 1 below. The compound of formula (B) may be prepared by techniques known in the art, e.g., as shown in WO 2000/047212 and J. Am. Chem. Soc., 1959, 81: 743-747. The compound of formula (C) may be prepared by techniques known in the art, e.g., as shown in WO 2006/059801 and Tetrahedron Letters, 2008, 49(12), 2034-2037; or as shown in Scheme 2.
[0000]
[0163] The compound of formula (C) of Scheme 1 may prepared from commercially available compound (A) as shown in Scheme 2 below, wherein “R 1 MgX” represents a Grignard reagent wherein R 1 is an alkyl group, and X is Cl, Br or I. The electrophilic acetylating reagent of Scheme 2 can be, but is not limited to, methyl or ethyl chloroformate or BOC 2 O.
[0000]
[0164] An exemplary reaction according to Scheme 2 is shown below.
[0000]
[0165] In another embodiment, the compound of formula (I) is prepared from compound (E) as shown in Scheme 3 below. Compound (E) is commercially available or may be prepared by techniques known in the art, e.g., as shown in U.S. Pat. No. 3,813,443 and Proceedings of the Chemical Society , London, 1907, 22, 302.
[0000]
[0166] In another embodiment, the compound of formula (N) is prepared from compound (M) as shown in Scheme 4 below. Compound (M) is commercially available or may be prepared by techniques known in the art, e.g., as shown in GB 585940 and J. Am. Chem. Soc., 1950, 72, 1215-1218.
[0000]
[0167] In another embodiment, the compound of formula (P) is prepared from compound (M) as shown in Scheme 4′ below.
[0000]
[0168] In another embodiment, the compound of formula (1) is prepared from compound (D) and compound (I) as shown in Scheme 5 below. Compound (J) may be prepared by techniques known in the art, e.g., as shown in WO 2009/117626 and Organometallics, 2008, 27(21), 5605-5611.
[0000]
[0169] In another embodiment, the compound of formula (2) is prepared from compound (L) and compound (P) as shown in Scheme 6 below, wherein the preparation of compound (P) is as shown in Scheme 4′ and the preparation of compound (L) is as shown in Scheme 5.
[0000]
[0170] In some embodiments, the preparation of the compound of formula (K) from compound (D) and compound (I) is air and/or moisture sensitive, and is therefore performed under an inert atmosphere, e.g., using nitrogen or argon gas.
[0171] Without being bound to a particular theory, the use of compound (D) as an intermediate in the preparation of the compound of formula (1) and the compound of formula (2) as shown above in Schemes 1 to 6 is an improvement over previously described processes for the preparation of the compound of formula (1) and the compound of formula (2). In some embodiments, the improvements include higher product yields, shorter reaction times. In some embodiments, the improvements are provided when R is tert-butyl in compound (D).
[0172] Schemes 1 to 6 are non-limiting examples of the process provided herein. Solvents and/or reagents are known compounds and may be interchanged according to the knowledge of those skilled in the art.
[0173] Abbreviations used in Schemes 1 to 6 are as follows:
[0000]
Ac
acetyl
BOC
tert-butoxycarbonyl
dba
dibenzylidineacetone
DIEA
N,N-diisopropylethylamine
DMAP
4-dimethylaminopyridine
DMF
dimethylformamide
EDAC
1-ethyl-3-(3-dimethylaminopropyl)carbodiimide HCl
IPA
isopropanol
iPr
isopropyl
Me
methyl
n-Bu
n-butyl
tBu
tert-butyl
THF
tetrahydrofuran
[0174] Unless indicated otherwise, the temperatures at which a reaction of Schemes 1 to 6 is conducted is not critical. In certain embodiments, when a temperature is indicated in a reaction, the temperature may be varied from about plus or minus 0.1° C., 0.5° C., 1° C., 5° C., or 10° C. Depending upon which solvent is employed in a particular reaction, the optimum temperature may vary. In some embodiments, reactions are conducted in the presence of vigorous agitation sufficient to maintain an essentially uniformly dispersed mixture of the reactants.
[0175] In conducting a reaction provided herein, neither the rate, nor the order, of addition of the reactants is critical unless otherwise indicated. Unless otherwise indicated, reactions are conducted at ambient atmospheric pressure. Unless otherwise indicated, the exact amount of reactants is not critical. In some embodiments, the amount of a reactant may be varied by about 10 mole percent or about 10% by weight.
[0176] Unless otherwise indicated, the organic solvents used in the processes provided herein may be selected from those commercially available or otherwise known to those skilled in the art. Appropriate solvents for a given reaction are within the knowledge of the skilled person and include mixtures of solvents. Examples of organic solvents provided herein for use include but are not limited to: pentane, hexane, heptane, cyclohexane, methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 2-butanone, dichloromethane, chloroform, carbon tetrachloride, 1,2-dichloroethane, tetrahydrofuran (THF), dimethylformamide (DMF), hexamethylphosphoramide (HMPA), N-methyl-2-pyrrolidinone (NMP), nitromethane, acetone, acetic acid, acetonitrile, ethyl acetate, diethyl ether, diethylene glycol, glyme, diglyme, petroleum ether, dioxane, methyl tert-butyl ether (MTBE), benzene, toluene, xylene, pyridine, 2-methyltetrahydrofuran, and mixtures thereof.
[0177] In some embodiments, an organic solvent used in the processes provided herein is an aprotic organic solvent. As provided herein, an aprotic solvent is a solvent that does not contain an acidic hydrogen atom or a hydrogen atom that is capable of hydrogen bonding (e.g., is not bound to an oxygen or a nitrogen atom). The aprotic organic solvent may be selected from the group consisting of dichloromethane, chloroform, acetone, acetonitrile, THF, DMF, NMP, HMPA, dioxane, nitromethane, pyridine, 2-methyltetrahydrofuran, and mixtures thereof. In some embodiments, the aprotic organic solvent is THF. In some embodiments, the aprotic organic solvent is DMF. In some embodiments, the aprotic organic solvent is acetonitrile.
[0178] As provided herein, a “tertiary amine base” refers to an amine that is substituted with three alkyl groups, e.g., triethylamine or N,N-diisopropylethylamine.
[0179] As provided herein, a “catalytic amount” refers to less than one molar equivalent of a reagent or reactant in a given reaction, as determined relative to another reagent or reactant in the reaction mixture. In some embodiments, a catalytic amount is described as a mole percent relative to another reagent or reactant in the reaction mixture.
[0180] As provided herein, a “source of palladium” refers to a source of palladium in a stable oxidation state, i.e., Pd(0), Pd(I), Pd(II) and/or Pd(IV). The palladium may be free metal, such as in a powder form, or may be bound to one or more ligands, e.g., PdCl 2 , Pd 2 dba 3 , PdCl 2 (PPh 3 ) 2 , Pd(PPh 3 ) 4 , Pd(OAc) 2 or [(cinnamyl)PdCl] 2 .
[0181] As provided herein, a “phosphine ligand” refers to a compound of formula PR′ 3 , wherein each R′ is independently selected from C 1 to C 6 alkyl or phenyl, wherein the aryl group is optionally substituted by C 1 to C 6 alkyl, phenyl, trialkylamino, alkoxy or halo.
[0182] As provided herein, unless otherwise defined, the term “about” means that the value or amount to which it refers can vary by ±5%, ±2%, or ±1%.
[0183] The products obtained by any of the processes provided herein may be recovered by conventional means, such as evaporation or extraction, and may be purified by standard procedures, such as distillation, recrystallization or chromatography
EXAMPLES
[0184] Compounds of the following examples are shown in Schemes 1 to 6 above and were named using Chemdraw® Ultra software. In addition to the abbreviations described above with respect to the schemes provided herein, the following abbreviations are used in the Examples:
[0185] “HPLC”=high pressure liquid chromatography; “IP”=in process; “ML”=mother liquor; “NLT”=no less than; “NMT”=no more than; “RB”=round bottom; “RT”=room temperature; “sm”=starting material; “DCM”=dichloromethane.
[0186] Unless indicated otherwise, compounds were characterized by HPLC and 1H NMR analysis and used in later reactions with or without purification. 1 H NMR analysis was performed at 400 MHz unless otherwise indicated. Unless specified otherwise, product yield/purity was determined by weight, qNMR, and/or HPLC analysis.
Example 1
Synthesis of tert-butyl 4-bromo-2-fluorobenzoate (Compound (C))
[0187] To a 100 ml jacketed reactor equipped with a mechanical stirrer was charged 4-bromo-2-fluoro1-iodobenzene, “Compound (A)” (5 g, 1.0 eq) and THF (25 ml). The solution was cooled to −5° C. 2M isopropyl magnesium chloride in THF (10.8 ml, 1.3 eq) was slowly added maintaining the internal temperature below 0° C. The mixture was stirred at 0° C. for 1 h. Di-tert-butyl dicarbonate (5.44 g, 1.5 eq) in THF (10 ml) was added. After 1 h, the solution was quenched with 10% citric acid (10 ml), and then diluted with 25% NaCl (10 ml). The layers were separated and the organic layer was concentrated to near dryness and chased with THF (3×10 ml). The crude oil was diluted with THF (5 ml), filtered to remove inorganics, and concentrated to dryness. The crude oil (6.1 g, potency=67%, potency adjusted yield=88%) was taken to the next step without further purification. 1H NMR (DMSO-d 6 ): δ 1.53 (s, 9H), 7.50-7.56 (m, 1H), 7.68 (dd, J=10.5, 1.9 Hz, 1H), 7.74 (t, J=8.2 Hz, 1H).
Example 2
Synthesis of tert-butyl 2-((1H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-bromobenzoate (Compound (D))
[0188] To a 3 L three-neck Morton flask were charged 1H-pyrrolo[2,3-b]pyridin-5-ol (80.0 g, 1.00 eq.), tert-butyl 4-bromo-2-fluorobenzoate (193 g, 1.15 eq.), and anhydrous DMF (800 mL). The mixture was stirred at 20° C. for 15 min. The resulting solution was cooled to about zero to 5° C. A solution of sodium tert-butoxide (62.0 g) in DMF (420 mL) was added slowly over 30 min while maintaining the internal temperature at NMT 10° C., and rinsed with DMF (30 mL). The reaction mixture was stirred at 10° C. for 1 hour (an off-white slurry) and adjusted the internal temperature to ˜45° C. over 30 min. The reaction mixture was stirred at 45-50° C. for 7 hours and the reaction progress monitored by HPLC (IP samples: 92% conversion % by HPLC). The solution was cooled to ˜20° C. The solution was stirred at 20° C. overnight.
[0189] Water (1200 mL) was added slowly to the reaction mixture at <30° C. over 1 hour (slightly exothermic). The product slurry was adjusted to ˜20° C., and mixed for NLT 2 hours. The crude product was collected by filtration, and washed with water (400 mL). The wet-cake was washed with heptane (400 mL) and dried under vacuum at 50° C. overnight to give the crude product (236.7 g).
[0190] Re-crystallization or Re-slurry: 230.7 g of the crude product, (potency adjusted: 200.7 g) was charged back to a 3 L three-neck Morton flask. Ethyl acetate (700 mL) was added, and the slurry heated slowly to refluxing temperature over 1 hr (small amount of solids left). Heptane (1400 mL) was added slowly, and the mixture adjusted to refluxing temperature (78° C.). The slurry was mixed at refluxing temperature for 30 min., and cooled down slowly to down to ˜−10° C. at a rate of approximate 10° C./hour), and mixed for 2 hr. The product was collected by filtration, and rinsed with heptane (200 ml).
[0191] The solid was dried under vacuum at ˜50° C. overnight to give 194.8 g, 86% isolated yield of the product as an off-white solid. MS-ESI 389.0 (M+1); mp: 190-191° C. (uncorrected). 1 H NMR (DMSO-d 6 ): δ 1.40 (s, 9H), 6.41 (dd, J=3.4, 1.7 Hz, 1H), 7.06 (d, J=1.8 Hz, 1H), 7.40 (dd, J=8.3, 1.8 Hz, 1H), 7.51 (t, J=3.4 Hz, 1H), 7.58 (d, J=2.6 Hz, 1H), 7.66 (d, J=8.3 Hz, 1H), 8.03 (d, J=2.7 Hz, 1H), 11.72 (s, 1H, NH).
Example 3
Synthesis of 2-chloro-4,4-dimethylcyclohexanecarbaldehyde (Compound (F))
[0192] To a 500 mL RB flask were charged anhydrous DMF (33.4 g, 0.456 mol) and CH 2 Cl 2 (80 mL). The solution was cooled down <−5° C., and POCl 3 (64.7 g, 0.422 mol) added slowly over 20 min @<20° C. (exothermic), rinsed with CH 2 Cl 2 (6 mL). The slightly brown solution was adjusted to 20° C. over 30 min, and mixed at 20° C. for 1 hour. The solution was cooled back to <5° C. 3,3-Dimethylcyclohexanone (41.0 g, 90%, ˜0.292 mol) was added, and rinsed with in CH 2 Cl 2 (10 mL) (slightly exothermic) at <20° C. The solution was heated to refluxing temperature, and mixed overnight (21 hours.).
[0193] To a 1000 mL three neck RB flask provided with a mechanical stirrer were charged 130 g of 13.6 wt % sodium acetate trihydrate aqueous solution, 130 g of 12% brine, and 130 mL of CH 2 Cl 2 . The mixture was stirred and cooled down to <5° C. The above reaction mixture (clear and brown) was transferred, quenched into it slowly while maintaining the internal temperature <10° C. The reaction vessel was rinsed with CH 2 Cl 2 (10 mL). The quenched reaction mixture was stirred at <10° C. for 15 min. and allowed to rise to 20° C. The mixture was stirred 20° C. for 15 min and allowed to settle for 30 min. (some emulsion). The lower organic phase was separated. The upper aq. phase was back extracted with CH 2 Cl 2 (50 mL). The combined organic was washed with a mixture of 12% brine (150 g)-20% K 3 PO 4 aq. solution (40 g). The organic was dried over MgSO 4 , filtered and rinsed with CH 2 Cl 2 (30 ml). The filtrate was concentrated to dryness under vacuum to give a brown oil (57.0 g, potency=90.9 wt % by qNMR, ˜100%). 1 H NMR (CDCl 3 ): δ 0.98 (s, 6H), 1.43 (t, J=6.4 Hz, 2H), 2.31 (tt, J=6.4, 2.2 Hz, 2H), 2.36 (t, J=2.2 Hz, 2H), 10.19 (s, 1H).
Example 4
Synthesis of 2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-enecarbaldehyde (Compound (G))
[0194] To a 250 mL pressure bottle were charged 2-chloro-4,4-dimethylcyclohex-1-enecarbaldehyde (10.00 g), tetrabutylammonium bromide (18.67 g), and acetonitrile (10 mL). The mixture was stirred at 20° C. for 5 min. 21.0 wt % K 2 CO 3 aq. solution (76.0 g) was added. The mixture was stirred at room temperature (rt) for NLT 5 min. followed by addition of 4-chlorophenylboronic acid (9.53 g) all at once. The mixture was evacuated and purged with N 2 for three times. Palladium acetate (66 mg, 0.5 mol %) was added all at once under N 2 . The reaction mixture was evacuated and purged with N 2 for three times (an orange colored mixture). The bottle was back filled with N 2 and heated to ˜35° C. in an oil bath (bath temp ˜35° C.). The mixture was stirred at 30° C. overnight (15 hours). The reaction mixture was cooled to RT, and pulled IP sample from the upper organic phase for reaction completion, typically starting material <2% (orange colored mixture). Toluene (100 mL) and 5% NaHCO 3 -2% L-Cysteine aq. solution (100 mL) were added. The mixture was stirred at 20° C. for 60 min. The mixture was filtered through a pad of Celite to remove black solid, rinsing the flask and pad with toluene (10 mL). The upper organic phase was washed with 5% NaHCO 3 aq. solution-2% L-Cysteine (100 mL) once more. The upper organic phase was washed with 25% brine (100 mL). The organic layer (105.0 g) was assayed (118.8 mg/g, 12.47 g product assayed, 87% assayed yield), and concentrated to ˜1/3 volume (˜35 mL). The product solution was directly used in the next step without isolation. However, an analytical sample was obtained by removal of solvent to give a brown oil. 1 HNMR (CDCl 3 ): δ 1.00 (s, 6H), 1.49 (t, J=6.6 Hz, 2H), 2.28 (t, J=2.1 Hz, 2H), 2.38 (m, 2H), 7.13 (m, 2H), 7.34 (m, 2H), 9.47 (s, 1H).
Example 5
Synthesis of tert-butyl 4-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazine-1-carboxylate (Compound (H))
[0195] To a 2 L three neck RB flask provided with a mechanical stirrer were charged a solution of 4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-carbaldehyde (50.0 g) in toluene (250 mL), BOC-piperazine (48.2 g) and anhydrous THF (250 mL). The yellow solution was stirred at 20° C. for 5 min. Sodium triacetoxyborohydride (52.7 g) was added in portion (note: the internal temperature rose to ˜29.5° C. in 15 min cooling may be needed). The yellow mixture was stirred at ˜25° C. for NLT 4 hrs. A conversion of starting material to product of 99.5% was observed by HPLC after a 3 hour reaction time.
[0196] 12.5 wt % brine (500 g) was added slowly to quench the reaction. The mixture was stirred at 20° C. for NLT 30 min and allowed to settle for NLT 15 min. The lower aq. phase (˜560 mL) was separated (note: leave any emulsion in the upper organic phase). The organic phase was washed with 10% citric acid solution (500 g×2). 500 g of 5% NaHCO 3 aq. solution was charged slowly into the flask. The mixture was stirred at 20° C. for NLT 30 min., and allowed to settle for NLT 15 min. The upper organic phase was separated. 500 g of 25% brine aq. solution was charged. The mixture was stirred at 20° C. for NLT 15 min., and allowed to settle for NLT 15 min. The upper organic phase was concentrated to ˜200 mL volume under vacuum. The solution was adjusted to ˜30° C., and filtered off the inorganic salt. Toluene (50 mL) was used as a rinse. The combined filtrate was concentrated to ˜100 mL volume. Acetonitrile (400 mL) was added, and the mixture heated to ˜80° C. to achieve a clear solution. The solution was cooled down slowly to 20° C. slowly at rate 10° C./hour, and mixed at 20° C. overnight (the product is crystallized out at ˜45-50° C., if needed, seed material may be added at 50° C.). The slurry was continued to cool down slowly to ˜−10° C. at a rate of 10° C./hours. The slurry was mixed at ˜−10° C. for NLT 6 hours. The product was collected by filtration, and rinsed with pre-cooled acetonitrile (100 mL). The solid was dried under vacuum at 50° C. overnight (72.0 g, 85%). MS-ESI: 419 (M+1); mp: 109-110° C. (uncorrected); 1 H NMR (CDCl 3 ): δ 1.00 (s, 6H), 1.46 (s, 9H), 1.48 (t, J=6.5 Hz, 2H), 2.07 (s, br, 2H), 2.18 (m, 4H), 2.24 (t, J=6.4 Hz, 2H), 2.80 (s, 2H), 3.38 (m, 4H), 6.98 (m, 2H), 7.29 (m, 2H).
Example 6
Synthesis of 1-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazine dihydrochloride (Compound (I))
[0197] To a 2.0 L three-neck RB flask equipped with a mechanical stirrer were charged the Boc reductive amination product (Compound (H), 72.0 g) and IPA (720 mL). The mixture was stirred at rt for 5 min, and 59.3 g of concentrated hydrochloride aq. solution added to the slurry. The reaction mixture was adjusted to an internal temperature of ˜65° C. (a clear and colorless solution achieved). The reaction mixture was agitated at ˜65° C. for NLT 12 hours.
[0198] The product slurry was cooled down to −5° C. slowly (10° C./hour). The product slurry was mixed at ˜−5° C. for NLT 2 hours, collected by filtration. The wet cake was washed with IPA (72 mL) and dried at 50° C. under vacuum overnight to give 73.8 g (95%) of the desired product as a bis-hydrochloride IPA solvate (purity >99.5% peak area at 210 nm). MS-ESI: 319 (M+1); 1 HNMR (D 2 O): δ 1.00 (s, 6H), 1.19 (d, J=6.0 Hz, 6H, IPA), 1.65 (t, J=6.1 Hz, 2H), 2.14 (s, br, 2H), 2.26 (m, 2H), 3.36 (br, 4H), 3.55 (s, br, 4H), 3.82 (s, 2H), 4.02 (septet, J=6.0 Hz, 1H, IPA), 7.16 (d, J=8.1 Hz, 2H), 7.45 (d, J=8.1 Hz, 2H); 1 HNMR (CDCl 3 ): δ 0.86 (s, 6H), 1.05 (d, J=6.0 Hz, 6H, IPA), 1.42 (t, J=6.1 Hz, 2H), 2.02 (s, br, 2H), 2.12 (m, 2H), 3.23 (m, 4H), 3.4 (s, br, 4H), 3.68 (s, 2H), 3.89 (septet, J=6.0 Hz, 1H, IPA), 7.11 (d, J=8.1 Hz, 2H), 7.41 (d, J=8.1 Hz, 2H).
Example 7
Synthesis of 3-nitro-4-(((tetrahydro-2H-pyran-4-yl)methyl)amino)-benzenesulfonamide (Compound (N))
[0199] To a 500 mL three-neck RB flask equipped with a mechanical stirrer were charged the 4-chloro-3-nitrobenzenesulfonamide, Compound M (10.0 g), diisopropylethylamine (17.5 g), (tetrahydro-2H-pyran-4-yl)methanamine (7.0 g) and acetonitrile (150 mL). The reaction mixture was adjusted to an internal temperature of 80° C. and agitated for no less than 12 hours.
[0200] The product solution was cooled down to 40° C. and agitated for no less than 1 hour until precipitation observed. The product slurry was further cooled to 20° C. Water (75 mL) was slowly charged over no less than 1 hour, and the mixture cooled to 10° C. and agitated for no less than 2 hours before collected by filtration. The wet cake was washed with 1:1 mix of acetonitrile:water (40 mL). The wet cake was then reslurried in water (80 mL) at 40° C. for no less than 1 hour before collected by filtration. The wet cake was rinsed with water (20 mL), and dried at 75° C. under vacuum to give 12.7 g of the desired product in 99.9% purity and in 91% weight-adjusted yield. 1 H NMR (DMSO-d 6 ): δ 1.25 (m, 2H), 1.60 (m, 2H), 1.89 (m, 1H), 3.25 (m, 2H), 3.33 (m, 2H), 3.83 (m, 2H), 7.27 (d, J=9.3 Hz, 1H), 7.32 (s, NH 2 , 2H), 7.81 (dd, J=9.1, 2.3 Hz, 1H), 8.45 (d, J=2.2 Hz, 1H), 8.54 (t, J=5.9 Hz, 1H, NH).
Example 8
Synthesis of tert-butyl 2-((1H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-(4-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazin-1-yl)benzoate (Compound (K))
[0201] General Considerations: this chemistry is considered air and moisture sensitive. While the catalyst precursors in their solid, dry form can be handled and stored in air without special precautions, contact with even small amounts of solvent may render them susceptible to decomposition. As a result, traces of oxygen or other competent oxidants (e.g., solvent peroxides) must be removed prior to combination of the catalyst precursors with solvent and care must be used to prevent ingress of oxygen during the reaction. Also, care must be taken to use dry equipment, solvents, and reagents to prevent formation of undesirable byproducts. The sodium t-butoxide used in this reaction is hygroscopic and it should be properly handled and stored prior to or during use.
[0202] To a 2.0 L three-neck RB flask equipped with a mechanical stirrer were charged the bis-hydrochloride salt (Compound (I), 42.5 g) and toluene (285 ml). 20% K 3 PO 4 (285 ml) was added and the biphasic mixture was stirred for 30 min. The layers were separated and the organic layer was washed with 25% NaCl (145 ml). The organic layer concentrated to 120 g and used in the coupling reaction without further purification.
[0203] NaOtBu (45.2 g) and Compound (I) in toluene solution (120 g solution−30 g potency adjusted) were combined in THF (180 ml) in a suitable reactor and sparged with nitrogen for NLT 45 min. Pd 2 dba 3 (0.646 g), Compound (J) (0.399 g), and Compound (D) (40.3 g) were combined in a second suitable reactor and purged with nitrogen until oxygen level was NMT 40 ppm. Using nitrogen pressure, the solution containing Compound (I) and NaOtBu in toluene/THF was added through a 0.45 μm inline filter to the second reactor (catalyst, Compound (J) and Compound (D)) and rinsed with nitrogen sparged THF (30 ml.).
[0204] The resulting mixture was heated to 55° C. with stirring for NLT 16 h, then cooled to 22° C. The mixture was diluted with 12% NaCl (300 g) followed by THF (300 ml). The layers were separated.
[0205] The organic layer was stirred with a freshly prepared solution of L-cysteine (15 g), NaHCO 3 (23 g), and water (262 ml). After 1 h the layers were separated.
[0206] The organic layer was stirred with a second freshly prepared solution of L-cysteine (15 g), NaHCO 3 (23 g), and water (262 ml). After 1 h the layers were separated. The organic layer was washed with 12% NaCl (300 g), then filtered through a 0.45 μm inline filter. The filtered solution was concentrated in vacuo to ˜300 mL, and chased three times with heptane (600 mL each) to remove THF.
[0207] The crude mixture was concentrated to 6 volumes and diluted with cyclohexane (720 ml). The mixture was heated to 75° C., held for 15 min, and then cooled to 65° C. over NLT 15 min. Seed material was charged and the mixture was held at 65° C. for 4 hours. The suspension was cooled to 25° C. over NLT 8 h, then held at 25° C. for 4 hours. The solids were filtered and washed with cyclohexane (90 ml) and dried at 50° C. under vacuum.
[0208] Isolated 52.5 g (88.9% yield) as a white solid. Melting point (uncorrected) 154-155° C. 1 H NMR (DMSO-d 6 ): δ 0.93 (s, 6H), 1.27 (s, 9H), 1.38 (t, J=6.4 Hz, 2H), 1.94 (s, 2H), 2.08-2.28 (m, 6H), 2.74 (s, 2H), 3.02-3.19 (m, 4H), 6.33 (dd, J=3.4, 1.9 Hz, 1H), 6.38 (d, J=2.4 Hz, 1H), 6.72 (dd, J=9.0, 2.4 Hz, 1H), 6.99-7.06 (m, 2H), 7.29 (d, J=2.7 Hz, 1H), 7.30-7.36 (m, 2H), 7.41-7.44 (m, 1H), 7.64 (t, J=6.7 Hz, 1H), 7.94 (d, J=2.7 Hz, 1H), 11.53 (s, 1H).
Example 9
Synthesis of 2-((1H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-(4-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazin-1-yl)benzoic acid (Compound (L))
[0209] Solution preparation: 10% KH 2 PO 4 (aq): KH 2 PO 4 (6 g) in water (56 g); 2:1 heptane/2-MeTHF:heptane (16 mL) in 2-MeTHF (8 mL).
[0210] Compound (K) (5.79 g), potassium tert-butoxide (4.89 g), 2-methyltetrahydrofuran (87 mL), and water (0.45 mL) were combined in a suitable reactor under nitrogen and heated to 55° C. until reaction completion. The reaction mixture was cooled to 22° C., washed with the 10% KH 2 PO 4 solution (31 g) twice. The organic layer was then washed with water (30 g).
[0211] After removal of the aqueous layer, the organic layer was concentrated to 4 volumes (˜19 mL) and heated to no less than 50° C. Heptane (23 ml) was slowly added. Alternatively, after removal of the aqueous layer, the organic layer was concentrated to 5 volumes and heated to no less than 70° C. and 5 volumes of heptane were slowly added. The resulting suspension was cooled to 10° C. Solids were then collected by vacuum filtration with recirculation of the liquors and the filter cake washed with 2:1 heptane/2-MeTHF (24 ml). Drying of the solids at 80° C. under vacuum yielded 4.0 g of Compound (L) in approximately 85% weight-adjusted yield. 1 H NMR (DMSO-d 6 ): δ 0.91 (s, 6H), 1.37 (t, J=6.4 Hz, 2H), 1.94 (s, br, 2H), 2.15 (m, 6H), 2.71 (s, br, 2H), 3.09 (m, 4H), 6.31 (d, J=2.3 Hz, 1H), 6.34 (dd, J=3.4, 1.9 Hz, 1H), 6.7 (dd, J=9.0, 2.4 Hz, 1H), 7.02 (m, 2H), 7.32 (m, 2H), 7.37 (d, J=2.6 Hz, 1H), 7.44 (t, J=3.0 Hz, 1H), 7.72 (d, J=9.0 Hz, 1H), 7.96 (d, J=2.7 Hz, 1H) & 11.59 (m, 1H).
Example 10
Synthesis of 4-(4-{[2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-en-1-yl]methyl}piperazin-1-yl)-N-({3-nitro-4-[(tetrahydro-2H-pyran-4-ylmethyl)amino]phenyl}sulfonyl)-2-(1H-pyrrolo[2,3-b]pyridin-5-yloxy)benzamide (Compound (1))
[0212] Solution preparation prior to reaction: 10% Acetic Acid:Acetic Acid (37 mL) in water (333 g); 5% NaHCO 3 :NaHCO 3 (9 g) in water (176 g); 5% NaCl:NaCl (9 g) in water (176 g).
[0213] Compound (N) (13.5 g), DMAP (10.5 g), EDAC (10.7 g) and dichloromethane (300 mL) were combined in a suitable reactor and agitated at 25° C. In a second suitable reactor was charged the Acid (Compound (L), 25 g), Et 3 N (8.7 g) and dichloromethane (120 mL). The resulting Acid (Compound (L)) solution was slowly charged to the initial suspension of Compound (N) and agitated until reaction completion. N,N-dimethylethylenediamine (9.4 g) was then charged to the reaction mixture with continued agitation. The reaction mixture was warmed to 35° C. and washed with 10% Acetic acid solution (185 mL) twice. The lower organic layer was diluted with more dichloromethane (75 mL) and methanol (12.5 mL). The organic, product layer was then washed with 5% NaHCO 3 solution (185 mL) and then washed with 5% NaCl solution (185 mL) at 35° C. The lower, organic layer was separated and then concentrated to 8 vol (˜256 mL) diluted with methanol (26 mL) and warmed to 38° C. Ethyl Acetate (230 mL) was slowly charged. The resulting suspension was slowly cooled to 10° C. and then filtered. The wet cake was washed twice with a 1:1 mix of dichloromethane and ethyl acetate (˜2 vol, 64 mL). After drying the wet cake at 90° C., 32 g (84%) of Compound (1) was isolated. 1 H NMR (DMSO-d 6 ): δ 0.90 (s, 6H), 1.24 (m, 2H), 1.36 (t, J=6.4 Hz, 2H), 1.60 (m, 2H), 1.87 (m, 1H), 1.93 (s, br, 2H), 2.12 (m, 2H), 2.19 (m, 4H), 2.74 (s, br, 2H), 3.06 (m, 4H), 3.26 (m, 4H), 3.83 (m, 2H), 6.17 (d, J=2.1 Hz, 1H), 6.37 (dd, J=3.4, 1.9 Hz, 1H), 6.66 (dd, J=9.1, 2.2 Hz, 1H), 7.01 (m, 2H), 7.31 (m, 2H), 7.48 (m, 3H), 7.78 (dd, J=9.3, 2.3 Hz, 1H), 8.02 (d, J=2.61 Hz, 1H), 8.54 (d, J=2.33 Hz, 1H), 8.58 (t, J=5.9 Hz, 1H, NH), 11.65 (m, 1H).
Example 11
Synthesis of ((1R,4R)-4-hydroxy-4-methylcyclohexyl)-methanaminium 4-methylbenzenesulfonate
[0214] Step A: 1.49 g of cyclohexanedione monoethylene acetal (1.0 equiv) and 15 mL of toluene were charged to a suitable reactor. The mixture was mixed for 30 minutes at 10° C. 1.4M methylmagnesium bromide solution (2.32 eq) in Toluene-THF (75-25) was charged to another reactor and mixed at 15° C. The starting material solution was added to the Grignard solution dropwise at around 10 to 20° C. in 4 hrs (addition rate=0.1 mL/min). The reaction progression was monitored by TLC. Upon reaction completion, the reaction mixture was charged to a 24% ammonium chloride solution (20 mL) slowly at a temperature of 25° C. The reaction mixture was mixed and settled, organic layer was separated and aqueous layer was extracted with ethyl acetate (3×20 mL). The combined organic layers were filtered over a bed of sodium sulfate and the filtrate was concentrated by distillation to dryness. 1.57 g. crude solids were isolated (95% yield) and carried to the next step. 1H NMR (400 MHz, Chloroform-d 1 ) δ ppm 3.88-4.01 (m, 4H), 1.85-1.96 (m, 2H), 1.08-1.64 (m, 7H). LCMS− (MS 310 and 292). Rf=0.074 by TLC (hexane-EtOAc=1-1).
[0215] Step B: 18 mL of 0.005N hydrochloric acid solution (0.02 equiv) was charged to the distillation residue from Step A. The reaction mixture was mixed at 70° C. for 3 hours and monitored by TLC. Upon reaction completion, the reaction mixture was cooled to 25° C. and charged to another suitable reactor containing 22 mL of a 5% sodium chloride solution. The reaction mixture was mixed until all salt dissolved followed by extraction with Ethyl Acetate (8×200 mL). The combined organic layers were filtered over a bed of sodium sulfate and the filtrate was concentrated by distillation to dryness. The product was isolated (99.38% yield) and was used directly in the next step. 1H NMR (400 MHz, Chloroform-d 1 ) δ ppm 2.68-2.80 (m, 2H), 2.16-2.39 (m, 3H), 1.77-2.04 (m, 4H), 1.41 (s, 3H), 1.33 (s, 1H).
[0216] Step C: Step B product (0.25 g) was dissolved with toluene (5 ml) to a 25 mL three neck flask equipped with a Dean-Stark trap. Nitrogen was bubbled through the reactor to remove air. 0.585 g of nitromethane (5 equiv) was charged to the reactor followed by 0.052 g of N,N-dimethylethylenediamine (0.3 equiv). The reaction mixture was heated to reflux, the water was removed by a Dean-Stark trap. The reaction mixture was mixed at reflux for 1 h and monitored by HPLC assay. The reaction mixture was then cooled to 20° C. when HPLC product assay stabilized, concentrated then chased with EtOAc and heptane to dryness. The residue was purified on a CombiFlash column (12 g column) from Hexane/EtOAc 80-20 to 60-40. Fractions were analyzed by HPLC and TLC, product containing fractions was distilled to dryness. A concentrated oil 0.23 g was obtained (68.09% yield) and used in Step D. 1H NMR (400 MHz, Chloroform-d 1 ) δ 5.88-5.90 (bs, 1H), 4.88-4.89 (bs, 2H), 2.16-2.40 (m, 4H), 1.78-1.85 (m, 1H), 1.33 (s, 3H).
[0217] Step D: Crabtree's catalyst (0.471 g; 0.585 mmol) was added under nitrogen to a 450 mL stirred SS Parr reactor. The reactor was purged with nitrogen and a solution of the (S)-1-methyl-4-(nitromethyl)cyclohex-3-enol (34.88 g; 58.5 mmol) in DCM (100 mL). Additional sparged DCM (80 mL) was added, the reactor was purged with argon, hydrogen and hydrogen pressure 100 psig. The mixture was agitated for 4 hours at 30° C. Reaction progress was monitored by NMR, Concentrated to an oil, chased 2× with THF (50 mL) then diluted with THF (50 mL). The product was carried further for subsequent RaNi reduction in Step E. 1H NMR (Chloroform-d 1 ): δ 4.33 (dJ=7.3 Hz, 2H), 4.32 (J=6.5 Hz, 1H), 2.36-2.20 (m, 1H), 1.92-1.69 (m, 1H), 1.64-1.40 (m, 1H), 1.39-1.18 (m, 1H).
[0218] Step E: RaNi (*d/(d−1) or *7/6)=2.04 g (20 wt %) was decanted 3 times with THF. The RaNi, solution of (1R,4R)-1-methyl-4-(nitromethyl)cyclohexanol and THF (50 mL) were added under nitrogen in a 450 mL stirred SS Parr reactor. The reactor was purged with nitrogen, hydrogen and the hydrogenation was carried out at 40 psi for 4 hours at 50° C. The reaction was monitored by GC and upon completion, it was filtered through a propylene filter funnel with diatomaceous earth/polyethylene fritted disc to remove catalyst. THF was used as a rinse to extract residual product from the filter cake. The combined filtrate gave an amber solution which was carried directly to next step. 1 H NMR (400 MHz, Chloroform-d 1 ) δ 2.61 (d, J=6.5 Hz, 2H), 1.25-1.50 (m, 12H), 0.80-1.17 (m, 3H).
[0219] Step F: 9.86 g of the solution of Step E was added to a 500 mL round bottom flask and distilled to dryness, chased twice with acetonitrile and then was dissolved in acetonitrile (100 mL). To the solution was added 4-methylbenzenesulfonic acid hydrate (11.68 g) upon which a solid precipitated out and temperature rose to 40° C. The slurry was mixed at 50° C. for 2 hours and cooled to 20° C. for 12 hours. Solids were filtered and washed with 40 mL acetonitrile.
[0220] The wetcake was dried under vacuum to give 14.24 g of product (77% yield). 1 H NMR (400 MHz, Deuterium Oxide-d 2 ) δ 2.79 (d, J=7.0 Hz, 2H), 1.48-1.68 (m, 5H), 1.31-1.46 (m, 2H), 0.90-1.29 (m, 5H).
Example 12
Synthesis of 4-({[(1R,4R)-4-hydroxy-4-methylcyclohexyl]methyl}-amino)-3-nitrobenzenesulfonamide (Compound (P))
[0221] 4-chloro-3-nitrobenzenesulfonamide (6.5 g, 27.5 mmol) and ((1R,4R)-4-hydroxy-4-methylcyclohexyl)methanaminium 4-methylbenzenesulfonate (11.26 g, 35.7 mmol) were combined in 35 mL of acetonitrile and stirred. N,N-diisopropylethylamine (8.88 g, 68.7 mmol) was added to the slurry at ambient temperature to result in an endotherm (200 to 17.5° C.). After 10 minutes, the reaction mixture was heated to 80° C. and maintained at that temperature for 24 hours. The reaction was monitored for completion by HPLC. Upon completion of the reaction, the reaction mixture was cooled to 40° C. Water (32.5 mL) was added over 15 minutes and held for 30 minutes. An additional 74.5 mL of water was added over 30 minutes. Solid product precipitated soon after the second portion of water was added. After stirring for 1 hour at 40° C., the product mixture was allowed to cool to 20° C., stirred for 12 hours, and then cooled to 0° C. with stirring for 2 additional hours. The product was filtered and dried under vacuum to afford 8.8 g of product (Yield 93%; purity >99 pa %). 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 8.52 (t, J=5.9 Hz, 1H), 8.45 (d, J=2.2 Hz, 1H), 7.80 (dd, J=9.1, 2.3 Hz, 1H), 7.24-7.30 (m, 3H), 4.23 (s, 1H), 1.60-1.74 (m, 3H), 1.52-1.57 (m, 2H), 1.26-1.40 (m, 2H), 1.06-1.25 (m, 5H).
Example 13
Synthesis of 4-(4-{[2-(4-chlorophenyl)-4,4-dimethylcyclohex-1-en-1-yl]methyl}piperazin-1-yl)-N-({3-nitro-4-[(1R,4R)-[4-hydroxy-4-methylcyclohexyl]methyl)amino]phenyl}sulfonyl)-2-(1H-pyrrolo[2,3-b]pyridin-5-yloxy)benzamide (Compound (2))
[0222] The Sulfonamide 4-((((1R,4R)-4-hydroxy-4-methylcyclohexyl)methyl)amino)-3-nitrobenzenesulfonamide (8.00 g, 23.29 mmol), EDAC-HCl (5.80 g, 30.3 mmol) and DMAP (8.54 g, 69.9 mmol) were mixed in DCM (186 mL, 14 vol) to a golden slurry. A solution of acid, 2-((1H-pyrrolo[2,3-b]pyridin-5-yl)oxy)-4-(4-((4′-chloro-5,5-dimethyl-3,4,5,6-tetrahydro-[1,1′-biphenyl]-2-yl)methyl)piperazin-1-yl)benzoic acid (13.3 g, 23.29 mmol) and TEA (6.49 mL, 46.6 mmol) in DCM (80 mL, 6 vol) was added over 2.5 hrs. by addition funnel followed by a rinse with 10 mL DCM. After mixing for 12 hours, N1,N1-dimethylethane-1,2-diamine (5.09 mL, 46.6 mmol) was added and stirring continued at 20° C. for 5 hours. The reaction mixture was washed with 10% HOAc (130 mL, 3×). The organic layer was washed with 5% NaHCO3 (140 mL) and 5% NaCl (140 mL). The organic layer was dried over Na 2 SO 4 . and concentrated to 7 volume of DCM solution. Methanol (10 vol, 140 mL) was added dropwise over 2 hours, and the solution cooled to 15° C. upon which the product precipitated. The product mixture was cooled to 5° C. and mixed for 2 hours. Upon filtration of the solid and blow drying with nitrogen for 2 hours, 17.35 g of product was obtained (Yield 83%; purity >99.5 pa %). 1 H NMR (400 MHz, DMSO-d 6 ) δ ppm 11.57-11.59 (bs, 1H), 8.48-8.52 (m, 2H), 7.97 (d, J=2.6 Hz, 1H), 7.73 (dd, J=9.2, 2.3 Hz, 1H), 7.43-7.50 (m, 3H), 7.29-7.31 (m, 2H), 6.98-7.03 (m, 3H), 6.65 (dd, J=8.9, 2.3 Hz, 1H), 6.35 (dd, J=3.4, 1.8 Hz, 1H), 6.16 (d, J=2.2 Hz, 1H), 4.41-4.44 (m, 1H), 3.71-3.75 (m, 2H), 2.98-3.51 (m, 11H), 2.74-2.76 (m, 3H), 2.02-2.26 (m, 6H), 1.88-1.92 (m, 2H), 1.47-1.70 (m, 5H), 1.24-1.40 (m, 4H), 1.08 (s, 5H), 0.89 (s, 6H).
[0223] All references cited herein are incorporated by reference in their entirety. While the methods provided herein have been described with respect to the particular embodiments, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit and scope as recited by the appended claims.
[0224] The embodiments described above are intended merely to be exemplary, and those skilled in the art will recognize, or will be able to ascertain using no more than routine experimentation, numerous equivalents of specific compounds, materials, and procedures. All such equivalents are considered to be within the scope of the invention and are encompassed by the appended claims.
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Provided herein is a process for the preparation of an apoptosis-inducing agent, and chemical intermediates thereof. Also provided herein are novel chemical intermediates related to the process provided herein.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Provisional Application No. 62/331,702 filed May 4, 2016. The disclosure of the above application is incorporated herein by reference.
FIELD
[0002] The present disclosure relates to athletic equipment and apparel, and more specifically to protective and performance enhancing football gloves.
BACKGROUND
[0003] The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
[0004] Typical football equipment includes padded pants, shoulder pads, and helmets among other protective or performance enhancing equipment. Football gloves are particularly important because they serve a dual function of protecting the players hands while improving the ability of the player in catching, holding, and throwing the football. As with other pieces of equipment, football gloves are tailored to particular player positions. For example, receiver's gloves include special materials that improve the players grip on the football in less than ideal weather conditions. Alternatively, linemen wear gloves that include padding intended to help prevent injuries.
[0005] While current forms of football gloves help improve player performance and provide protection against some injuries, there is a need for an improved football glove that advances performance while preventing new injuries and help previous injuries from getting worse or possibly even aid in healing.
SUMMARY
[0006] The present invention provides an athletic glove having a plurality of finger receptacles, a thumb receptacle, a closing system, a palm surface, and a backhand surface.
[0007] Further features and advantages of the present disclosure will become apparent by reference to the following description and appended drawings wherein like reference numbers refer to the same component, element or feature.
DRAWINGS
[0008] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way;
[0009] FIG. 1 is a is a top view of the backhand of an athletic glove according to the present disclosure;
[0010] FIG. 2 is a side view of an athletic glove according to the present disclosure;
[0011] FIG. 3 is a cross-sectional view of an athletic glove according to the present disclosure;
[0012] FIG. 4 is a palm view of a right and left hand athletic glove according to the present disclosure; and
[0013] FIG. 5 is a cross-sectional view of a portion of an athletic glove according to the present disclosure.
DETAILED DESCRIPTION
[0014] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0015] With reference to FIG. 1 , an exemplary an athletic glove 10 is illustrated and will now be described. The athletic glove 10 includes a palm portion 12 , a first finger receptacle 14 , a second finger receptacle 16 , a thumb receptacle 18 , and a cuff 20 . More specifically, the athletic glove 10 is generally assembled from several pieces of material. For example, a backhand 20 of the athletic glove may be a single first section 22 of material that forms a backhand portion of each of the palm portion 12 , the first finger receptacle 14 , and the second finger receptacle 16 . Additionally, the forehand 24 of the athletic glove may be a single second section 26 (more appropriately viewed in FIG. 2 ) of material that forms a forehand portion of each of the palm portion 12 , the first finger receptacle 14 , and the second finger receptacle 16 . Thus, the first section 22 and second section 26 of material may be formed from one or more layers of material, such as lycra, leather, neoprene, nylon, synthetic leather, and the like, and are joined by methods known in the art, such as sewing, knitting, and the like, to form a cavity 28 (more precisely shown in FIG. 3 ) for receiving the athlete's hand. Therefore, the first and second finger receptacles 14 , 16 and the thumb receptacle 18 combine to form the cavity 28 . In one example of the present invention, the second section 26 of material of the forehand 24 of the athletic glove is an outwardly facing abrasion resistant high tack material to enhance the athlete's grip. In other examples, the backhand 20 includes pads 30 having additional layers of material in specific areas to provide additional protection against impact to the bones of the hand. In particular, the pads 30 may include finger pads 32 , a knuckle pad 34 , a thumb pad 36 , and a backhand pad 38 .
[0016] The first and second finger receptacles 14 , 16 and thumb receptacle 18 extend from the palm portion 12 . The width of each of the first and second finger receptacles 14 , 16 is wide enough to receive two adjacent fingers of the athlete's hand. The width W 1 of the first finger receptacle 14 is wide enough to receive each of the little and ring fingers of the athlete's hand. Likewise, the width W 2 of the second finger receptacle 16 is wide enough to receive each of the index and middle fingers of the athlete's hand. The thumb receptacle 18 is sized to receive the thumb. However, other examples of the athletic glove that include a finger receptacle that is wide enough to receive three fingers does not fall outside the scope of the present invention.
[0017] The cuff 20 of the athletic glove includes a closing mechanism 40 as well as other protective features. The closing mechanism 40 is disposed on the cuff 20 to securely fix the athletic glove 10 to the athlete's hand. The closing mechanism 40 includes a strap 42 having a portion of a hook-and-loop fastening system 44 to enclose and tighten the wrist cuff 20 around the wrist of the athlete. However, other types of fastening systems may be utilized to secure the athletic glove 10 to the hand of the athlete without departing from the scope of the invention. For example, snap buttons or a strap buckle, among other methods, may be used as the closing mechanism 40 .
[0018] The first finger receptacle 14 includes a first end 46 and a second end 48 . The first end 46 of the first finger receptacle 14 is fixed to the palm portion 12 as the second end 48 extends outwardly from the palm portion. The second end 48 terminates in two lengths such that the second end 48 fits tightly to each of the little finger and ring finger given the differing lengths of the two fingers. A first length 50 tightly fits to the end of the little finger with the second length 52 tightly fitting to the end of the ring finger of the athlete's hand. Similarly, the second finger receptacle 16 includes a first end 54 and a second end 56 . The first end 54 of the second finger receptacle 16 is fixed to the palm portion 12 between the first finger receptacle 14 and the thumb receptacle 18 . The second end 56 of the second finger receptacle 14 also terminates in two lengths such that the second end 56 fits tightly to each of the middle finger and the index finger given the differing lengths of the two fingers. A first length 58 tightly fits to the end of the index finger with the second length 60 of the second end 56 of the second finger receptacle 16 tightly fitting to the end of the middle finger of the athlete's hand.
[0019] Turning now to FIGS. 2, 3 and 5 , a side view of the athletic glove 10 is depicted in FIG. 2 with cross-sections of an interior structure 62 of the athletic glove 10 illustrated in FIGS. 3 and 5 . Thus, the interior structure 62 of the athletic glove 10 will now be described. The first and second finger receptacles 14 , 16 of the athletic glove 10 each include a finger web 64 , 66 . More specifically, the first finger receptacle 14 includes the finger web 64 disposed proximate the center of the width of the first finger receptacle 14 and extends from the first end 46 to connect to the second end 48 of the first finger receptacle 14 . The finger web 64 further connects the backhand 20 to the forehand 24 of the first finger receptacle 14 separating the little finger from contacting the ring finger. The second finger receptacle 16 includes the finger web 66 disposed proximate the center of the width of the second finger receptacle 16 and extends from the first end 54 to connect to the second end 56 of the second finger receptacle 16 . The finger web 66 further connects the backhand 20 to the forehand 24 of the second finger receptacle 16 separating the index finger from contacting the middle finger. The finger webs 64 , 66 provide the capability for slight movement between the fingers without skin-to-skin friction thus preventing blisters or other skin injuries.
[0020] Referring now to FIG. 4 , another example of the athletic glove 10 is illustrated as a pair and will now be described. The forehand 24 and backhand 20 may include specialized materials to improve performance and protection. Additionally, the forehand 24 and backhand 20 may be configured to include designs such as team logos 68 or mascots. The covers may also include special reinforcing straps or materials to improve the stability of the athletic glove and more importantly the athlete's hand within the athletic glove.
[0021] The athletic glove may also include additional features without departing from the scope of the invention. In particular, protective features that prevent the hyperextension or otherwise mis-movement of the several joints of the athlete's hand, fingers, thumb and wrist may be incorporated into the athletic glove.
[0022] The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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An athletic glove is provided for an athlete participating in a sport or competition. The athletic glove includes specifically designed finger receptacles for enhanced stability and protection for the athlete's fingers and improved performance. A first finger receptacle encloses the little and ring fingers preventing them from moving relative to each other. A second finger receptacle encloses the index and middle finger thus preventing them from moving relative to each other.
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FIELD OF THE INVENTION
The present invention relates to a flow path switching valve for switching a flow path of a cooling medium, which is used for example in a freezing cycle using a heat pump system.
DESCRIPTION OF THE RELATED ART
A conventional flow path switching valve (a four-way valve) of a type described above is disclosed for example in Japanese Patent No. 4081290 (Patent Literature 1). For the flow path switching valve of Patent Literature 1, when switching from a cooling state to a heating state, or from a heating state to a cooling state, a support shaft supporting a main valve is rotatably moved and then a closing valve support member is rotatably moved above the main valve by a drive unit, and the rotation of the closing valve support member opens or closes a connection hole or a pressure equalization hole formed at the main valve. Furthermore, the rotation of the support shaft also rotates, above a valve seat, the main valve together with the closing valve support member. In addition, in a cooling state, the pressure equalization hole is “closed” and the connection hole is “opened” by a first closing valve. Also, in a heating state, the connection hole is “closed” and the pressure equalization hole is “opened” by a second closing valve.
Patent Literature 1: Japanese Patent No. 4081290
SUMMARY OF THE INVENTION
Technical Problem
However, for the flow path switching valve of Patent Literature 1, the main valve moves easily so the main valve is lifted above the valve seat. Thus, in order to switch from the state in which the pressure equalizing hole is “open” and the connection hole is “closed” to the state in which the pressure equalizing hole is “closed” and the connection hole is “open”, a motor is required to be inversely rotated for a predetermined angle which may cause the main valve to be move together therewith, leaving a room for an improvement. Furthermore, the closing valve which opens and closes the pressure equalizing hole and the connection hole may move freely with respect to the main valve, leaving a room for an improvement regarding to a sealing performance of the pressure equalizing hole and the connection hole.
Thus, an object of the present invention is to provide a simplified operation of an auxiliary valve to provide a reliable operation of the main valve during a flow path switching in which a flow path of the cooling medium between the cooling state and the heating state of the freezing cycle is switched.
Solution to Problem
The present invention according to a first aspect is a flow path switching valve for switching a direction of flow of a cooling medium for a cooling operation and a heating operation, having: a case member forming a cylindrical valve chamber; a valve seat arranged at an open end portion of the case member; a main valve arranged so as to slidably move in a direction of an axis of the valve chamber and about a valve axis; and a rotary drive unit for rotatably moving the main valve about the valve axis, wherein the valve seat includes four ports which are communicated with a discharge-side of a compressor, an intake-side of the compressor, an outdoor heat exchanger-side and an indoor heat exchanger-side, wherein the main valve includes: an outdoor heat exchanger-side communication path which selectively allows the port provided at the valve seat and communicated with the outdoor heat exchanger-side to communicate with the port communicated with the discharge-side of the compressor or with the port communicated with the intake-side of the compressor; and an indoor heat exchanger-side communication path which selectively allows the port provided at the valve seat and communicated with the indoor heat exchanger-side to communicate with the port communicated with the discharge-side of the compressor or with the port communicated with the intake-side of the compressor, wherein the flow path switching valve further includes: an outdoor heat exchanger-side pressure equalizing hole communicating the valve chamber with the outdoor heat exchanger-side communication path; and an indoor heat exchanger-side pressure equalizing hole communicating the valve chamber with the indoor heat exchanger-side communication path, wherein the main valve is provided with an auxiliary valve abutting portion at the valve chamber side of the main valve, the auxiliary valve abutting portion being arranged to receive a rotary drive of the auxiliary valve, wherein the auxiliary valve is arranged to slidably contact on the main valve and includes an occluding portion for a selectable opening and closing of the outdoor heat exchanger-side pressure equalizing hole and the indoor heat exchanger-side pressure equalizing hole, wherein the flow path switching valve further includes a main valve abutting portion for rotating the main valve, and wherein for a switching from the cooling operation to the heating operation, the main valve is rotatably moved while the outdoor heat exchanger-side pressure equalizing hole is closed and the indoor heat exchanger-side pressure equalizing hole is open, and for a switching from the heating operation to the cooling operation, the main valve is rotatably moved while the outdoor heat exchanger-side pressure equalizing hole is open and the indoor heat exchanger-side pressure equalizing hole is closed.
The present invention according to a second aspect is the flow path switching valve described above, wherein the main valve extends diametrically from a shaft receiving portion at a center and includes a partition portion separating the outdoor heat exchanger-side communication path from the indoor heat exchanger-side communication path, wherein the main valve is arranged so that in a position in which the main valve is rotated for about half of a rotation range during a switching process from the cooling operation to the heating operation, the outdoor heat exchanger-side communication path and the indoor heat exchanger-side communication path are partially overlapped on the port communicated with the discharge-side of the compressor and on the port communicated with the intake-side of the compressor, respectively.
The present invention according to a third aspect is the flow path switching valve described in the first aspect, wherein the main valve includes an outdoor heat exchanger-side path outer wall as an outer wall of the outdoor heat exchanger-side path and an indoor heat exchanger-side path outer wall as an outer wall of the indoor heat exchanger-side path, wherein the main valve is arranged so that the switching process between the cooling operation and the heating operation, the outdoor heat exchanger-side path outer wall crosses an opening of the port communicated with the outdoor heat exchanger-side, and the indoor heat exchanger side path outer wall crosses an opening of the port communicated with the indoor heat exchanger-side.
The present invention according to a fourth aspect is the flow path switching valve according to any one of the first to third aspects, further including, an elastic member exerting a force on the occluding portion of the auxiliary valve towards the outdoor heat exchanger-side pressure equalizing hole and towards the indoor heat exchanger-side pressure equalizing hole.
The present invention according to a fifth aspect is the flow path switching valve according to any one of the first to third aspects, wherein the auxiliary valve includes two occluding portions, the one being arranged at the outdoor heat exchanger-side pressure equalizing hole side and the other one being arranged at the indoor heat exchanger-side pressure equalizing hole side, and the auxiliary valve further includes a support portion arranged to lie in the same plane as the two occluding portions.
The present invention according to a sixth aspect is the flow path switching valve of the fifth aspect, wherein the two occluding portions and the support portion are disposed at an equal distance from a valve axis center.
Advantageous Effects of the Invention
According to the flow path switching valve of the first aspect, for the switching from the cooling operation to the heating operation, the main valve is rotatably moved while the outdoor heat exchanger-side pressure equalizing hole is closed and the indoor heat exchanger-side pressure equalizing hole is open, and for the switching from the heating operation to the cooling operation, the main valve is rotatably moved while the outdoor heat exchanger-side pressure equalizing hole is open and the indoor heat exchanger-side pressure equalizing hole is closed. Consequently, prior to a rotation of the main valve together with the auxiliary valve, the outdoor heat exchanger-side pressure equalizing hole is closed and the indoor heat exchanger-side pressure equalizing hole is opened, or the outdoor heat exchanger-side pressure equalizing hole is opened and the indoor heat exchanger-side pressure equalizing hole is closed. Therefore, the auxiliary valve only needs to be rotated in one direction only and thus the auxiliary valve does not need to be rotated in a reverse direction at a time of switching. As a result, a reliable switching can be achieved. Furthermore, the switching operation can be simplified, reducing a switching time.
According to the flow path switching valve of the second aspect, at a position rotated to about a half of the rotation range during the switching process, the high-pressure cooling medium from the port communicating with the discharge-side flows into both of the outdoor heat exchanger-side path and the indoor heat exchanger-side path. Thus, there is only a small seating force involved when the main valve is seated on the valve seat, reducing a friction force between the main valve and the valve seat. Consequently, the switching can be achieved smoothly even while the compressor is operating.
According to the flow path switching valve of the third aspect, in addition to the advantageous effect of the second aspect, since the high-pressure cooling medium flows over the outdoor heat exchanger-side path outer wall and the indoor heat exchanger-side path outer wall and further flows into the outdoor heat exchanger-side communication path and indoor heat exchanger-side communication path, via the port communicated with the outdoor heat exchanger-side and the port communicated with the indoor heat exchanger-side, thus the switching can be achieved even more smoothly.
According to the flow path switching valve of the fourth aspect, in addition to the advantageous effect of the first through third aspects, since the elastic member pushes the occluding portion of the auxiliary valve towards the outdoor heat exchanger-side pressure equalizing hole and towards the indoor heat exchanger-side pressure equalizing hole, the sealing performance of the closed state of the outdoor heat exchanger-side pressure equalizing hole and the indoor heat exchanger-side pressure equalizing hole can be increased.
According to the flow path switching valve of the fifth aspect, in addition to the advantageous effect of the first through third aspects, since the support portion is provided so as to lie in the same plane as the two occluding portions of the auxiliary valve, the tilt of the auxiliary valve with respect to the main valve can be prevented, further increasing the sealing performance.
According to the flow path switching valve of the sixth aspect, in addition to the advantageous effect of the fifth aspect, since the support portion and the occluding portions are arranged at an equal distance from a valve axis center, the rotation of the auxiliary valve can be smooth also.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a flow path switching valve according to a first embodiment of the present invention;
FIG. 2 is a planar view of a valve seat of the flow path switching valve;
FIGS. 3A and 3B are perspective views of a main valve of the flow path switching valve;
FIGS. 4A and 4B are perspective views of an auxiliary valve of the flow path switching valve;
FIGS. 5A to 5C are views showing a positional relationship of respective portions of the flow path switching valve during a cooling operation;
FIGS. 6A to 6C are views showing a positional relationship of respective portions of the flow path switching valve in a switching process;
FIGS. 7A to 7C are views showing a positional relationship of respective portions of the flow path switching valve during a heating operation;
FIG. 8 is a longitudinal sectional view of a flow path switching valve according to a second embodiment of the present invention;
FIG. 9 is a perspective view of a main valve of the flow path switching valve;
FIGS. 10A to 10C are views showing a positional relationship of respective portions of the flow path switching valve during the cooling operation;
FIGS. 11A to 11C are views showing a positional relationship of respective portions of the flow path switching valve in a switching process;
FIGS. 12A to 12C are views showing a positional relationship of respective portions of the flow path switching valve during the heating operation;
FIGS. 13A to 13D are views showing a flow of a cooling medium for the flow path switching valve in the switching process;
FIG. 14 is a view showing a structure of a main valve of a flow path switching valve according to a third embodiment and a flow of a cooling medium in a switching process; and
FIGS. 15A and 15B are views showing an auxiliary valve according to another embodiment for the flow path switching valve of the respective embodiments.
DESCRIPTION OF EMBODIMENTS
The following describes an embodiment of a flow path switching valve according to the present invention with reference to the drawings. FIG. 1 shows a longitudinal sectional view of a flow path switching valve according to a first embodiment of the present invention, FIG. 2 is a planar view of a valve seat of the flow path switching valve, FIG. 3 is a perspective view of a main valve of the flow path switching valve, FIG. 4 is a perspective view of an auxiliary valve of the flow path switching valve, and FIGS. 5 through 7 are views explaining an operation of the flow path switching valve. It is noted that FIG. 1 shows the main valve during which it is being switched.
The flow path switching valve according to the first embodiment includes a case member 1 and a valve seat member 2 . The case member 1 is provided with a valve chamber 11 cut and formed into a cylinder-like shape. Furthermore, the valve seat member 2 includes a valve seat 21 having a circular board shape and a ring 22 (refer to FIG. 1 ) attached to a circumference of the valve seat 21 . The valve seat 21 and the ring 22 are fitted to an opening portion of the valve chamber 11 , thereby sealing the valve chamber 11 . Furthermore, a main valve 3 and an auxiliary valve 4 are received inside the valve chamber 11 , and also a drive unit 5 is mounted so as to be provided for a portion from an upper portion of the case member 1 to the inside of the valve chamber 11 . In addition, a motor not shown of the drive unit 5 is received at the upper portion of the case member 1 .
As shown in FIG. 2 , the valve seat 21 is provided with a D port 21 D communicated to the valve chamber 11 and to a cooling medium discharge-side of a compressor not shown, a S port 21 S communicated to the valve chamber 11 and to a cooling medium intake-side of the compressor, a C selection port 21 C communicated to an outdoor heat exchanger-side not shown and a E selection port 21 E communicated to an indoor heat exchanger-side not shown, respectively. In addition, these ports open respectively at positions apart by 90 degrees.
As shown in FIG. 3 , the main valve 3 is a member made of a resin and having a circular circumference and includes a flared portion 31 near the valve seat 21 and a cylindrical piston portion 32 which are formed in one. A piston ring 32 a is arranged at a circumference of the piston portion 32 . With a central shaft receiving portion 33 fitted at a lower portion of a rotational shaft 51 of the drive unit 5 , the main valve 3 is arranged so as to rotatably move freely around a valve axis L. The flared portion 31 is provided with an outdoor heat exchanger-side communication path 31 A and an indoor heat exchanger-side communication path 31 B which are bored into a dome-like shape at both sides of the shaft receiving portion 33 .
Furthermore, as shown in FIG. 3A , at an inside of the piston portion 32 , an auxiliary valve seat 34 is formed at an upper portion of the flared portion 31 so as to project circumferentially around the shaft receiving portion 33 distant from a shaft hole 33 a . The auxiliary valve seat 34 is provided with an outdoor heat exchanger-side pressure equalizing hole 34 a penetrating from an outdoor heat exchanger-side communication path 31 A to the piston portion 32 and an indoor heat exchanger-side pressure equalizing hole 34 b penetrating from an indoor heat exchanger-side communication path 31 B to the piston portion 32 . The outdoor heat exchanger-side pressure equalizing hole 34 a and the indoor heat exchanger-side pressure equalizing hole 34 b are disposed at 180 degrees apart around the valve axis L.
Furthermore, a projection portion 35 is provided at a portion of an inner circumferential face of the piston portion 32 . The projection portion 35 is formed so as to project towards the valve axis L and formed for a range of about 90 degrees. The projection portion 35 is provided with auxiliary valve abutting portions 35 a , 35 b arranged at both ends thereof along a circumferential direction of the valve axis L, respectively. These auxiliary valve abutting portions 35 a , 35 b correspond to a later-described main valve abutting portions 46 a , 46 b of the auxiliary valve 4 . Furthermore, a stopper 36 is formed so as to stand perpendicularly from a circumferential portion of an upper portion of the piston portion 32 . This stopper 36 is arranged within a guiding groove 13 (refer to FIG. 5A through FIG. 7A ) formed circumferentially at an upper portion of the valve chamber 11 of the case member 1 , so that both end portions of the stopper 36 are arranged to contact with the end portions of the guiding groove 13 in order to regulate a rotation range of the main valve 3 . A difference between an angle between the ends of the guiding groove 13 along a length thereof as well an angle between the ends of the stopper 36 along a width thereof is 90 degrees, thus the rotation range of the main valve 3 is 90 degrees.
As shown in FIG. 4 , the auxiliary valve 4 includes a disc-like shaped auxiliary valve main body portion 41 to be received within the piston portion 32 of the main valve 3 and a boss portion 42 provided at a center of the auxiliary valve main body portion 41 . A rectangular shaped rectangular hole 42 a is formed at a center of this boss portion 42 . Furthermore, the auxiliary valve main body portion 41 is provided with a slide valve portion 43 protruding at a face of the auxiliary valve main body portion 41 towards the main valve 3 and protruding in an about 180-degree fan shape. One of both ends of this slide valve portion 43 corresponds to an occluding portion 43 A arranged at the outdoor heat exchanger-side pressure equalizing hole-side, and the other one thereof corresponds to an occluding portion 43 B arranged at the indoor heat exchanger-side pressure equalizing hole-side. Furthermore, a support portion 44 is formed at a position opposite of the slide valve portion 43 with respect to the rectangular hole 42 a . Moreover, on a circumference of a circle of the auxiliary valve 4 around the valve axis L, there are provided two pressure equalizing hole apertures 45 A, 45 B concaved with respect to the main valve 3 —side and arranged between the slide valve portion 43 and the support portion 44 . Furthermore, different-leveled portions at an outer circumference of the auxiliary valve main body portion 41 correspond to main valve abutting portions 46 a , 46 b . Moreover, these main valve abutting portions 46 a , 46 b lie in the same circumference with the auxiliary valve abutting portions 35 a , 35 b of the main valve 3 .
As shown in FIG. 1 , the drive unit 5 includes a worm wheel 52 rotatably arranged at a rotation drive shaft 51 and a worm gear 53 meshed to the worm wheel 52 , and this worm gear 53 is fixed at a drive shaft of a motor not shown. Furthermore, the worm wheel 52 is rotatably arranged at the rotation shaft 51 via a boss portion 52 a , and this boss portion 52 a is fitted to the rectangular shaped rectangular hole 42 a formed at the boss portion 42 of the auxiliary valve 4 . Consequently, the auxiliary valve 4 is able to slide only in a direction along the valve axis L with respect to the worm wheel 52 , while a rotation thereof about the valve axis L is regulated. Moreover, a coil spring 54 as a “force-exerting member” exerting a force on the auxiliary valve 4 towards the main valve 3 is provided between the worm wheel 52 and the auxiliary valve 4 , and this auxiliary valve 4 cooperates and rotates with the worm wheel 52 .
According to the structure described above, the auxiliary valve 4 is driven by the drive unit 5 and rotated. The main valve 3 rotates together with the auxiliary valve 4 while the main valve abutting portion 46 a is abutted on the auxiliary valve abutting portion 35 a or while the main valve abutting portion 46 b is abutted on the auxiliary valve abutting portion 35 b . Furthermore, the stopper 36 of the main valve 3 abuts on the end portion of the guiding groove 13 and the rotation of the main valve 3 stops. In addition, a cooling mode corresponds to abutting on the one end portion of the guiding groove 13 and a heating mode corresponds to abutting on the other end portion thereof. Furthermore, in the cooling mode, the outdoor heat exchanger-side pressure equalizing hole 34 a is opened by the pressure equalizing hole aperture 45 A of the auxiliary valve 4 and the indoor heat exchanger-side pressure equalizing hole 34 b is closed by the occluding portion 43 B of the slide valve portion 43 . In the heating mode, the indoor heat exchanger-side pressure equalizing hole 34 b is opened by the pressure equalizing hole aperture 45 B of the auxiliary valve 4 and the indoor heat exchanger-side pressure equalizing hole 34 a is closed by the occluding portion 43 A of the slide valve portion 43 .
The auxiliary valve 4 is pushed towards the main valve 3 by the coil spring 54 (elastic member), and thus the slide valve portion 43 (occluding portion) is pushed against the outdoor heat exchanger-side pressure equalizing hole 34 a or the indoor heat exchanger-side pressure equalizing hole 34 b , increasing the sealing performance in a closed state of the outdoor heat exchanger-side pressure equalizing hole 34 a or the indoor heat exchanger-side pressure equalizing hole 34 b . Furthermore, the support portion 44 is arranged to lie in the same plane with the two occluding portions 43 A, 43 B of the auxiliary valve 4 (a plane of the slide valve portion 43 ). Therefore, a tilt of the auxiliary valve 4 with respect to the main valve 3 can be prevented, further increasing the sealing performance. Moreover, since the support portion 44 and the occluding portion 43 A, 43 B are disposed at an equal distance from a center of the valve axis L, the rotation of the auxiliary valve 4 can be smooth.
Next, a switching operation of a cooling operation state and a heating operation state is explained in reference with FIG. 5 through FIG. 7 . FIG. 5 through FIG. 7 show a positional relationship of the respective portions viewing from the valve seat 21 towards the drive unit 5 . Solid lines, dotted lines, diagonal lines and such are not intended to show the antero-posterior position nor the structure. FIG. 5A , FIG. 6A and FIG. 7A show a positional relationship of the guiding groove 13 and the stopper 36 of the main valve, and FIG. 5B , FIG. 6B and FIG. 7B show a positional relationship of the inside of the piston portion 32 and the auxiliary valve 4 , and FIG. 5C , FIG. 6C and FIG. 7C show a positional relationship of the main valve 3 and the valve seat 21 . Furthermore, FIG. 5 corresponds to the cooling operation state, FIG. 6 corresponds to the switching process of the operation state and FIG. 7 corresponds to the heating operation state.
Firstly, during the cooling operation of FIG. 5 , as shown in FIG. 5C , the D port 21 D is communicated with the C switching port 21 C by the outdoor heat exchanger-side communication path 31 A, and the S port 21 S is communicated with the E switching port 21 E by the indoor heat exchanger-side communication path 31 B. In addition, the support portion 44 of the auxiliary valve 4 is slidably contacted on the auxiliary valve seat 34 . Due to the high-pressure cooling medium introduced from the D port 21 D, a pressure of a space outside the main valve 3 becomes high and a pressure of the indoor heat exchanger-side communication path 31 B becomes low. Therefore, the differential pressure acting on the main valve 3 causes the main valve 3 to be seated on the valve seat 21 in a closely contacted manner.
Next, at a time of switching from the cooling operation state to the heating operation state, when the compressor is stopped and the drive unit portion 5 is activated, only the auxiliary valve 4 rotates from a state shown in FIG. 5B in a clockwise direction. At this time, the support portion 44 of the auxiliary valve 4 slidably moves on the auxiliary valve seat 34 . Then, the main valve abutting portion 46 b of the auxiliary valve 4 abuts on the auxiliary valve abutting portion 35 b of the main valve 3 as shown in FIG. 6B , and the indoor heat exchanger-side equalizing pressure hole 34 b of the main valve 3 is opened by the equalizing pressure hole aperture 45 B of the auxiliary valve 4 , while the outdoor heat exchanger-side pressure equalizing hole 34 a closed by the occluding portion 43 A of the slide valve portion 43 of the auxiliary valve 4 . Consequently, a pressure of the valve chamber 11 above the piston ring 32 a provided at the piston portion 32 of the main valve 3 gradually becomes low, and the main valve 3 is lifted against the pushing force of the coil spring 54 . Therefore, the differential pressure acting on the main valve 3 decreases, and thus the pushing force by the coil spring 54 becomes larger than the lifting force of the main valve 3 , thereby the main valve 3 is seated on the valve seat 21 .
In addition, at this time, since the main valve abutting portion 46 b of the auxiliary valve 4 is abutted on the auxiliary valve abutting portion 35 b of the main valve 3 , the auxiliary valve 4 rotates together with the main valve 3 . Then, the stopper 36 of the main valve 3 abuts on the one end of the guiding groove 13 as shown in FIG. 7A , and the rotation of the auxiliary valve 4 and the main valve 3 is stopped. Then, the compressor is activated to produce the heating operation state. In addition, when the stopper 36 is abutted on the one end of the guiding groove 13 , a motor and a drive circuit of the drive unit 5 are overloaded, which can be detected to stop the motor.
In this heating operation state, as shown in FIG. 7C , the D port 21 D is communicated with the E switching port 21 E by the indoor heat exchanger-side communication path 31 B, and the S port 21 S is communicated with the C switching port 21 C by the outdoor heat exchanger-side communication path 31 A. Also, the indoor heat exchanger-side pressure equalizing hole 34 b is opened and the outdoor heat exchanger-side pressure equalizing hole 34 a is closed. Due to the high-pressure cooling medium introduced from the D port 21 D, a pressure of a space outside the main valve 3 becomes high and a pressure of the outdoor heat exchanger-side communication path 31 A becomes low. Therefore, the differential pressure acting on the main valve 3 causes the main valve 3 to be seated onto the valve seat 21 in a closely contacted manner. When switching from the heating operation state to the cooling operation state can be achieved by the operation reverse of the above-described operation.
As described above, when switching from the cooling operation to the heating operation, the auxiliary valve 4 is required to be rotated only in one direction. Consequently, the inverse rotation of the auxiliary valve (refer to the afore-mentioned Patent Literature 1) is not needed, preventing the displacement of the main valve 3 .
FIG. 8 is a longitudinal sectional view of a flow path switching valve according to a second embodiment of the present invention, FIG. 9 is a perspective view of a main valve of the above-described flow path switching valve, FIG. 10 through FIG. 12 are views explaining the above-described flow path switching valve, in which the components and elements similar to those of the first embodiment are indicated by the same reference sign used in the first embodiment to eliminate the detailed explanation. FIG. 11 is a view showing the main valve in while being switched.
The difference between the flow path switching valve according to the second embodiment and the flow path switching valve according to the first embodiment is the shape of the main valve 3 ′. As shown in FIG. 9 , the main valve 3 ′, similar to that of the first embodiment, is a member made of resin and has a circular circumference, and is constituted of a flared portion 37 near a valve seat 21 and a cylindrical piston portion 32 which are formed in one. The piston portion 32 includes a shaft receiving portion 33 , an auxiliary valve seat 34 , a projection portion 35 and a stopper 36 having the same structure similar to those in the first embodiment.
The flared portion 37 is provided with an outdoor heat exchanger-side communication path 37 A and an indoor heat exchanger-side communication path 37 B bored into a dome-like shape at both sides of the shaft receiving portion 33 . There is also provided a partition portion 371 extending diametrically from the shaft receiving portion 33 , and the outdoor heat exchanger-side communication path 37 A is separated from the indoor heat exchanger-side communication path 37 B by this partition portion 371 . Furthermore, there are provided an outdoor heat exchanger-side communication path outer wall 372 A and an indoor heat exchanger-side communication path outer wall 372 B extending from an end portion of the partition portion 371 and arranged parallel to the partition portion 371 . The outdoor heat exchanger-side communication path outer wall 372 A corresponds to an outer wall of the outdoor heat exchanger-side communication path 37 A, and the indoor heat exchanger-side communication path outer wall 372 B corresponds to an outer wall of the indoor heat exchanger-side communication path 37 B.
Similar to the first embodiment, during the cooling operation as shown in FIG. 10 , the D port 21 D is communicated with the C switching port 21 C by the outdoor heat exchanger-side communication path 37 A, and the S-port 21 S is communicated with the E switching port 21 E by the indoor heat exchanger-side communication path 37 B. Also, the outdoor heat exchanger-side pressure equalizing hole 34 a is opened and the indoor heat exchanger-side pressure equalizing hole 34 b is closed. Due to the high-pressure cooling medium introduced from the D port 21 D, a pressure of a space outside the main valve 3 ′ becomes high and a pressure of the indoor heat exchanger-side communication path 37 B becomes low. Therefore, the differential pressure acting on the main valve 3 ′ causes the main valve 3 ′ to be seated on the valve seat 21 in a closely contacted manner.
At a time of switching from the cooling operation state to the heating operation state, although in the first embodiment the compressor is at a stop, in the second embodiment the switching can be performed without stopping the compressor. First, when the drive unit portion 5 is activated, the auxiliary valve 4 rotates from a state shown in FIG. 10B in a clockwise direction, and the main valve abutting portion 46 b of the auxiliary valve 4 abuts on the auxiliary valve abutting portion 35 b of the main valve 3 ′ as shown in FIG. 11B . Also, the indoor heat exchanger-side equalizing pressure hole 34 b opens and the outdoor heat exchanger-side pressure equalizing hole 34 a closes. Consequently, a pressure of the valve chamber 11 above the piston ring 32 a provided at the piston portion 32 of the main valve 3 ′ gradually becomes low, and a pressure of a space outside the main valve 3 ′ below the piston ring 32 a and a space inside the outdoor heat exchanger-side communication path 37 A increase, producing a lifting force by which the main valve 3 ′ is lifted against the pushing force of the coil spring 54 . Therefore, the differential pressure acting on the main valve 3 ′ decreases, and thus the pushing force by the coil spring 54 becomes larger than the lifting force of the main valve 3 ′, thereby the main valve 3 ′ is seated on the valve seat 21 . It is noted that even in this condition, as explained in reference with FIG. 13 , a seating force of the main valve 3 ′ on the valve seat 21 is small.
At this time, since the main valve abutting portion 46 b of the auxiliary valve 4 is abutted on the auxiliary valve abutting portion 35 b of the main valve 3 ′, the auxiliary valve 4 rotates together with the main valve 3 ′. Then, the stopper 36 of the main valve 3 ′ abuts on the one end of the guiding groove 13 as shown in FIG. 12A , and the rotation of the auxiliary valve 4 and the main valve 3 ′ are stopped to produce the heating operation state. In this heating operation state, as shown in FIG. 12C , the D port 21 D is communicated with the E switching port 21 E by the indoor heat exchanger-side communication path 37 B, and the S-port 21 S is communicated with the C switching port 21 C by the outdoor heat exchanger-side communication path 37 A. Also, the indoor heat exchanger-side pressure equalizing hole 34 b is opened and the outdoor heat exchanger-side pressure equalizing hole 34 a is closed. The high-pressure cooling medium introduced from the D port 21 D causes a pressure of a space outside the main valve 3 ′ to be high as well as a pressure of the outdoor heat exchanger-side communication path 37 A to be low, and thus the main valve 3 ′ is seated onto the valve seat 21 in a closely contacted manner. When switching from the heating operation state to the cooling operation state can be achieved by the operation reverse of the above-described operation.
As described above, also in the second embodiment, the auxiliary valve 4 is required to be rotated only in one direction when switching from the cooling operation to the heating operation. Consequently, the inverse rotation of the auxiliary valve (refer to the afore-mentioned Patent Literature 1) is not in need, preventing the displacement of the main valve 3 ′.
FIG. 13 is a view explaining in detail a flow of the cooling medium in a switching process according to the second embodiment and shows the switching process from the cooling operation state to the heating operation state. As described above, the rotation of the auxiliary valve 4 causes the main valve 3 ′ to rotate in order according to FIG. 13A through FIG. 13D . FIG. 13B shows a position rotated to half of the rotation range of the switching process, in which the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B are partially overlapped with the D port 21 D and the S port 21 S, respectively. In addition, the outdoor heat exchanger-side communication path outer wall 372 A is arranged to cross over an opening of the C port 21 C communicated with the outdoor heat exchanger-side, and the indoor heat exchanger-side communication path outer wall 372 B is arranged to cross over an opening of the E port 21 E communicated with the indoor heat exchanger-side.
Therefore, the high-pressure cooling medium flowing from the D port 21 D flows into the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B via the D port 21 D. Also, the high-pressure cooling medium flowing from the D port 21 D flows around the circumference of the main valve 3 ′ and flows into the S-port 21 S and flows into the outdoor heat exchanger-side communication path 37 A via the C-port 21 C, and flows into the indoor heat exchanger-side communication path 37 B via the E-port 21 E. This cooling medium flows into the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B together flow into the S-port 21 S. Furthermore, as shown by arrows in FIGS. 13A , 13 C and 13 D, the condition in which the high-pressure cooling medium flows into the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B, and further flows into the S-port 21 S, is almost the same for the positions before and after with respect to the half of rotation range.
As described above, since during the switching process the high-pressure cooling medium flows into both of the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B, there is only a small force involved when the main valve 3 ′ is seated on the valve seat 21 , reducing a friction force between the main valve 3 ′ and the valve seat 21 . Consequently, even in a condition in which the compressor is operating, the switching can be achieved smoothly.
In the second embodiment described above, in a position of half of the rotation range of the main valve 3 ′ in the switching process and also in a process before and after that, the outdoor heat exchanger-side communication path outer wall 372 A and the indoor heat exchanger-side communication path outer wall 372 B are arranged so as to cross over the C-port 21 C and the E-port 21 E, thus the switching can be achieved even more smoothly. However, as shown in FIG. 14 , the shape of the outdoor heat exchanger-side communication path outer wall 372 A′ and the indoor heat exchanger-side communication path outer wall 372 B′ may be similar to that of the first embodiment. In this case also, the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B are partially overlapped on the D port 21 D and the S-port 21 S, respectively. Consequently, the high-pressure cooling medium flows from the D port 21 D into the outdoor heat exchanger-side communication path 37 A and the indoor heat exchanger-side communication path 37 B, thus the switching can be achieved smoothly even in a condition in which the compressor is operating.
FIG. 15 shows another embodiment of the auxiliary valve 4 , in which the auxiliary valve 4 and the main valve 3 (or the main valve 3 ′) are seen from the drive unit 5 . Although the occluding portion 43 A, 43 B is formed by the single slide valve portion 43 in the embodiment described above, the occluding portion 43 A and the occluding portion 43 B may be formed individually as shown in FIG. 15A . Furthermore, as shown in FIG. 15B , the two occluding portions 43 A, 43 B may be formed in 180 degrees apart, and two support portions 441 , 442 may be formed therebetween. In this case, the position of the outdoor heat exchanger-side pressure equalizing hole 34 a and the indoor heat exchanger-side pressure equalizing hole 34 b may also be changed according to the rotation range of the auxiliary valve 4 and the position of the occluding portions 43 A, 43 B.
REFERENCE SIGNS LIST
1 case member
3 , 3 ′ main valve
4 auxiliary valve
5 drive unit
11 valve chamber
21 valve seat
21 D D port
21 S S port
21 C C switching port
21 E E switching port
31 A outdoor heat exchanger-side communication path
31 B indoor heat exchanger-side communication path
34 a outdoor heat exchanger-side pressure equalizing hole
34 b indoor heat exchanger-side pressure equalizing hole
37 A outdoor heat exchanger-side communication path
37 B indoor heat exchanger-side communication path
371 partition portion
372 A outdoor heat exchanger-side communication path outer wall
372 B indoor heat exchanger-side communication path outer wall
43 A outdoor heat exchanger-side occluding portion
43 B indoor heat exchanger-side occluding portion
44 support portion
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A flow path switching valve arranged to rotate a main valve with an auxiliary valve to switch a cooling state and a heating state, which provides a reliable operation of the main valve by simplifying the rotation movement of the auxiliary valve and the main valve and provides reduced switching time. An outdoor heat exchanger-side pressure equalizing hole and an indoor heat exchanger-side pressure equalizing hole are formed at the main valve. An occluding portion for opening and closing of the pressure equalizing holes is formed at the auxiliary valve. The main valve is rotated 90 degrees by merely operating the auxiliary valve along one direction in forward or reverse direction to switch between the cooling state and the heating state.
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BACKGROUND OF THE INVENTION
The present invention relates to a cleaning apparatus for textile machines or the like, and includes track means disposed above and alongside a row of different types of textile machines, with the cleaning apparatus running on the track means and including suction and/or blowing hoses that extend to the side of the textile machines, whereby when passing from one type of machine to another, a lower hose portion is movable relative to an upper hose portion in a direction transverse to the direction of movement of the cleaning apparatus.
Such cleaning apparatus are conventionally mounted on track means above the textile machines and are movable along a row of such machines, with the cleaning apparatus serving to keep the textile machines clean via appropriate blowing and suction hoses. In conformity with the rail means that are provided, a number of textile machines can be passed "in a single operation", which offers an economical possibility for cleaning the textile machines.
For the purpose of providing an integrated manufacture, more and more frequently different types of textile machines are disposed in a single room, possibly closely adjacent one another. Accordingly, for example, ring spinning frames and winding frames are then disposed next to one another and should be cleaned with the same cleaning apparatus. For this purpose, a number of approaches have been proposed in order to achieve an adaptation of the position of the blowing and suction hoses to the different cleaning requirements of the different textile machines, in each case as a function of the textile machine that the cleaning apparatus will pass.
For example, it is known to roll up or raise a blowing hose when an obstacle is encountered, although in such a case the cleaning effect of the blowing and suction hoses are then essentially discontinued.
Pursuant to a further proposal, the hoses are mounted about a swivel joint that has a vertical axis of rotation, via which a pivoting is to be produced that at the same time allows an adaptation of width.
However, this approach has various drawbacks: For one thing the jet is always pivoted along during the pivoting movement, so that it is no longer possible to ensure an alignment relative to the textile machine. On the other hand, it has been shown that the movable hoses are especially inclined during a rotational movement toward centrifugal and swinging movements due to the centrifugal force; these movements can even be dangerous for the environment of the blowing hose, and in every case reduces the service life of the blowing hose.
Stronger material was therefore used for the hoses in order to keep the extent of damage as low as possible.
However, when stronger and hence heavier hoses are used, the centrifugal forces become greater, so that the bearings in the pivot joints must be correspondingly strengthened in order to absorb both the axial as well as the radial stresses.
It is furthermore known with these pivot joint hoses to ensure the position of the jets or suction nozzles of the hoses that face the textile machines by having special devices to compensate for the rotation of the hose and thereby hopefully keep the jets in position.
However, this approach is, on the one hand, expensive. In addition, this approach is very susceptible to problems since it is precisely in the region of the suction nozzles that dust can settle very easily in the pivot bearing gap for the respective suction nozzle, so that the turning device for the suction nozzle becomes stuck.
It is therefore an object of the present invention to provide a cleaning apparatus of the aforementioned general type for textile machines or like that permits an adaptation to different types of machines that must be travelled past one after the other, but which operates in a more reliable manner can be adapted in a more flexible manner, and yet requires very little structural expense.
BRIEF DESCRIPTION OF THE DRAWINGS
This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying schematic drawings, in which:
FIG. 1 shows the lower part of one exemplary embodiment of the inventive cleaning apparatus as it passes a ring spinning frame;
FIG. 2 shows the cleaning apparatus of FIG. 1 as it passes a winding frame; and
FIG. 3 is a partial view from above of part of the inventive cleaning apparatus of FIG. 1 showing two states of the cleaning apparatus as it cleans the ring spinning frame and as it cleans the winding frame.
SUMMARY OF THE INVENTION
The cleaning apparatus of the present invention is characterized by: a parallelogram guide means for controlling the transverse movement of the lower hose portion relative to the upper hose portion; and a control mechanism for mounting the parallelogram guide means in such a way that the guide means is laterally displaceable into at least two positions.
With the inventive translatory movement of the lower hose portion, the necessary adjustment in width can be accomplished with the least possible amount of movement. It is particularly advantageous that selectively the jets remain at the same level in both end positions due to the parallelogram guide means, or an adaptation of height to the desired extent can be undertaken. For this purpose, it is merely necessary to appropriately select the adjustment range of the parallelogram. An adjustment inwardly out of the vertical position results in an initially practically negligible but then increasing raising of the jets on the lower hose portion, which with a symmetrical parallelogram guide means corresponds to the same raising when the parallelogram is guided toward the outside.
The extent to which the jets on the lower hose portion move can be adapted to the requirements over a wide range by the geometry of the parallelogram guide means.
It is also particularly advantageous that the parallelogram guide means can be used in common for a plurality of hoses that are generally guided parallel to one another; in contrast to the known rotatability or pivotability about the vertical axis, this offers a considerable advantage with regard to structural expense. It should be noted that cleaning apparatus generally have a number of blowing and suction hoses.
The control mechanism for the parallelogram guide means, via which the adjustment into at least two positions is effected, can advantageously be embodied as a pressure cylinder, for example a hydraulic cylinder, that is mounted between two diagonally opposite securement points on the upper and lower hose portions. This enables a particularly easy adjustment of the parallelogram.
The inventive cleaning apparatus can be provided with an automatic adjustment of the cleaning width via straightforward means, for example by providing at the boundary between a row of ring spinning frames and a row of winding frames an actuation element that acts upon a corresponding sensor mounted on the cleaning apparatus. As soon as the sensor of the cleaning apparatus passes into the region of the actuation element, the control mechanism for the parallelogram guide means is activated, so that the suction and/or blowing hoses are brought into the desired position.
Pursuant to a specific embodiment of the present invention, the control mechanism can adjust the parallelogram guide means in a locking manner. Alternatively, the control mechanism can effect an infinite adjustment of the parallelogram guide means.
Further specific features of the present invention will be described in detail subsequently.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings in detail, FIG. 1 shows one exemplary embodiment of the inventive cleaning apparatus, and in particular illustrates a hose 10 that has two parts, namely an upper hose portion 12 and a lower hose portion 14. The upper hose portion 12 is connected with the fan of the cleaning apparatus, which is not shown in greater detail and which is supported above a ring spinning frame 16 via a rail means.
Provided between the upper hose portion 12 and the lower hose portion 14 is a parallelogram guide means 18 that permits a pivoting of the lower hose portion 14 to one side relative to the upper hose portion 12, and hence at the same time relative to the ring spinning frame 16. The parallelogram guide means 18 is provided with two guide rods 20 and 22, each of which extends from the upper hose portion 12 to the lower hose portion 14, and is movably mounted on each via bearing means 24, 26, 28, and 30. In the illustrated embodiment, the two guide rods 20 and 22 each have the same length, thereby ensuring an exact parallel guidance.
Extending between the two bearing means 26 and 28 that are disposed diagonally across from one another is a pressure cylinder 32, for example a hydraulic cylinder, that is operable with a pressure medium in a known manner, so that by changing the length of the pressure cylinder 32 at the same time an adjustment of the parallelogram guide means 18 is effected. When the pressure cylinder 32 is extended, the lower hose portion 14 is moved closer to the ring spinning frame 16, and when the pressure cylinder 32 is retracted, the lower hose portion 14 is moved away from the ring spinning frame 16.
Cleaning of the ring spinning frame 16 is effected via a plurality of jets and suction nozzles, with one jet 34 being illustrated in FIG. 1 and being mounted on the lower hose portion 14 for blowing against a region 36 of the ring spinning frame 16 that is to be cleaned.
For an airtight connection of the lower hose portion 14 to the upper hose portion 12, a sleeve or a very flexible hose (not illustrated in FIG. 1) is provided that permits not only a lateral movement but also a certain change in length, and that can, for example, be embodied as a bellows.
In the illustration of FIG. 2, parts that correspond to FIG. 1 have the same reference numeral and require no further explanation.
In the state illustrated in FIG. 2, the inventive cleaning apparatus is passing a winding frame 38 that has a greater overall width than does the ring frame 16 of FIG. 1. As a result, the parallelogram guide means 18 is in a different position, and the pressure cylinder 32 is not as long. In the state illustrated in FIG. 2, the axes 40 and 42 of the hose portions 12 and 14 are coaxial to one another. Accordingly, the bearing means 26 and 24 on the one hand and 30 and 28 on the other hand are disposed exactly over one another, and the parallelogram guide means 18 defines a rectangle, whereas in the position illustrated in FIG. 1, the parallelogram guide means 18 forms a trapezoid. In the coaxial position of the axes 40 and 42, the resistance of the hose 10 to flow is at its least, so that this position should be used for the greatest desired suction or blowing capacity.
Pursuant to the present invention, the same jet 34 is used to act upon and hence clean a corresponding region 36 of the winding frame 38.
In a modification of the illustrated embodiment, it is proposed to couple an adjustment of the jet 34 with an adjustment of the lower hose portion 14 via the parallelogram guide means 18 in order to achieve an even better adaptation to the desired cleaning effect of the winding frame 38.
Under very specific circumstances it can be expedient to replace the parallelogram guidance by a translatory guidance of the lower hose portion 14 relative to the upper hose portion 12, whereby a change in height of the jet 34, relative to the upper hose portion 12, is not effected.
In the illustration of FIG. 3, the inventive cleaning apparatus is shown in two states, namely in the cleaning position for the winding frame 38 as well as in the cleaning position for the ring spinning frame 16. A switching-over from the narrower cleaning position for the ring spinning frame 16 to the wider cleaning position for the winding frame 38 is effected via an actuation element 44 to which a correspondingly embodied sensor on the cleaning apparatus responds. As can be seen from FIG. 3, the parallelogram guide means 18 effects an adjustment of a number of hoses in a single operation, whereby a suction hose 46 and a blowing hose 48 that are mechanically interconnected in FIG. 3 are moved together via the parallelogram guide means 18.
It is, of course, also possible to pivot the inventive cleaning apparatus into more than two positions, and in particular into a position in which the axis 42 of the lower hose portion 14 comes to rest outwardly beyond the axis 40 of the upper hose portion 12. If desired, the coaxial position of the axes 40 and 42 can also be provided in a transition region between the two end positions in which the cleaning of different textile machines is effected.
The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.
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A cleaning apparatus for textile machines or the like is provided. A track is disposed above different types of machines. Extending to the side of the machines are suction and/or blowing hoses that are movable transverse to the direction of movement of the cleaning apparatus. This movement is controlled by a parallelogram guide means, which is mounted in such a way via a control mechanism that the parallelogram guide means is laterally displaceable into at least two positions.
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FIELD OF THE INVENTION
The invention relates to a pre-assembled plate consisting of reinforced concrete especially for use as a structural component of a permanent roadway for high-speed vehicles and to an accompanying method of installing and using the plates.
BACKGROUND OF THE INVENTION
A generic pre-assembled plate consisting of reinforced concrete is known from DE 197 33 909. The pre-assembled plate consisting of reinforced concrete is provided for constructing a compound plate construction, especially a solid roadway for high-speed rail traffic. At least two steel rods extending in the longitudinal direction of the plate and projecting over its two front sides are arranged in the pre-assembled plate consisting of reinforced concrete. Each steel rod is immovably anchored on only one position in the pre-assembled plate consisting of reinforced concrete and is otherwise freely extendable. This makes an extension stretch available that always has the length of each pre-assembled plate consisting of reinforced concrete and consequently exerts a great tensioning force on the concrete introduced into the butt joint. It turned out that this has the disadvantage that theoretical breaking points arranged at regular intervals in the pre-assembled plate consisting of reinforced concrete are bridged by the bracing and stress of the steel rods and thus loose their function. Unavoidable cracks in the pre-assembled plate consisting of reinforced concrete arise as a result at unpredictable locations, especially not in the area of the theoretical breaking points provided.
The method for producing a compound plate construction, especially a solid roadway for high-speed rail traffic that is also suggested in the DE 197 33 909 A1 consists in that at first the ends of the steel rods are frictionally and tensionally connected to each other and that thereafter the two pre-assembled plates consisting of reinforced concrete adjacent to one another are pressed apart from one another with a defined force of the steel rods. The pre-assembled plates consisting of reinforced concrete are held in this position and the entire butt joint between the two front sides adjacent to one another of the pre-assembled plates consisting of reinforced concrete is filled with a solidified filling mass. The defined force is subsequently released and the filling mass braced by the tensioning force of the steel rods that now occurs. This solution has the disadvantage that a positioning and exact adjusting of the pre-assembled plates consisting of reinforced concrete that took place prior to the application of the defined force is lost again since the complete plate must be moved for bracing. This results in a shifting of the plate on the underlying foundation, as a result of which the adjusting screws standing on the foundation are shifted or even somewhat tilted. The positioning and aligning of the pre-assembled plate consisting of reinforced concrete previously performed is distorted again as a consequence. Therefore, a new alignment of the plates is necessary after the filling of the butt joint. This necessitates an additional work expense and creates problems in the area of the filled butt joint.
DE 26 21 793 teaches a method of producing a compound grate or plate construction of pre-tensioned pre-assembled concrete parts. In this reference, the joints between the pre-assembled concrete parts are pre-tensioned after the joining together and aligning of the concrete pre-assembled parts. Tensioning member ends project from the concrete pre-assembled parts with which ends a connection is established between adjacent concrete pre-assembled parts. The joint produced is pressed apart with a pressing device, a mass is introduced into this joint as joint filling and the pressing device is not stress-relieved and removed until after the hardening or setting of the joint filling. After the setting of this mass, rod tighteners that were arranged on the tensioning member ends were tightened with a controlled force, which places the filled joints under a pre-tension. The concrete plates are subsequently underfilled or underpressed. Lastly, the recesses for the rod strainers are closed and sealed. This method has the disadvantage that the pre-tension of the tensioning rod ends is altered by the underfilling or underpressing of the concrete plates. Moreover, the adjusting is possibly influenced by this method so that a subsequent check must take place. Even different temperatures during tensioning or filling of the butt joints and during the underfilling have a negative influence on the precision of the alignment of the concrete plates.
The present invention has the problem of avoiding the disadvantages of the state of the art and in particular of assuring a precise alignment of the pre-assembled plates consisting of reinforced concrete.
This problem is solved by the features of the claims presented here.
SUMMARY OF THE INVENTION
In a pre-assembled plate consisting of reinforced concrete each steel rod is anchored in the area between the front side of the pre-assembled plate and a surface defined groove which defines the first theoretical breaking point and is supported in a substantially freely movable manner, starting from this anchoring, in the direction of the particular front side in its longitudinal direction. This assures that the theoretical breaking point is not loaded with pressure, thus possibly loosing its effect. As a result of the fact that the steel rod is movably supported in a defined area directed away from the pre-assembled plate, traction forces in a plate segment limited by the theoretical breaking point are introduced onto the pre-assembled plate containing no theoretical breaking point. This produces cracks in the area of the theoretical breaking point. This is desired since as a consequence thereof the other plate parts remain substantially free of cracks. All theoretical breaking points introduced in the pre-assembled plate can thus fulfill their task.
If the theoretical breaking point is a dummy joint running transversely to the longitudinal direction of the pre-assembled plate the theoretical breaking point can be produced in a simple manner in the casting or pouring of the pre-assembled plate already. As a result of the dummy joint the thickness of the pre-assembled plate is reduced at this position. Cracks then arise in the immediate vicinity of this dummy joint and can thus be purposefully checked for their magnitude. The state of the pre-assembled plate can thus be readily monitored.
It proved to be especially advantageous if the anchoring of the steel rod is approximately 50 cm removed from the front side of the pre-assembled plate. This yields a sufficient length of the steel rod for extending it in accordance with the requirements in a permanent joining of several pre-assembled plates. As a result of the extension a pressure force is applied to the joint that can bring about a penetration of water and therewith a destruction of the joint or of the concrete.
In order to make possible an extension of the steel rod or to prevent the steel rod from being permanently connected in the corresponding area during the manufacture of the pre-assembled plate, it is provided that the steel rod is jacketed in the area between the front side of the pre-assembled plate and the anchoring by a tube or hose, especially by a shrinkdown plastic tubing such as a heat-shrinkable sleeve. This can assure that the steel rod is arranged within the tube or hose or, if the shrinkdown plastic tubing was reduced from a greater diameter to a smaller diameter after the setting of the concrete, is movably arranged in its longitudinal direction in the pre-assembled plate. The anchor point of the steel rod is again located thereby in the first segment of the pre-assembled plate. The steel rod is to be extended from this anchor point to the end of the steel rod relative to the pre-assembled plate. A so-called tenso binding which results also yields a reliable corrosion protection in the non-concreted area.
A sliding of the steel rod within the jacketing is possible, in particular if the jacketing of the steel rod has a greater inside diameter than the outside diameter of the steel rod. The jacketing is permanently connected to the concrete thereby whereas the steel rod can rotate within the jacketing. A sliding between the concrete and the shrinkdown plastic tubing is possible if a shrinkdown plastic tubing is used.
If the steel rod ends in a pocket of the pre-assembled plate, fastening means for joining the steel rod of the one pre-assembled plate to a steel rod of the adjacent pre-assembled plate can be introduced in a simple manner. The pocket also permits the tension path of the steel rod to be sufficiently large.
If the pocket is open toward the top of the pre-assembled plate the steel rod and the end of the steel rod and fastening means connected to them can be readily accessed. Tools for tensioning the steel rod can therefore be introduced in a simple manner.
If the pocket is closed in the direction of the bottom of the pre-assembled plate the substratum can be sealed off or encased in a simple manner. The bottom of the pre-assembled plate thus forms a substantially straight line along the front side of the pre-assembled plate so that appropriate sealing means are simple to apply. Moreover, it is more readily possible with this straight-line closure edge to seal off the substratum and less sealing material is required.
If the pocket has an undercut, such as a back taper, when viewed from the top, an additional clawing of the adjacent pre-assembled plates is produced during the grouting of the pocket, e.g., with concrete. The pocket thus brings about a vertical fixing of the pre-assembled plates to each other so that an additional safeguard against an unintentional shifting of the pre-assembled plates toward each other is provided.
If the pocket of the one pre-assembled plate corresponds to a corresponding pocket of the adjacent pre-assembled plate, a wide joint is produced between the adjacent pre-assembled plates. This wide joint is for its part suited for receiving a fastener for the two pre-assembled plates and facilitates the accessibility to these fastening means during their mounting. In addition, a sufficient free space for the tensioning of the steel rods is achieved.
If a narrow joint is provided between two steel rods of the pre-assembled plate and/or toward the edge of the pre-assembled plate, a sealing compound can be introduced in a defined manner between the two pre-assembled plates.
If the bottom of the front side of the pre-assembled plate has a substantially straight-line course and/or the top has alternating narrow and wide joints, this yields on the one hand a good seal of the substratum below the pre-assembled plate and on the other hand a ready mounting of the tensioning device for the steel rods.
It is especially advantageous if a connecting means for connecting the steel rod of the one pre-assembled plate to the steel rod of the adjacent pre-assembled plate can be arranged inside the wide joint. This substantially facilitates the mounting of the pre-assembled plates. In addition, if a disassembly of the pre-assembled plate is necessary, the connection means can be accessed in a relatively simple manner.
If adjusting devices, especially spindles, are arranged on the pre-assembled plate, the pre-assembled plate can have its height precisely adjusted to the required degree. It is important, especially in the case of high-speed traffic means, that the pre-assembled plates and therewith the guide means for the high-speed vehicles are aligned very exactly with each other.
If the pre-assembled plate is manufactured from fiber concrete, a part of the traditional reinforcement can be dispensed with. Moreover, in addition to this advantage there is the further advantage of lesser crack widths.
If the narrow joint and/or the wide joint is/are filled up with a sealing compound, such as concrete applied between two pre-assembled plates, when a traction force is applied onto the steel rods, a support of the two pre-assembled plates is assured via the filled-up narrow joint. This compresses the narrow joint, reliably preventing the penetration of water into the joint.
In order to fix the fine adjustment of the pre-assembled plate a substratum mass, in particular a bituminous cement mortar, is introduced between the pre-assembled plate and the foundation. This viscous substratum mass is introduced through fill openings in the pre-assembled plate from above or laterally from the plate edge into the hollow space between the pre-assembled plate and the substratum. The hardening of this substratum mass takes place in a substantially temperature-dependent manner, that is, the pre-assembled plate hardens independently of the outdoor temperature in the position that had been precisely aligned previously. The fine adjustment of the pre-assembled plate thus remains substantially preserved.
If the substratum mass is encased in particular with a sealing element, especially with an elastic, preferably porous plastic, the need for additional expensive sealing elsewhere during the underpouring of the pre-assembled plate is avoided. The sealing element is sufficiently elastic that it nevertheless still makes contact with the bottom of the pre-assembled plate and with the top of the foundation during an adjustment in height of the pre-assembled plate for aligning the pre-assembled plate. This arrangement prevents the substratum from running out. A reliable pouring of the substratum is brought about with the aid of these especially advantageous sealing elements even in the sloped regions of the roadway.
Sealing elements have proven to be especially advantageous include a rubber or sponge mat, especially one consisting of neoprene. The elements can either be left where they are after the hardening of the substratum or can be reused when underpouring another pre-assembled plate. Moreover, the use of a sponge makes it possible that air is forced through the sponge by the sealing compound and thus does not result in inclusions under the pre-assembled plate.
If spacers are arranged in the area of the joints, a fixing of the adjacent pre-assembled plates can also take place therewith, instead of the sealing, in order to be able to tension the steel rods. The spacers can be arranged in the area of the narrow joint or of the wide joint. It is especially advantageous if the joint is poured in one piece. The spacers serve to hold the pre-assembled plates in position following the fine adjustment and both before and/or after the tensioning of the steel rods. The spacers may be wedge-shaped to facilitate adjustment to the precise interval position.
In one method in accordance with the invention a compound plate pre-assembled plates consisting of reinforced concrete with at least two steel rods extending in the longitudinal direction of the pre-assembled plate and projecting over its concrete surface on the front side and with a joint between adjacent pre-assembled plates the pre-assembled plate is first placed down and finely adjusted. The finely adjusted pre-assembled plate is then underpoured with a substratum mass and after the substratum has hardened, the pre-assembled plate is joined to the adjacent pre-assembled plate by filling up the joint and connecting the steel rods. This produces a compound plate construction that is precise in its position. Contrary to prior art methods, the individual pre-assembled plate is first brought into its exact position and substantially fixed in this position. This prevents the pre-assembled plate, once it has been aligned, from being shifted out of its position by the joining with other pre-assembled plates of the compound plate construction and thus having to readjusted. After the finely adjusted pre-assembled plate is fixed in this position it is first connected to the other pre-assembled plate. This creates a compound plate construction that is very precise in its position and is permanently fixed. During the connecting of the steel rods of adjacent pre-assembled plates the position of the pre-assembled plates. having been precisely adjusted previously, is retained since the finely adjusted pre-assembled plates had been fixed with a hardened substratum mass. This achieves an especially precise and also a rapid and therewith economical finishing of a compound plate construction that substantially renders a post-adjustment superfluous. Another substantial advantage is that if a pre-assembled plate is damaged, e.g., if a train derails, individual pre-assembled plates can be removed from a compound plate construction and replaced with a new pre-assembled plate. This achieves an assembly that is quite compatible with the method of production in accordance with the invention that has great advantages not only during the first assembly but also during repairs.
The steel rods are advantageously extended in order to connect adjacent pre-assembled plates. This creates a tension between the adjacent pre-assembled plates that assures an additional fixing in place and a water-tight connection of a joint between the pre-assembled plates.
If narrow joints and wide joints are provided at the plate joint, it is especially advantageous if the narrow joints are provided with a sealing compound at first, the steel rods are then tensioned and, finally, the wide joints are closed. This achieves a uniform loading of the pre-assembled plates and of the sealing compound.
If the steel rods are not tensioned until after the hardening of the sealing compound in the narrow joints, a pressing together of the joints between the pre-assembled plates is achieved in an advantageous manner. Any shrinking or contracting, of the sealing compound during setting is thus compensated for and a watertight connection between the pre-assembled plates is obtained.
It is especially favorable for the assembly if the steel rods of adjacent pre-assembled plates are connected by rod tensioners or strainers. The tensioners can be operated in a simple manner with a hand tool or with appropriate tool machines to impart a sufficient tension to the steel rods.
As an alternative to rod tensioners, it may be advantageous in some instances to weld the steel rods to each other. The appropriate welding methods also bring about an extension of the steel rods by heat during the welding and a resulting tension occurs when the welded rods are cooled.
Spindles have proven to be advantageous for a fine adjustment of the pre-assembled plate. Sensitive adjustment of the pre-assembled plates in the order of millimeters may be achieved with the spindles.
If concrete, especially high-grade concrete, is used as sealing compound for the joints between the pre-assembled plates a good permanence of the joint is assured.
A bituminous cement mortar proved to be especially advantageous as substratum mass. Bituminous cement mortar is viscous and is suitable for filling up the intermediate space between the pre-assembled plate and the foundation completely without bubble formation. Additionally, the bituminous cement mortar establishes a good connection to the pre-assembled plate and, moreover, to the foundation, which is frequently a hydraulically bound carrier layer or to an asphalt carrier layer. This bituminous cement mortar brings about an exact positioning of the pre-assembled plate on the foundation and fixes the pre-assembled plate, which had been adjusted prior to the introduction of the substratum mass, in its position.
If an elastic, especially a porous sealing element is used as casing for the substratum, an especially simple, economical and efficient sealing of the intermediate space between the pre-assembled plate and the foundation is obtained. The sealing element prevents the substratum from flowing out of this intermediate space. The casing can be placed before the fine adjustment, in particular before the placing of the pre-assembled plate. On account of its elasticity, it adapts precisely to the intermediate space between the pre-assembled plate and the substratum even during the fine adjusting and brings about a sealing of the hollow space.
If the pre-assembled plate is used as a carrier for rails, it has been found to be especially advantageous to brace the rails on the pre-assembled plate in rail fastenings before the fine adjustment of the pre-assembled plate. Since the proper positioning of the rails is necessary for the overall structural alignment, the rail braces and fastenings are advantageous since any imprecisions in the rail alignment can be compensated.
After the pre-assembled plate has been aligned and the steel rods connected to each other, the wide joints are closed and the rails joined to each other. After this concluding work the compound plate construction with rails is ready for high-speed rail traffic.
It is especially advantageous and an alternative to the filling up of the narrow joint before the bracing of the steel rods if the finely aligned pre-assembled plate is fixed to the adjacent pre-assembled plate with spacers, especially with wedges. following which, the joint is subsequently filled up.
If the spacers are arranged in the area of the narrow joints and/or the wide joints a good support of the spacers on the two pre-assembled plates occurs. After the joints are filled, the spacers can be relieved or removed.
Other advantages of the invention are presented in the following description of the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a top view of a part of a pre-assembled plate consisting of reinforced concrete.
FIG. 2 shows a section transversal to the longitudinal direction of a pre-assembled plate consisting of reinforced concrete.
FIGS. 3 a to 3 d show different method steps in the joining of two pre-assembled plates consisting of reinforced concrete.
FIG. 4 shows a detailed view in longitudinal section of a pre-assembled plate consisting of reinforced concrete in accordance with FIG. 3 c.
FIG. 5 shows a butt joint with spacers.
FIG. 6 shows a spacer in a top view.
FIG. 7 shows a spacer in a lateral view.
DETAILED DESCRIPTION
FIG. 1 illustrates a top view a part of a pre-assembled plate 10 consisting of reinforced concrete. Pre-assembled plate 10 consisting of reinforced concrete comprises a plurality of elevated regions 12 in this exemplary embodiment. Alternatively, a continuous band or a concrete conduit that is continuous or interrupted is also possible. Elevated regions 12 are arranged in two rows in the longitudinal direction of pre-assembled plate 10 , as a result of which they can be used in the purpose shown here for fastening rails for, e.g., high-speed tracks. A rail 30 is fastened on each of the rows of elevated regions 12 . Rail 30 is fastened on each elevated region 12 with a fastener 31 . Fasteners 31 can be fixed as needed in prefabricated sockets 32 or in other appropriate holes.
Two elevated regions 12 are each arranged on one segment of the pre-assembled plate 10 and in the transverse direction with respect to pre-assembled plate 10 . The individual segments are separated from each other by dummy joints 15 . Dummy joints 15 function as theoretical breaking points in which unavoidable small cracks of pre-assembled plate 10 consisting of reinforced concrete are purposefully produced in pre-assembled plate 10 . As a result of these intentional cracks, the remaining pre-assembled plate 10 consisting of reinforced concrete is substantially spared from cracks and can thus be made stable and its state can be readily checked. The design of pre-assembled plate 10 consisting of reinforced concrete is therefore selected in such a manner that the cracks occur in the area of the theoretical breaking points or dummy joints 15 .
In addition to the usual reinforcement of pre-assembled plate 10 , several traction or steel rods 19 are arranged in a longitudinal direction in pre-assembled plate 10 . Steel rods 19 , acting as traction anchor in pre-assembled plate 10 , extend from one end of the pre-assembled plate to the other end of pre-assembled plate 10 . Steel rods 19 project out of the concrete surface at front sides 17 of pre-assembled plate 10 and can be connected, as will be described in detail later, to the adjacent pre-assembled plate or to its steel rods.
Front side 17 comprises a substantially straight-line, continuous edge and two recesses or pockets 24 in this exemplary embodiment. Pockets 24 are setoffs in relation to straight-line front surface 17 in which setoffs steel rods 19 project out of the concrete surface. In addition, pockets 24 comprise undercuts (shown in dotted lines) that additionally improve the stability of the connection of pre-assembled plate 10 to the adjacent pre-assembled plate (not shown). Moreover, the subsequent filling up of the joints between two pre-assembled plates 10 can be achieved in a more permanent fashion since the penetration of water, among other things, is prevented by these undercuts.
Pre-assembled plate 10 comprises several filling openings 13 (only one shown here). A substratum filler is introduced under pre-assembled plate 10 in its completely aligned state through these filling openings 13 .
FIG. 2 shows a part of a section transversal to the longitudinal axis of pre-assembled plate 10 and its foundation. Elevated regions 12 are again arranged on pre-assembled plate 10 on which rail 30 is arranged with fasteners 31 . Fasteners 31 are fixed in sockets 32 formed in pre-assembled plate 10 . The pre-assembled plate consisting of reinforced concrete can be designed in a traditional manner with the customary reinforcement. As an alternative, it is especially advantageous if pre-assembled plate 10 is produced with reinforced concrete. Steel bars or wires that impart great strength to pre-assembled plate 10 are present in the reinforced concrete. The steel wires can be bent, wound or have some other shape with which they support the interlacing in the concrete. This makes it possible to obtain an extremely solid reinforced concrete for pre-assembled plates 10 , which display an especially great strength and service life in particular in the edge areas or in the areas in which fastenings 31 are fixed.
Several spindles 37 are arranged on pre-assembled plate 10 for aligning pre-assembled plate 10 into the required position. Spindle 37 is supported upon plate 38 in order to provide a solid and uniform foundation which permits a fine adjustment of plate 10 in its height. Spindle 37 extends in this construction through a recess in pre-assembled plate 10 in order to permit a large adjustment path. Pre-assembled plate 10 is brought into its position by adjusting screw 39 on spindle 37 . Before pre-assembled plate 10 is placed on a hydraulically bound carrier layer 45 , elastic casing 41 is placed in the edge area of pre-assembled plate 10 . This casing 41 serves to prevent underfilling 42 poured under pre-assembled plate 10 after it had been aligned from running out. The preferably viscous substratum 42 is held under pre-assembled plate 10 by casing 41 . Casing 41 is preferably an elastic or plastic material. In particular, spongy materials with coarse pores or neoprene or similar plastics have proven to be advantageous. Casing 41 can either remain at this position after the substratum has hardened and thus provide a certain protection against moisture. If the casing is to be used for more substrata, it is also possible to remove this casing 41 from the pre-assembled plate 10 out and reuse it.
The individual steps of the joining of two pre-assembled plates 10 is described in the following with reference made to FIGS. 3 a to 3 d . At first, pre-assembled plates 10 are precisely aligned in their height by spindles 37 and nuts 39 . Steel rods 19 of the two pre-assembled plates to be connected are substantially aligned in their longitudinal axis ( FIG. 3 a ). Substratum 42 is subsequently poured under pre-assembled plate 10 via filling openings 13 . Substratum 42 preferably consists of a bituminous mortar concrete. Substratum 42 joins pre-assembled plate 10 to hydraulically bound carrier layer 45 prepared below it. When substratum 42 has completely hardened, narrow joints located between the two plates 10 are filled up with a sealing compound, preferably concrete ( FIG. 3 b ). The pouring can take place solely in the area of joint abutments 21 of pre-assembled plate 10 or also fill up the lower area between pre-assembled plates 10 in which wide joints 27 following above are located. As soon as the sealing compound has hardened, steel rods 19 are connected to each other by tighteners 28 and extended. This produces a pressure on sealing mass 25 in narrow joints 26 and thus effectively prevents the entry of water. It is noted that the precise alignment of pre-assembled plates 10 previously carried out during the tensioning of steel rods 19 is not altered by this procedure since the pre-assembled plates are supported on sealing compounds 25 and are fixed with respect to the foundation by substratum 42 ( FIG. 3 c ).
After steel rods 19 have been connected to each other and extended, the wide joint 27 can be closed in order to prevent corrosion ( FIG. 3 d ). The closure can also take place by introducing a sealing compound 25 , e.g., concrete. Alternatively, a removable covering can also be provided here. However, a firmer joining of the two pre-assembled plates 10 takes place by filling up wide joint 27 since this brings about an additional cogging of pre-assembled plates 10 given a corresponding shape of wide joint 27 .
The procedure for the joining of the two pre-assembled plates 10 was presented in FIGS. 3 a to 3 d without a built-on rail 30 . If the pre-assembled plates are used for high-speed rail traffic, it is advantageous if rail 30 has already been built on for the aligning of pre-assembled plates 10 since rail 30 is decisive for the aligning of pre-assembled plates 10 .
FIG. 4 shows the joint of two pre-assembled plates 10 prepared up to the work step of FIG. 3 c in more detail. The pre-assembled plates 10 are cut lengthwise in the area of steel rods 19 . Pre-assembled plates 10 are arranged on substratum 42 that is supported on a hydraulically bound carrier layer. Casing 41 prevents substratum from breaking out of the area of pre-assembled plate 10 during the underpouring or underpressing of pre-assembled plate 10 .
Pre-assembled plate 10 comprises elevated regions 12 on which rail 30 is fastened with fastenings 31 . Dummy joints 15 are arranged at regular intervals in pre-assembled plates 10 and represent theoretical breaking points for pre-assembled plate 10 . Several steel rods 19 have been introduced into pre-assembled plate 10 . Each steel rod 19 has opposed ends. Each steel rod 19 has one of its opposed ends projecting from the first front side 17 of the plate 10 and the other of its ends projecting from the second or opposite front side 17 of the plate 10 . Each rod 19 has a first near end portion that extends within the plate 10 over a distance that extends substantially from the undercut 29 of the pocket 24 in the first front side and terminates longitudinally before the first transverse groove that forms a dummy joint 15 . As shown in FIG. 4 for example, a tube 20 surrounds each first near end portion of each rod 19 . Similarly, each rod 19 has a second near end portion on the other side of rod 19 from the first near end portion. Each rod 19 defines an intermediate portion that is secured to the plate 10 and that is between the first near end portion and the second near end portion. Thus, each steel rod 19 is substantially firmly anchored in pre-assembled plate 10 . However, each steel rod 19 is not connected to the concrete of the pre-assembled plate only in the area from dummy joint 15 to the end of the particular pre-assembled plate 10 and can thus be freely extended. To this end steel rod 19 is in a tube 20 that prevents a connection of steel rod 19 with a sealing compound 25 . Narrow joints 26 are filled up with sealing compound 25 . Steel rods 19 are connected to each other by tightener 28 and extended. The extension brings it about that the steel rods are extended in their freely movable area in the particular tube 20 and thus effect a pre-tensioning. Sealing compound 25 is pressed and the composite construction stabilized by the pre-tension so that the penetration of water into the joints is prevented. In addition, pre-assembled plates 10 are pressed firmly against each other via sealing compound 25 . The fact that steel rod 19 is movably supported only in the area between dummy joint 15 and the end of pre-assembled plate 10 brings it about in a reliable manner that dummy joint 15 is not bridged with a pressure force and loses its function therewith. The force on the concrete body is introduced only in the last segment, namely, between dummy joint 15 and the end of pre-assembled plate 10 via steel rods 19 .
If pocket 24 , in which tighteners 28 and the ends of steel rod 19 are located, is designed so that it has an undercut 29 in a top view onto the plate, an additional cogging of pre-assembled plates 10 with each other is achieved if wide joint 27 formed by pockets 24 is filled up with sealing compound 25 ′. Pre-assembled plates 10 are additionally hindered therewith from moving vertically.
Substratum 42 can be removed again in the instance in which the plate or the substratum lowers in the course of the using of the plate. This happens in that substratum 42 is bored through transversely to the longitudinal direction of the plate. A saw, especially a saw cable, is introduced into the borehole and saws through the substratum under the plate. The plate can then be precisely realigned, e.g., with spindles, and more matter can be poured under it again.
FIG. 5 shows a top view onto a butt joint between two pre-assembled plates 10 and 10 ′: Spacers 50 are arranged for fixing pre-assembled plates 10 and 10 ′. Spacers 50 are located in the area of a narrow joint. Alternatively or additionally, two spacers 50 ′ can be provided in the area of the wide joints. It is assured in each of the embodiments that the finely aligned state of pre-assembled plates 10 and 10 ′ is retained during the tensioning of the steel rods.
FIG. 6 shows a top view onto a spacer 50 . Spacer 50 consists of base plate 51 fastened on pre-assembled plate 10 and 10 ′. This base plate 51 can either be cast in pre-assembled plate 10 , 10 ′ or have been subsequently applied. One of base plates 51 comprises guides 52 for a wedge 53 . Wedge 53 is introduced into guides 52 between the two base plates 51 when pre-assembled plates 10 and 10 ′ have been aligned. This fixes the interval of pre-assembled plates 10 and 10 ′ so that during a tensioning of the steel rods the pre-assembled plates 10 and 10 ′ can not move toward one another and the alignment of the plates is not changed.
FIG. 7 shows a lateral view of spacer 50 . Pre-assembled plates 10 , 10 ′ located on substratum 42 or carrier layer 45 are held at a defined interval by wedge 53 . This interval is permanently fixed after the bracing of the steel rods in that the joint is filled up with sealing compound 25 . After the hardening of sealing compound 25 the position of pre-assembled plates 10 , 10 ′ to one another is permanently determined. Wedge 53 can be removed as needed and used for the next butt joint. In a special embodiment sealing compound 25 can also be hollowed out at least temporarily in the area of spacer 50 . After the hardening of the rest of sealing compound 25 the complete spacer 50 can be removed from the butt joint together with wedge 53 and used for another connection position.
The use of the spacers permits an immediate application of tractive force on the steel rods and a subsequent common sealing of the wide and of the narrow joint. This is especially advantageous if unfavorable temperature and climate conditions for the sealing of the joint are present. A more favorable temperature and a suitable climate can be waited for the final filling up of the wide and of the narrow joint so that an optimum processing of the material is given.
The present invention is not limited to the design presented. Pre-assembled plates 10 can also be used for applications other than the described ones. Steel rods 19 can also be prevented from joining with the concrete of pre-assembled plate 10 in the last segment in a variety of ways. Combinations of the individual features are of course also within the protective scope of the invention.
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The invention relates to a pre-assembled plate consisting of armored concrete, especially for the use as a component of a solid roadway for high-speed means of transport. At least two steel rods extending in the longitudinal direction of the pre-assembled plate of armored concrete ( 10 ) and protruding over the concrete surface thereof on the front face ( 17 ) are provided. The pre-assembled plate ( 10 ) is provided with at least one, preferably several, predetermined breaking points ( 15 ) which extends crosswise in relation to the steel rods ( 19 ). The steel rod ( 19 ) is anchored in the area between the front face ( 17 ) of the pre-assembled plate ( 10 ) and the first predetermined breaking point ( 1 ) respectively and is mounted in the direction towards the respective front face ( 17 ) in the longitudinal direction thereof in an essentially freely moveable manner. According to a method for producing a plate composite structure of pre-assembled plates of armored concrete ( 10 ), the pre-assembled plate ( 10 ) is placed and exactly positioned. A casting compound ( 42 ) is underpoured under the exactly positioned pre-assembled plate. The pre-assembled plate ( 10 ) is connected to the adjacent pre-assembled plate ( 10 ) by casting the joint and connecting the steel rods ( 19 ) after the casting compound ( 42 ) has hardened.
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BACKGROUND OF THE INVENTION
This invention relates to an improved intake system for a multiple valve type engine and more particularly to an improved induction arrangement that provides good running throughout the engine speed and load ranges and which ensures against the accumulation of unnecessary combustion deposits in the induction passages. In addition, the invention relates to an improved spark plug arrangement for such an engine.
It has been proposed to improve the output of an internal combustion engine by providing at least a pair of separate intake passages that deliver the intake charge to the combustion chambers of the engine. In order to ensure good running at low speeds, it has been proposed to employ a throttle valve arrangement in one of the induction passages that is operated in sequence with the main throttle valve so that the idle and low load charge requirements are supplied through only one of the intake passages. In this way higher velocities of induction are possible so as to improve the running under these conditions. However, the remaining induction passage is generally stagnant during such running even though the associated intake valve with it opens and closes. As a result, it is possible that combustion deposits such as carbon may accumulate in the non-utilized intake passage. In addition, since there is no flow of intake air across this intake valve, it may not be cooled sufficiently and cause overheating and/or early wear.
It is, therefore, a principal object of this invention so as to provide an improved induction system for an internal combustion engine.
It is another object of the invention to provide an induction system for an internal combustion engine embodying plural intake passages wherein good running is achieved throughout the engine speed and load ranges without detrimental effects in the induction system.
Engines embodying multiple intake passages and throttle valves for controlling the flow so that only one of the intake passages serves the major portion of the charge requirements at low loads may have different flow conditions existing within the combustion chamber when different numbers of the intake passages are serving the chambers. That is, when only one of the intake passages is serving the chamber, a swirling pattern may be established in the combustion chamber. When both passages, however, are supplying the charge, either a non-swirling pattern may be established or a flow path in a completely different direction may exist. Thus, if only a single spark plug is employed in the combustion chamber, this plug may not be positioned at the optimum location to fire the charge under all running conditions.
It is, therefore, a further object of this invention to provide an improved combustion chamber and spark plug location for a multiple intake passage internal combustion engine.
SUMMARY OF THE INVENTION
A first feature of this invention is adapted to be embodied in an induction system for an internal combustion engine of the type having a pair of intake ports serving the same chamber of the engine with separate intake passages each independently serving a respective one of the intake ports. Throttle valve means are provided in the intake passages for controlling the flow therethrough and means actuate the throttle valve means so that the low load condition will be served primarily through the first induction passage and the high load condition will be served through both of the induction passages. In accordance with this feature of the invention, an interconnecting passage extends between the first and second intake passages downstream of the throttle valve means so that a portion of the idle charge requirements will be supplied through the second intake passage.
Another feature of the invention is adapted to be embodied in an induction system for an internal combustion engine having a combustion chamber that is defined at least in part by a cylinder head, a cylinder bore and a piston. A pair of intake ports communicate with the combustion chamber and a pair of intake valves control the flow through the respective intake ports. In accordance with this feature of the invention, a pair of spark plugs are provided in the combustion chamber having their terminals disposed on diametrically opposite sides of the chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a bottom plan view, with portions broken away, of the cylinder head and induction system of an engine constructed in accordance with this invention and is taken generally in the direction of the line 1--1 of FIG. 2.
FIG. 2 is an enlarged cross-sectional view taken through a single cylinder of the engine.
FIG. 3 is a bottom plan view, with portions broken away, similar to FIG. 1 and shows another embodiment of the invention.
FIG. 4 is a bottom view with portions broken away similar to FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings the reference numeral 11 indicates generally an internal combustion engine embodying this invention. The engine 11 in the illustrated embodiment is of the single cylinder type; however, it should be readily apparent to those skilled in the art that the invention may be used in conjunction with engines having a greater number of cylinders and engines of other types.
The engine 11 includes a cylinder block 12 having a cylinder bore 13 in which a piston 14 is supported for reciprocation in a known manner. A cylinder head, indicated generally by the reference numeral 15, is affixed to the cylinder block 12 in a known manner. The cylinder head 15 has a recess 16 which with the piston 14 and cylinder bore 13 forms a chamber of volume which varies as the piston 14 reciprocates. The cavity 16 will, at times, hereinafter be referred to as the combustion chamber.
A pair of exhaust ports 17 are formed in one side of the cylinder head 15 and communicate with the combustion chamber 16 via exhaust valves 18 that are operated in any suitable manner, for example by means of an overhead mounted camshaft 19 and rocker arms 21. The exhaust valves 18 are positioned on one side of a vertically extending plane 22 (FIG. 1) that includes the axis of the cylinder bore 13.
On the other side of the plane 22, the cylinder head 15 is formed with a primary intake passage 23 and a secondary intake passage 24. The primary and secondary intake passages 23, 24, communicate with the combustion chamber 16 through respective intake valves 25. The intake valves 25 are operated in unison by means of the overhead camshaft 19 via individual rocker arms 26. The intake valves 25 are positioned on the diametrically opposite side of the plane 22 from the exhaust valves 18.
A staged, two barrel carburetor, indicated generally by the reference numeral 27 is provided for delivering a fuel/air charge to the intake passages 23 and 24. The carburetor 27 has a primary barrel 28 that is aligned with the primary intake passage 23 and a secondary barrel 29 that is aligned with the cylinder head secondary intake passage 24. Sliding pistons 32 and 33 are provided in the barrels 28 and 29, respectively, for controlling the size of the venturi therein and for controlling the amount of fuel discharge as is well known with this type of carburetor. The barrels 28 and 29 receive an intake charge of air from an air cleaner (not shown).
A throttle valve 34 is positioned in the primary carburetor barrel 28 downstream of its sliding piston 32. The primary throttle valve 34 is adapted to be coupled to any suitable form of mechanical actuator that is operated by the operator. The primary throttle valve 34 is supported upon a primary throttle valve shaft 35 which is connected, by means of a coupling mechanism 36 to a secondary throttle valve shaft 37. A secondary throttle valve 38 is affixed to the secondary throttle valve shaft 37 in the carburetor barrel 29 downstream of the piston 33. The coupling mechanism 36 is designed so that the secondary throttle valve 38 and its shaft 37 are opened after a predetermined opening of the primary throttle valve 34. Once this predetermined opening is reached, the secondary throttle valve 38 will be progressively opened so that both throttle valves 34 and 38 either reach their fully opened position at the same time, or so that the secondary throttle valve 38 may continue to move to its opened position once the primary throttle valve 34 is fully opened. Any of the well known linkage arrangements may be employed for this purpose.
The construction of the engine 11 as thus far described may be considered to be conventional. With such an arrangement, the idle and low speed charge requirements for the engine will be supplied primarily through the primary intake passage 23. With previously constructed arrangements of this type, however, the lack of flow through the secondary intake passage 24 has been found to provide inadequate cooling for its associated intake valve and, furthermore, exhaust gases and solid carbon particles may be blown back into the passage 24 so as to obstruct the operation of the secondary throttle valve 38. To avoid these difficulties, a connecting passage 39 is formed in a wall 41 that divides the primary intake passage 23 from the secondary intake passage 24. The connecting passage 39 permits a portion of the intake charge from the primary intake passage 23 to flow into the secondary intake passage 24 at such times as the secondary throttle valve 38 is closed. This cross flow will provide sufficient flow through the secondary intake passage 24 so as to cool the intake valve associated with it as well as to eliminate the accumulation of deposits in the secondary intake passage 24 and on the secondary throttle valve 38. The size and orientation of the connecting passage 39 may be chosen to achieve the desired cross flow between the primary intake passage 23 and the secondary intake passage 41. If desired, the connecting passage may be formed at an angle between the two intake passages 23 and 24 as shown by either FIG. 3 wherein the passage is inclined as shown by the reference numeral 42 or FIG. 4 wherein the opposite inclination is shown by the reference numeral 43. The connecting passage may be formed either by drilling or by casting an insert in place or in any other suitable manner.
In operation, when the engine 11 is running at low speeds and only the primary throttle valve 34 is partially opened, the intake charge will be delivered to the chamber 16 primarily through the intake valve 25 associated with the primary intake passage 23. Of course, as has been noted, a small amount of charge will also be delivered to the chamber through the connecting passageway 39 and secondary intake passage 24. Because the primary portion of the charge is delivered through the primary intake passage 23, a swirl will be generated in the intake charge as indicated by the arrow 45 in FIG. 1. This swirling motion will tend to cause the heavier fuel particles to be driven outwardly in the chamber so that there will be a richer fuel/air mixture at the periphery of the chamber 16 than in the center. For this reason, a spark plug 46 is located on the plane 22 at the outer peripheral edge of the chamber 16. Thus, it will be ensured that the fuel/air mixture of combustible proportions will be present at the gap of the spark plug 46 at the time it is fired.
When the engine 11 is operating at higher speeds and both throttle valves 34 and 38 are opened, this swirl will no longer be present. In order to ensure complete combustion at higher speeds, a second spark plug 47 is positioned on the plane 22 diametrically opposite the plug 46. Thus, under these running conditions there will be good ignition and complete combustion within the chamber.
Rather than placing the spark plugs 46 and 47 on the plane 22, they may be placed on a plane that is perpendicular to this plane as indicated by the phantom lines 48 and 49 in FIG. 1. The same good ignition will occur with this location and again it should be noted that the spark plugs 48 and 49 are positioned with their gaps at the periphery of the chamber 16.
It should be readily apparent that embodiments of the invention have been disclosed that provide good running characteristics throughout the complete engine speed and load ranges. In addition, an arrangement is provided wherein the secondary induction passage does deliver a small portion of the charge to the engine even at low speed running so as to cool the intake valve associated with this passage and to eliminate the likelihood of deposits forming on the throttle valve associated with it. In addition, this flow ensures that a balanced pressure will be exerted on opposite sides of the secondary throttle valve 38 so as to not interfere with its opening. Although some embodiments are disclosed, it should be obvious to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention, as defined by the appended claims.
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An improved performance internal combustion engine having a pair of intake passages that supply the charge to a single chamber of the engine. A valving arrangement is provided so that the idle charge is supplied primarily through one of the intake passages and the full load charge is supplied through both passages. An interconnecting passage interconnects the passages with each other downstream of the throttle valves so that at least a portion of even the idle charge will be supplied through both passages to cool the intake valves associated with the passages and to ensure against the collection of deposits. In accordance with a feature of the invention, a pair of spark plugs are positioned in the chamber at its outer periphery on diametrically opposite sides of the cylinder.
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FIELD OF THE INVENTION
The instant invention relates to a process for the manufacture of devices produced by micromachining silicon and adapted to contain or to convey gaseous or liquid fluids. More specifically, the invention relates to the manufacture of micropumps made of silicon produced using photolithographic machining techniques.
DESCRIPTION OF THE PRIOR ART
A particular design of a silicon micropump excited by a piezo-electric element is disclosed in patent application PCT-WO 91/07591. This specification also cites problems connected with the fact that silicon is a hydrophobic material resulting in the fact that silicon surfaces in contact with the fluid to be pumped are of moderate wettability. This problem is all the more acute since this type of micropump is often used to convey medicaments presented in the form of aqueous solution. Under these conditions, and without taking special precautions, it is impossible to correctly fill the pumping chamber and/or the chambers of the inlet and outlet valves.
The solution to this problem raised in the above-mentioned international patent application, namely rendering the surfaces in contact with the fluid to be conveyed hydrophilic, consists in oxidizing the silicon pump body after its manufacture so as to form a very thin superficial layer of silicon oxide which, for its part, is hydrophilic and can thus considerably improve the wettability of the volumes of the pump in contact with the fluid to be conveyed. More specifically, the above-mentioned document proposes dipping the completed pump body in boiling nitric acid for a sufficient period of time to create a suitable thickness of the hydrophilic layer.
This procedure does, however, have the disadvantage that, in oxidizing the pump body in this manner, the entire silicon surface exposed undergoes the treatment, including the surfaces on which the cover glasses of the pump will subsequently be welded.
It is, however, known that it is difficult or impossible to weld glass to a silicon oxide surface.
The presence of the oxide layer covering the silicon exposed to the fluid does, however, remain desirable since it also has another advantage in that it makes it possible to protect the silicon from attack by the fluid, assuming, of course, that it displays aggressive behaviour vis-a-vis the silicon. For example, it can be imagined that the fluid may be composed of a corrosive gas, the deleterious effects of which on silicon are nullified under these conditions. Moreover, the oxide layer can act as an electric insulation when the fluid conducts electricity.
OBJECTS OF THE INVENTION
It is an object of the invention to overcome the above-mentioned disadvantage of the prior art and to provide a process for the manufacture of micromachined devices of the type indicated hereinabove which makes it possible to guarantee a good bonding between the silicon body of the device and the glass closure plates while still conserving an oxide layer on the surfaces exposed to the fluid.
BRIEF SUMMARY OF THE INVENTION
It is thus an object of the invention to provide a process for the manufacture of a micromachined device adapted to contain or to convey liquid substances, this process consisting of:
machining a silicon plate by means of selective oxidation and photolithographic operations to form therein at least one cavity adapted to contain or to convey said fluid, and to oxidize the wall of said cavity to render it hydrophilic, and
to complete said device by fixing closure plates to the body of the device thus formed,
this process being characterised in that it consists in:
preceding said machining operations by covering the surfaces of said piece adapted to be in contact with said closure plates with a screening layer resistant to said machining operations;
after completing said machining operations, oxidizing the surfaces of said piece adapted to be exposed to said fluid to form therein an oxide layer favouring the wettability of these surfaces;
removing said screening layer; and
fixing said closure plates to said piece.
BRIEF DESCRIPTION OF THE INVENTION
According to another feature of the invention, said screening layer is made of silicon nitride and deposited on said piece with interposition of an intermediate oxide layer.
According to another feature of the invention, said intermediate oxide layer has a thickness less than that of said oxide layer favouring the wettability, the process consisting inter alia, after removing said screening layer, in removing said intermediate oxide layer while said oxide layer favouring the wettability is exposed.
It is also a feature of the invention to provide a micromachined device obtained by the process such as defined hereinabove.
It emerges from these features that the assembly of the closure plates, which operation completes the micromachined device, remains easy to carry out with highly reliable results, whereas the silicon surfaces of the micromachined device adapted to come into contact with the fluid to be conveyed or stored, are hydrophilic and/or resistant to any aggression by this fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the instant invention will emerge from the following description given solely by way of example and made with reference to the appended drawings, in which:
FIGS. 1a and 1b are diagrammatic plan views from above and below respectively, of an example of the micromachined device produced using the process of the invention, this example relating to a piezo-electrically driven micropump, the invention being, however, in no way limited thereto;
FIG. 2 is a transverse sectional view of the micropump shown in FIGS. 1a and 1b, said view being taken along the line II--II of these figures;
FIG. 3 shows, by a partially diagrammatic section along the line III--III of FIGS. 1a and 1b, the successive operations needed to carry out the process of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will first be made to FIGS. 1a, 1b and 2 to describe by way of example the carrying out of the process of the invention, a piezo-electrically driven micropump, said object being particularly suitable for carrying out using this process. It will be noted that the terms "above" and "below" are only used for descriptive purposes, it being possible to use the pump in any spatial position.
The micropump has a base plate 1 or first closure plate, preferably made of glass and pierced through by two channels 2 and 3 which are, respectively, the inlet channel and the outlet channel of the micropump.
Fixed to this base plate 1 is a plate 4 forming the pump body and made of silicon, this plate being micromachined to form therein, by means of the process of the invention, the various active cavities and organs of the pump, as will be described below.
Fixed to a plate 4 forming the pump body is a third plate 5 that is relatively thin and preferably made of glass. This plate constitutes the second closure plate of the pump. Disposed thereon is a piezo-electric transducer 6 extending on one part of its outer surface, this transducer being designed, by virtue of its vibratory state induced when it is excited by an electric voltage, to deform the second closure plate 5 and then to vary the volume of the pumping chamber of the pump during its operation.
For sake of clarity and solely by way of example it may be noted that a micropump constructed in this manner has a general dimension of 22×22 mm, the thicknesses of the plates 1, 4 and 5 being 1.5 mm, 280 microns and 0.3 mm respectively.
The intermediate plate 4 forming the pump body constitutes an inlet chamber 7 (FIG. 2) communicating with the inlet channel 2 drilled in the base plate 1. This inlet chamber 7 surrounds an inlet valve 8, the gasket 9 of which is formed by a thin and deformable film machined in the silicon of the plate 4. The gasket 9 cooperates with a seating of the valve 10 which is not of a special material, but is formed by the corresponding part of the surface of the base plate 1 onto which the gasket 9 abuts. It will be noted that this gasket 9 has a ring-shaped seal 9a which is provided during the process of the invention and which is adapted to slightly bend the thin film and thereby guarantee good application of the gasket 9 to its seating 10.
The gasket 9 is provided with a central communicating hole 11 which opens, from the side of the film opposite the inlet chamber 7, into a pumping chamber 12 above which the piezo-electric transducer 6 is placed. It is thus the volume of this pumping chamber 12 which is caused to change periodically to achieve the pumping action of the micropump.
The pumping chamber 12 communicates with a transfer chamber 13 via the intermediary of a communicating orifice 14, this transfer chamber surrounding a second valve of the pump which is the outlet valve 15 thereof. This valve is constructed in substantially the same manner as the inlet valve and thus has a gasket 16, a gasket seal 16a, a seating 17 and a central communicating orifice 18. This latter connects, as appropriate, that is to say when the outlet valve 15 is open, the transfer chamber 13 with an outlet chamber 19 located above the outlet valve 15. This outlet chamber 19 communicates, in turn, with the outlet channel 3 of the pump via the intermediary of a communicating orifice 20.
The construction of the micropump that has just been described is known per se and no detailed operating description will therefore be given, particularly since this may easily be reconstructed from the following description of this construction.
The process of manufacturing the pump body 4 will now be described, emphasising the essential features of the instant invention which, as already indicated at the beginning of this text, are directed at improving the hydrophilic properties and resistance to the aggressivity of the fluids to be pumped of the surfaces of the pump body 4 in contact with this fluid during the operation of the pump.
FIGS. 3a to 3j represent diagramatically a partial sectional view of a pump body 4 taken along the line III--III of FIGS. 1a and 1b during various stages of the process of the invention. It should be noted that in the following description of the process the values of all parameters such as layer thicknesses, time spent in furnaces, etc. are only given by way of example and should not be considered as limiting to the instant invention.
A silicon piece 21, in which several pump bodies may be formed simultaneously using conventional technology, is first subjected to wet oxidation (stage of FIG. 3a) which forms an oxide layer 22 on the two surfaces thereof. The layer may be 1 micron thick and the process may be carried out in a furnace containing a water vapour atmosphere brought to a temperature of 1100° C. The water vapour may be created by a bubbler into which oxygen is introduced at a rate of 0.5 l/min and nitrogen at a rate of 4 l/min.
The sheet thereby provided with the oxide layers 22 is subjected to a conventional photolithographic operation involving attacking the oxide with fluorohydric acid buffered with ammonium fluoride in a ratio of 1:7 and at ambient temperature across a photoresistant mask so as only to retain the annular zones 23 adapted to subsequently form the seals 9a and 16a of the valves. (It should be noted that FIGS. 3a to 3j only show the zone corresponding to a single outlet valve 15).
The piece resulting from the stage of FIG. 3b is then entirely covered with an oxide layer 24 of predetermined thickness (1000 Angstroms in the example) by dry oxidation in a tubular furnace at 1100° C. in which a current of oxygen circulates at a rate of 2 l/min. The oxide layers thus obtained which act as a connecting layer, are covered in turn by a layer 25 of silicon nitride (Si 3 N 4 ) by liquid phase chemical vapour deposition (LPCVD) at 800° C. and to a thickness of 1500 Angstroms. According to one embodiment, the silicon nitride may be replaced by the same thickness of aluminium oxide (Al 2 O 3 ).
The following stage of the process, illustrated on FIG. 3d, consists in selectively removing the layers 24 and 25 to delimit the areas 26 and 27 on the piece in which the various cavities of the pump will subsequently be formed. As regards FIGS. 3a to 3j, these relate respectively to the outlet chamber 19 and to the transfer chamber 13. The annular zones corresponding respectively to the seals 9a and 16a are preserved. This stage thus comprises a conventional photolithographic operation by means of a photoresist during which the silicon nitride is first selectively removed by plasma attack and then the oxide by attack with buffered fluorohydric acid.
The piece 21 is then again subjected to an oxidation operation on its two faces outside the zones already covered by the silicon nitride to form the layers 28 (see FIG. 3e). This oxidation is effected in the same way as that which formed the layers 22 (see FIG. 3a), the thickness of the layers 28 being, for example, 3000 Angstroms.
A circular opening 29 is then provided in the oxide layer 28 at the points where the central passages of the valves 8 and 15 must be located. This opening is provided by subjecting the piece to photolithographic operations by means of a photoresist, the attack itself being effected using buffered fluorohydric acid. This results in the configuration shown in FIG. 3f.
A cavity 30 is then made in the silicon by subjecting the piece to a solution of KOH at a temperature between 40° and 60° C. to attack it in anisotropic manner until the depth of the cavity is approximately equal to 50 microns, after which the residual, as yet not removed, oxide is removed by KOH attack, by again subjecting the piece to a solution of fluorohydric acid buffered with ammonium fluoride in a ratio of 1:7 and at ambient temperature until all the oxide has disappeared on both faces of the piece. This operation leads to the configuration shown in FIG. 3g.
The piece is then again subjected to anisotropic attack with KOH by dipping in a solution of this compound for sufficient time so that what has become the body of each valve is no more than 50 microns thick. This operation also leads to the piercing of the piece at the centre of the valve and to the formation of the various cavities provided for the pump, as shown in FIG. 3h.
The piece is then subjected to wet oxidation under the same conditions as those which led to formation of the layer 22 until an oxide layer 31 about 3000 Angstroms thick is obtained, this layer covering with oxide all the areas of the pump intended to come into contact with the fluid. As shown in FIG. 3i, the zones which remained covered with silicon nitride during all the stages of the process that have just been described are not affected by this oxidation operation.
The following stage of the process consists in eliminating the silicon nitride of the layer 25 still present on the piece by subjecting the latter to an 85% phosphoric acid solution at a temperature of about 180° C. and then to a solution of buffered fluorohydric acid solution to remove the oxide of the layer 24, previously underlying the silicon nitride. This latter operation also leads to the partial removal of the oxide layer 31. However, since the oxide layer 25 was about 1000 Angstroms thick, the operation of removing the last formed oxide layer leaves sufficient thickness on the surfaces exposed to the fluid (about 2000 Angstroms) for the surfaces to have sufficient wettability and to be sufficiently protected against any attack by this fluid. This last operation leads to the configuration shown in FIG. 3j which shows that one oxide layer 32 remains.
It will be noted that this configuration corresponds to the completed pump body to which it is then sufficient to fix the closing plates 1 and 5 by anodic welding and to position the piezo-electric transducer to complete construction of the micropump.
As will be noted, the hydrophilic and protection layer 32 is applied during the process of manufacturing the pump body without need for subsequent dipping operations capable of not only oxidizing the surfaces which really need to be oxidized, but also the surfaces 33 to which the closing plates of the pump have to be fixed, as was the case in the prior art.
Finally, the process of the invention makes it easy to obtain an oxide layer thicker than was the case in the prior art, which means that it also provides better electrical insulation.
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This process consists of machining a silicon piece (4) by means of selective oxidation operations and photolithography to form therein at least one cavity (7, 12) adapted to contain or convey a fluid, and of oxidizing the wall of the cavity to make this hydrophilic. The device is completed by fixing closing plates (1, 5) to its body thus formed. Prior to the machining operations the surfaces of the piece (4) adapted to be in contact with the closing plates (1, 5) are covered with a screening layer that resists these machining operations. Then, after these have been completed, the surfaces of the piece intended to be exposed to the fluid are oxidized to form therein an oxide layer favoring the wettability of these surfaces. The screening layer is then removed and the closing plates are fixed to the piece.
The invention has applications, notably in micropumps.
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RELATED CASES
This is a continuation-in-part of co-pending patent application Ser. No. 07/105,607, filed in the U.S. Patent and Trademark Office on Oct. 6, 1987 now U.S. Pat. No. 4,875,956.
FIELD OF THE INVENTION
This invention relates to the joining of solid pieces of plastic material, such as acrylic, at an interface to produce an intermolecular bond which, when viewed normal to the interface, is virtually invisible. The invention is particularly valuable in the production of fluidic valves and manifolds. Because of this, there may be formed at the interface various conduits, paths, ports, cavities, and the like, for conducting gasses and/or fluids in a plurality of directions without leakage. Valves and even electronic elements may be located at the interface integrated with the passageways and encapsulated in a fluid and airtight bond.
BACKGROUND OF THE INVENTION
Fluidic valves and manifolds are in common use today in technologies requiring complicated control of the flow of gasses and/or fluids in fields such as medical processing equipment and the like. Essentially, the manifolds or valves comprise solid blocks, often of plastic material, having an internal maze of interconnected passageways, channels, ports and cavities, which, if not contained within a module, would require a substantially larger and more complicated assemblage of tubes, hoses, receptacles and chambers to be assembled. Many of the channels are not linear but rather are arcuate. Some intersect at angles and are three dimensional.
It is virtually impossible to drill a curved channel or passageway wholly within a solid block. However, a curved channel can be milled in a surface of a block and that surface can subsequently be joined to a surface of another block to produce a curved channel. Likewise, some passageways have to be at least an inch or more in length and are very narrow, often the size of a needle. Drilling such passageways in plastic, such as acrylic, while maintaining close tolerances, is extremely difficult. Accordingly, fluidic valves or manifolds have been made by machining various passageways, ports, openings and conduits in one surface of a plastic block, and then attaching another block to that surface whereby the passageways are then located in the interior of the combined blocks. As an alternative, occasionally both halves of the combined blocks are machined with mirror-image configurations in their mating surfaces which surfaces subsequentially are brought together into intimate contact. This invention is directed to the process of bonding such surfaces together to form a module and to make fluidic valves and manifolds.
It is essential that the contacting surfaces be airtight, particularly if the module is to be used for valving or conducting pressurized fluids or gasses. It is obvious that the component halves could be screwed or bolted together but this causes stress concentration and only assures tightness in the areas immediately surrounding the screw or bolt. Furthermore, since the modules are frequently small, room is not available for locating screws or bolts which would otherwise interfere with the passageways or valves.
It would also be obvious to clamp the members together but this adds to the bulk and would out down on the visibility.
Another method which immediately comes to mind as an expedient for securing together the component halves, is through the use of glue or cement. This is unacceptable for a number of reasons. Cements can contaminate the gasses or fluids flowing through the passageways in the modules. Furthermore, if not extremely carefully applied, cement can leak into and partially or completely block the passageways. Furthermore, gluing or cementing frequently results in the presence of bubbles which can be detrimental to the optical properties of the molecules. Also, in many instances, it is not only desirable but mandatory that the passageways be readily visible for inspection of the passage of fluids or gasses. Glue or cement can change the index of refraction between the two component halves or render the interface opaque.
It is thus an object of the present invention to be able to secure two or more component portions of a module together without the use of screws, glues or any third element.
SUMMARY OF THE INVENTION
An intermolecular bonded interface between two pieces of plastic material is produced by the following combination of steps. First, the plastic pieces are preshrunk to obtain dimensional stability. Thereafter, an interface surface is formed on each piece, the surfaces conforming in shape with each other. The interface surfaces are then cleaned to free them of contaminents, after which the pieces are assembled with the interface surfaces in contact with each other. All of the external surfaces of the pieces are confined against expansion and they are then heated to induce expansion of the pieces against their confinement. This expansion causes transmigration of molecules from one interface to the other to bond the pieces together.
Utilizing the basic process, a fluidic module can be made from two or more bonded plastic pieces by forming at least one fluidic passageway in at least one of the interface surfaces. As an alternative, a fluidic passageway which is a mirror image of the first one, is formed in the other interface surface. Pieces are then assembled, confined and heated as described above.
Optionally, the interface surfaces may be subjected to a second surfacing to remove any burrs at the interface. To obtain the maximum clarity at the interface, the interface surfaces may be polished prior to being cleaned, confined and heated.
The finished product may be subjected to an annealing process to relieve unwanted stresses.
To assure that the fluidic passageways do not become reduced or blocked in the process, a continuous band of uncut or uninterrupted surface is left around the entire periphey of the interface. A second technique is to allow the assembled pieces to expand a predetermined amound in a direction normal to the interface surface.
The above and other features of the invention including various novel details of construction and combinations of parts will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular method of bonding plastic embodying the invention is shown and described by way of illustration only and not as a limitation of the invention. The principles and features of this invention may be employed in varied and numerous embodiments without departing from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view on an enlarged scale of two component portions of a fluidic valve module prior to their being bonded in accordance with the present invention,
FIG. 2 is a flow diagram of the processing steps involved in carrying out the invention,
FIG. 3 is a perspective view of a portion of the apparatus employed in the bonding process,
FIG. 4 is a perspective view on an enlarged scale, similar to FIG. 1, of two component portions made in accordance with a modified aspect of the invention, and
FIG. 5 is a view similar to FIG. 3 of a portion of modified apparatus employed in the bonding process.
DETAILED DESCRIPTION OF THE INVENTION
At least one of the materials found to be of value in the present process are the acrylics. They offer the advantages of being strong and durable, transparent, easily machined and if properly prepared, maintain their physical integrity under stress and temperature changes. Various types of acrylic materials are available in sheet form which may generally be between from about 1/8 to about 11/2 inches in thickness. Initially, the sheets are cut to the appropriate size of two components of the finished product, which for example, could be two inches square by one inch thick. These are represented as the blocks B 1 and B 2 in FIG. 1. The sides 10 and 12 are, for example, each two inches wide and one inch thick. The surfaces 2 are two inches square.
While the invention will be described with reference to a two-part valve module comprising blocks B 1 and B 2 , it should be understood that modules of three or more components are possible. Furthermore, the process is equally applicable to making of a plurality of modules simultaneously in mass production.
While the invention will be described relative to a rectangular module it could be of any other configuration, as for example cylindrical.
Referring to FIG. 2, the process steps will be seen in a block diagram. The first step is preshrinking. After the parts or components are cut to approximate size, they are preshrunk before being machined. Preshrinking assures that the most accurate dimensions can be maintained in the finished product. If the parts were machined without being preshrunk, subsequent annealing could cause the grooves, channels and other configurations to change dimensionally.
Preshrinking is not merely a temporary state but once having been preshrunk, the acrylic material retains its dimensional stability even after machining, annealing or other stressful processes. Because of the structure of cast acrylic, shrinkage in two directions results in an increase in size in another. This may be akin to a conservation of volume. In the preshrinking process, the block will shrink along one or two axes and increase along another. This is due to the prestressed molecular structure created during its manufacturing process.
The block is placed in an annealing oven where it is shrunk in two directions and enlarged in the third. In other words, as seen in FIG. 1, it might decrease in size along the X and Y axes and increase along the Z axis or any combination of two axes.
Typically, a block which is two inches by two along the X and Y axes and one inch along the Z axis is placed in an annealing oven. The temperature is raised gradually to approximately 185° F. over a period of about 6 hours where it is maintained for about 8 hours. It is then allowed to cool slowly for about 6 hours. Heat can penetrate a small block more quickly than a large block, the larger the piece, the longer the heating time. The block(s) are then allowed to cool.
Once having been preshrunk the block retains that size and does not change dimensions in subsequent manufacturing processes. Furthermore subsequent annealing will not add to the shrinking process. In other words, the block becomes stable after preshrinking, it does not drift in dimension.
The next step is squaring and surfacing the block(s) to prepare their surfaces for further processing. This step is performed by machining a block so that its opposite sides are parallel and their contiguous sides are square relative to each other. This is performed by conventional machining processes, as for example, by flycutting. As a result of the preshrinking step, the orientation of the blocks relative to their original orientation before being cut from the sheet material is immaterial. However, proper surface preparation is essential. Very little stock is removed from the block per pass, in fact the flycutter which rotates at a very high speed, virtually only skims the surface of the block.
The flycutting technique as practiced today, produces a series of microscopically small arcuate hills and valleys in the surface of the work piece. Short of polishing, it is the smoothest surface cutting technique available. Each block of the module is prepared in this manner.
The next step in the process is the machining of the desired fluidic configuration in one or both of the the interface surfaces. While this step is not essential to effect a bond at the interface, it is necessary to produce a functional valve or manifold. As seen in FIG. 1 the blocks B 1 and B 2 both have their interface surfaces 2 machined with a plurality of channels 4 and 5, pockets 6, and passageways 8, etc. In the example shown in FIG. 1 both of the surfaces 2 are machined as mirror images of each other. If however, the passageways were formed only as semicircular grooves in the block B 1 when the blocks are assembled, the passageways would be semicircular in cross-section, but when the passageways are formed half from block B 1 and half in that block B 2 the combined passageway is circular in configuration and twice the cross-sectional area. If the fluidic pattern is formed in only one of the surfaces 2, say block B 1 for example, when the block B 2 having no machining in its surface 2 is secured to B 1 , each of the passageways, channels, pockets or holes would have one flat side.
It is also within the scope of this invention that various components such as valves, electronic components and the like can be inserted into the surface 2, as for example by holes being drilled and components pressed into them. Likewise, various materials in sheet form , as for example, Mylar--a polyethylene film sold by the duPont Company, may be positioned at the interfaces to subsequently be encapsulated in the assembled module comprising blocks B 1 and B 2 .
In addition to clear acrylic, successful bonding has taken place between black and/or white and clear and various colors or other color to color.
The cutting operation is by conventional machine tools with dimensions being taken from the pre-smoothed and squared surface 2. Note that passageway 5 is curved, having been milled in the surfaces 2.
Even with the most precise machining it is possible that burrs can be produced at the edges of the cuts or grooves. To remove such burrs or irregularities, the surfaces 2 may be subjected to another or second surfacing treatment, as for example by flycutting. Only a minimum amount of stock is removed from the surface. This is so as not to interfere with the precut fluidic pattern in order to maintain the tolerances of the various channels and grooves 4, 5, 6 and 8. This process step is optional.
If desired, rubber gaskets or O-Rings can be inserted in pre-drilled holes in the surfaces 2 if needed for the operation of the module. Furthermore, magnetic stirrers could also be included. This is done preferably by press or forced fitting them into holes to eliminate the need for adhesives which could be detrimental to the fluids or gasses subsequently to flow through the module.
The second surfacing step not only gets rid of burrs but also improves the overall surface finish. For example, if the initial squaring technique were performed with a heavy cut, the second of the surfacing steps by comparison would be essentially a polishing step.
Up to this point there has been no cleaning steps although conventional use of fluids are employed during the various cutting operations, primarily for cooling the work piece and for chip removal.
The next step to be performed is that of polishing. This is not absolutely essential to all processes but in some instances it is required, for example, where fluid flow requirements dictate that the actual channels or passageways have to be polished. This may be done by conventional polishing processes.
Under certain circumstances the actual interface surfaces 2 are polished prior to bonding. This is done primarily to improve the transparency of the ultimate bonded interface. Conversely, if it is desired to assure that the actual channels and passageways 4, 5 and 8 be visible, they would be left unpolished and the interface 2 polished. In the completed bonded module the somewhat greyish machined finish of the channels would make them more visible.
The polishing step of the interface 2 is performed primarily to make the ultimate bonded interface more clear than if the flycut surfaces were bonded together. Buffing and/or sanding and lapping techniques may be used in polishing the surface as well as the use of chemical vapors. Flame polishing techniques may also be incorporated. Vapor polishing would be used in that case. Vapor polishing is the technique of choice for getting inside small holes.
As seen in FIG. 2 the next step in the process is cleaning the surface 2. This may be done as simply as by the use of soap and water or more commonly is done by the commercial ultrasonic Freon Tank Method. Any contaminant or foreign body must be removed from the surfaces such as oil or chips of the acrylic from the machining steps. The Freon Tank Method includes a plurality of emersion steps.
The next process step is defined broadly as confining as seen in FIG. 2.
Referring next to FIG. 3, there will be seen a containing fixture 18. It comprises a hollow block 20 having parallel walls 22 and 24. Were the blocks cylindrical, the interior of the fixture would be cylindrical. The inner surfaces 25 and 26 of the walls are perfectly flat. They are just large enough to accept the blocks B 1 and B 2 in a sliding fit. The two blocks B 1 and B 2 are placed and thus combined within the fixture block 20 with their interface surfaces 2 in engagement with each other. The surfaces 10 and the surfaces 12 of the blocks then each constitute a continuous flat surface in engagement with one of the surfaces 25 or 26.
Inserts 30 which have the same configuration as the opening in the fixture 20 are moved toward each other into the fixture from opposite sides. Each of the inserts 30 has a flat surface 32 which engages an opposite side of the block B 1 or B 2 which is parallel to the interface surface 2. Whereas FIG. 3 shows the fixture schematically with simple handles 34 it will be understood that the inserts 30 can be machined operated. The inserts 30 are moved towards each other to a predetermined stop point pressing against the blocks B 1 and B 2 .
The fixture 20 may be made of aluminum or any other good heat conducting material. The insides 25 and 26 of the walls 22 and 24 are smooth and highly polished since they are to impart a polished appearance to the surface of the acrylic module which comes in engagement with them.
Once the inserts 30 have been moved into position to the predetermined stop points and are against the acrylic components B 1 and B 2 , they are not moved further. It is to be emphasized that the inserts 30 do not continuously move during the bonding process but rather, once having be set to a predetermined spaced part distance they remain at that distance. Thus, it will be seen that the assembled module made up of the two components B 1 and B 2 is confined on all six sides or, were it cylindrical, around the cylinder and on its ends.
The fixture 18, including the inserts 30 and the workpieces B 1 and B 2 , are next placed in an annealing oven at a predetermined temperature and for a predetermined amount of time. By increasing the temperature the acrylic tends to expand. The pressure which the stationary inserts 30 and the walls 24 and 25 apply to the assembled components B 1 and B 2 causes the module to tend to expand normal to the directions of applied pressure which direction is shown bY the arrows in FIG. 3. This forces the exterior of the module against the smooth polished walls 25 and 26 of the fixture. Obviously, the induced pressure also forces the interface surfaces 2 against one another. Simultaneously, pressure builds up at the mating interface of the surfaces 2. The pressure is a function of temperature not movement of the inserts 30 which are stationary.
The temperature is never so great as to cause the acrylic to become viscous, otherwise the machined portions 4, 5, 6 and 8, would fill up and possibly disappear. During the process, molecules at the interfaces of block B 1 transmigrate across to the interface of block B 2 and vice versa. This essentially eliminates the interface and causes the two blocks essentially to become a single block. The interface surfaces ultimatelY become invisible when viewed at right angles and the grooves and passageways, if they haven't been polished, stand out visibly. If however, they have been polished, while they still can be seen, they are not as readily visible as if they had not been polished.
To assure that the machined portions 4, 5, 6 and 8 do not become reduced in size or blocked during the bonding process, a preventative technique is employed. The channels 4 and 5 and any other opening formed in the interface surfaces 2, are terminated short of reaching the vertical surfaces 10 and 12 of the block, as will be seen in FIG. 4. Passageway 8 terminates at 8'. Passageways 4 and 5 terminate at points 4' and 5', respectively, and the passageway 7 leading from the pocket 6 terminates at 7'. Thus, a continuous band 9' of uncut or uninterrupted surface area is left around the entire periphey of the interface 2.
When the blocks B 1 and B 2 are superposed on one another in mating relationship, during the bonding process air will be trapped in the respective channels, passageways and pockets creating a pressure to prevent the passageways and pockets from collapsing or otherwise diminishing in size due to the expansion of the acrylic.
Subsequently, these passageways are placed in communication with the surfaces 10 and 12, and those opposite them which cannot be seen, by drilling from the surfaces into the channels and passageways after bonding has taken place.
Another technique for preventing the passageways and channels from filling up or being reduced in size due to the expansion of the acrylic during the bonding process is to allow limited expansion of one of the two acrylic members, B 1 or B 2 . Stating it differently, this is accomplished by allowing expansion of the restraining members in one direction.
Referring to FIG. 5, mechanism for permitting expansion will be seen. The container 18 is similar to that shown in FIG. 3, and comprises a similar hollow block 20, having parallel walls 22 and 24. Were the blocks cylindrical, the interior of the fixture would be cylindrical. The inner surfaces 25 and 26, as in the earlier example, are flat and just large enough to accept the acrylic blocks B 1 and B 2 with a sliding fit. The bottom of the hollow block 20 is closed by an insert 23, or the hollow block may be secured to a flat, rigid surface As described above, the two workpiece blocks, B 1 and B 2 , are placed in the fixed block 20 with their interface surfaces 2 in engagement with each other. The surfaces 10 and the surfaces 12 of the blocks then each constitute a continuous flat surface in engagement with one of the surfaces 25 or 26.
One upper insert 30, which fits within the walls 25 and 26, is secured to a carrier member 40 which is somewhat larger in size than the insert 30, and as herein shown, fits upon the upper surface 42 of the hollow block 20.
An upper cap 44 fits over the carrier 40, and is bolted to the fixture block 20 by bolts 46, only one of which is shown, the bolts passing freely through holes 48 in the carrier 40.
Guidepins 50 are fitted in the carrier 40, and may either be fitted into or abut the lower surface of the cap 44. Surrounding the guidepins 50 are springs 52. The cap 46 is positioned above the top 42 of the hollow block 24 a distance sufficient to permit the carrier and the insert 30 to move upwardly a slight amount out of the confines of the block 24 during the bonding process.
The blocks B 1 and B 2 are located with their interfaces 2 in engagement in the confines of the hollow block 24. One acrylic block, B 1 or B 2 , engages the bottom 23. The carrier 30 is placed on top of the superposed blocks and the cap adjustfully positioned in place.
During the heating process, as the acrylic expands and the molecules migrate across the interface, the tendency is for the milled grooves 4 and 5 and the passageways 8 to diminish in size as the acrylic material expands. In some instances this is permissible, i.e., where the size is not of absolute criticality. However, where it is desired to maintain the grooves at substantially the size they were when first milled as the bonding takes place, the blocks B 1 and B 2 will expand against the walls 23, 25 and 26, and exert pressure upwardly on the insert 30, causing the insert and the carrier 40 to move upwardly toward the cap 44, compressing the springs 52. This pressure release prevents the grooves 4 and 5 and the passageway 8 from being constricted.
The bonding input results from temperature increase as distinguished from pressure application because, at the outset, little or no pressure is applied to the module by the walls 25 and 26 and the inserts 30 are only moved against the opposite faces of the assembled module parts B 1 and B 2 with manual pressure. It is the temperature which causes the volumetric expansion of the module that creates the pressure.
The time of bonding is a function of the mass of the module. As examples, the following times and temperatures have been found to be satisfactory.
EXAMPLE 1
Two pieces of acrylic B 1 and B 2 , each 1.50 inches square (X and Y directions) and 0.250 inches thick (Z direction), were bonded without preheating in an oven at 300° F. with the temperature varying plus or minus 10 degrees. Heating was continued for 30 minutes and the module was allowed to cool in ambient air.
EXAMPLE 2
Two pieces B 1 and B 2 each measuring 2.980 inches by 3.063 inches in the X and Y directions were bonded. One of the pieces was 0.206 inches thick, i.e., in the Z direction, and the other was 0.396 inches thick. They were heated in an oven at 300° F. with a variance of plus or minus 10° for 30 minutes with no preheating and cooled in ambient air.
EXAMPLE 3
A three layer module was successfully bonded the outer layers each were 0.395 inches by 1.147 inches in the X and Y directions and 0.087 inches thick, i.e., in the Z direction. The inner layer was also. 0.395 inches by 1.147 inches but it was 0.210 inches thick in the Z direction. Without preheating, the laminate was placed in an oven at 285° F., with a variance of plus or minus 10°, for 30 minutes and allowed to cool in ambient air.
Once reaching the bonding temperature, the temperature is not exceeded but maintained for the predetermined time. Then the ovens are allowed to cool down. At the completion of the bonding process, the then bonded module is removed from the fixture and it is allowed to cool.
The module, having undergone the application of pressure and temperature is subject to the development of internal stresses which are not desirable and which can be detected by employing cross-polarized light or ethyl acetate testing.
The stresses are removed by annealing. This is accomplished by subjecting the bonded module to heat for a predetermined period of time. The acrylic module, at this time, is unconfined. The annealing operation takes essentially eight hours at a temperature from about 170° F. to about 200° F. which is substantially lower than the bonding temperature. This causes a "settling" of the molecules of acrylic in their proper resting place, free of unwanted stress.
Subjecting the module to testing in ethyl acetate, wherein cracks develop in the stressed parts, is in effect destructive testing. This process merely indicates whether or not the module has been annealed. An annealed module does not evidence stress cracks. Consequently, any part subjected to ethyl acetate testing which does not show stress cracks, can, all things being equal, an acceptable module.
After annealing, any subsequent machining operations may be performed on the module as for example, drilling of screw holes which generally is required for mounting the module. This,in no way affects the bonding which has taken place.
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A method of producing a fluidic module from two or more pieces (B 1 B 2 ) of plastic material having an intermolecular bonded interface, comprises forming an interface surface (2) on each piece, forming at least one fluidic passageway (4) in at least one of the interface surfaces, assembling the pieces with the interface surfaces in contact with each other and confining them against expansion. Heat is applied to the assembled pieces to induce their expansion against total or limited confinement to cause transmigration of molecules from one interface surface to the other to bond the pieces together.
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FIELD
[0001] The invention relates to a road construction machine of the road paver or feeder type.
BACKGROUND
[0002] In road construction, for example, generic road pavers or feeders, hereinafter summarized as road construction machines, are used for laying base layers, for example concrete or asphalt layers. If the paving material is laid using a road paver, the feeder serves as an intermediate storage and for the transfer of paving material in the paving process. During the paving process, the road paver is supplied with paving material either directly by a transport vehicle, for example a truck, or via a feeder. When a feeder is involved, this feeder is supplied with paving material from a transport vehicle, and transfers said material to the road paver via a suitable conveyor device, typically a conveyor belt. Typically, these road construction machines are self-propelled. Both the road paver and the feeder comprise a machine frame and a chassis, for example comprising crawler tracks or wheels, which is driven by a drive unit, which may be a diesel combustion engine in most cases. A material hopper is provided at the front in the working direction of the road construction machine. The working direction of the road construction machine refers to the direction in which the road construction machine travels during working or paving operation. The material hopper is a storage space for paving material, the size of which can be increased and/or decreased by displacing and/or tilting the walls of the material hopper. The paving material is conveyed by the road construction machine from the material hopper via a conveyor device, for example a scraper belt, to the rear, where, in the case of a feeder, a conveyor is arranged, which transfers the paving material from the feeder to the road paver. In the case of a road paver, the machine comprises at its rear a transverse conveyor device, for example a screw conveyor, and a screed, via which the paving material is distributed, smoothened and pre-compacted across the entire paving width. A smooth, pre-compacted layer of the paving material is left behind the road paver, which can be further compacted by means of rollers, for example, in order to achieve a finished road.
[0003] The transfer of the paving material from the transport vehicle, in particular a truck, to the generic road construction machine, whether feeder or road paver, is in each case done in the same way. A truck loaded with the paving material backs until being directly in front of the road construction machine traveling in the working direction, and stops there. Now, a controlled collision between the two vehicles is effected. To that end, collision rolls may be provided on the end of the construction machine located in the front in the working direction, the rolls getting in contact with the rear of the transport vehicle as the road construction machine advances slowly. The road construction machine then pushes along the transport vehicle via the collision rolls while the paving process of the road paver is continued. The transport vehicle can then transfer the paving material into the material hopper of the road construction machine, which is located at the front in the working direction, by tilting the loading area to the rear. Once the transfer is completed, the loading area can be lowered, and the transport vehicle drives away in the forward direction.
[0004] In order to ensure the complete emptying of the hopper, the hopper typically comprises a discharge flap. The discharge flap accounts for the main part of the hopper base and further comprises flap side walls, which are located at the periphery transversely to the working direction, the flap side walls extending next to the inner side of the hopper side wall and being fastened to the flap base. Thus, the flap side wall vertically protrudes upward from the hopper base substantially parallel to the hopper side wall extending in the working direction. Typically, it is supported to be moveable in relation to the hopper side wall. In order to put paving material located on the discharge flap completely into the conveyor device of the road paver or feeder for further processing, the discharge flap is designed to be pivotable about a pivot axis extending transversely to the working direction. The discharge flap, together with the flap base and flap side walls, can thus be pivoted vertically upward and against the working direction about the pivot axis extending transversely to the working direction. As a result of this movement, paving material located on the discharge flap is dumped into the conveyor device of the road paver or feeder, which is located behind the material hopper in the working direction. In this way, the material hopper can be completely emptied of paving material.
[0005] As already indicated above, the flap side wall extends vertically upward from the flap base next to the hopper side wall. The hopper side wall refers to the lateral boundary of the entire hopper space. The side of the hopper side wall located outward transversely to the working direction forms part of the outer contour of the road paver or feeder. In contrast, the flap side wall is located inside the material hopper next to the hopper side wall. It goes without saying that such an arrangement of hopper side wall and flap side wall is present on both sides of the material hopper. In the working mode of the road paver or feeder, the flap side wall and the hopper side wall either directly rest against one another or are spaced from one another by a narrow gap. In practice, paving material will often enter the gap between the flap side wall and the hopper side wall. The entered paving material spreads the flap side wall from the hopper side wall and increases the gap between the two side walls. In this way, the intrusion of additional paving material between the two side walls is facilitated, and the gap between the flap side wall and the hopper side wall is further increased. In this way, paving material may on the one hand fall between the hopper side wall and the flap side wall onto the ground. Moreover, paving material may jam between the hopper side wall and the flap side wall, which leads to a jamming of the flap side wall or the discharge flap per se, whereby its function is limited. Insistently jammed paving material may also result in a deformation of the discharge flap in this region, and thus in a damage.
SUMMARY
[0006] The object of the present invention is to solve the described problems. In particular, it is to be ensured that paving material cannot enter between the flap side wall and the hopper side wall, so that damages and restricted functioning of the discharge flap are prevented.
[0007] The object is achieved by means of a road paver or a feeder according to the independent claim. Preferred embodiments are described in the dependent claims.
[0008] Specifically, in a road construction machine of the road paver or feeder type, the object is achieved in that a protective cover is arranged on the hopper side wall, which at least partially engages around the edge of the flap side wall. In particular, the edge of the flap side wall refers to the edge of the flap side wall directed forward in the working direction and vertically upward. At this place, in particular during the transfer process of paving material from a transport vehicle into the material hopper, there is a particularly high risk for paving material to enter between the flap side wall and the hopper side wall. The protective cover extends from the hopper side wall at least partially vertically over the flap side wall and then, on the side of the flap side wall opposite the hopper side wall, partially vertically downward around the flap side wall. In this way, the protective cover at least partially closes or covers the gap between the hopper side wall and the flap side wall and thus prevents paving material from falling between the two hopper and flap side walls, in particular when coming from the front and from above in the working direction. In other words, the protective cover forms a roof fixed to the hopper side wall, which extends over and around the flap side wall. Of course, the protective cover needs to be configured in such a way that it does not limit the movability of the flap side wall and thus of the discharge flap per se. Thus, the discharge flap is located outside the pivoting curve travelled by the discharge flap and particularly the flap side wall during a tilting of the discharge flap about the pivot axis. Thus, the protective cover according to the invention does not negatively affect the functioning of the discharge flap, while intrusion of paving material into the gap between the flap side wall and the hopper side wall is reliably prevented.
[0009] Typically, the flap side wall of a road paver or a feeder comprises a base edge fixed to the flap base, an inner edge and a curve edge. Thus, the base edge is the edge which is located at the side or edge of the flap side wall fixed with the flap base. When the base flap is pivoted downward, the base edge simultaneously is the vertically lower edge of the flap side wall. The inner edge is the edge of the flap side wall which is oriented vertically upward and rearward in the working direction. The edge of the flap side wall located on the inner edge is typically directed away from the transport vehicle during the loading process of the material hopper, so that there is a negligible small risk for paving material to enter between the flap side wall and the hopper side wall. The curve edge is the edge of the flap side wall which is oriented vertically upward and forward in the working direction. The curve edge extends along the pivoting curve defined by the pivoting movement about the pivot axis. In other words, this edge is oriented in the direction of the transport vehicle in the transfer process of the paving material from the transport vehicle into the material hopper. As a result, the risk of paving material getting between the flap side wall and the hopper side wall is the highest on the curve edge. For this reason, it is preferred that the protective cover at least partially engages round the curve edge. The protective cover thus particularly extends beyond and around the curve edge of the flap side wall. It is preferred when the protective cover covers the curve edge, for example, by at least 70%, preferably at least 80%, more preferably at least 90%, and most preferably completely, in particular on the upper edge of the flap side wall. The greater the part of the curve edge covered by the protective cover, the better the protective cover according to the invention can fulfill its function and prevent paving material from getting between the hopper side wall and the flap side wall.
[0010] Thus, a basic idea of the invention is that the gap between the hopper side wall and the flap side wall, in particular upward in the vertical direction, is covered or protected or closed by the protective cover. It has proven advantageous that the flap side wall is at least partially engaged by the protective cover, in addition to closing the gap in the vertical direction, in such a way that the protective cover retains the flap side wall on the hopper side wall. In a preferred embodiment, the protective cover thus includes a bridging part arranged on the hopper side wall, and an overlapping part arranged on the bridging part, which together with the hopper side wall form a guiding space, in which the edge of the flap side wall, in particular the curve edge, is arranged. The bridging part refers in particular to the part of the protective cover which is arranged vertically above the flap side wall or the curve edge of the flap side wall or protrudes from the hopper side wall into the hopper space. The overlapping part refers to the part of the protective cover by means of which the protective cover engages around the flap side wall. The overlapping part is thus the part of the protective cover that is located on the side of the flap side wall opposite the hopper side wall. Thus, the protective cover encloses a guiding space together with the hopper side wall, in which the flap side wall is located with its edge, in particular its curve edge. In this embodiment, the protective cover is particularly configured in the form of a guidance rail, which prevents that the curve edge of the flap side wall detaches from the hopper side wall. The flap side wall is held on the hopper side wall as the overlapping part of the protective cover engages round the curve edge of the flap side wall. Accordingly, the protective cover ensures a constant maximum gap distance between the flap side wall and the hopper side wall and thus not only prevents paving material from entering between the flap side wall and the hopper side wall, but it also prevents the gap between the two side walls from widening. When the discharge flap is tilted about the pivot axis, the flap side wall, in particular the curve edge thereof, is guided within the guiding space of the protective cover. Widening of the gap between the two side walls is thus efficiently prevented even during the pivoting process.
[0011] It is preferred for the guiding space to be designed to be closed in the working direction and vertically upward, in particularly by means of the bridging part. A complete closure of the guiding space in the working direction and vertically upward ensures that the intrusion of paving material between the hopper side wall and the flap side wall is effectively prevented in this place.
[0012] Generally, the biggest risk for paving material to get between the flap side wall and the hopper side wall lies with the paving material transfer process from a transport vehicle into the material hopper of the road paver or the feeder. During the transfer process, the discharge flap is typically pivoted downward in its essentially horizontal position. Appropriately, the protective cover engages around the edge of the flap side wall in particular in the horizontal position of the discharge flap. However, in the case that the material hopper of the road paver or the feeder is filled to a significant extent, paving material may enter between the side walls even in other positions of the discharge flap. Thus, it is preferred that the protective cover has a profile, in particular curved, which is adapted to the movement of the flap side wall when the discharge flap is tilted about the pivot axis, in particular in such a way that the engagement of the protective cover around the edge of the flap side wall is maintained during the entire tilting process. In other words, the guiding space of the protective cover is formed across the entire course of the pivoting curve of the curve edge of the flap side wall. In particular, the guiding space is configured to be closed in the working direction and vertically upward over its entire length along the pivoting curve of the curve edge. Thus, the curve edge of the flap side wall is engaged around by the protective cover, in particular essentially completely, in each of the positions of the flap side wall enabled by the pivoting of the discharge flap about the pivot axis. This configuration does not only reliably prevent paving material from entering between the side walls across the entire tilting movement, but a precise guidance of the flap side wall along the hopper side wall is ensured at a constant clearance across the entire tilting movement at the same time. This also efficiently prevents a widening of the gap between the flap side wall and the hopper side wall.
[0013] The different parts of the protective cover can be formed as separate components, which will then be fastened to the road paver or the feeder. This may be of advantage since a comparatively inexpensive manufacture is possible then. However, the protective cover according to the present invention will be especially stable if at least the bridging part is formed integrally with the hopper side wall. In this case, the hopper side wall is already completely produced together with the bridging part, so that merely the overlapping part as a further component has to be fastened to the hopper side wall or the bridging part. As an alternative, it is also possible for the bridging part to be formed integrally with the overlapping part. In this case, the bridging part and the overlapping part together form one single component, which can be fixed to the hopper side wall. In another alternative, it is also possible that the bridging part and the overlapping part are together formed integrally with the hopper side wall. In this case, which ensures highest possible stability of the protective cover, the hopper side wall is thus completely produced together with the protective cover or the bridging part and overlapping part thereof. No other component needs to be fastened on the road paver or the feeder for providing the protective cover.
[0014] Basically, any material that has a sufficient stability can be selected for the protective cover, in order to withstand the working conditions in the material hopper of the road paver or the feeder. For example, the protective cover could be made of metal, in particular steel, or plastic. It is also possible to produce the protective cover from different materials; it would be possible, for example, to form the bridging part of metal, in particular steel, and to fasten an overlapping part made of plastic on this bridging part. However, it is preferred to form the bridging part and the overlapping part at least from the same material or consisting of the same material.
[0015] Depending on the material that the individual components of the protective cover are made of, there are different fastening options for the protective cover on the material hopper or the hopper side wall. Metal parts, in particular steel parts, may be welded to the material hopper, for example, while plastic parts are fastened by means of fastening means. In one exemplary embodiment, the bridging part is welded to the hopper side wall and the overlapping part is welded to the bridging part. According to an alternative embodiment, the bridging part is welded to the hopper side wall and the overlapping part is detachably fastened to the bridging part by means of at least one releasable fastening means. The releasable fastening means may be a fastening screw, for example, which is inserted through the bridging part and screwed in a threaded hole on the hopper side wall. As an alternative, the releasable fastening means could also be a threaded bolt welded to the hopper side wall, which is inserted through the bridging part and on which a nut can be screwed for fastening the bringing part. In another alternative embodiment, the bridging part is detachably fastened to the hopper side wall by means of at least one releasable fastening means and the overlapping part is detachably fastened to the bridging part by means of at least one further fastening means. In this embodiment, the bridging part and the overlapping part can thus be released from one another separately in each case by releasing the fastening means from the hopper side wall or from one another. Another alternative embodiment provides that the bridging part and the overlapping part are detachably fastened together on the hopper side wall by means of at least one releasable fastening means. In this case, the bridging part and the overlapping part are thus fastened to one another and to the hopper side wall via the same fastening means, so that they can be mounted and demounted together and in a simple and fast manner. All of the above-mentioned exemplary embodiments are also suitable for retrofitting an existing road paver or feeder with a protective cover according to the invention.
[0016] In order to ensure a trouble-free tilting movement of the discharge flap, a pivot recess may be formed in the flap base directly next to the flap side wall at the front end of the flap base in the working direction, in which part of the protective cover is received when the discharge flap is tilted. In other words, the protective cover is partially guided through the pivot recess in the flap base when pivoting or tilting the discharge flap about the pivot axis. The pivot recess in the flap base is preferably used when the flap side wall in the horizontal position of the discharge flap essentially extends as far in the working direction as the flap base. In this case, the pivot recess prevents a collision of the part of the protective flap engaging around the flap side wall with the flap base. By providing the pivot recess, tilting the discharge flap can be effected without any problems.
[0017] According to an alternative embodiment, the flap side wall projects beyond the flap base in the working direction and the protective cover engages only around the part of the flap side wall projecting beyond the flap base. Projecting in the working direction particularly relates to the horizontal position of the discharge flap. The flap side wall thus projects beyond the flap base in such a way that the edge of the flap side wall can be engaged around by the protective cover, without the flap base colliding with the protective cover in a pivoting movement of the discharge flap about the pivot axis. In this case, the discharge flap can be freely tilted about the pivot axis without having to provide a pivot recess in the flap base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Hereinafter, the invention will be described in greater detail by means of the exemplary embodiments shown in the figures. In the schematic figures:
[0019] FIG. 1 is a side view of a road paver;
[0020] FIG. 2 is a side view of a feeder;
[0021] FIG. 3 is a perspective view of a material hopper from obliquely in front and vertically above;
[0022] FIG. 4 is a detailed view according to detail section A of FIG. 3 ;
[0023] FIG. 5 is a sectional view of a first embodiment along line V of FIG. 4 ; and
[0024] FIG. 6 is a sectional view of a second embodiment along line V of FIG. 4 .
DETAILED DESCRIPTION
[0025] Like or equivalent components are indicated by like reference numerals. Recurring components may not be separately indicated in each figure.
[0026] FIGS. 1 and 2 show generic road construction machines, namely a road paver 1 ( FIG. 1 ) and a feeder 9 ( FIG. 2 ). The road construction machines 1 , 9 include an operator platform 2 and a machine frame 3 . Furthermore, they comprise a chassis 6 driven by a drive unit 4 , which in most cases comprises a diesel combustion engine, by means of which the road construction machines 1 , 9 can move forward in the working direction a in the working mode. The road paver 1 comprises a screed 7 at its rear, by means of which it can distribute, smoothen and compact a paving material transversally to the working direction a. In contrast, the feeder 9 does not include a screed 7 , but a feeding conveyor 10 , by means of which it can transfer paving material onto the road paver 1 . Both the road paver 1 and the feeder 9 have a material hopper 5 for paving material. The feeder 9 can transfer, i.e., load, paving material from its material hopper 5 via the feeding conveyor 10 into the material hopper 5 of the road paver 1 . Furthermore, both the road paver 1 and the feeder 9 can be supplied with paving material by a transport vehicle (not shown), for example a truck. For this kind of loading, the road construction machines 1 , 9 comprise collision rollers 8 in the working direction a at the front. Using these collision rollers 8 , they push along a transport vehicle in front of them during the loading process, while paving material is being transferred from the transport vehicle into the material hopper 5 . While laying a base layer by means of a road paver 1 , a plurality of loads of paving material must normally be transferred from transport vehicles onto the road paver 1 and/or the feeder 9 .
[0027] FIG. 3 shows a perspective, oblique top view from the front onto the material hopper 5 of the road construction machines 1 , 9 in the working direction a. The material hopper 5 comprises a hopper base (below the flap base 12 ) and side walls 14 vertically protruding on both sides transversely to the working direction. During working operation, the side walls 14 of the material hopper 5 can be pivoted/displaced, in order to enable a loading of the hopper and/or to influence the size of the loading area. A conveying screw 11 is located on the rear side of the material hopper 5 , viewed in the working direction a, the screw transferring paving material from the material hopper 5 onto a scraper belt 13 , from which the paving material is transported against the working direction a through the road construction machine 1 , 9 and transferred either to a screed 7 or to a feeding conveyor 10 . A stop element 15 , mostly a rubber element, is located on the side of the material hopper 5 located in the working direction a, which prevents paving material from falling out in the working direction a. Furthermore, the material hopper 5 includes a discharge flap 22 , which includes a flap base 12 and a flap side wall 16 . In the exemplary embodiment shown, the material hopper 5 comprises two such discharge flaps 22 , which are arranged on both sides of the material hopper 5 opposite one another transversely to the working direction a in a mirror-symmetrical fashion. The discharge flaps 22 are used to supply paving material to the conveying screws 11 , in that the discharge flaps 22 can be tilted or pivoted about a pivot axis S extending transversely to the working direction a. In this way, paving material located on top of the discharge flap 22 is poured into the conveying screws 11 .
[0028] FIG. 4 shows an enlarged view according to detail section A of FIG. 3 . The flap side wall 16 is shown in FIG. 4 with its respective edges. In particular, the flap side wall 16 comprises a base edge 26 , at which the flap side wall 16 is connected to the flap base 12 , an inner edge 27 oriented vertically upward and to the rear, viewed in the working direction a, and a curve edge 28 oriented vertically upward and pointing to the front, viewed in the working direction a. The curve edge 28 of the flap side wall 16 extends along the pivot curve which is defined by the pivot movement of the discharge flap 22 about the pivot axis S. Furthermore, FIG. 4 shows the protective cover 21 arranged on the hopper side wall 14 . As illustrated in FIG. 4 , the flap side wall 16 is essentially completely engaged around by the protective cover 21 on its curve edge 28 . The protective cover 21 essentially completely covers the curve edge 28 of the flap side wall 16 in the working direction a and vertically upward, so that no paving material can enter between the flap side wall 16 and the hopper side wall 14 . At the same time, the protective cover 21 forms a guide 17 for the flap side wall 16 , which guides the flap side wall 16 in its movement along the pivot curve when being tilted or pivoted about the pivot axis S. In this way, the flap side wall 16 is held close to the hopper side wall 14 and a widening or spreading of the flap side wall 16 away from the hopper side wall 14 is prevented. In order to perform this pivoting movement without problems, a pivot recess 20 is provided on the flap base 12 . The pivot recess 20 accommodates the protective cover 21 when the discharge flap 22 is tilted about the pivot axis S. In this way, movement freedom of the discharge flap 22 is not limited by the protective cover 21 . The protective cover 21 is fastened to the hopper side wall 14 by fastening means 18 across the entire course along the pivoting curve.
[0029] FIGS. 5 and 6 each show different exemplary embodiments of the protective cover 21 and the fastening thereof on the hopper side wall 14 . FIGS. 5 and 6 are sectional views along the line V according to FIG. 4 . As can be seen from the figures, the protective cover 21 comprises a bridging part 23 and an overlapping part 24 . The bridging part 23 is that part of the protective cover 21 that extends from the hopper side wall 14 transversely to the working direction a towards the center of the machine and in particular bridges over the gap 25 . The overlapping part 24 is that part of the protective cover 21 that extends vertically downwards on the side of the flap side wall 16 opposite the hopper side wall 14 . The bridging part connects the overlapping part 24 with the hopper side wall 14 . In the embodiment according to FIG. 5 , the bridging part 23 and the overlapping part 24 are formed integrally. In the embodiment according to FIG. 6 , in contrast, the bridging part 23 and the overlapping part 24 are two separate components. The protective cover 21 , i.e., its bridging part 23 and overlapping part 24 , form a guiding space 19 together with the hopper side wall 14 , in which the curve edge 28 of the flap side wall 16 is received. As can be taken from the figures, the guiding space 19 and in particular the gap 25 between the flap side wall 16 and the hopper side wall 14 are formed to be closed upwards. The guiding space 19 extends in the protective cover 21 along the pivot curve of the curve edge 28 of the flap side wall 16 . This way, it is reliably prevented that paving material can enter the gap 25 from vertically above between the flap side wall and the hopper side wall 14 , namely in every pivoting position of the discharge flap 22 . At the same time, the overlapping part 24 forms a guidance 17 , said guidance preventing the flap side wall 16 from moving away from the hopper side wall 14 due to a widening of the gap 25 . Altogether, a movement transversely to the working direction a of the flap side wall 16 is limited by the hopper side wall 14 on the one hand, and by the guide 17 , i.e., the overlapping part 24 of the protective cover 21 , on the other hand. This way, the protective cover 21 contributes to a constant gap size of the gap 25 between the flap side wall 16 and the hopper side wall 14 . Altogether, this prevents a jamming of the flap side wall 16 and therefore a loss of function of or a damage to the discharge flap 22 .
[0030] The fastening of the protective cover 21 according to the embodiments of FIGS. 5 and 6 is configured differently. For example, the integrally-formed protective cover 21 according to FIG. 5 is fixed to the hopper side wall 14 by means of multiple fastening means 18 distributed along its longitudinal axis, for example threaded bolts with nuts or screws. This way, the protective cover 21 can easily be demounted from or mounted to the hopper side wall 14 . A replacement of a damaged protective cover 21 is also possible without problems. In the embodiment according to FIG. 6 , the protective cover 21 is formed in two parts, i.e., with the bridging part 23 and the overlapping part 24 formed separately from one another. In the exemplary embodiment shown, the bridging part 23 is welded to the hopper side wall 14 and therefore connected thereto in a permanent manner. The overlapping part, in contrast, is fixed to the bridging part 23 by means of a releasable fastening means 18 , for example a screw or a threaded bolt having a nut. In this embodiment, only the overlapping part 24 is thus formed to be releasable or demountable and can be replaced separately from the bridging part 23 without the bridging part. Both embodiments of FIGS. 5 and 6 of the protective cover according to the invention are suitable for trouble-free retrofitting on existing road pavers 1 or feeders 9 .
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The invention relates to a road paver or a feeder having a chassis driven by a drive unit, and a material hopper arranged in the working direction at the front of the road paver or the feeder, the material hopper having a hopper side wall extending in the working direction and a discharge flap tiltable about a pivot axis extending transversely to the working direction, the discharge flap comprising a flap base and a flap side wall which extends next to the hopper side wall and is fixed to the flap base and supported to be moveable relative to the hopper side wall, a protective cover, which at least partially engages around the edge of the flap side wall, being arranged on the hopper side wall.
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[0001] This application claims the priorities of German application Nos. 199 19 437.8, filed Apr. 29, 1999, and 199 42 040.8, filed Sep. 3, 1999, the disclosures of which are expressly incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to an arrangement for preventing the squealing of a disk brake including a particular brake disk, with friction rings, and brake linings. The brake linings have a partial circumference length which relates to an approximately mean circumference of the brake disk. An imposed natural oscillation mode of the brake disk with n-nodes is obtained. Slots are provided in the friction rings.
[0003] German Patent Document DE 195 07 102 A1 relates to a disk brake which is tuned such that squealing noises during a braking operation are eliminated or reduced by way of adjacent brake linings. This takes place by establishing a certain ratio of the brake lining length to the brake disk circumference.
[0004] German Patent Document DE 40 41 010 relates to an arrangement for preventing the squealing of a disk brake. In this arrangement, the friction linings, which consist of a semi-metallic or asbestos-free material, are pressed onto a disk rotor or onto a brake disk for carrying out braking. The rotor is divided such that the second order resonance frequency of the longitudinal oscillation of the rotor is larger than 15 kHz. Division of the disk rotor takes place by way of slots which are arranged on the inside and the outside of the rotor.
[0005] It is an object of the invention to provide a disk brake in which the occurrence of squealing noises is prevented by a detuning of the natural frequency mode of the brake system.
[0006] According to the invention, this object is achieved by providing the friction rings of the brake disk, in at least one surface area of at least one friction surface thereof, with a local weakening of the section modulus such that a detuning node oscillation which is unequal to a natural vibration mode of the brake disk can be achieved. The nodes are formed from the ratio n u/L, wherein u is a median brake disk circumference and L is a partial circumference length of the brake linings. Additional advantageous characteristics are also claimed.
[0007] Principal advantages achieved by the invention include detuning the natural oscillation behavior of existing brakes in the event of a squealing action such that brake squealing is reduced or eliminated.
[0008] According to the invention, this is essentially achieved by having a local weakening of the section modules “W” in at least one surface area of the friction surfaces of the friction ring of a solid brake disk, or of the friction rings of an internally ventilated brake disk, such that a detuning natural oscillation, which is unlike the natural oscillation mode of the brake disk with the oscillation node “W”, can be achieved.
[0009] The local weakening or weakenings of the section modulus in one or both friction rings of the brake disk preferably are provided by one or several slots which separate the friction ring or rings and extends or extend from the brake disk center to approximately the outer edge or edges of the friction ring or rings.
[0010] A resulting detuning of the natural oscillation mode of the brake disk is provided by correspondingly arranged and dimensioned slots in both friction rings or in one friction ring in order to achieve locally reduced section moduli in one or several areas of the friction rings of the brake disk.
[0011] According to one embodiment of the invention, the slots may be arranged between the cooling ducts of the brake disk as well as on the ribs. Furthermore, the slots may be provided in the outer friction ring as well as in the inner friction ring or in both friction rings. In addition, the slots can also be provided in an alternating sequence in the outer and the inner friction rings.
[0012] Since each of the slots may separate parts of the friction rings, special links may be required by way of ribs, such as double ribs, which are situated closely side-by-side. When the brake rings have opposed slots, the ribs, which are situated side-by-side, are connected with one another by way of a transverse web.
[0013] According to the invention, the courses of the slots in the friction rings can be adapted to the courses of the ribs of the cooling ducts so that radial and diagonally extending slots are used which extend on the rib as well as between the ribs. It is also conceivable to arrange slots oppositely diagonally to the ribs and so as to cross over the ribs.
[0014] If a slot is arranged in the rib of the cooling duct, a wide rib is usually required so that the rib still results in sufficient stiffness. The number of ribs which are wider than the other ribs is selected corresponding to the requirements for preventing brake squealing. Thus, one wider rib or several wider ribs may be required. The width of the slot should be as narrow as possible so that the brake disk is not stressed by unnecessary rubbing effects. For this reason, it is also advantageous for the slot to have chamferings in the friction surface of the brake disk.
[0015] In every case, a locally reduced section modulus on the brake disk or in the friction rings achieves a detuning of the original natural oscillation mode of the brake disk. The local reduced section modulus achievable by the slots is preferably arranged at the same mutual distance and is designed unequal to the modes of the natural oscillation mode so that, for example, with a six-node oscillation, weakening of the brake disk occurs at four points.
[0016] Embodiments of the invention are illustrated in the drawings and will be described in detail.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a schematic representation of a brake having a brake disk, a friction ring and brake linings;
[0018] [0018]FIG. 2 is a view of an internally ventilated brake disk with a uniform section modulus as seen along the circumference of the brake disk;
[0019] [0019]FIG. 3 is a view of an internally ventilated brake disk with an imposed oscillation mode with n-nodes (six nodes);
[0020] [0020]FIG. 4 is a view of an internally ventilated brake disk with locally reduced section moduli W 1 to Wn at x-points;
[0021] [0021]FIG. 5 is a view of the internally ventilated brake disk according to FIG. 4 with a detuned natural oscillation mode Vs;
[0022] [0022]FIG. 6 is a view of a brake disk with four slots in the internal brake ring;
[0023] [0023]FIG. 7 is a view of a brake disk with four alternating slots in the outer and inner brake rings;
[0024] [0024]FIG. 8 is a view of a brake with opposed slots in the inner and outer brake rings;
[0025] [0025]FIG. 9 is a view of a brake disk with, for example, five slots in the inner brake ring;
[0026] [0026]FIG. 10 is a view of a brake disk with radial partial slots in the inner brake ring;
[0027] [0027]FIG. 11 is a view of a part of the brake disk with a slot in the brake ring on a bent rib of a cooling duct;
[0028] [0028]FIG. 12 is a view of a part of the brake disk with a slot in the brake ring on a radial rib of a cooling duct;
[0029] [0029]FIG. 13 is a view of a diagonally set slot in the brake ring between two diagonally extending or bent ribs of the brake disk;
[0030] [0030]FIG. 14 is a view of a radially extending slot in the brake ring between two radially extending ribs;
[0031] [0031]FIG. 15 is a view of a radially set slot which crosses the radial ribs of the cooling ducts;
[0032] [0032]FIG. 16 is a view of a diagonally set slot which crosses the ribs of cooling ducts extending diagonally in arch shapes;
[0033] [0033]FIG. 17 is a view of an embodiment according to FIGS. 11 or 12 with a slot ending in the rib;
[0034] [0034]FIG. 18 is a view of another embodiment with a slot ending in a double rib;
[0035] [0035]FIG. 19 is a sectional view of the brake disk of FIG. 6 along line A-A;
[0036] [0036]FIG. 20 is a sectional view of the brake disk of FIG. 8 along line B-B;
[0037] [0037]FIG. 21 is a sectional view of a brake disk having a groove in each friction surface of the friction ring;
[0038] [0038]FIG. 22 is a view of another embodiment of a brake disk having an air duct with a hexagonal cross-section;
[0039] [0039]FIG. 23 is a top view of an internally ventilated brake disk with a wide rib having a slot and in which the friction surface is partially cut-open;
[0040] [0040]FIG. 24 is a sectional view of the internally ventilated brake disk in the area of the slot; and
[0041] [0041]FIG. 25 is a sectional view of the friction surface of the internally ventilated brake disk with chamferings of the slot.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] A disk brake 1 is schematically illustrated in FIG. 1 and comprises essentially an internally ventilated brake disk 2 with two friction rings 3 , 4 . The friction rings have friction surfaces R 1 and R 2 on the outsides, which friction surfaces R 1 and R 2 can be acted upon by brake linings 5 , 6 . These brake linings 5 , 6 are held in a caliper and can be displaced by way of a brake piston or brake pistons. Between the two friction rings 3 , 4 , cooling ducts 20 are formed between the ribs 7 which connect the two friction rings 3 , 4 with one another. In each of FIGS. 2 to 5 , the brake disk 2 is illustrated along the circumference U, so that a natural oscillation mode Es, a detuned oscillation mode Vs, and the locally reduced section moduli W 1 to Wn with the defined oscillations of the brake disk 2 which can be achieved therefrom, can be shown.
[0043] The natural oscillation form Es of the brake disk 2 is essentially a function of the ratio of the approximately median brake disk circumference U to the brake lining length L. This means that when the brake disk circumference U is, for example, n=6 times as large as the lining length L, a natural oscillation mode Es, also with six nodes K 1 to K 6 , is imposed on the brake disk, as illustrated in detail in FIG. 3.
[0044] In the particular case of existing brake systems, and in other cases, the brake disk circumference U as well as the lining length L can no longer be changed. In these cases, so that a significant influence can be achieved with respect to the noise behavior (squealing action), a detuning of the brake system is to be achieved with respect to its original natural oscillation mode Es.
[0045] A brake system, in the squealing condition, describes a six-node oscillation (“n=6”). If the noise behavior is to be optimized in such a brake system, optimization takes place by using a brake disk which is changed with respect to the section modulus. On the basis of its construction, this brake disk is forced to carry out a different oscillation mode; that is, the local section moduli “x=W1 to Wn” (FIG. 4) of the brake disk 2 are unequal to the nodes “n=K1 to K6” of the natural oscillation mode “Es” of the brake disk 2 . This permits a detuning of the brake system because the section modulus of the brake disk 2 is weakened in a targeted manner, whereby “x” is unequal to “n” in every case.
[0046] [0046]FIG. 5 illustrates the natural oscillation mode Es of a brake disk 2 with a locally reduced section modulus W 1 to Wn. The position of the reduced section modulus W 1 to Wn in the brake or friction rings 3 , 4 occurs as a result of the selection of the number “x” of the locally weakened section moduli W 1 to Wn (for example, x=4), as in the following.
[0047] The locally reduced section moduli W 1 to Wn are formed by slots 10 in the first friction ring 3 , the second friction ring 4 , or both of these friction rings. According to one embodiment, the slots 10 separate the brake ring 3 and/or 4 so that, at “x=4”, four partial segments S 1 to S 4 are obtained.
[0048] FIGS. 6 to 10 illustrate several embodiments having various arrangements of the slots 10 . Locally reduced section moduli “W1 to Wn” corresponding to the natural oscillations for “Es” and the resulting modes “K” are obtained; such is illustrated, for example, in FIG. 9 by way of five segments S 1 to S 5 .
[0049] According to FIG. 6, the slots 10 are arranged in the inner friction ring R 1 ; according to FIG. 7, the slots are arranged so as to alternate in the outer and inner friction rings R 2 , R 1 ; and according to FIG. 8, the slots are arranged in both friction rings R 1 and R 2 .
[0050] Arrangements of the slots 10 similar to those of FIGS. 6 to 8 can also be provided when “x=5” and with five segments S 1 to S 5 .
[0051] According to another embodiment shown in FIG. 10, the inner friction ring, the outer friction ring, or both the inner and the outer friction rings R 1 and R 2 is or are provided with partial slots 11 which extend from the outer edge 12 radially toward the interior to the center Z and end approximately in the mean circumference U of the brake disk 2 .
[0052] [0052]FIGS. 11 and 12 show that the slots 10 can be arranged directly on the rib 7 of the cooling ducts 20 following their course. FIGS. 13 and 14 show that each slot can be arranged between the ribs 7 of the cooling ducts 20 .
[0053] According to FIGS. 15 and 16, the slots 10 are set in the brake disk 2 at an angle α, α 1 diagonally to the ribs 7 . According to the invention, the slots 10 can also be arranged corresponding to the embodiment of FIGS. 6 to 10 .
[0054] In an arrangement of the slot 10 on at least one of the ribs 7 of the brake disk 2 , the rib can either be continuous or end in the center of the rib 7 , as illustrated in detail in FIG. 17.
[0055] Such an arrangement of the slots 10 can take place, for example, so as to alternate between the outer and inner friction rings R 2 and R 1 .
[0056] According to another embodiment of the invention according to FIG. 18, the slot 10 is arranged between two ribs 7 and 7 b which are directly adjacent and form, between one another, a cooling duct 21 additional to the existing cooling ducts 20 between the ribs 7 of the brake disk 2 .
[0057] In the case of an arrangement of the slots 10 according to FIG. 8 with opposed slots in the friction rings 3 and 4 , the ribs 7 are connected with one another by way of at least one transverse web 15 , as illustrated in detail in FIG. 5.
[0058] According to the embodiment of FIG. 21, a reduced local section modulus is achieved by grooves 22 in the friction surfaces R 1 and R 2 in the brake rings which extend from the center Z to the outer edge 12 .
[0059] Furthermore, the reduced section modulus can also be achieved by at least one cooling duct 24 which is enlarged in its cross-section with respect to the surface in comparison to other cooling ducts 20 . The wall d of the brake ring is smaller in the area of the cooling duct 24 than the wall thickness D in the area of the cooling duct 20 .
[0060] As illustrated in detail in FIGS. 11 and 12, the slot 10 is arranged approximately in the center of the rib 7 . In this embodiment, the ribs 7 are all of the same width b. So that the slot 10 does not weaken the rib, according to another embodiment of FIGS. 23 to 25 , a rib 7 a with the measurement b 1 is provided which is wider than the rib 7 and in which the slot 10 is arranged. The slot 10 preferably has a width of <2 mm, particularly of 1.4 mm, the depth t of the slot 10 extending approximately to half the brake disk thickness a. The slot 10 is provided, on both sides of the friction ring surface 30 , with a chamfering 31 , 32 having a width c and an angle a. The slot 10 may be arranged on the outer friction ring surface and/or on an inner friction ring surface. Five wider ribs 7 a are preferably provided which are arranged to be uniformly distributed along the circumference.
[0061] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
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In order to prevent squealing of a disk brake, the disk brake has a brake disk with friction rings having locally weakening section moduli which detune corresponding to the natural oscillation mode. As a result, the natural oscillation mode of the brake disk is changed to such an extent that brake squealing is avoided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a manufacturing method of a semiconductor device in which is formed a MOS FET (Metal-Oxide-Semiconductor Field Effect Transistor) having a trench structure, and a semiconductor device suitably manufactured through the manufacturing method.
2. Description of Related Art
A semiconductor device includes a type provided with a MOS FET (MOS Field Effect Transistor) having a trench structure. In a semiconductor device of this type, a source region and a channel region are placed along the depth direction of the trench, which makes it possible to achieve miniaturization of elements and a reduction of power consumption.
FIG. 3 is a schematic cross section showing a structure of a semiconductor device provided with a MOS FET having the trench structure, obtained through a conventional manufacturing method.
An N − epitaxial layer 52 is formed on the surface of a silicon substrate 51 , and a diffusion region 65 is formed on the N − epitaxial layer 52 . Trenches 54 , each of which penetrates through the diffusion region 65 and halfway through the N − epitaxial layer 52 in the thickness direction, are formed at regular intervals. Inside each trench 54 is provided a gate electrode 55 made of polysilicon, and a gate oxide film 56 is provided to surround the gate electrode 55 .
N + source regions 57 and P + base regions 58 are formed in the surface layer portion of the diffusion region 65 , and the rest of the diffusion region 65 forms a P − channel region 53 . The N + source regions 57 are formed on the periphery (rim portion) of each trench 54 . The P + base region 58 is formed between every two adjacent N + source regions 57 , and is connected to the P − channel region 53 .
Insulation films 59 made of silicon oxide are formed to cover above each trench 54 . The insulation films 59 are also present on the periphery of each trench 54 (on the N + source regions 57 ) when viewed in a plane. A space between every two adjacent insulation films 59 forms a contact hole 60 . An electrode film 61 made of metal, such as aluminum, is formed on the diffusion region 65 and the insulation films 59 . The electrode film 61 is placed to fill in the contact holes 60 .
While the semiconductor device described above is operating, a current flows from the N + source regions 57 toward the silicon substrate 51 through the P − channel region 53 along the gate oxide films 56 .
FIG. 4 ( a ), FIG. 4 ( b ), and FIG. 4 ( c ) are schematic cross sections used to explain a manufacturing method of the semiconductor device of FIG. 3 .
Initially, the N − epitaxial layer 52 is formed on the silicon substrate 51 . Then, impurities used to control a conduction type to be a p-type are introduced into the surface layer portion of the N − epitaxial layer 52 , whereby the P − channel region 53 is formed. Subsequently, the P + base regions 58 and the trenches 54 are formed. Although it does not matter which of the P + base regions 58 and the trenches 54 are formed first, the following description will describe a case where the P + regions 58 are formed first.
A mask layer 71 having openings (hereinafter, referred to as base-region forming openings) 70 in portions corresponding to the P + base regions 58 is formed on the P − channel region 53 . Then, impurities are implanted and diffused into the P − channel region 53 through the base-region forming openings 70 , whereby the P + base regions 58 are formed (FIG. 4 ( a )). The mask layer 71 is then removed. Subsequently, the N + source regions 57 are formed through the same method using another mask layer having openings.
Then, a first resist film 73 having openings (hereinafter, referred to as trench forming openings) 72 in portions corresponding to the trenches 54 is formed on the P − channel region 53 . Then, the N + source regions 57 , the P − channel region 53 , and the upper portion of the N − epitaxial layer 52 are etched away through the trench forming openings 72 , whereby the trenches 54 are formed (FIG. 4 ( b )). The first resist film 73 is then removed, and the inner wall surface of each trench 54 is subjected to thermal oxidation, whereby the gate oxide film 56 is formed.
Then, a polysilicon film is formed to fill in the trenches 54 . Impurities are introduced into the polysilicon film to make the polysilicon film electrically conductive, whereby the gate electrodes 55 are formed. The top surfaces of the respective gate electrodes 55 are flush with the surfaces of the P + base regions 58 and the N + source regions 57 .
Subsequently, a silicon oxide film 76 is formed across the entire surface of the silicon substrate 51 having undergone the foregoing processes. A second resist film 75 having openings 74 in portions corresponding to the contact holes 60 is then formed on the silicon oxide film 76 (FIG. 4 ( c )). The silicon oxide film 76 is etched away through the openings 74 of the second resist film 75 , whereby the contact holes 60 are formed. Residual portions of the silicon oxide film 76 form the insulation films 59 . After the second resist film 75 is removed, the electrode film 61 is formed on the silicon substrate 51 having undergone the foregoing processes. The semiconductor device shown in FIG. 3 is thus obtained.
The base-region forming openings 70 and the trench forming openings 72 are formed through the lithographic technique using a stepper (exposure apparatus). For this reason, the trench forming openings 72 are aligned and formed so that the trenches 54 will be formed at predetermined positions with respect to the P + base regions 58 .
Also, the openings 74 used to form the contact holes 60 are aligned and formed so as to avoid portions above the trenches 54 (gate electrodes 55 ).
Referring to FIG. 3, because the P + base regions 58 need to be spaced apart from the gate oxide films 56 , the base-region forming openings 70 are aligned with accuracy within a diffusion margin Md, which is equal to intervals between the P + base regions 58 at the predetermined positions and the gate oxide films 56 . Also, because the insulation films 59 need to be present between the respective gate electrodes 55 and the electrode film 61 , the contact holes 60 are aligned with accuracy within a contact margin Mc, which is equal to intervals between the contact holes 60 at adequate positions and the gate electrodes 55 .
Incidentally, in order to meet the demand to reduce power consumption of the power MOS FET, miniaturization of cell pitches has been advancing recently, and the diffusion margin Md and the contact margin Mc are also becoming smaller. On the other hand, according to the manufacturing method as described above, for example, a shift in alignment of approximately 0.3 μm is inevitably caused during exposure by the exposure apparatus. For these reasons, it has been becoming difficult to form a microscopic MOS FET having a trench structure through the method described above.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a manufacturing method of a semiconductor device, capable of manufacturing a semiconductor device provided with a microscopic MOS FET having a trench structure.
Another object of the invention is to provide a semiconductor device provided with a MOS FET having a trench structure that can be miniaturized.
A manufacturing method of a semiconductor device of the invention is a method of manufacturing a semiconductor device provided with a MOS field effect transistor having a channel region of a first conduction type formed in a surface layer portion of a semiconductor substrate, a source region of a second conduction type formed on a rim portion of a trench made to penetrate through the channel region, and a base region of the first conduction type formed in the surface layer portion of the semiconductor substrate adjacently to the source region. The method includes: a step of introducing impurities used to control a conduction type to be the first conduction type into the surface layer portion of the semiconductor substrate in order to form the channel region; a step of forming a mask layer having a base-region forming opening corresponding to the base region and a trench forming opening corresponding to the trench on the semiconductor substrate in which the channel region is formed; a step of introducing the impurities used to control a conduction type to be the first conduction type into a surface layer portion of the channel region through the base-region forming opening in the mask layer in order to form the base region; a step of forming the trench that penetrates through the channel region by etching away the surface layer portion of the semiconductor substrate through the trench forming opening in the mask layer; and a step of forming a gate insulation film on an inner wall surface of the trench.
According to the invention, the positions of the base region and the trench in the surface layer portion of the semiconductor substrate are determined by the base-region forming opening and the trench forming opening made in the mask layer. Hence, for example, in a case where the base region is formed first and then the trench is formed, the trench is formed while being aligned exactly with respect to the base region. Likewise, in a case where the trench is formed first, and then the base region is formed, the base region is formed while being aligned exactly with respect to the trench. The trench forming opening and the trench together form a single concave having a continuous inner sidewall surface.
When the base region is formed, for example, the impurities may be introduced through the base-region forming opening by temporarily filling the trench forming opening with resist or the like. Likewise, when the trench is formed, for example, the surface layer portion of the semiconductor substrate may be etched away by temporarily filling the base-region forming opening with resist or the like. The resist is removed after the base region or the trench is formed.
As has been described above, according to the manufacturing method of the semiconductor device, the base region and the trench are aligned automatically (self-aligned), and a process for performing exact alignment is no longer needed. It is thus possible to manufacture a semiconductor device provided with a microscopic MOS FET having a trench structure.
It is preferable that the method further includes: a step of forming a polysilicon film in a region from inside the trench to a lower portion inside the trench forming opening and at a lower portion inside the base-region forming opening; a step of making the polysilicon film electrically conductive by introducing impurities into the polysilicon film; a polysilicon film oxidizing step of forming a silicon oxide film by oxidizing, of the polysilicon film, an upper portion of the polysilicon film inside the trench, the polysilicon film inside the trench forming opening, and the polysilicon film inside the base-region forming opening; a step of forming resist on the silicon oxide film inside the trench forming opening and inside the base-region forming opening after the polysilicon film oxidizing step; a step of forming a source-region forming opening corresponding to the source region between the base region and the trench by etching away the mask layer using the resist as a mask; and a step of introducing impurities used to control a conduction type to be the second conduction type into the surface layer portion of the channel region through the source-region forming opening in order to form the source region.
For example, the polysilicon film may be formed on the semiconductor substrate entirely, and removed through etching, so that the polysilicon film is only left and formed inside the trench, at the lower portion inside the trench forming opening, and at the lower portion inside the base-region forming opening.
In the step of oxidizing the polysilicon film, a silicon oxide film is formed in a portion from the upper portion of the trench to the lower portion of the trench forming opening. By forming an electrode film in the step later so as to cover above the silicon oxide film, the silicon oxide film then lies between the gate electrode and the electrode film. Hence, the silicon oxide film thus obtained can be used as an insulation film. The electrode film can be formed in such a manner so as to be connected to the source region through the use of a space between two adjacent insulation films as a contact hole.
Of the polysilicon film that is made electrically conductive through introduction of impurities, part of the polysilicon film inside the trench is not oxidized and left intact as polysilicon. The polysilicon thus left forms a gate electrode.
The gate electrode and the insulation film are both obtained from the polysilicon film that is formed inside the concave formed by the trench forming opening and the trench. Hence, the insulation film is formed directly above the gate electrode, and the side surface of the insulation film extends from the inside to the outside of the trench along the inner sidewall surface of the trench.
As has been described, the insulation film is formed while being aligned automatically with respect to the trench. Hence, the contact hole is formed while being aligned automatically with respect to the trench, etc.
Further, because the source-region forming opening is formed in such a manner that the opening portion (the base-region forming opening and the trench forming opening) and the non-opening portion of the mask layer are inverted, the position of the source region is also determined by the mask layer. Hence, the source region is formed while being aligned automatically with respect to the base region and the trench.
As has been described, according to the manufacturing method of the semiconductor device, the base region, the trench, the source region, and the insulation film (contact hole) are aligned automatically, and a step of performing exact alignment is no longer needed. It is thus possible to manufacture a semiconductor device provided with a microscopic MOS FET having a trench structure.
The mask layer may be a layer having resistance to an etching medium used in the trench forming step, and for example, it may be a layer made of silicon oxide. In this case, for example, the trench can be formed through dry etching.
A semiconductor device of the invention includes: a channel region of a first conduction type formed in a surface layer portion of a semiconductor substrate; a source region of a second conduction type formed on a rim portion of a trench made to penetrate through the channel region; a base region of the first conduction type formed in the surface layer portion of the semiconductor substrate adjacently to the source region; a gate insulation film formed on an inner sidewall surface of the trench; a gate electrode placed inside the trench to oppose the channel region with the gate insulation film in between; and an insulation film provided from an inside to an outside of the trench above the gate electrode and having a side surface extending along an inner sidewall surface of the trench from the inside to the outside of the trench.
The above and other objects, features, and advantages of the invention will become more apparent from the following description of embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross section showing a structure of a semiconductor device according to one embodiment of the invention;
FIG. 2 ( a ) through FIG. 2 ( i ) are schematic cross sections used to explain a group of processes in a manufacturing method of the semiconductor device of FIG. 1;
FIG. 3 is a schematic cross section showing a structure of a semiconductor device provided with a MOS FET having a trench structure obtained through a conventional manufacturing method; and
FIG. 4 ( a ), FIG. 4 ( b ), and FIG. 4 ( c ) are schematic cross sections used to explain a manufacturing method of the semiconductor device of FIG. 3 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic cross section showing a structure of a semiconductor device provided with a MOS FET having a trench structure according to one embodiment of the invention.
An N − epitaxial layer 2 is formed on the surface of a silicon substrate 1 , and a diffusion region 30 is formed on the N − epitaxial layer 2 . Trenches 17 , each of which penetrates through the diffusion region 30 and halfway through the N − epitaxial layer 2 in the thickness direction, are formed at regular intervals. The respective trenches 17 extend in parallel with one another in a direction perpendicular to the sheet plane of FIG. 1 .
Inside each trench 17 is placed a gate electrode 26 made of polysilicon that has been made electrically conductive through the introduction of impurities. A gate oxide film 18 is provided to surround each gate electrode 26 .
N + source regions 25 and P + base regions 14 are formed in the surface layer portion of the diffusion region 30 , and the rest of the diffusion region 30 forms a P − channel region 4 . The N + source regions 25 are formed on the periphery (rim portion) of each trench 17 , and the P + base regions 14 are formed so that the N + source region 25 are adjacent thereto and on either side. The P + base regions 14 are connected to the p − channel region 4 .
The P + base regions 14 have a greater thickness than the N + source regions 25 . In other words, the P − region 4 is thinner in a portion adjacent to the P + base regions 14 than in a portion adjacent to the N + source regions 25 . Also, the P + base regions 14 and the N + source regions 25 are formed to have a high concentration of impurities and thereby have low resistance in comparison with the P + channel region 4 . According to the arrangement as described above, in a case where the MOS FET is used as a switch, a surge current generated when the switch is turned OFF flows through a portion including the P + base regions 14 having low resistance. This makes it possible to avoid an unwanted event that the semiconductor element heats and breaks. In short, the MOS FET has a large L load capacity.
An insulation film 28 made of silicon oxide is formed above each gate electrode 26 . The insulation films 28 are formed in a region from the inside to the outside of the respective trenches 17 . The side surface 28 a of each insulation film 28 has no step or the like and extends from the inside to the outside of the trench 17 along the inner sidewall surface of the trench 17 . A space between every two adjacent insulation films 28 forms a contact hole 31 . A metal electrode film 27 is formed on the diffusion region 30 and the insulation films 28 . The metal electrode film 27 is placed to fill in the contact holes 31 , and thereby comes in contact with the diffusion region 30 exposed inside the contact holes 31 .
While the semiconductor device described above is operating, a current flows between the N + source regions 25 and the silicon substrate 1 through the P − channel region 4 along the gate oxide films 18 .
FIG. 2 ( a ) through FIG. 2 ( i ) are schematic cross sections used to explain a manufacturing method of the semiconductor device of FIG. 1 .
Initially, the N − epitaxial layer 2 is formed on the silicon substrate 1 . Then, the silicon substrate 1 on which the N − epitaxial layer 2 is formed is heated, whereby a thermal oxidation film 3 is formed in the surface layer portion of. the N − epitaxial layer 2 . A thickness of the thermal oxidation film 3 is, for example, 100 to 1000 Å approximately.
Then, boron ions are implanted into the surface layer portion of the N − epitaxial layer 2 through the thermal oxidation film 3 , whereby the P − channel region 4 is formed. This state is illustrated in FIG. 2 ( a ). When the boron ions are implanted, energy for accelerating boron ions is, for example, 100 keV approximately, and a concentration of boron ions is, for example, 1×10 13 to 10×10 13 atoms/cm 2 .
Then, a silicon oxide film 5 is formed on the thermal oxidation film 3 , for example, through the CVD (Chemical Vapor Deposition) method. A thickness of the silicon oxide film 5 is, for example, 1000 to 10000 Å. The thermal oxidation film 3 and the silicon oxide film 5 together form a silicon oxide film 6 . Further, a first resist film 7 is formed on the silicon oxide film 6 , in which openings 8 and 9 are made at predetermined positions through lithography. The openings 8 and the openings 9 extend in a direction perpendicular to the sheet plane of FIG. 2 ( b ).
The silicon oxide film 6 is then etched away through the openings 8 and 9 in the first resist film 7 . Consequently, in the silicon oxide film 6 , the base-region forming openings 10 are formed in portions corresponding to the openings 8 and the trench forming openings 11 are formed in portions corresponding to the openings 9 . The base-region forming openings 10 and the trench forming openings 11 are placed alternately.
The P − channel region 4 is exposed at the bottoms of the base-region forming openings 10 and the trench forming openings 11 . This state is illustrated in FIG. 2 ( b ). Widths of the base-region forming openings 10 and the trench forming openings 11 are, for example, 0.4 to 0.6 μm approximately. The first resist film 7 is then removed.
Then, a second resist film 13 is formed, in which openings 12 are made at predetermined positions through lithography. Consequently, the base-region forming openings 10 are positioned inside the openings 12 and the trench forming openings 11 are filled with the second resist film 13 .
Subsequently, boron ions are implanted into the surface layer portion of the P − channel region 4 through the base-region forming openings 10 inside the openings 12 , whereby the P + base regions 14 are formed (FIG. 2 ( c )). In this instance, the silicon oxide film 6 functions as a mask that prevents boron ions from being implanted into regions of the P − channel region 4 other than those corresponding to the base-region forming openings 10 . A density of boron ions to be implanted is, for example, 1×10 15 to 10×10 15 atoms/cm 2 . The second resist film 13 is then removed.
Then, a third resist film 16 is formed, in which openings 15 are made at predetermined positions through lithography. Consequently, the trench forming openings 11 are positioned inside the openings 15 and the base-region forming openings 10 are filled with the third resist film 16 .
Subsequently, the trenches 17 , each of which penetrates through the P − channel region 4 and halfway through the N − epitaxial layer 2 in the thickness direction (to the top portion of the N − epitaxial layer 2 ), are formed by means of etching through the trench forming openings 11 inside the openings 15 (FIG. 2 ( d )). A depth of the trenches 17 is determined by a thickness of the P − channel region 4 or the like, and for example, it is determined to be 0.5 to 3.0 μm. Etching is performed, for example, through dry etching. In this case, the silicon oxide film 6 has resistance to an etching medium, and thereby functions as a hard mask that protects portions other than those corresponding to the trench forming openings 11 from the etching medium.
Each trench forming opening 11 and the corresponding trench 17 form a single concave having a continuous inner sidewall surface along substantially the same plane. The third resist film 16 is then removed.
Then, the silicon substrate 1 having undergone the foregoing processes is heated, whereby the gate oxide film 18 is formed in the vicinity of the inner surface of each trench 17 through thermal oxidation. In this instance, the vicinities of the surfaces of the P + base regions 14 exposed in the base-region forming openings 10 are subjected to thermal oxidation concurrently.
Then, a polysilicon film 19 is formed on the silicon substrate 1 having undergone the foregoing processes, for example, through the CVD method. The polysilicon film 19 is formed so as to fill in the trenches 17 , the trench forming openings 11 , and the base-region forming openings 10 . Subsequently, the polysilicon film 19 is etched away to leave the polysilicon film 19 at the lower portions inside the base-region forming openings 10 , inside the trenches 17 , and at the lower portions inside the trench forming openings 11 . This state is illustrated in FIG. 2 ( e ). Impurities are then implanted into the polysilicon film 19 and the polysilicon 19 is thereby made electrically conductive.
Then, the silicon substrate 1 having undergone the foregoing processes is subjected to oxidation, which gives rise to oxidation of the entire polysilicon film 19 inside the base-region forming openings 10 and inside the trench forming openings 11 , and the upper portions of the polysilicon film 19 inside the trenches 17 (FIG. 2 ( f )).
Consequently, the thermal oxidation films in the vicinity of the surfaces of the P + base regions 14 , the oxidized polysilicon film 19 , and the silicon oxide film 6 together form a silicon oxide film 20 . The silicon oxide film 20 is provided with concaves 21 and 22 in portions corresponding to the base-region forming openings 10 and the trench forming openings 11 , respectively. The polysilicon film 19 let inside each trench 17 without being oxidized forms the gate electrode 26 .
Then, a fourth resist film 23 is formed to fully cover the surface of the silicon oxide film 20 . Subsequently, the fourth resist film 23 is etched back, so that the fourth resist film 23 is present inside the concaves 21 and 22 alone (FIG. 2 ( g )).
Then, the silicon oxide film 20 is etched away using the fourth resist mask 23 inside the concaves 21 and 22 as a mask. Etching is performed, for example, through dry etching (for instance, reactive ion etching (RIE)) Consequently, source-region forming openings 24 are formed in the silicon oxide film 20 . In other words, the source-region forming openings 24 are formed while being aligned exactly between the base regions 14 and the trenches 17 in such a manner that the opening portions (the base-region forming openings 10 and the trench forming openings 11 ) and the non-opening portions of the silicon oxide film 6 (see FIG. 2 ( b )) are inverted.
In this state, the P − channel region 4 between the trenches 17 and the P + base regions 14 is exposed inside the respective source-region forming openings 24 . Also, the silicon oxide film 20 is present above each gate electrode 26 and above each P + base region 14 .
Subsequently, impurities used to control the conduction type to be an n-type are implanted into the surface layer portion of the P − channel region 4 through the source-region forming openings 24 , and the silicon substrate 1 having undergone the foregoing processes is annealed, whereby the N + source regions 25 are formed. The fourth resist film 23 is then removed. This state is illustrated in FIG. 2 ( h ).
Then, a fifth resist film 29 is formed, in which openings 32 are made at predetermined positions through lithography. Consequently, the silicon oxide film 20 above each gate electrode 26 is covered with the fifth resist film 29 , and the silicon oxide film 20 above each P + base region 14 is exposed inside the corresponding opening 32 (FIG. 2 ( i )).
The exposed silicon oxide film 20 above each P + base region 14 is then removed, for example, through wet etching. The fifth resist film 29 is then removed. Further, a metal electrode film 27 is formed on the silicon substrate 1 having undergone the foregoing processes. The silicon oxide film 20 above each gate electrode 26 forms the insulation film 28 that lies between the gate electrode 26 and the metal electrode film 27 . In this manner, the semiconductor device shown in FIG. 1 is obtained.
As described above, the insulation films 28 are obtained by oxidizing part of the polysilicon film 20 formed inside the trenches 17 and the trench forming openings 11 . For this reason, the side surface 28 a of each insulation film 28 extends in a direction along which the inner sidewall surface of the trench 17 extends (a direction perpendicular or nearly perpendicular to the silicon substrate 1 ), and therefore has no step or the like.
In the manufacturing method as described above, the positions of the P + base regions 14 and the trenches 17 are determined respectively by the base-region forming openings 10 and the trench forming openings 11 made in the silicon oxide film 6 (see FIG. 2 ( c ) and FIG. 2 ( d )). The positions of the base-region forming openings 10 and the trench forming openings 11 are determined respectively by the openings 8 and 9 in the first resist film 7 (see FIG. 2 ( b )).
Also, as can be understood from comparison between FIG. 2 ( g ) and FIG. 2 ( h ), the N + source regions 25 are formed in portions corresponding to the silicon oxide film 6 (silicon oxide film 20 ) present between the bases-region forming openings 10 (concaves 21 ) and the trench forming openings 11 (concaves 22 ). Hence, the positions of the N + source regions 25 are also determined by the positions at which the base-region forming openings 10 and the trench forming openings 11 are formed in the silicon oxide film 6 .
Further, the positions of the insulation films 28 (the positions of the contact holes 31 ) are determined by the trench forming openings 11 in the silicon oxide film 6 .
Hence, the relative positional relations among the P + base regions 14 , the trenches 17 , the N + source regions 25 , and the insulation films 28 (contact holes 31 ) are all determined by a single silicon oxide film 6 . This eliminates the need of separate alignment when each is formed. In other words, the P + base regions 14 , the trenches 17 , the N + source regions 25 , and the insulation films 28 (contact holes 31 ) can be aligned automatically (self-aligned).
The openings 12 in the second resist film 13 need to be formed while being aligned with respect to the base-region forming openings 10 and the trench forming openings 11 (FIG. 2 ( c )). However, the openings 12 only have to be formed in such a manner that the end portion of each opening 12 is positioned on the silicon oxide film 6 present between the base-region forming opening 10 and the trench forming opening 11 . Thus, an alignment margin of the openings 12 is large in comparison with the diffusion margin Md and the contact margin Mc (see FIG. 3) in the conventional manufacturing method. As has been described, highly precise alignment is not needed when the openings 12 are formed.
Likewise, large alignment margins are allowed for the openings 15 in the third resist film 16 (FIG. 2 ( d )) and for the openings 32 in the fifth resist film 29 (FIG. 2 ( i )).
Also, the fourth resist film 23 can be formed to be present inside the concaves 21 and 22 alone by only controlling its etching thickness, which makes the alignment in the horizontal direction unnecessary.
As has been described, according to the manufacturing method of the semiconductor device, because a process of performing exact alignment is no longer needed, it is possible to manufacture a semiconductor device provided with a microscopic MOS FET having a trench structure. Consequently, for example, even in a case where the elements are formed according the 0.4 μm rule using the conventional stepper (exposure apparatus), a cell density (the number of cells per unit area) can be improved markedly, that is, three to five times larger than the density conventionally achieved.
For example, when it is designed that the width of the trenches 17 and the width of the P + base regions 14 are both 0.4 μm, according to the manufacturing method of the semiconductor device of the invention, the cell pitch width can be set to as narrow as 1.5 to 2.0 μm, for example. When the cells are miniaturized, the number and the width of the P − channel region 4 per unit area can be increased, which in turn makes it possible to enlarge the channel area. Consequently, the channel resistance can be reduced, and hence, the ON resistance of the semiconductor device can be reduced.
While the above description described the embodiment of the invention, the invention can be implemented in another embodiment. For example, the embodiment above described a case of a semiconductor device provided with an n-type channel MOS FET. However, the semiconductor device may be provided with a p-type channel MOS FET.
Also, in the embodiment above, the P + base regions 14 are formed first (FIG. 2 ( c )) and then the trenches 17 are formed (FIG. 2 ( d )). However, the trenches 17 may be formed first followed by the P + base regions 14 .
While the above description described embodiments of the invention in detail, it should be appreciated that these embodiments represent examples to provide clear understanding of the technical contents of the invention, and the invention is not limited to these examples. The sprit and the scope of the invention, therefore, are limited solely by the scope of the appended claims.
This application is based on Application No. 2002-137517 filed with the Japanese Patent Office on May 13, 2002, the entire content of which is incorporated hereinto by reference.
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A method of manufacturing a semiconductor device provided with a MOS field effect transistor having a channel region of a first conduction type formed in a surface layer portion of a semiconductor substrate, a source region of a second conduction type formed on a rim portion of a trench made to penetrate through the channel region, and a base region of the first conduction type formed in the surface layer portion of the semiconductor substrate adjacently to the source region. The method includes: a step of forming a mask layer having a base-region forming opening corresponding to the base region and a trench forming opening corresponding to the trench on the semiconductor substrate in which the channel region is formed; a base-region forming step of introducing impurities through the base-region forming opening; a trench forming step of forming the trench through the trench forming opening; and a step of forming a gate insulation film on an inner wall surface of the trench.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a superconducting device and a method for manufacturing the same, and more specifically to a superconducting device including an extremely thin superconducting channel formed of oxide superconductor material, and a method for manufacturing the same.
2. Description of Related Art
Typical three-terminal devices which utilize a superconductor include a so called superconducting-base transistor and a so called super-FET (field effect transistor). The superconducting-base transistor includes an emitter of a superconductor or a normal conductor, a tunnel barrier of an insulator, a base of a superconductor, a semiconductor isolator and a collector of a normal conductor, stacked in the named order. This superconducting-base transistor operates at a high speed with a low power consumption, by utilizing high speed electrons passing through the tunnel barrier.
The super-FET includes a semiconductor layer, and a superconductor source electrode and a superconductor drain electrode which are formed closely to each other on the semiconductor layer. A portion of the semiconductor layer between the superconductor source electrode and the superconductor drain electrode has a greatly recessed or undercut rear surface so as to have a reduced thickness. In addition, a gate electrode is formed through a gate insulating layer on the recessed or undercut rear surface of the portion of the semiconductor layer between the superconductor source electrode and the superconductor drain electrode.
A superconducting current flows through the semiconductor layer portion between the superconductor source electrode and the superconductor drain electrode due to a superconducting proximity effect, and is controlled by an applied gate voltage. This super-FET also operates at a high speed with a low power consumption.
In addition, in the prior art, there has been proposed a three-terminal superconducting device having a channel of a superconductor formed between a source electrode and a drain electrode, so that a current flowing through the superconducting channel is controlled by a voltage applied to a gate formed above the superconducting channel.
Both of the above mentioned superconducting-base transistor and the super-FET have a portion in which a semiconductor layer and a superconducting layer are stacked to each other. However, it is difficult to form a stacked structure of the semiconductor layer and the superconducting layer formed of an oxide superconductor which has been recently advanced in study. In addition, even if it is possible to form a stacked structure of the semiconductor layer and the oxide superconducting layer, it is difficult to control a boundary between the semiconductor layer and the oxide superconducting layer. Therefore, a satisfactory operation could not been obtained in these superconducting devices.
In addition, since the super-FET utilizes the superconducting proximity effect, the superconductor source electrode and the superconductor drain electrode have to be located close to each other at a distance which is not greater than a few times the coherence length of the superconductor materials of the superconductor source electrode and the superconductor drain electrode. In particular, since an oxide superconductor has a short coherence length, if the superconductor source electrode and the superconductor drain electrode are formed of the oxide superconductor material, a distance between the superconductor source electrode and the superconductor drain electrode has to be not greater than a few ten nanometers. However, it is very difficult to conduct a fine processing such as a fine pattern etching so as to ensure the very short separation distance. Because of this, in the prior art, it has been impossible to manufacture the super-FET composed of the oxide superconductor material.
Furthermore, it has been confirmed that the conventional three-terminal superconducting device having the superconducting channel shows a modulation operation. However, the conventional three-terminal superconducting device having the superconducting channel could not realize a complete ON/OFF operation, because a carrier density is too high. In this connection, since an oxide superconductor material has a low carrier density, it is expected to form a three-terminal superconducting device which has a superconducting channel and which can realize the complete ON/OFF operation, by forming the superconducting channel of the oxide superconductor material. In this case, however, a thickness of the superconducting channel has to be made on the order of five nanometers.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a superconducting device and a method for manufacturing the same, which have overcome the above mentioned defects of the conventional ones.
Another object of the present invention is to provide a superconducting device including a superconducting region constituted of an extremely thin oxide superconductor film, which can be manufactured by using existing established processing techniques with a good repeatability.
Still another object of the present invention is to provide an FET type superconducting device including a superconducting channel composed of an extremely thin oxide superconductor film, and a method for manufacturing the same with a good repeatability by using existing established processing techniques.
The above and other objects of the present invention are achieved in accordance with the present invention by a superconducting device comprising a substrate, a superconducting channel constituted of an oxide superconductor thin film formed on the substrate, a superconductor source electrode and a superconductor drain electrode formed at opposite ends of the superconducting channel, so that a superconducting current can flow through the superconducting channel between the source electrode and the drain electrode, and a gate electrode located through an insulating layer on the superconducting channel so as to control the superconducting current flowing through the superconducting channel, the oxide superconductor thin film of the superconducting channel being formed of a c-axis oriented oxide superconductor crystal, and the oxide superconductor thin film of the superconductor source electrode and the superconductor drain electrode being formed of an a-axis oriented oxide superconductor crystal, the superconducting channel being continuous to the superconductor source electrode and the superconductor drain electrode.
Here, the source electrode should be understood to include not only an electrode corresponding to the electrode which is called a "source electrode" in the field of a semiconductor MOSFET, but also a source region which is formed adjacent to and continuous to the superconducting channel and on which the source electrode is formed, and the drain electrode should be understood to include not only an electrode corresponding to the electrode which is called a "drain electrode" in the field of the semiconductor MOSFET, but also a drain region which is formed adjacent to and continuous to the superconducting channel and on which the drain electrode is formed.
As seen from the above, the superconducting device in accordance with the present invention is characterized in that the oxide superconductor thin film of the superconducting channel is formed of a c-axis oriented oxide superconductor crystal, and the oxide superconductor thin film of the superconductor source electrode and the superconductor drain electrode is formed of an a-axis oriented oxide superconductor crystal.
Therefore, the superconducting device in accordance with the present invention is constructed so that a main current flows through the superconducting channel and is controlled by the gate voltage. Therefore, differently from the conventional super-FET in which a superconducting current flows through the semiconductor channel due to the superconducting proximity effect, the limitation in the fine processing techniques required for manufacturing the super-FET can be relaxed.
In general, the oxide superconductor has large crystalline inhomogeneity. In particular, the critical current density is larger in directions perpendicular to the c-axis, than in a direction parallel to the c-axis. Therefore, if a superconductor source electrode and a superconductor drain electrode have been formed of c-axis oriented oxide superconductor thin films, it has been difficult to cause a superconducting current to uniformly flow through an extremely thin superconducting channel of an oxide superconductor. As mentioned above, in the superconducting device in accordance with the present invention, since the superconductor source electrode and the superconductor drain electrode are formed of an a-axis oriented oxide superconductor thin film, the main current is allowed to flow within the superconductor source electrode and the superconductor drain electrode in a direction perpendicular to the substrate. On the other hand, since the superconducting channel is formed of a c-axis oriented oxide superconductor thin film, the main current is allowed to flow within the superconducting channel in a direction parallel to the substrate. Therefore, in each of the superconductor source electrode, the superconductor drain electrode and the superconducting channel, the main current is caused to flow in a direction having a large critical current density of the oxide superconductor crystal.
The c-axis oriented oxide superconductor thin film superconducting channel can be easily formed by maintaining the substrate at a temperature of about 700° C. when the oxide superconductor thin film is deposited. On the other hand, the a-axis oriented oxide superconductor thin film superconductor source electrode and superconductor drain electrode can be easily formed by maintaining the substrate at a temperature of not greater than about 650° C. when the oxide superconductor thin film is deposited. In any case, the oxide superconductor thin film can be deposted by a sputtering such as an off-axis sputtering, a reactive evaporation, an MBE (molecular beam epitaxy), a vacuum evaporation, a CVD (chemical vapor deposition), etc.
In a preferred embodiment, the oxide superconductor thin film is formed of a material selected from the group consisting of a Y-Ba-Cu-O type compound oxide superconductor material, a Bi-Sr-Ca-Cu-O type compound oxide superconductor material, and a Tl-Ba-Ca-Cu-O type compound oxide superconductor material.
In addition, the substrate, on which the oxide superconductor thin film is deposited, can be formed of an insulating substrate, preferably an oxide single crystalline substrate such as MgO, SrTiO 3 , and CdNdAlO 4 . These substrate materials are very effective in forming or growing a crystalline film having a high orientation property. However, the superconducting device can be formed on a semiconductor substrate if an appropriate buffer layer is deposited thereon. For example, the buffer layer on the semiconductor substrate can be formed of a double-layer coating formed of a MgAl 2 O 4 layer and a BaTiO 3 layer if a silicon substrate is used.
In order to ensure that the superconducting channel can be turned on and off by a voltage applied to the gate electrode, a thickness of the superconducting channel has to be not greater than five nanometers in the direction of an electric field created by the voltage applied to the gate electrode.
According to one aspect of the method in accordance with the present invention for manufacturing the superconducting device in accordance with the present invention, the superconducting channel is formed of an extremely thin portion of the c-axis oriented oxide superconductor film formed on a projecting insulating region formed on a principal surface of the substrate.
In this connection, if the oxide superconductor thin film is simply deposited on the substrate having the projecting insulating region, the thickness of an oxide superconductor thin film portion on the projecting insulating region is the same as that of the other portion of the deposited oxide superconductor thin film. Therefore, a surface of the oxide superconductor thin film deposited on a whole surface of the substrate is planarized so that the extremely thin portion of the c-axis oriented oxide superconductor thin film is left or formed on only the projecting insulating region.
According to another aspect of the method in accordance with the present invention for manufacturing the superconducting device in accordance with the present invention, a superconductor source electrode and a superconductor drain electrode of an a-axis oriented oxide superconductor thin film are previously formed on a planar principal surface of a substrate separately from each other, and thereafter, an extremely thin c-axis oriented oxide superconductor thin film is deposited on the substrate between the superconductor source electrode and the superconductor drain electrode so that a superconducting channel is formed between the superconductor source electrode and the superconductor drain electrode. The extremely thin c-axis oriented oxide superconductor thin film has a thickness on the order of for example five nanometers. This extremely thin oxide superconductor film can be formed in a conventional process by precisely controlling the growth speed and the growth time of the thin film. For this purpose, a sputtering can be preferably used. However, since the oxide superconductor crystal has a multi-layer structure in which respective constituent elements are stacked in a layered structure, it is possible to stack a desired number of unit cells of oxide superconductor, by using a MBE (molecular beam epitaxy). In addition, as mentioned above, the extremely thin oxide superconductor film can be formed by maintaining the substrate temperature at about 700° C. when the oxide superconductor thin film is deposited.
Thereafter, a gate electrode is formed through a gate insulator on a portion of the c-axis oriented oxide superconductor thin film between the superconductor source electrode and the superconductor drain electrode, and if necessary, a source electrode and a drain electrode of a normal conductor material may be formed on the superconductor source electrode and the superconductor drain electrode, respectively.
Specifically, the superconductor source electrode and the superconductor drain electrode are formed as follows: First, a crystal disturbing layer is deposited on a selected position of the principal surface of the substrate corresponding to a position where an oxide superconductor thin film for the superconducting channel is to be formed in the future. For example, this crystal disturbing layer is formed of SiO 2 and has a thickness of about 200 to 300 nanometers.
Then, an a-axis oriented oxide superconductor thin film is uniformly deposited on the principal surface of the substrate so as to cover the crystal disturbing layer. This a-axis oriented oxide superconductor thin film has a thickness substantially equal to that of the crystal disturbing layer, and can be formed by preferably the off-axis sputtering maintaining the substrate temperature at about 650° C. or less. In the process of the deposition, a portion of the a-axis oriented oxide superconductor thin film deposited on the crystal disturbing layer becomes non-superconductive, because crystallizability is disturbed. Then, the non-superconductor oxide thin film deposited on the crystal disturbing layer and the crystal disturbing layer itself are selectively removed, so that the superconductor source electrode and the superconductor drain electrode are formed separately from each other.
In the above mentioned process, no fine-processing such as a fine-etching or a fine-patterning is required. Therefore, the limitation in the fine processing technique required for manufacturing the super-FET is relaxed.
The above and other objects, features and advantages of the present invention will be apparent from the following description of preferred embodiments of the invention with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1H and 1J are diagrammatic sectional views for illustrating a first embodiment of the process in accordance with the present invention for manufacturing a super-FET; and
FIGS. 2A to 2H are diagrammatic sectional views for illustrating a second embodiment of a process in accordance with the present invention for manufacturing the super-FET;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
Referring to FIGS. 1A to 1H and 1J, a first embodiment of the process in accordance with the present invention for manufacturing the super-FET will be described.
First, a substrate 5 is prepared as shown in FIG. 1A. This substrate 5 is formed of for example, an insulating substrate such as a MgO (100) substrate, a SrTiO 3 (100) substrate or others, or a semiconductor substrate such as a silicon (100) substrate having a principal surface coated with insulating films. However, if the semiconductor substrate is used, after a projection mentioned hereinafter is formed on the principal surface, the insulating films are formed on the principal surface.
As shown in FIG. 1B, a photoresist mask 8 is formed on a portion of the principal surface of the substrate 5 corresponding to a projection forming position, and the principal surface of the substrate 5 is selectively etched or recessed by a dry etching process such as an Ar ion etching, so that a projection 50 is formed on the principal surface of the substrate 5. Thereafter, the photoresist mask 8 is removed.
In the case that a semiconductor substrate is used, a crystalline direction is important, and therefore, the process is modified. For example, if a silicon substrate is used, a photoresist mask 8 is formed so as to ensure that a gate length direction (a channel current direction) is in parallel to a Si(100) plane and perpendicular to a Si(110) plane. The silicon substrate partially masked with the photoresist 8 is etched with an etching liquid such as KOH or APW, so that a projection 50 is formed. Thereafter the photoresist mask 8 is removed, and the principal surface having the projection 50 is continuously coated with MgAl 2 O 4 by a CVD process and with BaTiO 3 by a sputtering process.
Then, as shown in FIG. 1C, a c-axis orientated oxide superconductor thin film 1 is deposited on the principal surface of the substrate 5, by for example an off-axis sputtering, a reactive evaporation, an MBE (molecular beam epitaxy), a CVD, etc. The oxide superconductor material is preferably formed of, for example, a Y-Ba-Cu-O type compound oxide superconductor material, a Bi-Sr-Ca-Cu-O type compound oxide superconductor material, and a Tl-Ba-Ca-Cu-O type compound oxide superconductor material.
In the case of forming the c-axis orientated thin film of Y 1 Ba 2 Cu 3 O 7-x , the off-axis sputtering is performed under the condition that a sputtering gas is composed of Ar and O 2 at the ratio of Ar:O 2 =90%:10%, the sputtering gas pressure is 10 Pa, and the substrate temperature is 700° C.
The oxide superconductor thin film 1 has a thickness of not greater than five nanometers in a portion on the projection 50. For realizing the thickness of not greater than five nanometers, since the oxide superconductor thin film 1 as deposited has a uniform thickness anywhere, it is necessary to firstly deposit a photoresist layer (not shown) on the oxide superconductor thin film 1 in such a manner that the deposited photoresist layer has a plat upper surface, and then, to etch back and planarize the deposited photoresist layer and an upper surface of the deposited oxide superconductor thin film so as to form an extremely thin oxide superconductor film portion on the projection 50.
Then, as shown in FIG. 1D, an insulating layer 16 is deposited on the oxide superconductor thin film 1. The insulating layer 16 has a thickness sufficient to prevent a tunnel current, for example, a thickness of not less than 10 nanometers. In addition, the insulating layer 16 is preferably formed of an insulating material such as MgO, which does not form a large density of energy levels between the superconductor thin film 1 and the insulating layer 16.
Furthermore, as shown in FIG. 1E, a normal conductor layer 17 for a gate electrode is deposited on the insulating layer 16. The normal conductor layer 17 is preferably formed of a refractory metal such as Ti, W, etc., or Au, or a silicide thereof. It is preferred that the insulating layer 16 and the normal conductor layer 17 are continuously deposited on the superconductor thin film 1 without being taken out of a deposition chamber, in order to reduce the density of energy levels at a boundary, to prevent contamination, and to reduce a mechanical stress.
Then, a refractory mask 9 for a gate electrode patterning is formed on the normal conductor layer 17 at a position where a gate electrode is to be formed in future and which is therefore positioned above the projection 50. The insulating layer 16 and the normal conductor layer 17 which are not covered by the refractory mask 9 are etched by the reactive ion etching or the Ar-ion milling so as to form an gate electrode 4 and a gate insulator 6, as shown in FIG. 1F. The refractory mask 9 is formed of a refractory metal such as Mo, and can be deposited by a vacuum evaporation process. If necessary, the gate insulator 6 is side-etched in comparison with the gate electrode 4 so that the length of the gate insulator 6 is shorter than that of the gate electrode 4. A portion of the oxide superconductor thin film 1 above the projection 50 and underneath the gate electrode 4 forms a superconducting channel 10.
After formation of the gate electrode 4 and the gate insulator 6, portions 12 and 13 of the oxide superconductor thin film 1 at both sides of the superconducting channel 10 are etched or recessed so that an upper surface of the portions 12 and 13 becomes lower than that of the superconducting channel 10 by a depth of not less than ten nanometers, as shown in FIG. 1G.
As shown in FIG. 1H, an a-axis oriented thin film of the same oxide superconductor as that of the oxide superconductor thin film 1 is deposited so as to form a source electrode 2 and a drain electrode 3 on the recessed portions 12 and 13 of the oxide superconductor thin film 1, respectively. The source electrode 2 and the drain electrode 3 have a thickness of about 200 nanometers, and can be formed by any deposition process such as an off-axis sputtering, a reactive evaporation, an MBE, a CVD, etc. In the case of forming the a-axis orientated thin film of Y 1 Ba 2 Cu 3 O 7-x by the off-axis sputtering, the sputtering condition is that a sputtering gas is composed of Ar and O 2 at the ratio of Ar:O 2 =90%:10%, the sputtering gas pressure is 10 Pa, and the substrate temperature is 640° C.
In this process, it is considered that a film 19 of the a-axis orientated oxide superconductor thin film is deposited on the refractory mask 9 as shown in FIG. 1H. In fact, however, if the refractory mask 9 is formed of Mo, an oxide superconductor thin film deposited on the refractory mask 9 is sublimed in the process of the deposition of the a-axis oriented oxide superconductor electrodes 2 and 3. Thereafter, the refractory mask 9 is removed. Thus, the superconducting device is completed as shown in FIG. 1J. The mask 9 can be also formed of an insulating film in place of the refractory metal. In this case, the mask 9 can be left on the gate electrode, since it does not give any influence on the gate characteristics.
Thus, the super-FET shown in FIG. 1J includes the oxide superconductor thin film 1 formed on the principal surface of the substrate 5 having the projection 50. The oxide superconductor thin film 1 is formed of the c-axis oriented oxide superconductor thin film and has a substantially planarized upper surface. The portion of the oxide superconducting thin film 1 on the projection 50 is thinner than the other portion of the oxide superconducting thin film 1, and forms a superconducting channel 10 of not greater than five nanometers. At both sides of the superconducting channel 10, the oxide superconductor thin film 1 is recessed by the depth of about ten nanometers, and the source electrode 2 and the drain electrode 3 formed of the a-axis oriented oxide superconducting thin film are located at the two recessed portions of the oxide superconducting thin film 1, respectively. In addition, the gate electrode 4 is located on the superconducting channel 10 through the gate insulator 6.
As explained above, if the above mentioned super-FET is manufactured in accordance with the above mentioned process, since a superconducting current can be flowed uniformly through the superconducting channel, the performance of the super-FET can be increased. Furthermore, the limitation in the fine processing technique required for manufacturing the super-FET is relaxed. In addition, since the substantially planarized upper surface is obtained, it become easy to form conductor wirings in a later process. Accordingly, it is easy to manufacture the super-FET with good repeatability, and the manufactured super-FET has a stable performance.
Embodiment 2
Referring to FIGS. 2A to 2H, a second embodiment of the process in accordance with the present invention for manufacturing the superconducting device will be described.
First, the substrate 5 is prepared as shown in FIG. 2A. Similarly to the Embodiment 1, this substrate 5 is formed of for example, an insulating substrate such as a MgO (100) substrate, a SrTiO 3 (100) substrate or others, or a semiconductor substrate such as a silicon (100) substrate having a principal surface coated with insulating films. However, if the silicon substrate is used, the principal surface of the substrate is continuously coated with MgAl 2 O 4 by the CVD process and with BaTiO 3 by the sputtering process.
As shown in FIG. 2B, a SiO 2 layer 15 having a thickness of not less than 200 nanometers is formed on a central portion of the principal surface of the substrate 5 corresponding to a superconducting channel forming position.
Then, as shown in FIG. 2C, an a-axis orientated oxide superconductor thin film 15 also having a thickness of not less than 200 nanometers is deposited on the principal surface of the substrate 5, by for example an off-axis sputtering.
Similarly to the Embodiment 1, the oxide superconductor material is preferably formed of, for example, a Y-Ba-Cu-O type compound oxide superconductor material, a Bi-Sr-Ca-Cu-O type compound oxide superconductor material, and a Tl-Ba-Ca-Cu-O type compound oxide superconductor material.
In the case of forming the a-axis orientated thin film of Y 1 Ba 2 Cu 3 O 7-x by the off-axis sputtering, the sputtering condition is that a sputtering gas is composed of Ar and O 2 at the ratio of Ar:O 2 =90%:10%, the sputtering gas pressure is 10 Pa, and the substrate temperature is 640° C.
A portion 52 of the a-axis orientated oxide superconductor thin film 15 deposited on the SiO 2 layer 51 becomes a non-superconductor layer because crystallizability in the portion 52 deposited on the SiO 2 layer 51 is disturbed or destroyed.
Thereafter, the non-superconductor layer 52 and the SiO 2 layer 51 are removed by a dry etching process such as the Ar-ion etching, as shown in FIG. 2D, so that a superconductor source region (electrode) 12 and a superconductor drain region (electrode) 13 formed of the a-axis oriented oxide superconductor thin film are left or formed because of the etching speed difference due to difference in crystallizability between the a-axis orientated oxide superconductor thin film 15 and the non-superconductor layer 52.
Then, as shown in FIG. 2E, a c-axis oriented oxide superconductor thin film 11, which has a thickness of not greater than five nanometers and which is formed of the same superconductor material as that of the a-axis oriented oxide superconductor thin film 15, is deposited on the principal surface of the substrate 5, the superconductor source region 12 and the superconductor drain region 13, by for example an off-axis sputtering, a reactive evaporation, the MBE, the CVD, etc. In the case of forming the c-axis orientated thin film 11 of Y 1 Ba 2 Cu 3 O 7-x by the off-axis sputtering, the sputtering condition is that a sputtering gas is composed of Ar and O 2 at the ratio of Ar:O 2 =90%:10%, the sputtering gas pressure is 10 Pa, and the substrate temperature is 700° C.
Then, as shown in FIG. 2F, an insulating layer 16 is deposited on the oxide superconductor thin film 11, and a normal conductor layer 17 for a gate electrode is deposited on the insulating layer 16. The insulating layer 16 has a thickness sufficient to prevent a tunnel current, for example, a thickness of not less than 10 nanometers. In addition, the insulating layer 16 is preferably formed of an insulating material such as Si 3 N 4 or MgO, which does not form a large density of energy levels between the superconductor thin film 11 and the insulating layer 16. The normal conductor layer 17 is deposited by any deposition process, for example, the vacuum evaporation, to have a thickness of about 200 nanometer. The normal conductor layer 17 is preferably formed of a refractory metal such as Ti, W, etc., or Au, or a silicide thereof. It is preferred that the insulating layer 16 and the normal conductor layer 17 are continuously deposited on the superconductor thin film 11 without being taken out of a deposition chamber, in order to reduce a mechanical stress.
Then, the insulating layer 16 and the normal conductor layer 17 are selectively etched by the reactive ion etching and the Ar-ion milling so as to form an gate electrode 4 and a gate insulator 6, as shown in FIG. 2G. In this process, the gate insulator 6 is side-etched in comparison with the gate electrode 4 so that the length of the gate insulator 6 is shorter than that of the gate electrode 4.
After formation of the gate electrode 4 and the gate insulator 6, the c-axis oriented oxide superconducting thin film 11 on the superconducting source region 12 and the superconductor drain region 13 are removed, and then, a source electrode 2 and a drain electrode 3 formed of the same material as that of the gate electrode 4 are deposited on the superconducting source region 12 and the superconducting drain region 13, respectively, as shown in FIG. 2G.
Thus, the super-FET shown in FIG. 2H includes the extremely thin c-axis oriented oxide superconductor film 11 formed on the principal surface of the substrate 5, and the superconducting source region 12 and the superconducting drain region 13 formed of the a-axis oriented oxide superconductor thin film. The superconducting channel 10 is formed of the extremely thin c-axis oriented oxide superconductor film having the thickness of about five nanometers. On the other hand, the superconductor source region 12 and the superconductor drain region 13 are formed of the a-axis oriented oxide superconductor thin film having the thickness of about 200 nanometers.
In addition, the gate electrode 4 is located on the superconducting channel 10 through the gate insulator 6. The source electrode 2 and the drain electrode 3 are formed on the superconductor source region 12 and the superconductor drain region 13.
As explained above, in the super-FET in accordance with the present invention, a main current flows through the superconducting channel and is controlled by the gate voltage. Therefore, differently from the conventional super-FET in which a superconducting current flows through the semiconductor channel due to the superconducting proximity effect, the limitation in the fine processing techniques required for manufacturing the super-FET can be relaxed. In addition, since it is not necessary to stack the superconductor and the semiconductor, a high performance superconducting device can be realized by using an oxide superconductor. Therefore, the application of the superconduction technology to the electronic devices can be promoted.
The invention has thus been shown and described with reference to the specific embodiments. However, it should be noted that the present invention is in no way limited to the details of the illustrated structures but changes and modifications may be made within the scope of the appended claims.
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A superconducting device includes a superconducting channel consituted of an oxide superconductor thin film formed on a substrate, a superconductor source electrode and a superconductor drain electrode formed at opposite ends of the superconducting channel, so that a superconducting current can flow through the superconducting channel between the source electrode and the drain electrode. A gate electrode is located through an insulating layer on the superconducting channel so as to control the superconducting current flowing through the superconducting channel. The oxide superconductor thin film of the superconducting channel is formed of a c-axis oriented oxide superconductor crystal, and the oxide superconductor thin film of the superconductor source electrode and the superconductor drain electrode are formed of an a-axis oriented oxide superconductor crystal. The superconducting channel is continuous with the superconductor source electrode and the superconductor drain electrode.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims benefit of U.S. Provisional Patent Application No. 61/427,599, filed Dec. 28, 2010, entitled GAS TURBINE ENGINE WITH BYPASS MIXER, which is incorporated herein by reference.
GOVERNMENT RIGHTS
The present application was made with the United States government support under Contract No. F33615-03-D-2357, awarded by the United States Air Force. The United States government may have certain rights in the present application.
FIELD OF THE INVENTION
The present invention relates to gas turbine engines, and more particularly, gas turbine engines with bypass mixers.
BACKGROUND
Gas turbine engines that produce bypass flow remain an area of interest. Some existing systems have various shortcomings, drawbacks, and disadvantages relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology.
SUMMARY
One embodiment of the present invention is a gas turbine engine with a bypass mixer. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for gas turbine engines and bypass mixers. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
BRIEF DESCRIPTION OF THE DRAWINGS
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
FIG. 1 schematically illustrates some aspects of a non-limiting example of a gas turbine engine in accordance with an embodiment of the present invention.
FIGS. 2A and 2B schematically illustrate some aspects of a non-limiting example of bypass mixer for a gas turbine engine in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
For purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the invention is intended by the illustration and description of certain embodiments of the invention. In addition, any alterations and/or modifications of the illustrated and/or described embodiment(s) are contemplated as being within the scope of the present invention. Further, any other applications of the principles of the invention, as illustrated and/or described herein, as would normally occur to one skilled in the art to which the invention pertains, are contemplated as being within the scope of the present invention.
Referring to the drawings, and in particular FIG. 1 , a non-limiting example of some aspects of a gas turbine engine 10 in accordance with an embodiment of the present invention is schematically depicted. In one form, gas turbine engine 10 is an aircraft propulsion power plant. In other embodiments, gas turbine engine 10 may be a land-based engine or marine engine. In one form, gas turbine engine 10 is a multi-spool turbofan engine. In other embodiments, gas turbine engine 10 may take other forms.
Gas turbine engine 10 includes a fan system 12 , a bypass duct 14 , a compressor system 16 , a diffuser 18 , a combustion system 20 , a turbine system 22 , a bypass mixer 24 , a discharge duct 26 and a nozzle 28 . Bypass duct 14 and compressor system 16 are in fluid communication with fan system 12 . Diffuser 18 is in fluid communication with compressor system 16 . Combustion system 20 is fluidly disposed between compressor system 16 and turbine system 22 . In one form, combustion system 20 includes a combustion liner (not shown) that contains a continuous combustion process during the operation of engine 10 . In other embodiments, combustion system 20 may take other forms, and may be, for example, a wave rotor combustion system, a rotary valve combustion system, or a slinger combustion system, and may employ deflagration and/or detonation combustion processes.
Fan system 12 includes a fan rotor system 30 . In various embodiments, fan rotor system 30 includes one or more rotors (not shown) that are powered by turbine system 22 . Bypass duct 14 is operative to transmit a bypass flow generated by fan system 12 to nozzle 28 . Compressor system 16 includes a compressor rotor system 32 . In various embodiments, compressor rotor system 32 includes one or more rotors (not shown) that are powered by turbine system 22 . Turbine system 22 includes a turbine rotor system 34 . In various embodiments, turbine rotor system 34 includes one or more rotors (not shown) operative to drive fan rotor system 30 and compressor rotor system 32 . Turbine rotor system 34 is drivingly coupled to compressor rotor system 32 and fan rotor system 30 via a shafting system 36 . In various embodiments, shafting system 36 includes a plurality of shafts that may rotate at the same or different speeds and directions. In some embodiments, only a single shaft may be employed. Turbine system 22 is operative to discharge an engine 10 core flow to nozzle 28 .
Discharge duct 26 extends between a bypass duct discharge portion 38 , a turbine discharge portion 40 and engine nozzle 28 . Discharge duct 26 is operative to direct bypass flow and core flow from bypass duct discharge portion 38 and turbine discharge portion 40 , respectively, into nozzle system 28 . In some embodiments, discharge duct 26 may be considered a part of nozzle 28 . Nozzle 28 in fluid communication with fan system 12 and turbine system 22 . Nozzle 28 is operative to receive the bypass flow from fan system 12 via bypass duct 14 , and to receive the core flow from turbine system 22 , and to discharge both as an engine exhaust flow, e.g., a thrust-producing flow.
During the operation of gas turbine engine 10 , air is drawn into the inlet of fan 12 and pressurized by fan 12 . Some of the air pressurized by fan 12 is directed into compressor system 16 as core flow, and some of the pressurized air is directed into bypass duct 14 as bypass flow, which is discharged into nozzle 28 via bypass mixer 24 and discharge duct 26 . Compressor system 16 further pressurizes the portion of the air received therein from fan 12 , which is then discharged by compressor system 16 into diffuser 18 . Diffuser 18 reduces the velocity of the pressurized air, and directs the diffused core airflow into combustion system 20 . Fuel is mixed with the pressurized air in combustion system 20 , and is then combusted. The hot gases exiting combustion system 20 are directed into turbine system 22 , which extracts energy in the form of mechanical shaft power to drive fan system 12 and compressor system 16 via shafting system 36 . The core flow exiting turbine system 22 is directed along an engine tail cone 42 and into discharge duct 26 , along with the bypass flow from bypass duct 14 . Discharge duct 26 is configured to receive the bypass flow and the core flow, and to discharge both as an engine exhaust flow, e.g., for providing thrust, such as for aircraft propulsion.
In some situations, it is desirable to control the ratio between the bypass flow and the core flow supplied to nozzle 28 , e.g., based on engine 10 operating parameters and output requirements. For example, an engine 10 high thrust operating mode may employ a lower bypass ratio than an engine 10 high specific fuel consumption (SFC) operating mode. Bypass mixer 24 is configured to vary the bypass ratio by increasing or decreasing the bypass flow area exposed to discharge duct 26 and nozzle 28 .
Referring to FIGS. 2A and 2B , some aspects of a non-limiting example of bypass mixer 24 in accordance with an embodiment of the present invention is schematically illustrated. Bypass mixer 24 is a variable area bypass mixer, and is configured to vary the bypass ratio of engine 10 , i.e., to vary a ratio of the bypass flow to the core flow that is directed into nozzle 28 to form the engine exhaust flow. Bypass mixer 24 includes a sled 44 and a plurality of actuators 46 (only a single actuator 46 is illustrated). Actuators 46 are coupled to sled 44 , and are configured to translate sled 44 . In one form, each actuator 46 is an electro-mechanical actuator, e.g., a linear actuator. In other embodiments, actuators 46 may be one or more other types of actuators, including linear or rotary pneumatic and hydraulic actuator types in addition to or in place of electro-mechanical actuators. In one form, the plurality of actuators 46 are spaced apart circumferentially at different locations around engine 10 . In other embodiments, other arrangements may be employed, including the use of a single actuator 46 .
Actuator 46 is configured to translate sled 44 between a first position yielding a maximum bypass flow area of bypass duct 14 that is exposed to engine nozzle 28 ; and a second position yielding a minimum bypass flow area of bypass duct 14 exposed to engine nozzle 28 . Maximum, minimum and intermediate flow areas may vary with the needs of the application. In one form, sled 44 is configured to translate parallel to an engine centerline 48 . In particular, sled 44 is configured to translate in a forward direction 50 and in an aft direction 52 . In other embodiments, sled 44 may be configured to translate in other directions in addition to or in place of forward direction 50 and aft direction 52 . In one form, sled 44 is disposed within bypass duct 14 . In other embodiments, sled 44 may be disposed in other locations internal and/or external to engine 10 .
In one form, sled 44 is piloted by a guide member 54 . Guide member 54 forms a part of an outer core flowpath wall 56 . An inner core flowpath wall 58 is formed by tail cone 42 . In other embodiments, outer core flowpath wall 56 and inner core flowpath wall 58 may be formed by other structures in addition to or in place of guide member 54 and tail cone 42 , respectively. Outer core flowpath wall 56 and inner core flowpath wall 58 define a core flowpath 60 in turbine discharge portion 40 of turbine system 22 . Core flowpath 60 channels core flow toward discharge duct 26 and nozzle 28 .
Bypass duct 14 includes an outer flowpath wall 64 and an inner bypass flowpath wall 66 . Outer flowpath wall 64 and inner bypass flowpath wall 66 define a bypass flowpath 68 that channels bypass flow toward nozzle 28 . In one form, actuator 46 is disposed in bypass flowpath 68 in bypass duct 14 . In other embodiments, actuator 46 may be disposed in other engine 10 locations. In one form, a forward portion 70 of actuator 46 is mounted on a fixed portion 72 of inner bypass flowpath wall 66 via a hinge joint 74 . In other embodiments, forward portion 70 may be mounted in other locations, e.g., such as outer flowpath wall 64 , via the same or a different mounting arrangement. In some embodiments, a hinge joint may not be employed. In one form, an aft portion 76 of actuator 46 is mounted on sled 44 via a hinge joint 74 . In other embodiments, aft portion 76 may be mounted in other locations and/or otherwise coupled to sled 44 .
Sled 44 is configured as a translatable flowpath wall structure. Sled 44 is disposed between core flowpath 60 and bypass flowpath 68 . In one form, sled 44 is configured as a ring structure, e.g., for embodiments wherein bypass flowpath 68 is annular in shape at locations adjacent to sled 44 . In other embodiments, sled 44 may take other forms. Outer bypass flowpath wall 64 includes a throat portion 78 . Throat portion 78 extends radially inward, e.g., toward core flowpath 60 . Throat portion 78 forms a part of bypass duct discharge portion 38 . Sled 44 is positioned adjacent to throat portion 78 and upstream of discharge duct 26 . In other embodiments, sled 44 may be positioned in other locations.
Sled 44 includes an inner surface 80 that forms a portion of outer core flowpath wall 56 . Sled 44 also includes an outer surface 82 that forms a portion of inner bypass flowpath wall 66 . Outer surface 82 of sled 44 is disposed opposite to outer bypass flowpath wall 64 . Outer surface 82 may have any suitable shape. Inner surface 80 of sled 44 is disposed opposite to outer core flowpath wall 56 . Inner surface 80 may have any suitable shape. In one form, throat portion 78 of outer bypass flowpath wall 64 and outer surface 82 of sled 44 form a converging nozzle 84 operative to discharge the bypass flow into discharge duct 26 and nozzle 28 . In other embodiments, a converging nozzle may not be formed as between outer bypass flowpath wall 64 and outer surface 82 of sled 44 .
Actuator 46 is configured to translate sled 44 between a first position yielding a maximum bypass flow area A 1 and a second position yielding a minimum bypass flow area A 2 . In the depiction of FIGS. 2A and 2B , the bypass flow areas A 1 and A 2 have a shape corresponding to the frustum of a cone. In other embodiments, other shapes may be employed. In some embodiments, bypass mixer 24 is configured for a non-zero minimum area A 2 , whereas in other embodiments, bypass mixer 24 may be configured to provide a minimum area A 2 of zero. During the operation of engine 10 , actuator 46 is employed to selectively translate sled 44 in direction 50 and/or direction 52 in order to obtain a desired flow area for discharging the bypass flow into discharge duct 26 , thereby obtaining a desired bypass ratio.
Embodiments of the present invention include a gas turbine engine, comprising: a fan system operative to generate a bypass flow; a bypass duct in fluid communication with the fan system and operative to transmit the bypass flow from the fan system; a compressor system in fluid communication with the fan system; a combustion system in fluid communication with the compressor system; a turbine system in fluid communication with the combustion system and operative to discharge an engine core flow; an engine nozzle in fluid communication with the fan system and the turbine system, wherein the engine nozzle is operative to receive the bypass flow and the core flow and to discharge both as an engine exhaust flow; and a variable area bypass mixer configured to vary a ratio of the bypass flow to the core flow directed into the engine nozzle to form the engine exhaust flow, wherein the variable area bypass mixer includes a translatable sled; and wherein the variable area bypass mixer is configured to translate the sled between a first position yielding a maximum bypass flow area of the bypass duct exposed to the engine nozzle and a second position yielding a minimum bypass flow area of the bypass duct exposed to the engine nozzle.
In a refinement, the bypass mixer includes an actuator coupled to the sled; and wherein the actuator is configured to translate the sled between the first position and the second position.
In another refinement, the actuator is an electro-mechanical actuator.
In yet another refinement, the sled is disposed within the bypass duct.
In still another refinement, the bypass duct includes an outer bypass flowpath wall; and wherein the sled forms at least a portion of an inner bypass flowpath wall disposed opposite to the outer bypass flowpath wall.
In yet still another refinement, the turbine system includes a discharge portion having an inner core flowpath wall; and wherein the sled forms at least a portion of an outer core flowpath wall.
In a further refinement, the bypass duct includes an outer bypass flowpath wall; wherein the turbine system includes a discharge portion having an inner core flowpath wall; and wherein the sled is configured as a ring structure disposed between the outer bypass flowpath wall and the inner core flowpath wall.
In a still further refinement, the bypass duct includes an outer bypass flowpath wall; and wherein the sled is configured to form, in conjunction with the outer bypass flowpath wall, a converging nozzle operative to discharge the bypass flow into the engine nozzle.
Embodiments include a gas turbine engine, comprising: a fan system operative to generate a bypass flow; a bypass duct in fluid communication with the fan system and operative to transmit the bypass flow from the fan system, wherein the bypass duct includes a bypass duct discharge portion operative to discharge the bypass flow; a compressor system in fluid communication with the fan system; a combustion system in fluid communication with the compressor system; a turbine system in fluid communication with the combustion system and operative to discharge an engine core flow, wherein the turbine system includes a turbine system discharge portion operative to discharge the core flow; a discharge duct in fluid communication with the turbine system discharge portion and the bypass duct discharge portion, wherein the discharge duct is configured to receive the bypass flow and the core flow, and to discharge an engine exhaust flow formed of the bypass flow and the core flow; and a translatable flowpath wall structure configured to translate in a first direction to increase a flow area of the bypass duct discharge portion exposed to the discharge duct, and to translate in a second direction to decrease the flow area.
In a refinement, the translatable flowpath wall structure is disposed between the bypass duct discharge portion and the turbine system discharge portion.
In another refinement, the engine further comprises an actuator coupled to the flowpath wall structure and operative to translate the flowpath wall structure in the first direction and in the second direction.
In yet another refinement, the actuator is disposed in the bypass duct.
In still another refinement, the bypass duct includes an outer bypass flowpath wall having a throat portion; and wherein the throat portion is shaped to extend radially inward toward the translatable flowpath wall structure.
In yet still another refinement, the translatable flowpath wall structure is disposed within the bypass duct.
In a further refinement, the bypass duct includes an outer bypass flowpath wall; and wherein the translatable flowpath wall structure is configured to form, in conjunction with the outer bypass flowpath wall, a converging nozzle operative to discharge the bypass flow into the discharge duct.
In a yet further refinement, the translatable flowpath wall structure is operative to translate between a first position yielding a maximum bypass flow area and a second position yielding a minimum bypass flow area.
In a still further refinement, the translatable flowpath wall structure is disposed upstream of the discharge duct.
In a yet still further refinement, the translatable flowpath wall structure is positioned aft of the turbine system.
Embodiments include a gas turbine engine, comprising: a fan system operative to generate a bypass flow; a bypass duct in fluid communication with the fan system and operative to transmit the bypass flow from the fan system, wherein the bypass duct includes a bypass duct discharge portion operative to discharge the bypass flow; a compressor system in fluid communication with the fan system; a combustion system in fluid communication with the compressor system; a turbine system in fluid communication with the combustion system and operative to discharge an engine core flow, wherein the turbine system includes a turbine system discharge portion operative to discharge the core flow; a discharge duct in fluid communication with the turbine system discharge portion and the bypass duct discharge portion, wherein the discharge duct is configured to receive the bypass flow and the core flow, and to discharge an exhaust flow formed of the bypass flow and the core flow; and means for varying a ratio of the bypass flow to the core flow in the discharge duct.
In a refinement, the means for varying is configured to translate between a first position yielding a maximum bypass flow area and a second position yielding a minimum bypass flow area.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment(s), but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as permitted under the law. Furthermore it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the invention, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and/or “a portion” is used the item may include a portion and/or the entire item unless specifically stated to the contrary.
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One embodiment of the present invention is a gas turbine engine with a bypass mixer. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for gas turbine engines and bypass mixers. Further embodiments, forms, features, aspects, benefits, and advantages of the present application will become apparent from the description and figures provided herewith.
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TECHNICAL FIELD
[0001] This application relates to the general field of magnetic tunneling junctions (MTJ) and, more particularly, to etching methods for forming MTJ structures.
BACKGROUND
[0002] Tantalum (Ta) is one of the best hard masks for MTJ reactive ion etching (RIE) due to a very low etching rate using Methanol and high etching selectivity to MTJ materials. Usually, a Ta hard mask is patterned by a dielectric hard mask, for example silicon dioxide (SiO 2 ) or silicon nitride (SiN x ), and the dielectric hard mask is patterned by photoresist (PR). This is because there will be a fencing issue if PR is used directly to pattern Ta. However, SiO 2 etching by high SiO 2 /PR selectivity chemical etching, e.g. C 4 F 8 , will generate severe striations around the SiO 2 sidewall which will transfer to the Ta and even to the MTJ sidewall and lead to rough sidewalls and poor uniformity within the chip. Etching SiO 2 by CF 4 usually has much less sidewall striation; however, the poor SiO 2 /PR selectivity will limit the thickness of SiO 2 and also Ta that can be etched with the same thickness PR.
[0003] Several patents show the use of various hard masks in etching MTJ stacks. These include U.S. Pat. No. 8,722,543 (Belen et al), U.S. Pat. No. 8,450,119 (Torng et al), U.S. Pat. No. 7,593,193 (Inomata et al), and U.S. Pat. No. 7,001,783 (Costrini et al). Other patents show passivating processes: U.S. Pat. No. 7,169,654 (Zia et al), U.S. Pat. No. 6,395,621 (Mizushima et al), U.S. Pat. No. 8,716,072 (Bangsaruntip et al), and U.S. Pat. No. 7,471,445 (Pan). The process of the present disclosure is not taught or suggested by any of these references.
SUMMARY
[0004] It is an object of the present disclosure to provide a hard mask and an etching scheme to improve etching profile and etching uniformity in forming MTJ structures.
[0005] Yet another object of the present disclosure is to provide a hard mask and etching scheme for MTJ structures wherein a thick Ta layer remains as a top electrode without increasing the thickness of a photoresist layer.
[0006] In accordance with the objectives of the present disclosure, a method for etching a magnetic tunneling junction (MTJ) structure is achieved. A stack of MTJ layers is provided on a bottom electrode. An electrode layer is deposited on the stack of MTJ layers. A photoresist mask is formed on the electrode layer. The electrode layer is etched away where it is not covered by the photoresist mask to form a metal hard mask. The metal hard mask is passivated during or after etching to form a smooth hard mask profile. Thereafter, the photoresist mask is removed and the MTJ structure is etched using the metal hard mask wherein the metal hard mask remaining acts as a top electrode. The resulting MTJ device has smooth sidewalls and uniform device shape.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the accompanying drawings forming a material part of this description, there is shown:
[0008] FIGS. 1 through 4 illustrate in cross-sectional representation steps in a preferred embodiment of the present disclosure.
DETAILED DESCRIPTION
[0009] The present disclosure provides a method of etching the whole MTJ structure to make the electric isolation between MTJ junctions. This method can improve etching uniformity and etching profile within wafers and within chips. For example, a STT-RAM (spin transfer torque random access memory) can be manufactured based on a Ta (or TaN, Ti, TiN, W, etc.)/PR etching mask scheme. Usually when PR is used to directly pattern a metal hard mask layer, fencing occurs. The fencing issue can be solved by a passivation step, which is to purge O 2 , H 2 O vapor, or air into the chamber or to treat the wafer by low power O 2 plasma after the metal hard mask opening or in between metal hard mask etching steps but before the PR strip, or to expose the wafer to air, or to water-rinse the wafer after metal etching This passivation step can generate a more uniform etching profile with smoother sidewalls. This method can also generate thick Ta remaining as the top electrode without increasing the thickness of the PR.
[0010] One previous method of etching a MTJ stack used a hard mask stack of Ta/SiO 2 /PR, in which Ta was also used for the top electrode of the MTJ. The SiO 2 (or similar dielectric layer) was defined by PR and etched by CF 4 . The Ta (or similar metal layer) was defined by SiO 2 and etched by CF 4 . Then, the Ta layer was used as the MTJ etching mask and as the top electrode after the MTJ etch.
[0011] Etch rate and selectivity are listed in Table I and Table II.
[0000]
TABLE I
Etch Rate of Different MTJ Etch Mask Materials.
Etch Rate (nm/min) in
Etch Rate (nm/min) in
Material
CF 4
CH 3 OH
PR
203.40
NA
Ta
83.4
4.10
SiO2
126.00
26.70
[0000]
TABLE II
Etching Selectivity in CF 4 of Different MTJ Etch mask Materials
Etch
Materials
Selectivity
SiO 2 /PR
0.62
Ta/SiO 2
0.66
Ta/PR
0.41
[0012] The old MTJ etch using Ta/SiO 2 /PR masks has more limitations to generating good uniformity and smooth sidewalls. One reason is the necessity to transfer the pattern twice. Although the selectivity of Ta/SiO 2 /PR using CF 4 is comparable to Ta/PR using CF 4 , as shown in Table II, a SiO 2 protection layer (˜150-200 A) was required before PR strip to obtain a better profile, which limited Ta thickness although thicker Ta is always desired. PR strip also will consume SiO 2 , which will limit the Ta thickness even further. However, CF 4 can generate a relatively smoother sidewall than other high selectivity etch chemistries.
[0013] The new MTJ etching mask of the present disclosure will be described in more detail with reference to the drawing FIGS. 1-4 . Referring now more particularly to FIG. 1 , there is shown a bottom electrode layer 10 . On the bottom electrode have been formed a stack of layers 14 that will be patterned to form a MTJ structure. A layer 16 of Ta, or alternately tantalum nitride (TaN), titanium (Ti), titanium nitride (TiN), tungsten (W), or the like, is deposited on the MTJ stack 14 . This Ta layer, or electrode layer, 16 should have a thickness of between about 380 and 1000 Angstroms. A photoresist layer is deposited to a thickness of between about 1000 and 4700 Angstroms and patterned to form photoresist mask 20 .
[0014] Since the PR layer is coated on Ta instead of transparent SiO 2 or SiN X , a better profile PR mask 20 can be obtained.
[0015] Now, referring to FIG. 2 , the Ta or electrode layer mask 17 is defined by the PR mask 20 , using reactive ion etching (RIE) with Fluorine or Chlorine based chemicals.
[0016] One more step is added after Ta etching, but before stripping the PR mask. A passivation step is performed by flowing O 2 , H 2 O vapor, or air into the etching chamber or by low power O 2 plasma after Ta etching. Alternatively, the wafer can be exposed to the ambient air or be water rinsed after etching. This step is critical to form smooth sidewalls and a uniform shape of the device.
[0017] The passivation step after Ta-etching is critical for the Ta (or TaN, Ti, TiN, W, etc.)/PR etching mask. Without passivation or with insufficient passivation, the shape of the MTJ device will be impacted due to the fencing issue, which will lead to rough device sidewalls and a non-uniform shape of the device. The current tool has limitations on H 2 O vapor and air flow and O 2 flow rate and pressure, so we can use the alternative method for passivation, which is low power O 2 plasma treatment or exposure of the wafer to the ambient air or water rinsing the wafer. The exposure time has been found to be not very critical to the smoothness of the sidewall. For example, preferred flow rates for H 2 O vapor or O 2 or air are between about 500 and 3000 sccm, at a pressure of between about 1 and 3 Torr. The preferred O 2 plasma treatment is low power (source power<100 W, and bias power=0).
[0018] As another alternative, the passivation may be performed during the Ta etching step instead of after the Ta etching by flowing H 2 O vapor or O 2 or air into the etching chamber along with the etching gases. For example, preferred flow rates for H 2 O vapor or O 2 or air are between about 500 and 1000 sccm, at a pressure of between about 1 and 3 Torr.
[0019] Sometimes, if the electrode layer 18 is thicker than 380 Angstroms, the metal etch needs to be separated into two or more steps, and the passivation is required between every two steps.
[0020] The critical passivation step before PR removal provides a very uniform electrode mask 18 with smooth sidewalls. Now, the PR mask 20 is removed using conventional stripping methods, leaving Ta or electrode mask 18 on the MTJ layer stack, as shown in FIG. 3 .
[0021] The passivated mask 18 then is used as the MTJ etching mask to etch the MTJ device 15 , by either RIE or ion beam etching (IBE) as shown in FIG. 4 . The MTJ is etched using CH 3 OH based chemicals or CO and NH 3 -based chemicals. For example, the etchant can be CH 3 OH or CH 3 OH with other gases such as Ar, O 2 , H 2 , N 2 , or the like.
[0022] The remaining mask 18 is used as the top electrode after the MTJ etch. It should be noted that a thick Ta layer is required for IBE due to poor selectivity of IBE. The method of the present disclosure can be also beneficial because this new method can etch thicker Ta with the same thickness of PR.
[0023] The new MTJ etch process of the present disclosure using Ta (or TaN, Ti, TiN, W, etc.)/PR etching mask with added passivation step can give us a better PR profile because:
the PR is coated on metal instead of on transparent SiO 2 or SiN x there are fewer pattern transfer steps the SiO 2 or SiN X striation effect is avoided the hard mask has a smooth profile resulting in a better etching profile and better uniformity of the MTJ device within the wafer and within the chip a thicker Ta layer can be etched using the same thickness of PR, which will provide a larger CMP process window, and leave enough thickness of Ta as the top electrode of the MTJ.
[0029] The present disclosure provides an improved process for MTJ etching by using a simple Ta/PR etching mask stack and by adding a passivation step during or after metal etching and prior to PR stripping. A better photoresist and etch profile and better uniformity within the chip and across the wafer are obtained. The passivation step by O 2 , O 2 plasma, H 2 O vapor, H 2 O, or air is critical to obtain smooth sidewalls and uniform devices. This simple mask stack also can be beneficial to etch a thicker top electrode (Ta).
[0030] Although the preferred embodiment of the present disclosure has been illustrated, and that form has been described in detail, it will be readily understood by those skilled in the art that various modifications may be made therein without departing from the spirit of the disclosure or from the scope of the appended claims.
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A hard mask stack for etching a magnetic tunneling junction (MTJ) structure is described. An electrode layer is deposited on a stack of MTJ layers on a bottom electrode. A photoresist mask is formed on the electrode layer. The electrode layer is etched away where it is not covered by the photoresist mask to form a metal hard mask. The metal hard mask is passivated during or after etching to form a smooth hard mask profile. Thereafter, the photoresist mask is removed and the MTJ structure is etched using the metal hard mask wherein the metal hard mask remaining acts as a top electrode. The resulting MTJ device has smooth sidewalls and uniform device shape.
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RELATED APPLICATIONS
[0001] This application is a divisional of co-pending U.S. patent application Ser. No. 10/653,448, filed Sep. 2, 2003, which claims the benefit of U.S. patent application Ser. No. 09/556,169, filed Apr. 21, 2000, (now U.S. Pat. No. 6,645,201) entitled “Systems and Methods for Treating Dysfunctions in the Intestines and Rectum,” which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to systems and methods for treating interior tissue regions of the body. In particular, this invention relates to the treatment of hemorrhoids.
BACKGROUND OF THE INVENTION
[0003] Hemorrhoids are cushions of tissue and varicose veins located in and around the rectal area. Hemorrhoids are very common, especially during pregnancy and after childbirth. It has been estimated that about half the population has hemorrhoids by age 50. They are caused by increased pressure in the veins of the anus. The most common cause is straining during bowel movements. Constipation, prolonged sitting during bowel movements, and anal infection may also contribute to the development of hemorrhoids. In some cases, hemorrhoids may be a manifestation of other diseases, such as liver cirrhosis.
[0004] Symptoms of hemorrhoids include rectal bleeding, particularly after bowel movements, pain during bowel movements, anal itching, mucus discharge, epithelial cell changes, thrombosis, incarcerations, skin tags, and disordered defecation. Symptoms may range from mild to severe.
[0005] In many cases, hemorrhoids are diagnosed by rectal examination. However, stool guaiac testing for the presence of occult blood, as well as sigmoidoscopy, anoscopy, and proctoscopy procedures may also be useful in establishing a diagnosis.
[0006] Treatment is generally based on the severity of symptoms. Mild cases may be controlled by conservative, non-invasive techniques such as drinking fluids, adhering to a high-fiber diet, use of stool softeners, and/or use of stool-bulking agents such as fiber supplements. In addition, treatments for symptomatic relief may include corticosteroid cream and/or warm baths to reduce pain and swelling.
[0007] For more severe cases involving severe pain and itching in patients who have not responded to conservative therapy, surgical intervention may be required to prevent more serious complications. For example, frequent or prolonged bleeding may result in iron deficiency anemia.
[0008] Conventional surgical techniques may be generally classified in three categories as being directed to either the anal sphincter, the hemorrhoidal tissue, or to the hemorrhoid feeding vessels. Surgical procedures directed to stretching or cutting of the internal anal sphincter include Lord's procedure, incisional sphincterotomy, and closed lateral anal sphincterotomy. However, these procedures may result in incontinence and thus are rarely indicated.
[0009] Surgical procedures directed to hemorrhoidal tissue include excisional hemorrhoidectomy and laser-assisted hemorrhoidectomy. Such procedures are relatively invasive and thus have a longer recovery period.
[0010] Surgical procedures directed to the feeder vessels include elastic or rubber band ligation, sclerosis, and photocoagulation. These procedures are associated with a variety of complications, including infection, hemorrhage, ulceration, oleogranuloma, allergic reaction, and prostate infection.
[0011] The need remains for minimally-invasive systems and methods for treating hemorrhoids.
SUMMARY OF THE INVENTION
[0012] The invention provides systems and methods that treat hemorrhoids. The systems and methods introduce a treatment device into the anal canal to extend above a hemorrhoidal plexus and adjacent a tissue region containing blood vessels that feed the hemorrhoidal plexus. The systems and methods operate the treatment device to affect tissue morphology in the tissue region to occlude or otherwise reduce blood flow through the vessels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an anatomical view of the rectum and anal canal.
[0014] FIG. 2 is a section view taken along line 2 - 2 in FIG. 1 .
[0015] FIG. 3 is an anatomical view of an external hemorrhoid.
[0016] FIG. 4 is an anatomical view of an internal hemorrhoid.
[0017] FIG. 5 is an anatomical view of a mixed internal and external hemorrhoid.
[0018] FIG. 6 is a schematic view of a system for treating hemorrhoids that includes a treatment device with a tissue-piercing member.
[0019] FIG. 7 illustrates a treatment device deployed in the anal canal with the tissue-piercing member in a retracted position.
[0020] FIG. 8 is a view similar to FIG. 7 and illustrating the tissue-piercing member piercing tissue containing blood vessels that feed the internal and external hemorrhoidal plexes.
[0021] FIG. 9 illustrates a treatment device with multiple tissue-piercing members deployed in the anal canal and having multiple tissue-piercing members in a retracted position.
[0022] FIG. 10 is a view similar to FIG. 9 and illustrating the tissue-piercing members piercing tissue containing blood vessels that feed the internal and external hemorrhoidal plexes.
[0023] FIG. 11 illustrates the shrinkage of tissue in a feeder vessel region that occludes or otherwise reduces flow through the feeder vessels.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
[0000] I. Anatomy of the Rectum and Anal Canal
[0025] As FIG. 1 shows, the rectum 10 is the terminal part of the large intestine 12 . The rectum 10 extends from the sigmoid flexure 14 (which is the narrowest part of the colon) to the anal orifice 16 . The rectum 10 is about 15 to 17 cm in overall length.
[0026] The lower or inferior portion of the rectum 10 is called the anal canal 18 . It typically extends about 4 to 5 cm above the anal orifice 16 . A visible line of demarcation between tissue, called the pectinate (dentate) line 20 , exists about 2.5 to 3 cm above the anal orifice 16 .
[0027] As best seen in FIG. 2 , feeder vessels 22 descend to the anal canal 18 in three locations, the right posterior (RP), right anterior (RA), and left posterior (LP). Each of the three locations (RP, RA, and LP) then splits to form an internal hemorrhoidal plexus (or cushion) 24 (see FIG. 3 ) located above the dentate line 20 and an external hemorrhoidal plexus (or cushion) 26 located below the dentate line 20 . That is, there are three internal hemorrhoidal plexes 24 (RP, RA, and LP) located above the dentate line 20 and three external hemorrhoidal plexes 26 (RP, RA, and LP) located below the dentate line 20 .
[0028] Increased pressure in the veins of the anus causes the enlargement and swelling of one or more hemorrhoidal plexes 24 or 26 . This inflamed state is commonly referred to as a hemorrhoid (or pile). When the inflammation occurs in a hemorrhoidal plexus 26 below the dentate line 20 at the anal opening 16 , it is referred to as an external hemorrhoid, shown in FIG. 3 . When the inflammation occurs in a hemorrhoidal plexus 24 above the dentate line 20 near the beginning of the anal canal 18 , it is referred to as an internal hemorrhoid, shown in FIG. 4 . In some cases, a mix of internal and external hemorrhoids may be present, as illustrated in FIG. 5 . A hemorrhoid may even protrude outside the anus.
[0029] It should be noted that the views of the rectum 10 and anal canal 18 shown in FIG. 1 , and elsewhere in the drawings, are not intended to be strictly accurate in an anatomic sense. The drawings show the rectum 10 and anal canal 18 in somewhat diagrammatic form to demonstrate the features of the invention.
[0000] II. System Overview
[0030] A tissue treatment system 28 that embodies features of the invention is shown in FIG. 6 . The tissue treatment system 28 includes a tissue treatment device 30 . The treatment device 30 is sized and configured to affect tissue morphology above the dentate line 20 , to occlude or otherwise reduce blood flow through one or more feeder vessels for one or both hemorrhoidal plexus 24 or 26 .
[0031] The treatment device 30 can affect tissue morphology by different physiologic mechanisms. For example, the treatment device 30 can serve to inject an agent used to seal vascular access sites, e.g., collagen or PEG hydrogel material—or to place a material that cause blood to clot, e.g., platinum coils deployed at the site of an aneurysm. In the illustrated embodiment, heat is applied to shrink tissue. In this arrangement, the treatment device 30 is coupled to a source of energy 32 by cable 33 . If desired, the system 28 can also include certain auxiliary processing equipment. In the illustrated embodiment, the auxiliary processing equipment comprises an external fluid delivery or irrigation source 34 coupled to the treatment device 30 by tubing 35 .
[0032] A. The Tissue Treatment Device
[0033] The tissue treatment device 30 serves to deliver energy to tissue regions at or near feeder vessels 22 above the internal or external hemorrhoidal plexes 24 and 26 to occlude or otherwise reduce the blood supply to the hemorrhoidal plexes 24 and 26 . In the illustrated embodiment, the energy source 32 supplies radiofrequency energy. It is contemplated that other forms of energy can be applied, e.g., coherent or incoherent light, heated or cooled fluid, resistive heating, microwave, ultrasound, a tissue ablation fluid, or a cryogenic fluid. Energy is delivered submucosally to heat targeted feeder vessel regions to create scar tissue and shrink tissue, thereby occluding or otherwise reducing blood flow through a vessel or vessels 22 . By occluding or otherwise reducing blood supply from above the hemorrhoidal plexes 24 or 26 , blood is essentially prevented from pooling in the vessels 22 and the hemorrhoidal plexes 24 or 26 . Since blood is prevented from pooling, hemorrhoids are shrunk or prevented.
[0034] As FIG. 6 shows, the tissue treatment device 30 includes a handle or hand grip 36 that carries an operative element 38 . In the illustrated embodiment, the operative element 38 takes the form of a hollow tubular barrel 40 , although it should be appreciated that a semi-circular device, e.g., shaped like curved tongue depressor, could be used as well. In the illustrated embodiment, the barrel 40 may be made from a transparent, molded plastic material or other suitable material to enable visualization through the barrel 40 . The barrel 40 terminates with a blunt, rounded distal working end 42 to aid passage of the barrel 40 through the anal canal 18 without need for a separate introducer. The hand grip 36 desirably includes a viewing port 44 for looking into the transparent, hollow interior of the barrel 40 to visualize surrounding tissue.
[0035] The hand grip 36 and operative element 38 can form an integrated construction intended for single use and subsequent disposal as a unit. Alternatively, the hand grip 36 can comprise a nondisposable component intended for multiple uses. In this arrangement, the operative element 38 comprises a disposable assembly, which the physician releasably connects to the hand grip 36 at the time of use and disconnects and discards after use. The proximal end of the barrel 40 can, for example, include a male plug connector that couples to a female plug receptacle on the hand grip 36 .
[0036] With reference to FIGS. 7 and 8 , a tissue-piercing member 46 is movably contained within the barrel 40 . In the illustrated embodiment, the tissue-piercing member 46 takes the form of a needle electrode. The electrode 46 is selectively movable between a retracted position ( FIG. 7 ) and an extended position ( FIG. 8 ). Means are provided for moving the electrode 46 between the retracted and extended positions. For example, the needle electrode 46 can be mechanically linked to a finger-operated pull lever 48 on the hand grip 36 . By operation of the pull lever 48 , the distal ends of the needle electrodes 46 are moved between the retracted position and the extended position. An electrical insulating material 50 is desirably coated about the needle electrodes 46 , except for a prescribed region of the distal ends, where radio frequency energy is applied to tissue.
[0037] In an alternate embodiment, the operative element 38 carries an array of needle electrodes 46 . The array of electrodes 46 is configured to deliver energy in a prescribed pattern to a targeted treatment site. It is contemplated that the number and placement of electrodes 46 can vary as needed for the desired procedure and to accommodate individual anatomy. FIGS. 9 and 10 illustrate an embodiment in which a pair of needle electrodes 46 is movably contained in a side-by-side relationship on the barrel 40 .
[0038] The barrel 40 also preferably carries temperature sensor 52 , one of which is associated with each needle electrode 46 . The sensors 52 sense tissue temperature conditions in the region adjacent to each needle electrode 46 . Preferably, the distal end of each needle electrode 46 also carries a temperature sensor 54 .
[0039] In an optional embodiment, the treatment agent delivery apparatus 30 may convey processing fluid from a fluid source 34 for discharge at or near the treatment site. The processing fluid can comprise, e.g., saline or sterile water, to cool surface tissue while energy is being applied by the electrode 46 to thereby protect the surface tissue from thermal injury. For example, as seen in FIG. 6 , barrel 40 may be coupled via tubing 35 to the fluid source 34 to convey fluid, e.g., through holes (not shown) in the barrel 40 , to contact tissue at a localized position surrounding the electrodes 46 . Alternatively, one or more electrodes 46 deployed by the operative element 38 can also be used to inject the fluid into the treatment site. In this arrangement, the electrode 46 includes an interior lumen (not shown) and the fluid source 34 is coupled to the lumen.
[0000] III. System Use
[0040] In use, the physician grasps the hand grip 36 and guides the barrel 40 into the anal canal 18 (see FIGS. 7 and 9 ). The pull lever 48 is in the neutral position and not depressed, so the needle electrodes 46 occupy their normal retracted position. Looking through the viewing port 44 , the physician visualizes the pectinate (dentate) line 20 through the barrel 40 . Looking through the barrel 40 , the physician positions the distal ends of the needle electrodes 46 at a desired location above the pectinate (dentate) line 20 , e.g., 2-4 cm above the dentate line 20 . A fiberoptic can also be inserted into the barrel 40 to provide local illumination, or the physician can wear a headlamp for this purpose. In an embodiment where the barrel is not completely circumferential, but more U-shaped (thereby not occupying the entire anal canal 18 ), an endoscope or mirrors may be used to acquire visualization of the dentate line 20 .
[0041] It may be desirable to bias the end of the treatment device 30 with a bend, to thereby facilitate contact with tissue in this region of the anal canal, as tissue in this region tends to be loose or flaccid. An expandable member may be desired to dilate tissue in this region in concert with use of the treatment device 30 .
[0042] Once the distal end of the barrel 40 is located at the targeted site, the physician depresses the pull lever 48 . The needle electrodes 46 advance to their extended positions (see FIGS. 8 and 10 ). The distal ends of the electrodes 46 pierce and pass through the mucosal tissue adjacent the targeted feeder vessel region without penetration of a hemorrhoidal plexus 24 or 26 . The physician applies radio frequency energy through the needle electrodes 46 . The energy can be applied simultaneously by all electrodes 46 , or in any desired sequence, to apply energy in a selective fashion to a targeted feeder vessel region below mucusal tissue. The applied energy creates one or more lesions, or a prescribed pattern of lesions, below the mucosal surface. The electrodes 46 are then retracted, and the device 30 withdrawn.
[0043] If desired, the process may be repeated to form a desired lesion pattern at a single location or at multiple locations. With the electrodes 46 in the retracted position, the operative element 38 may be rotated and/or axially advanced or retracted. The electrodes 46 are then advanced to their extended position and energy is again applied to form a lesion or series of lesions. The lesion pattern may be along a particular feeder vessel region for treatment of a single hemorrhoidal plexus 24 or 26 . Alternatively, the lesions may be created in multiple feeder vessel regions for treatment of multiple hemorrhoidal plexes 24 or 26 . For example, FIG. 11 illustrates the formation of a pair of lesions 58 A in a first internal hemorrhoidal plexus 24 A, and a second pair of lesions 58 B in a second internal hemorrhoidal plexus 24 B. As FIG. 11 also illustrates, the lesions 58 A and 58 B occlude or otherwise reduce, at least in part, blood flow through the feeder vessels 22 and thereby occlude or otherwise reduce the blood supply from above the hemorrhoidal plexes 24 A and 24 B. As a result, blood is essentially prevented from pooling in the vessels 22 and the hemorrhoidal plexes 24 A and 24 B. Since blood is prevented from pooling, hemorrhoids are shrunk or prevented. By targeting selected feeder vessel regions, the procedure can be adapted for the treatment of a single or multiple internal hemorrhoids, a single or multiple external hemorrhoids, or a combination of internal and external hemorrhoids.
[0044] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
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Systems and methods treat hemorrhoids by introducing a treatment device into the anal canal to extend above a hemorrhoidal plexus and adjacent a tissue region containing blood vessels that feed the hemorrhoidal plexus. The systems and methods operate the treatment device to affect tissue morphology in the tissue region to occlude or otherwise reduce blood flow through the vessels.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/144,665 filed Jan. 14, 2009 and U.S. Provisional Patent Application Ser. No. 61/144,694 filed Jan. 14, 2009, and incorporates by reference the entirety of each thereof.
BACKGROUND
1. The Field of the Invention
This invention relates to oil and gas production and, more particularly, to novel systems and methods for environmental protection from, and remediation of, production materials and processes.
2. The Background Art
The production and transportation of petroleum resources, including oil and natural gas, often involves the introduction of emissions of substances considered pollutants into the natural environment. Often the production areas are in locations regarded as being particularly environmentally sensitive. Sources of pollutants include engines, heaters, flares, road surfaces, and production fluids themselves. Production water often contains dissolved solids (e.g., salts) that make it unsuitable for ordinary beneficial (e.g., agricultural, culinary, etc.) use or release directly into the environment. Hauling water to and from the production site usually requires extensive and expensive trucking over roads through environmentally sensitive areas. Similarly, large amounts of waste heat from numerous engines, heaters, burners, flares, or combinations thereof are released into that same sensitive environment. Any company or state with extensive fossil fuel reserves will have much at stake over these issues.
What is needed is a system and method to address the issues of effectively mitigating environmental impacts associated with fossil fuel development and production.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing, in accordance with the invention as embodied and broadly described herein, a method and apparatus are disclosed in one embodiment of the present invention as including a source of combustion exhaust, a substantially horizontal “stack” acting also as a scrubber, and a recovery system. The recovery system may typically include a blower, a cyclone, a condenser, and various heat exchangers.
Saline production water is often available in the same location as flares, burners, heaters, engines and compressor stations. Basic design concepts have been developed for using production water to effectively scrub the emissions of volatile organic compounds, unburned hydrocarbons, combustion particulates, and sulfurous oxides. From these combustion sources, systems in accordance with the invention simultaneously put the waste heat from these combustion sources to beneficial use to evaporate production brine, thus reducing the volume of saline production water to be disposed of, in an environmentally responsible manner.
In many oil/gas fields, the quantities of waste heat available are not sufficient to process the amount of saline water produced in the same area. In such situations, the same design concepts provide for clean emission-scrubbed combustion of field gas to supplement any waste heat available. An efficient energy recovery system makes evaporation a cost effective way to dispose of the saline water with minimal environmental impact. In addition, the energy recovery system also returns a large fraction of the saline production water as clean distilled water.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1 is a schematic perspective view of one embodiment of an apparatus in accordance with the invention;
FIG. 2 is a schematic perspective view of an alternative embodiment of an apparatus in accordance with the invention;
FIG. 3 is a schematic perspective view of the embodiment of FIG. 1 augmented with a bank of heat exchangers;
FIG. 4 is a schematic perspective view of an alternative embodiment of an apparatus in accordance with the invention, augmented with heat and moisture recycling heat exchangers;
FIG. 5 is a schematic perspective view of the embodiment of FIG. 4 with double walled scrubber recycling heat and moisture from the heat exchangers;
FIG. 6 is an end cross-sectional view of one embodiment of passages of a heat exchanger in accordance with the invention;
FIG. 7 is a top quarter perspective view of the heat exchanger of FIG. 6 ; and
FIG. 8 is a side elevation view of the heat exchanger of FIGS. 6 and 7 assembled with end manifolds.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
It will be readily understood that the components of the present invention, as generally described and illustrated herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented here and in the Appendix attached hereto, is not intended to limit the scope of the invention, as claimed, but is merely representative of various embodiments of the invention.
Notwithstanding consolidation of multiple wells at a single production site, as well as various waste containment and site restoration, environmental impacts continue from the production of natural gas and oil. Typically, sources of particulate emissions include heaters used to reduced the viscosity of oil. Likewise, various motors or engines designed to run on petroleum byproducts such as “field gas” produce heat and hydrocarbon emissions. Meanwhile, production of small quantities of field gas in oil fields results in gas having to be flared off. Thus, flares and other sources contribute particulate and thermal emissions. The alternative to flaring is to release unburned hydrocarbons into the atmosphere. Even after burning or other remediation methods, unburned volatiles are still often returned into the environment intentionally or accidentally.
Heaters typically burn field gas to warm crude oil to reduce its viscosity for better handling. The high viscosity of crude oil is often responsible for high pumping costs. Pumping costs may be reduced by reducing viscosity of the oil. Some crude oil is so thick that it actually behaves as a thixotropic material. Also, as part of the separation process for separating water from oil, gas, or both heaters may be employed.
Engines used in oil fields and gas occur in two principal functions. Natural gas typically is compressed to increase the mass flow rate to collection points from the distribution networks at individual oil fields Likewise, crude oil must be pumped or otherwise transported from the well head to a collection point. Some wells produce little enough to transport it on trucks. Others produce sufficient volume to justify pumping from the well head to collection points. From collection points, crude oil may still be trucked or otherwise transported.
In any event, pumping requires drive motors. Thus, engines are integral to the transport of crude oil and natural gas. Meanwhile, production of oil requires pumps drawing oil from the earth. Moreover, drilling processes themselves rely on engines. Thus, whether driving a pump, compressor, generator, or drilling rig, engines are a burner of fuels, and a generator of thermal and other emissions.
Flares have been reduced in recent years but remain in several circumstances. Typically, if a field produces substantial quantities of natural gas, commercially significant volumes, then collection is developed and an infrastructure is put in place to do so. In other circumstances insufficient quantities may not justify collection and transport. In these circumstances, unsteady or gas may be flared off. Meanwhile, gas production may not be uniform. In such circumstances, periodic gas generation may require flaring. Thus, some amount of flaring of field gas is substantially unavoidable. However, the vision of a tall stack with a large, orange, sooty flame flaring at the top thereof creates public relations issues as well as legitimate environmental concerns.
Meanwhile, unburned volatiles existing in the process of producing natural gas and crude oil arise in several circumstances. For example, unburned volatiles may be part of the production water separated from oil and gas products. Meanwhile, various combustion processes (e.g., engines, heaters, etc.) may still pass unburned volatiles through. Unburned hydrocarbons, whether heavy or volatile, can result from heavy molecular chains that are not completely or efficiently broken down and combusted. Likewise, unburned volatiles may simply result from processes and equipment that burn at temperatures and in flow patterns that do not complete combustion of all volatiles. Meanwhile, volatiles can arise from other sources as well.
The result is tank batteries, sumps, holding ponds, possible exposure to leaks or breaks in containment structures, and the like. All of these may give rise to the need to handle unburned volatiles.
In summary, oil, gas, saline water, (production water), and the like are the typical fluids from oil and gas production. Since evaporation ponds, injection wells, and hauling are all subject to their own difficulties, an apparatus and method in accordance with the invention may augment the disposal of production water. Since containment, hauling, reinjection, evaporation, and the like all have risks and limits, an apparatus and method in accordance with the invention deals with production water at a wide variety of salinity values, net volumes, and so forth.
In various embodiments of apparatus and methods in accordance with the invention, production water is used to scrub oil and gas emissions in the field. Meanwhile, waste heat from combustion sources is used in evaporating production water. The production water vapor from evaporation may be dispersed into the atmosphere, or may be re-condensed as distilled water for use in systems that would otherwise not tolerate the water as a saline solution.
Referring to FIGS. 1 and 2 , in one embodiment of an apparatus 10 or system 10 in accordance with the invention, a horizontal remediator 200 may act as an evaporator 200 , as a scrubber 200 , or both. The scubber-evaporator 200 relies on a blower 202 to draw a flow 204 of combustion emissions. Combustion emissions may exist, for example, as an exhaust stream 204 from a flare, a heater, an engine, or the like. A gas burner 206 device or region may hold a flame 207 burning field gas as a heat source or may augment combustion of unburned hydrocarbons (e.g., volatile organic compounds or VOCs) in the exhaust stream 204 , or may serve to do both.
Meanwhile, an upstream damper 208 on the flow 204 may be used to regulate the back pressure on the engine, burner, or other source feeding an exhaust stream into the system. A system of nozzles 210 optimized to effect evaporation of water injects an atomized spray 212 of production water (brine, typically) from a feed line 214 into the exhaust stream 204 . The system 10 typically contains salts, and recovers them from the exhaust stream 204 in a cyclone 216 . A blower 202 maintains a draw on the cyclone 216 . Feeding the exhaust stream 204 from a scrubbing “stack” 200 , oriented as a horizontal tube 201 intersecting at the edge of the cyclone 216 , promotes the separation of solids, liquids, or both from the vapor and gases, by the cyclone 216 .
In certain embodiments, a burner 206 may be installed as an integral part of the evaporation module 200 in accordance with the invention. In such an embodiment, the burner 206 may be installed in a separate or integrated conduit 218 fed by air flow regulated through a damper 208 . The flow 204 of combustion products is then transported through the conduit 218 to be directly intercepted by atomized sprays 212 of production water. Thereafter, the exhaust products, scrubbed by the liquids, together with the evaporated liquids (now vapors) and precipitated or in trained solids, may be sent into the cyclone 216 for separation.
Ultimately, the blower 202 draws the noncondensible gases and the vapors out, exhausting them to the atmosphere or a condenser. Salt as solids, heavy hydrocarbons, other particles scrubbed out, as well as liquids may remain behind, exiting the bottom 219 of the cyclone 216 , such as through a drain 220 , after being separated out by the cyclone 216 .
In the cyclone 216 , the flow 204 containing multiple phases such as noncondesible gases, vapors, liquids, and solids, is received as an incoming flow 222 . The incoming flow 222 tends to strike the wall 224 of the cyclone 216 , directing the flow 222 in a circumferential direction centripetal force moves heavier (denser) materials outward 226 , where they may strike the wall 224 and fall downward toward the bottom 219 . Lighter (less dense) materials, more easily accelerated by fluid drag of surrounding vapors and gases, move inward 228 . These less dense, more easily entrained, materials eventually follow a path 230 upward toward an outlet line 232 or conduit 232 evacuating the cyclone 216 .
The outlet line 232 feeds into an inlet 234 or inlet portion 234 receiving the noncondensible gases (oxygen, nitrogen, etc.), vapors (water, etc.) from the flow 204 . Thus, the discharge 236 from the blower 202 may pass into the atmosphere or into a device, such as a condenser, for further processing.
Not only does the damper 208 provide the opportunity to control back pressure on a heat source such as an engine, heater, flare, or the like, the injection nozzles 210 may be designed to provide repeatedly a cone of spray that will completely cover the cross section of the “stack” 200 formed by the conduit 218 . (The reference numeral 218 refers to conduits generally, and when used with a trailing letter indicates a specific instance thereof.) Thus, by spraying axially along a conduit (forward, backward, or both with respect to the exhaust flow) the flow 204 may pass through several conical curtains of spray 214 that effectively present a barrier across the entire cross section of the conduit 201 of the evaporator 200 or scrubber 200 . Spray 212 direction, velocity, particle size, chemical content, or the like may be optimized for scrubbing, evaporating, or both.
In some circumstances, the balance between scrubbing and evaporating may be accomplished by adjusting the length of the scrubber 200 to provide the needed quantity of evaporation as well as scrubbing required. Again, the damper 208 may also be used to optimized flows, balancing back pressure on the burner 206 (or engine, flare, heater, etc.) while also regulating the mixture of dry ambient air mixed into the exhaust flow 204 .
A secondary flame 207 or burner 206 for reacting or oxidizing unburned hydrocarbons or volatile organic compounds remaining in an exhaust stream 204 may be operated or installed according to need. If comparatively clean field gas, predominantly natural gas (e.g., methane), is available, the presence of volatile organic compounds may be manageable. By contrast, a diesel engine operating on a well site may release more particulate emissions and unburned volatile or non-volatile organic compounds. Likewise, burning field gas having a higher fraction of larger molecules than does methane, and perhaps some very large petroleum molecules entrained, may tend toward higher levels of volatile organic compounds in the exhaust.
Referring to FIG. 3 , while continuing to refer generally to FIGS. 1-8 , in one embodiment, a remediator device 200 acting as a scrubber 200 , evaporator 200 , or combination 200 , may also be combined with a recovery module 240 . The recovery module 240 may include one or more condensers 242 to recover water vapor as, effectively, distilled water. A discharge line 244 may send a flow 243 of the recycled condensate to feed the line 214 into the nozzles 210 . In certain embodiments, the condensers 242 may be oriented vertically, so air flows promote a natural chimney-effect buoyancy. For example, air flows 243 , drawn in and used to cool the water vapor and exhaust gases received from the blower 202 , will receive heat therefrom, tending to cause and upwardly rising flow 248 of scrubbed exhaust gases, water vapor, and ambient air as a result of the decreased density thereof out of the system 10 .
In certain embodiments, the blower 202 drawing on the cyclone 216 and the scrubber 200 or evaporator “stack” 200 may be configured to raise the pressure in the condensers 242 . Thus, the resulting, reduced, upstream pressure may promote evaporation in the scrubber 200 or evaporator 200 , as well as in the cyclone 216 . The increased pressure in the subsequent or downstream condenser system 242 beyond the blower promotes increased condensation.
The flow 243 in the line 244 fed from the condensers 242 is distilled water. Optionally, a makeup flow 249 of water may be required. The makeup flow 249 may pass through the line 245 into the feed line 214 to supply the nozzles 210 . The extent to which the flow 246 from the condenser 242 is insufficient to completely supply the scrubber 200 is driven by the net evaporation of water in the discharge flow 248 , as well as the drained brine exiting the cyclone 216 through the bottom drain 220 . The condensers 242 may be configured modularly in order to best match the flows 222 , 236 , 243 throughout the system 10 .
In general, flows 246 of ambient air may pass through the inlet 247 into a manifold 248 feeding the condensers 242 . Meanwhile, in a concurrent flow arrangement, passages feeding an exhaust flow 236 from the blower 202 run vertically, adjacent to passages feeding the ambient air flow 246 upward through the condensers 242 . Adjacency may be horizontal in a rectangular, circular, or other configuration. The illustrated embodiment relies on radially concentric, adjacent passages. Thus, cooled exhaust and warmed ambient air form the mixed flows 248 exiting the condensers 242 .
Referring to FIG. 4 , and FIGS. 1-8 generally, in other alternative embodiments, a heat recovery section 250 or module 250 may be added. The recovery module 250 may be connected by providing manifolds 252 , 254 on the inlet and outlet ends 256 , 258 , respectively, of one or more condensers 242 acting as heat exchangers 242 . For example, a counter-flow (or even a cross-flow) heat exchanger 242 may provide ambient air coming into an inlet 260 , passing through the heat exchangers 242 , and continuing onward toward an outlet 262 .
As seen in FIGS. 4 and 5 , in certain embodiments, the outlet 262 may feed into a double-walled conduit 218 . For example, the scrubber 200 may have a double wall as illustrated in order to feed the output flow from the outlet 262 into an outer shell or annulus of the conduit 218 . The outer annulus of the conduit 218 , in turn, empties into the axially central portion of the conduit upstream of and feeding into the flame 207 of the burner 206 thereat. Thus, preheating uses heat and mass flows recaptured by the heat exchangers 242 and recycled into the exhaust flow 24 near the inlet to the scrubber 200 .
This ambient air flow 246 passes through one set of channels (e.g., the channels formed by the supporting, corrugated dividers in one annulus of the several concentric annuli) in the heat exchanger 242 . The corresponding heat transfer flow or opposing flow may travel in an opposite direction through radially adjacent annuli flanking the first. This corresponding or opposite flow, when implemented in a rectangular system, may run either parallel to or orthogonal to the channels or overall passages carrying scrubbed exhaust 236 exiting the blower 202 . Leaving the heat exchanger, the discharge 236 becomes an exiting flow 264 issuing from the exhaust outlet 266 .
Air and water may be preheated by a condenser 242 acting as a heat exchanger 242 recovering the sensible heat of gases, as well as the potentially substantial latent heat of vaporization out of the distilled water output from the condenser 242 . The outlet 262 passing pre-warmed ambient air into the evaporator 200 may connect to the conduit 201 of the evaporator 200 further upstream along the exhaust flow 204 . In either configuration, significant energy inputs and water (distilled)) may be recovered into the exhaust flow 204 . Thus, a certain portion of the heat may be continually added into the exhaust flow 204 , and yet be re-extracted prior to final exit of the exhaust flow 264 out of the system 10 .
Referring to FIG. 5 , while continuing to refer generally to FIGS. 1-8 , in other embodiments, waste heat from another device, such as a heater, engine, flare, or the like, outside the system 10 , may not be available. For example, remediation of production water may require burning field gas directly to evaporate water. Thus, in certain embodiments an apparatus 10 in accordance with the invention may burn field gas in a burner 206 creating the hot exhaust flow 204 for the specific purpose of evaporating water to be run through a evaporator 200 and cyclone 216 . Ultimately, the system 10 may condense a portion of the water back to distilled water.
By providing heat exchange as in the embodiment of FIG. 4 , the system 10 may preheat air and water. Heat may be recovered from both the sensible heat recovered from the discharged flow 264 and the latent heat recovered from the condensed distilled water. Pressure increased in the condenser due to pressure from the blower 202 enhances condensation. The pressure drop in the evaporator 200 , due to the draw by the blower 202 demand for input enhances evaporation, as described hereinabove.
Referring to FIGS. 6-7 while continuing to refer generally to certain to FIGS. 1-8 , in certain embodiments, a condenser 242 may provide a flow of heat, exchanged through concentric cylinders 270 spaced apart. The spacers 272 themselves may take the form of corrugated metal sheets or the like. Thus, the spacers 272 may act as fins while supporting each annulus 274 between adjacent cylinders 240 , forming channels 276 between the fins.
Adjacent annuli 274 carry flows in opposite directions for counter-flow heat exchange. Accordingly, excellent thermal contact between the exhaust 236 , with its condensing vapors, and the cooling air receiving heat therefrom may be achieved. A structurally robust configuration results from essentially very thin materials, such as sheet metal, for example.
Referring to FIG. 8 , while continuing to refer generally to FIGS. 1-7 , such a heat exchanger 242 , using concentric tubular structures 270 , may be interfaced with a manifold 272 , 274 . Manifolds may be mechanically attached in fluid communication with the condensers 242 at either end. Passages in the manifolds 272 , 274 each provide access to only periodically occurring (e.g., typically alternating) annular spaces 274 .
For example, an ambient air flow 246 may enter an inlet 260 of the manifold 254 . Passing through the channels 276 a , the air is heated by exhaust flows 204 in adjacent annuli 274 a , 274 b , radially adjacent channels 276 . Adjacency between annuli 274 each with its own set of channels 276 distributed circumferentially therearound, contributes to comparatively high rates of heat transfer therebetween, due to thin annular walls and the fin effect of the spacers 272 .
By the time the exhaust flow 264 exits the outlet 266 , it has released most of its heat into the ambient air flow 246 . The exact heat exchange and temperature changes depend upon the specific values of parameters such as thicknesses, hydraulic diameters, lengths, fluid properties, velocities, and so forth controlling heat transfer.
Moreover, a significant amount of latent heat from any water vapor condensed therein has also been so transferred. The manifolds 252 , 254 support distribution and collection of flows into distinct annuli 274 by having each inlet or outlet end of annulus 274 connect to a particular layer 278 of the respective manifold 252 , 254 .
Thus, various apparatus and methods in accordance with the invention may significantly reduce the environmental impact of saline water as well as that of chemical, thermal, particulate, and other exhaust emissions. To the extent that these processes can be balanced, a highly symbiotic relationship may exist between remediation of production water, remediation of organic compositions including VOCs, remediation of rejected heat, and remediation of combustion products.
Meanwhile, the tall stack, so familiar, with the flare of a production facility or refinery, may be laid down as a horizontal tube, less expensive to manufacture, easier to maintain, and easier to support. Meanwhile, stacks may have immediate and affirmative back pressure control by attachment of dampers. Meanwhile, scrubbing reduces emissions of volatile organic compounds, oxides of sulfur, particulates, and heat, while recovering heat, distilled water, or both to be recycled from saline production.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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Petroleous production is associated with effluents well known to foul lines, nozzles, and containers while consuming substantial energy to assist in both production and remediation. A heat exchanger and manifold system maximizes flows, minimizes changes in flow cross-section, and maximizes heat transfer area, while recycling both water and heat between processes. Dirty regions and clean regions result from scrubbing horizontal exhaust stacks and evaporation of production water in concert to remediate one another, while recycling a significant portion of the energy consumed by each. The heat exchanger relies on a manifold having many layered conduits, each connected to a single layer level of one or more cylindrical conduits in the exchanger. The cylinders of the exchanger themselves are arranged in multiple layers, each layer of a heat exchanger element being connected to a single layer of the manifold. Any shape of cylinder may work, but a right circular cylinder having corrugated sheets spacing the layers may be simple to construct.
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FIELD OF THE INVENTION
[0001] This invention relates to the field of synthetic steroids and particularly to oestrene derivatives. Specifically, the invention relates to stabilized pharmaceutical compositions and dosage forms of tibolone (7α, 17α)-17-hydroxy-7-methyl-19-nor-17-pregn-5(10)-en-20-yn-3-one, and to methods of preparing the same.
BACKGROUND OF THE INVENTION
[0002] Tibolone (C 21 H 28 O 2 ) is a synthetic steroid of the oestrane series (a Δ 5(10) -oestrene derivative) known to have combined oestrogenic, progestogenic and androgenic characteristics. Tibolone is structurally related to the progestogens norethindrone and norethynodrel. For a general review of the pharmacology of tibolone see van der Vies, Maturitas Suppl. 1:15-24 (1987). Tibolone is used inter alia, in pharmacological preparations having gonadomimetic, ovulation-inhibiting or immuno-modulatory action (see Tax et al., Progress in Basic Clinical Pharmacology 6:143-159 (1991) and Tax et al., Maturitas Suppl. 1:3-13 (1987)) for a general review of the clinical pharmacology of tibolone).
[0003] Unfortunately, tibolone dosage forms (e.g., tablets or capsules) are both difficult to prepare and are plagued by instability problems. One of the tibolone polymorphs generally found in tibolone preparations, particularly in preparations which are not enriched for a particular polymorph, has been shown to be difficult to dissolve. In addition, the resulting formulations obtained generally suffer from limited storage stability especially under dry conditions. The inherent stability is due to the presence of an impurity (i.e., (7α, 17α)-17-hydroxy-7-methyl-19-nor-17-pregn-4-en-20-yn-3-one), which increases during the preparation of pharmaceutical dosage units. Unfortunately, the amount of the destabilizing impurity also increases during storage by conversion of (7α, 17α)-17-hydroxy-7-methyl-19-nor-17-pregn-5(10)-en-20-yn-3-one into (7α, 17α)-17-hydroxy-7-methyl-19-nor-17-pregn-4-en-20-yn-3-one by acid catalyzed isomerization.
[0004] Various attempts have been reported to try to overcome these problems. Hence, for example EP 159739 discloses a number of tablet formulations of tibolone containing conventional tablet excipients. EP 159739 however, does not address the stability problems associated with tibolone formulations.
[0005] EP 389035 describes the production of two pure polymorphic forms (forms I and II) of tibolone. This patent further postulates that polymorph I is appreciably more stable than the polymorph II. Allegedly more stable preparations comprising a crystalline pure or virtually pure form which is completely or, virtually completely free from the other crystalline form are disclosed and are presently marketed under the mark LIVIAL™ in the United Kingdom.
[0006] WO 98/47517 describes the use of a high percentage (above 10%) of starch in a tibolone formulation and claims that better stability is obtained, particularly under relatively dry storage conditions or with lower doses of tibolone.
[0007] Although the approaches found in the art may to some extent improve some of the problems still associated with tibolone formulation (i.e., stability and solubility), there remains a need to identify compositions and methods better suited to arrive to stable as well as soluble tibolone preparations.
SUMMARY OF THE INVENTION
[0008] The invention meets the present needs by providing compositions comprising tibolone and a pH-adjusting agent which are stable.
[0009] Additional aspects of the invention relate to methods of preparing tibolone compositions comprising a pH-adjusting agent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a representation of a graph showing the dissolution profiles of (a) representative formulations RDT0328 prepared by wet granulation, and RDT0329 prepared by dry granulation, according to the invention (see specifics for Formulation A in example 3 hereinafter) at time 0 and after 6 weeks of storage at 40° C. and 75% relative humidity, and of (b) IP0022 and IP0047, both are polymorph I-enriched formulations (see EP 389035).
[0011] [0011]FIG. 2 is a representation of a graph showing the stability profiles of (a) representative formulation A according to the invention (see Example 3 hereinafter) at both time 0, after 6 weeks, and after 4 months of storage at 40° C. and 75% relative humidity, and of (b) Formulation B which is polymorph I-enriched (see EP 389035).
DETAILED DESCRIPTION OF THE INVENTION
[0012] Surprisingly, it has now been discovered that the inclusion of a pH-adjusting agent increases the stability of formulations of oestrene derivatives such as tibolone formulations.
[0013] Moreover it has been found that even formulations containing more than threshold percentages of polymorph II—which has been reported in the literature to be associated with instability and solubility problems—may be stabilized by the inclusion of a pH adjusting agent in the formulation. The aim of the present invention is therefore to obtain compositions which are stable, soluble, and do not necessarily require pure or quasi-pure crystalline preparations.
[0014] The patents, published applications, and scientific literature referred to herein establish the knowledge of those with skill in the art and are hereby incorporated by reference in their entirety to the same extent as if each was specifically and individually indicated to be incorporated by reference. Any conflict between any reference cited herein and the specific teachings of this specification shall be resolved in favor of the latter. Likewise, any conflict between an art-understood definition of a word or phrase and a definition of the word or phrase as specifically taught in this specification shall be resolved in favor of the latter.
[0015] Any suitable materials and/or methods known to those of skill can be utilized in carrying out the present invention. However, preferred materials and methods are described. Materials, reagents and the like to which reference is made in the following description and examples are obtainable from commercial sources, unless otherwise noted.
[0016] Technical and scientific terms used herein have the meaning commonly understood by one of skill in the art to which the present invention pertains, unless otherwise defined. Reference is made herein to various methodologies and materials known to those of skill in the art. Standard works setting forth the general principles of pharmaceutical dosage form preparation techniques including granulation, mixing, coating techniques include for example, Lachman et al. Eds., The Theory and Practice of Industrial Pharmacy, 3 rd Ed., (1986), and Lieberman et al., Eds. Pharmaceutical Dosage Forms , Marcel Dekker Inc., New York and Basel (1989).
[0017] As used in this specification, the singular forms “a,” “an” and “the” specifically also encompass the plural forms of the terms to which they refer, unless the content clearly dictates otherwise. Similarly, in the specification and the appended claims, the singular forms include plural referents unless the context clearly dictates otherwise.
[0018] As used in this specification, whether in a transitional phrase or in the body of the claim, the terms “comprise(s)” and “comprising” are to be interpreted as having an open-ended meaning. That is, the terms are to be interpreted synonymously with the phrases “having at least” or “including at least.” When used in the context of a process, the term “comprising” means that the process includes at least the recited steps, but may include additional steps. When used in the context of a compound or composition, the term “comprising” means that the compound or composition includes at least the recited features or components, but may also include additional features or components.
[0019] The invention provides pharmaceutical compositions containing tibolone in admixture with one or more excipients, and a pH adjusting agent. The term “pH adjusting agent” is used to denote an agent which when mixed with one or more compounds in a formulation adjusts the acidity of the formulation and may additional have antioxidative properties. In some embodiments the pH adjusting agent may have synergistic antioxidative properties with other compounds in the formulation to which the pH adjusting agent is added. The pH adjusting agent may be the salt of an acid, particularly a weak acid, such as a carboxylic acid. Suitable salts of carboxylic acids include salts of citric, fumaric, acetic, tartaric, maleic, succinic or benzoic acid. Particular examples of pH adjusting agents are salts of polybasic acids, such as the acid salts of citric acid, for example monosodium dihydrogen citrate, disodium hydrogen citrate and especially sodium citrate. The polybasic acid may also be an inorganic polybasic acid. Salts of inorganic polybasic acids that may be mentioned include phosphate, hydrogen phosphate, carbonate and hydrogen carbonate, in particular potassium and especially sodium hydrogen carbonate (also known as sodium bicarbonate). Borates, for example sodium borate, may also be mentioned.
[0020] Where the pH adjusting agent is the salt of an acid, the cation may be inorganic or organic. Suitable inorganic cations include the alkali metals, e.g., sodium and potassium, and the alkali earths, in particular magnesium and calcium. Organic cations include quaternary ammonium salts.
[0021] Alternatively, the pH adjusting agent may be the salt of a weak base, for example, an ammonium salt, such as ammonium chloride. The pH adjusting agent may also be a buffering agent, particularly an organic buffering agent. A particular buffering agent that may be mentioned is Tris buffer, tris-(hydroxymethyl)methyl ammonium chloride.
[0022] One of skills in the art will appreciate that the compositions of the invention may be solid as well as liquid depending on the specific exigencies and circumstances.
[0023] In certain embodiments the compositions of the invention are liquid compositions comprising a 1%w/v aqueous solution of the pH adjusting agent having a pH of from about 4 to about 10, more preferably from about 6 to about 9 and most preferably from about pH 7 to about pH 9.
[0024] The term “about” is used herein to mean approximately, in the region of, roughly, or around. When the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. In general, the term “about” is used herein to modify a numerical value above and below the stated value by a variance of 20%.
[0025] Examples of pH of a 1%w/v aqueous solutions of suitable pH adjusting agents are as follows:
TABLE I 1% w/v Sodium pH 8.2 aqueous Bicarbonate solution 1% w/v Sodium pH 8.75 aqueous Citrate solution
[0026] Insofar as both solid as well as liquid compositions are contemplated, it is understood that the pH adjusting agent according to the invention may be in a solid form such as a crystalline or a dry/fine powder form.
[0027] The dosage unit forms exemplified hereinafter include 2.5 mg of tibolone in a tablet form or 100 mg of a pharmaceutically acceptable powder in capsules (i.e., 2.5%). However, there is a long-felt need to provide lower dosage forms to fine-tune therapeutic regimens to individual patients' needs. Unfortunately, simply lowering the tibolone content results in a dramatic and prohibitive decrease in stability and concurrent shelf life. Inclusion of the pH adjusting agent according to the invention is therefore also useful to stabilize formulations having a low (i.e., less than 2.5 mg) tibolone content.
[0028] In certain embodiments of the invention, the ratio of pH adjusting agent to tibolone is from about 10 parts agent to about 1 part tibolone to about 0.01 parts agent to about 1 part tibolone.
[0029] For oral administration, the compositions of the invention may be presented as discrete units such as capsules, caplets, gelcaps, cachets, pills, or tablets each containing a predetermined amount of the active ingredient as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil emulsion and as a bolus, etc.
[0030] Alternately, administration of a composition of all of the aspects of the present invention may be effected by liquid solutions, suspensions or elixirs, powders, lozenges, micronized particles and osmotic delivery systems. Pharmaceutical dosage forms especially contemplated in the present invention include solid dosage form such as tablets or capsules, as well as other dry (non-solid) or liquid forms. One of skill in the art will appreciate that the compositions of the invention are easily adapted without undue experimentation for administration by other routes.
[0031] A pharmaceutical oral dosage form, such as for example a tablet, may be made by a variety of methods known in the art (see e.g., Lachman et al. (supra) and Lieberman et al. (supra) compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing, in a suitable machine, the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, preservative, surface active or dispersing agent. Molded tablets may be made by molding, in a suitable machine, a mixture of the powdered compound moistened with an inert liquid diluent. The tablets may be optionally coated or scored and may be formulated to provide a slow or controlled release of the active ingredient therein.
[0032] The methods set forth in the examples provided hereinafter are merely representative examples to illustrate some of the possible ways available and are not meant to limit the scope of the invention.
[0033] The compositions according to the invention may be prepared by the simple addition of the active agent (i.e., tibolone) to the powder, tablet, capsule or granule mix with all the other components described herein.
[0034] In a further embodiment, tibolone, the pH adjusting agent are mixed together and then granulated with a solution of binder in water or organic solvent e.g., an alcohol. Any auxiliary components e.g., starch may be mixed subsequently as well. The binder may in principle be any suitable pharmaceutical binder such as any cellulose derivative e.g., hydroxy propyl methyl cellulose or polymers such as polyvinyl pyrrolidone. In certain embodiments, the compositions of the invention may further include components useful to achieve the release of tibolone over time or to delay the release of tibolone (e.g., extended release, continued release or delayed release) such as for examplehydroxypropylmethylcellulose, hydroxy propylcellulose, ethylcellulose, hydroxyethylcellulose, castor oils, vegetable oils, xanthan gum, and waxes.
[0035] In some embodiments, the compositions of the invention further comprise antioxidant compounds such as for example vitamin E, vitamin C, carotene, ascorbyl palmitate, ascorbyl stearate, propylgallate, lactic acid, and erythrobic acid.
[0036] In particular a starch paste or other starch derivative is particularly preferred. In addition the binder compound could be added to the dry mix and granulated with pure water or solvent.
[0037] It will be understood that in all embodiments of this invention conventional pharmaceutical excipients can be added to the compositions.
[0038] The compositions according to the invention are optionally formulated with any of the well known pharmaceutically acceptable carriers, including diluents and excipients (see Remington's Pharmaceutical Sciences 18 th Ed., Gennaro, Mack Publishing Co., Easton, Pa. 1990 , Remington: The Science and Practice of Pharmacy , Lippincott, Williams & Wilkins, 1995, and The Handbook of Pharmaceutical Excipients, 3 rd Ed., American Pharmaceutical Association and Pharmaceutical Press, 2000). This includes bulking agents such as sugars, e.g., lactose; cellulose derivatives e.g., microcrystalline cellulose; calcium salts e.g., calcium phosphate or calcium sulphate; disintegrants e.g., sodium starch glycolate, crosscarmellose; lubricants e.g., magnesium stearate, sodium stearyl fumarate and surfactants, and wetting agents, e.g., sodium lauryl sulphate, conventional poloxamers, polyethylene glycols, sodium tetradecylsulphate, and sorbitan esters.
[0039] Other pharmaceutical excipients such as colors, flavors, etc. may also be added. While the type of pharmaceutically acceptable carrier/vehicle employed in generating the compositions of the invention will vary depending upon the mode of administration of the composition to a mammal, generally pharmaceutically acceptable carriers are physiologically inert and non-toxic. Formulations of compositions according to the invention may contain more than one active ingredient as well any other pharmacologically active ingredient useful for the treatment of the symptom/condition being treated.
EXAMPLES
[0040] The following examples are intended to further illustrate certain preferred embodiments of the invention and are not limiting in nature. Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, numerous equivalents to the specific substances and procedures described herein.
Example 1
Preparation of Tibolone/Sodium Bicarbonate Formulations
[0041] This example is provided to illustrate the preparation of a representative solid form tibolone formulation as described in more details heretofore. 2.5 g of tibolone (obtained from Chemo Iberia, Italy) was admixed and triturated with 2.5 g of sodium bicarbonate (Industriale Chimica s.r.l, Spain). This preparation was subsequently blended with 84 g of lactose (Merck KGaA, Germany), 10 g of starch (Colorcon, UK), and 1 g of magnesium stearate (Merck KGaA, Germany). The blend was then compressed into tablets of 100 mg each, containing 2.5 mg of tibolone. Samples were analyzed (λ=200-240 nm) to identify conjugated impurities (here identified as RC01 and RC04).
TABLE II RC04 RC01 TOTAL IMPURITY Formulation without Sodi 1.32% 2.98% 7.47% Bicarbonate 100 g batch with Sodium 1.69% 1.48% 5.61% Bicarbonate
Example 2
Preparation of Tibolone/Sodium Citrate Formulations
[0042] This example is provided to illustrate the preparation of representative tibolone blends as described in more details heretofore. 2.5 g of tibolone (obtained from Industriale Chimica SRL, Italy) was admixed and triturated with 2.5 g of sodium citrate (Merck KgaA, Germany) and 5 g of starch. This preparation was subsequently granulated with 5% solution of hydroxy propylmethyl cellulose in water, and then dried. Granules were then milled and dry blended with 85 g of lactose, 2 g of sodium starch glycolate, and 1 g of magnesium stearate. The blend was then compressed into tablets of 100 mg each, containing 2.5 mg of tibolone. Samples were analyzed (λ=200-240 nm) to identify conjugated impurities (here identified as RC01 and RC04).
TABLE III RC04 RC01 TOTAL IMPURITY Formulation without Sodi 1.32% 2.98% 7.47% Citrate 100 g batch with Sodium 1.78% 1.22% 5.29% Citrate 400 g batch with Sodium 1.58% 1.62% 5.65% Citrate
[0043] In another experiment a tibolone/sodium citrate formulation was prepared essentially as described in the above paragraph and further comprising standard pharmaceutical excipients as described in more details above. The final 2.5 mg tibolone unit dose (Formulation A) form included:
TABLE IV Formulation A Composition Tibolone 2.5 mg Lactose 86.1 mg Lactose monohydrate (200 mesh) 52.775 Spray dried lactose 33.33 (dried compression grade) Pregelatinized starch 8.0 mg Ascorbyl palmitate 0.2 mg Sodium Citrate 0.69 mg Sodium Lauryl Sulphate 0.005 mg Croscarmellose Sodium 2.0 mg Mg Stearate 0.5 mg
Example 3
Solubility of Tibolone Preparations
[0044] It has been observed that tibolone preparations which have not been enriched for a particular polymorph (i.e., polymorph I) are plagued by an inherent lower solubility hindering their value for pharmaceutical purposes. To ascertain that the compositions of the invention are soluble, a series of dissolution tests were performed including the one included hereinafter for illustrative purposes. In this experiments the % dissolution for Formulation A (see Example 3 above) and Formulation B which is polymorph I-enriched (see EP 389035) were compared (for both wet and dry granulation methodologies).
[0045] As shown in FIG. 1, the dissolution profiles of (a) representative formulations RDT0328 prepared by wet granulation, and RDT0329 prepared by dry granulation, according to the invention (see specifics for Formulation A in example 3 hereinafter) at time 0 and after 6 weeks of storage at 40° C. and 75% relative humidity, were comparable to the dissolution profiles observed for (b) Formulation B samples IP0022 and IP0047 (both are polymorph I-enriched formulations (see EP 389035)).
Example 4
Analytical Evaluation of Tibolone Preparations—Stability
[0046] This example is provided to evidence the stability of the compositions according to the invention. For this purpose, the tibolone preparation Formulation A of Example 3 above was analyzed and further characterized. It was established that the tibolone of the preparation of Example 3 had a polymorphic ratio of 85% form I, and 15% of form II. It was found that there was no detectable transition from form II to form I upon prolonged storage. To test and compare the stability of the formulations according to the invention, Formulation A according to the invention (see Example 3, supra) was tested at both time 0, after 6 weeks, and after 4 months of storage at 40° C. and 75% relative humidity, and of (b) Formulation B which is polymorph I-enriched (see EP 389035).
[0047] The specific dissolution parameters for this set of experiments were as follows:
Apparatus: Paddles Rotation Speed: 75 rpm Dissolution Medium: 0.25% w/w sodium dodecyl (Lauryl) sulphate Medium Volume: 900 ml Medium Temperature: 37° C. ± 0.5° C. Detection: UV @ 210 nm Sampling Times: 15 mins
[0048] [0048] TABLE V FORMULATION FORMULATION A B TIME ZERO 3 WEEKS 6 WEEKS 4 MONTHS ASSAY 96.9% 112.4% 99.3% 96.7% 95.3% (99.7 mg) (110.0 mg) (97.6 mg) (95.3 mg) (91.7 mg) DISSOLUTION 100% 108% N/T 88% 91% AT 15 MINS (100 mg) (106 mg) (92.5 mg) (95.0 mg) TOTAL 5.21% 1.03% 1.57% 1.34% 3.2% RELATED SUBSTANCE
[0049] As shown in FIG. 2 the stability of Formulation A preparations according to Example 3 were comparable to that observed for polymorph I-enriched preparations reported to be stable (see EP 389035) even after 4 month under accelerated storage conditions.
[0050] Similarly, sample formulations matching those described in Examples 1 and 2 but omitting the pH adjusting agents (i.e., sodium citrate and sodium bicarbonate) were included as well as samples as negative controls. These tests also showed that the presence of the pH adjusting agents stabilized the formulations (data not shown).
Example 5
Pharmacokinetic Studies of Representative Tibolone Compositions
[0051] To illustrate the properties of the compositions according to the invention, in a pilot study, several subjects received two single oral administration of 2.5 mg tibolone as the test and reference formulations according to a cross-over design. Each administration was separated by a two weeks wash out period. Standard bioavailability studies demonstrate that the active ingredient (i.e., tibolone) in the compositions disclosed herein reaches its maximal concentration (t max ) within published ranges, that it is also biologically converted to its isomeric form, and that the AUC values are within accepted ranges for bioequivalence (data not shown). Pharmacokinetic parameters for tibolone and A4-tibolone are calculated according to standard methods described in the literature.
Equivalents
[0052] Reference is made hereinafter in detail to specific embodiments of the invention. While the invention will be described in conjunction with these specific embodiments, it will be understood that it is not intended to limit the invention to such specific embodiments. On the contrary, it is intended to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. In the instant description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail, in order not to unnecessarily obscure the present invention
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This invention relates to the field of synthetic steroids and particularly to oestrene derivatives. Specifically, the invention relates to stabilized compositions of tibolone (7α, 17α)-17-hydroxy-7-methyl-19-nor-17-pregn-5(10)-en-20-yn-3-one, and to methods of preparing the same.
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BACKGROUND OF THE INVENTION
This invention relates to a feeding bottle for a child. More particularly, it relates to a multiple compartment feeding container of the type useful for children in the range of 3 months to 41/2 years of age. The container is of the type capable of holding and separately dispensing two or more separate liquids through a nipple, a sipper or a straw. The container also has a bottom compartment for containing and disposing solid or pureed food.
BRIEF SUMMARY OF THE INVENTION
One of the objectives of the present invention is to provide a two compartment bottle for holding two liquids at the same time, thereby allowing a child to access one or the other liquid through a dual straw action or a nipple or a sipper without spillage.
Another objective is a container bottle which holds two separate liquids, which is uniquely shaped for easy gripping, and which includes a wide base for stability. The base forms a separate bottom compartment to hold either dry or pureed food.
Still another objective is a nipple useful with a baby bottle, which nipple simulates a mother's breast with regard to size, shape and texture.
This invention relates to a combination baby bottle and food container comprising a liquid container comprising at least two separate compartments, separated by one another by a vertically extending wall, and a separate container for holding dry food forming the base for the liquid container. The liquid container is preferably shaped to facilitate gripping by a baby or infant. The liquids are selectively dispensed from one of the compartments using a straw, a sipper cup or a nipple. The liquid is dispensed from a selected compartment through a rotatable valve which is actuated relative to a seal between an open and a closed position. The valve actuator includes a handle which is located at the top of the liquid dispenser, or at the bottom thereof where it is joined to a shaft or arm extending through the liquid container to rotatably engage the valve. The shaft extends through a tube contained within a vertically extending wall which serves to separate the liquid compartments from one another. The tube covers the shaft. The removable base of the liquid container includes a separate food compartment, a fixed cover having an access opening and a second cover having at least one access opening, a handle to rotate the second cover relative to the first cover to index the openings, and a storage cap closely fitting over the two covers.
This invention further relates to a combination baby bottle and food container having: a) a tubular bottle container for liquids divided into at least two longitudinal compartments, b) a food container detachably attached to the base of the tubular bottle container, adapted to hold food for dispensing with a spoon or fingers, said food container including a cover to hold food in the container until needed, c) a liquid dispensing means that allows for controlled release of liquid nourishment, d) a valve releasing actuator that selectively controls the release of liquids from any one of the longitudinal compartments, said actuator accessible from the top or the bottom of the bottle to release the liquid, e) a sealing valve and a seal to close the longitudinal compartments and to avoid leakage of liquid therefrom, f) vents in the seal to allow air to control the flow of liquid from the bottle container by movement of said actuator relative to the sealing valve and seal. The invention also encompasses a uniquely designed spoon adapted to be clipped to the side of the container for easy access. The combination includes a cap covering the liquid dispenser, the cap including a pocket which is inverted when the cap is in place. The base likewise includes a pocket, the two pockets cooperating to hold the spoon when not in use. A clip can also be mounted on the side of the bottle to hold the spoon by its handle. The liquid compartments are sealed against leakage using a seal which cooperates with the valve. An actuator is manipulated, preferably by a handle, to rotate the valve relative to the seal to allow liquid to be selectively dispensed from one of the liquid compartments. The handle may be at the top of the baby bottle, being accessible with the cap removed. Alternatively, the handle is at the bottom of the bottle and is joined to the valve by a shaft extending through the liquid container whereupon rotating the handle at the bottom actuates the valve at the top. The handle is accessible by removing the base from the liquid container. The base of the second container includes a food compartment, a fixed cover having an access opening and a second cover having at least one access opening, a handle to rotate the second cover relative to the first cover to index the openings, and a cap closely fitting over the two covers.
The invention includes, in combination with a liquid container such as a baby bottle, a nipple for use in dispensing liquid from the container. The nipple is adapted to simulate a woman's breast with regard to size, shape and texture. The nipple includes a nipple extension and a series of openings on the top of the extension. The texture of the surface area of the nipple on top of, and surrounding the nipple extension, has a raspberry effect. The nipple is preferably composed of silicon latex plastic. The nipple is particularly useful with a liquid container having multiple liquid compartments, the container being contoured to be easily grasped by a baby or infant. A dry food compartment preferably forms the base of the liquid container.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawing:
FIG. 1 is a composite drawing of 3 versions. On the left is a special nipple to simulate a women's anatomy. In the center is a sipper version and on the right is a straw version with 2 straws.
FIG. 2 is a top view of the seal for the nipple, sipper and straws.
FIG. 3 is cross sectional view of the bottle compartment taken on line 3--3 of FIG. 2 showing the two compartments and the bottom actuator.
FIG. 4 is bottom view of the bottom actuator.
FIG. 5 is an exploded view of the top actuated sipper version. The nipple version of the bottom actuated in FIG. 1 would be similar as would the straw version on the right in FIG. 1.
FIG. 6 is cross section view of FIG. 5. The sipper version seen in FIG. 5 showing 2 compartments for liquids but only one tube for emptying the right compartment. The left tube would be similar to the right tube.
FIG. 7 shows the top actuating valve of FIG. 5 with the venting system.
FIG. 8 show another view of the actuating valve and the seals for fluid control.
FIG. 9 shows another view of the operation of the flow control.
FIG. 10 shows a cross sectional view of the sipper of FIG. 11 along the line of 10--10 of FIG. 11
FIG. 11 shows a view of the sipper and the seals and vents for the bottle
FIG. 12 shows a bottom view of the seal and the compartment divider seen in FIG. 5
FIG. 13 shows a side view of the seal and the compartment divider as well as the tubes that extend to the bottom of each compartment.
FIG. 14 is a top view of the valve actuator. The flow control opening for the vents and the liquid
FIG. 15 is a cross sectional view of the actuator along the line 15--15 of FIG. 14
DETAILED DESCRIPTION OF THE INVENTION
The invention relates to a multiple feeding container comprising a bottle having two or more liquid-containing compartments, and a bottom section that forms the base of the container and that holds dry, whole or pureed fold. The bottom section can be accessed by dialing the right proportion of food to be removed and a bottom lid or cap serving to prevent spillage in the purse. The device also includes a uniquely designed spoon which serves to initiate transition of a child from liquid to pureed foods. The spoon is designed for a young child's oral cavity. It is adapted to be secured on the side of the container when not in use.
The compact unit further includes three interchangeable multiple dispensing units. One of the units comprises dual straws; the second comprises a sipper cup and uses a three way flow controlling dispensing valve which eliminates the need for more than one sipper cup, which is spill proof and which allows flow of liquid from one drop to full flow. The valve is practical and economical, and is accessed either from the top or the bottom of the unit.
The babies bottle and food container is designed to meet the needs of a baby from a few weeks to 41/2 years old. It is specially designed features allow care givers to provide two types of liquid i.e. milk or juice in two separate compartments with two separate accesses, dry or wet snack on the bottom when at home, on the run to provide instant versatility, accessibility and organization with gratification for mother and child.
There is a valve actuator in the bottom of the bottle that is accessible, once the bottom food compartment is removed, to permit the child or mother to switch the fluid containers to the open or closed position, using any of the three tops: nipple, sipper or straw depending on the need of the mother or child.
In FIG. 1, 10 is a cup covering the nipple 11, the sipper 12 or the straws 13, one of which is shown at 14.
On the left is the nipple 11 made of silicon latex plastic. This nipple is specially designed to simulate the mother's breast in size shape and texture around the orifice 16 and the tip 15 of the nipple. Observe too the nipple itself is to function in a natural manner.
The mother would use the dial/actuator 22 and handle 25 on the bottom of the bottle 24 to select.
Now for a description of the sipper version of FIG. 1, which is shown in the central core of FIG. 1. The mother has the option of using any one of the three versions. She would use the nipple on the left and leave out the sipper 12 on the other hand she could put the two straw version on the right and leave out the sipper 12 or the nipple 11.
To use the sipper 12, she would take off the cup 10, remove the food compartment 20, spoon 21 and turn valve actuator 22 which fits in and extends through a tube 23 in the plastic molded bottle 24. This valve actuator 22 has a square cross section at 16 which is the end of the actuator which fits into the axial hole 51 in sealing valve 19 and rotates the sealing valve 19 so that the child may take fluid from either compartment e.g. milk or juice. The valve actuator includes upper and lower seals 50, 50' which provide a fluid-tight fit in tube 23. Vents 27 were created to allow the child to go from drops to a dribble flow.
Below the valve 19 is the seal 28 having flanges 29 separated from one another by slot 75 which receives the wall 72 serving as a divider or barrier for the liquids in the respective compartments.
Tube 32 on the right and tube 33 on the left enter down into the lower reaches of each compartment so that suction will empty the entire compartment.
In the straw version 13 on the right, sipper 12 is taken out and the straw version is used in its place. Actuator 22 and its handle 25 are rotated to line up the straws. This depends on vacuum alone. The child creates a vacuum and fluid from one or the other compartment is sucked up. Bayonet joints 45 are used to fasten the straw version 13 to the bottle 24 and the food container to the bottle. Food container 20 has a pocket 35 to support spoon 21 and cup 10 has a inverted pocket 36 to support the opposite ends 37, 37' of the spoon. The spoon has a raised or indented center portion 46 to allow the child to take food off the center of the spoon.
In the food container are a series of layer 39-40 as well as a close fitting cap 41 to close off the compartment.
The combination of the narrow center in bottle 24 allows small hand of baby's to grasp the middle of the bottle tight.
There is a second straw on the opposite side of the hemispheric member 13.
FIGS. 2, 3 & 4 show the relationship of the valve actuator 19 which controls the seal and the flow control opening for the seal when the mother or care giver moves the valve actuator so that the sipper will take fluid from the right compartment or the left compartment. As the handle 25 is moved there will be an opening 49 for fluid to be sipped by the child and a series of air vents. See FIG. 7.
Returning to other feature of the nipple and how it is used. The nipple simulated the mother's breast in having a nipple 15 with a series of opening on the top formed in the shape of a cross and the adjacent area has a roughened area sometimes called a raspberry effect 47. It is mounted with a plastic ring 18 which seals the latex flange 17 to the bottle 24. The actuator and seal fit under the nipple as shown in FIG. 1.
The straw version is sealed as shown at 14 with O-ring 48 which the mother pulls out to access each compartment separately.
To explain how this baby bottle and food compartment will work in practice let us go through a trip that the mother might take with her child. She would fill the two compartment bottle with milk and juice and a medicine if it was prescribed. At any period in the baby's development he or she would be on the nipple, the sipper or straws. The mother would assemble the bottle with the nipple leaving the sipper and straws in the case. When the baby cried wanting milk the mother would turn the valve actuator handle 25 which rotates actuator shaft 22 and the square head 16 to move the fluid opening 49 of valve 19 seen in FIG. 3 to the correct compartment either left or right. If for some reason the mother wished to shift to the other compartment for juice or medicine she would turn handle 25 to the other compartment.
If at different time the mother wanted to use the sipper she would assemble the sipper 12 on top of sealing valve 19 and seal 28 and move the actuator to be connected to the desired liquid compartment of the bottle.
The steps for the straw are different only in that the hemisphered member 13 is attached in place of the sipper 12. The other steps are the same.
Top Actuated Bottle
An alternative way to actuate the valve actuator describe in connection with FIGS. 1-4 is shown in FIGS. 5-15 where the valve actuator is moved by the care giver by turning the handle 61 to the right or the left to connect the fluid controls to the sipper 12 as shown in FIGS. 5 and 6. The details of how the control works is shown in FIGS. 7, 8 & 9. An outlet hole 62 is shown in FIG. 7 and another pair of oval shaped holes are shown at 63 and 64. These are connected all to the same compartment.
When the valve actuator handle 61 is moved to the right or left the fluid opening 62 is connected to the compartment supplying fluid to the child as he or she sips the fluid. On the opposite side of the valve 19 are a series of vent holes 65, 66 of different size. These allow controls so that the liquid the child receives can be controlled. Detent 86 (shown more clearly in FIG. 15) is midway between slots 78, 79 when handle 61 is in the `off` position. As the handle is turned to the left, the detent reaches and enters slot 78 (see FIG. 8) to form a positive registry. In like manner, registry of the detent in slot 79 (as shown in FIG. 9) is achieved when the handle is turned clockwise to the right.
FIG. 8 shows one variation in the holes in the seal 28 illustrated. See vents 65 (large) and 66 smaller). FIG. 9 shows a move clockwise with the varieties to the vents which are large, medium and small. The seal is fixed to the center divider and does not rotate. The valving works the same whether it is activated from the top or the bottom.
The food container for solid food is shown at 20. The food container is first removed from the bottom of the bottle and is inverted to feed the child. There is a fixed opening cover 39 and a small handle 68 to rotate cover 40 so that opening 69 can register with opening 70 so that a spoon or small fingers may pass through the opening and the child can be self fed or feed themselves. When the child is full the process is reversed and cover 41 is positioned to seal the food container.
FIG. 6 shows a cross sectional view of the bottle divided into two compartment with a wall 72 dividing the bottle into two compartments. There is a tube 73 reaching into the bottom of one compartment and a similar tube for the other compartment.
FIG. 10 shows details of the sipper in cross section with the bayonet lock at 74. A top view of the sipper is shown in FIG. 11 with an opening at 76 for sipping and at least one vent hole at 77 movement over the other hole will reduce the flow of liquid but allow the child to continue to suck. FIG. 12 is a bottom view of the seal showing the compartment divider and the outlet that holds tube 73 extending down into the bottle compartment. A series of vents for such compartment are shown at 80-and 81 and at 82 and 83 for the other compartment. FIG. 13 shows seal 28 with flanges 29, and slot 75 into which the vertical compartment divider (not shown) fits. Also shown are oval holes 63, 64 adapted to be engaged by straws (not shown).
FIG. 14 and FIG. 15 show the details of the valve actuator with its handle 61 and the flow control opening 84 and vents 85.
The top actuated version operates similar to the bottom actuated except for the fact that the bottle must be opened or loosened slightly to release seal pressure to operate the actuator 61.
FIGS. 1-4 show the bottom actuator version and the remaining figure shows a top actuated version. This three-way flow controlling dispensing valve is not only intended for exclusive use with children, but with the option to be used medically in the long run with all ages that develop any type of swallowing malfunction. Changes may be made in size and proportions to suit these individual's needs. Thirdly, there is a uniquely designed nipple which is patterned after and encompasses the human mother's breast as close as possible. This specially designed nipple keeps the baby and mother's needs in mind. It presents the infant with a nipple that resembles the mother's breast in regard to shape and texture and nothing could resemble this closer, except for the real thing. The nipple can access the two liquids by a simple rotation from the bottom of the bottle moving the valve actuator. This allows for hygienic qualities that will enable mothers to switch liquids on their baby if needed. For example, medicine may be in one compartment and milk in the other which allows for an easy transition from medicine to liquid food. Therefore, this nipple is not only created for marketing purposes, per se, to meet the public need, but it entails pediatrician ramifications with its unique hygienic bottom control dispensing valve. This complete unit was created as a whole. However, it can be separated from each other without departing from the spirit or sacrificing any advantages of the invention.
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A combination baby bottle and solid food compartment with spoon is adapted for use with a small child in the range of 3 months to 41/2 years of age. The bottle is uniquely shaped for easy gripping by the child and is divided into multiple compartments for holding separate liquids. The compartments are accessed through a valve arrangement, and the liquids can be dispensed by means of a sipper, straws or a nipple. The nipple is adapted to simulate a woman's breast, with the texture of the surface area of the nipple extension and surrounding the extension having a raspberry effect. The food compartment fits on the bottom of the bottle in an inverted position to provide a wide base for the combination. The handle of the spoon is shaped to fit the contour of the bottle to which it is secured by a clip. The spoon is uniquely shaped to fit the child's mouth or oral cavity.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a stable biosynthetic liquid cerebrospinal fluid control and method of use. Additionally, this invention relates to the isolation and purification of stable liquid human prealbumin, a component in the biosynthetic cerebrospinal fluid control.
2. Description of Related Art
Cerebrospinal fluid is formed by an ultrafiltration of the plasma. Normal values for cerebrospinal fluid analytes are not the same as plasma values. This difference is a result of the filtration process being selective and the fact that the chemical composition is adjusted by the blood-brain barrier. Analysis of this chemical composition is an important diagnostic procedure. Disease increases cerebrospinal fluid protein concentrations. Elevated cerebrospinal fluid total protein is an indicator of central nervous system pathology such as damage to the blood-brain barrier caused by meningitis or hemorrhage. IgG is the primary immunoglobulin of cerebrospinal fluid. It is increased in several neurological conditions such as multiple sclerosis and viral meningoencephalitis. Analysis of cerebrospinal fluid by serum protein electrophoresis is an important diagnostic test in the diagnosis of multiple sclerosis. Low glucose values signal infections such as bacterial, tuberculous or fungal meningitis. Low values are also seen as a result of infiltration of the meninges with malignant cells. High lactic acid levels in cerebrospinal fluid indicate bacterial or tuberculous infection and rule out viral meningitis. Low cerebrospinal fluid chloride levels can be used as an indicator of tuberculous meningitis.
Since the chemical composition of cerebrospinal fluid is similar to plasma comparable tests are performed. However, the levels of these constituents are not the same resulting in different normal values than those used for plasma. In order to assess the accuracy and precision of these diagnostic tests, a control similar to cerebrospinal fluid must be run. In the case of serum protein electrophoresis, a known protein control is always run in a separate well. The protein fractions in cerebrospinal fluid are not always clearly detected. Therefore, a control in which all the serum protein fractions are clearly defined is important. Most cerebrospinal fluid controls are prepared from actual spinal fluid. There are no tests, however, to detect the presence of infectious diseases in spinal fluid. Additionally, the recovery of spinal fluid is difficult and expensive and the quality is varied. Other cerebrospinal fluid controls have been made from normal human blood serum diluted with a diluent containing glucose and chloride ions, and then lyopholized. Reconstitution of the control is then required before it can be used. See U.S. Pat. No. 3,753,925.
SUMMARY OF THE INVENTION
The present invention relates to biosynthetic cerebrospinal liquid controls based on human serum spiked with prealbumin. Two controls are disclosed: one simulating normal spinal fluid and the second simulating abnormal spinal fluid. The product is prepared from human serum and purified human prealbumin in a buffer matrix formulated to simulate human cerebrospinal fluid. In particular, this invention relates to a stable liquid human based cerebrospinal fluid control made by the process comprising: (a) combining a sufficient amount of lactic acid, chloride, glucose, serum, purified prealbumin, and potassium in a buffer to simulate normal human cerebrospinal fluid; (b) gassing said filtered fluid with oxygen to obtain normal electrophoretic pattern for human cerebrospinal fluid, and (c) filtering said fluid to remove all microbial contaminants.
The present invention also relates to high purity prealbumin and a process to make prealbumin. In particular, this invention relates to a purified prealbumin made by the process comprising: (a) diluting human serum with a first buffer; (b) extracting globulins, ceroplasm and albumin from normal serum diluted in a first buffer using ion exchange chromatography; (c) isolating the prealbumin containing fractions eluded from Step (b) by immunodiffusion; (d) pooling, concentrating and buffer exchanging the prealbumin containing fractions of Step (c) with a second buffer; (e) removing albumin from the said prealbumin containing pooled fractions of Step (d) by affinity chromatography; (f) isolating the prealbumin containing fractions eluted from Step (e) by immunodiffusion; (g) pooling and concentrating and buffer exchanging said prealbumin containing fractions of Step (f) with a third buffer to increase the prealbumin concentration; (h) removing globulins from said pooled fractions of Step (g) by ion exchange chromatography; (i) pooling, concentrating and buffer exchanging with a fourth buffer to increase prealbumin concentrations; (j) purifying the prealbumin containing fractions of Step (i) by gel filtration to remove any residual proteins; (k) isolating purified prealbumin fractions from Step (j) by electrophoresis and immunodiffusion; and (l) pooling, concentrating and sterile filtering said purified prealbumin fractions of Step (k).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows protein electrophoresis of cerebrospinal fluid prepared according to this method.
FIG. 2 shows protein electrophoresis of cerebrospinal fluid prepared according to this method.
FIG. 3 shows protein electrophoresis of prealbumin prepared by the present method. Analysis by serum protein electrophoresis.
FIG. 4 shows an overlay of protein electrophoresis of prealbumin prepared by the present method, on to normal human serum pattern.
FIG. 5 shows protein electrophoresis of prealbumin prepared by the Raz method; analysis by serum protein electrophoresis.
FIG. 6 shows an overlay of protein electrophoresis of prealbumin prepared by the Raz method, onto normal human serum pattern.
DETAILED DESCRIPTION OF THE INVENTION
The disclosed invention involves diluting human serum with constituents adjusted within ranges for cerebrospinal fluid. Cerebrospinal fluid contains a very small amount of protein as compared to serum. The protein fractions are similar to those found in serum; however, for serum the quantity of prealbumin present is less than 1% whereas the quantity present in cerebrospinal fluid is 2 to 7% of the total proteins. In order to increase the level of this protein, a prealbumin spike was added. This protein was effectively isolated from human serum using column chromatography.
The product is formulated by the addition of the required constituents to a 50 to 80 mM HEPES buffer matrix. The pH of the buffered matrix is 7.3. Serum and prealbumin are added to the specifications required for each level. Glucose, lactic acid, chloride, sodium, potassium are added to obtain the desired concentrations as specified in Table I. The buffered solution is then gassed with 100% oxygen to remove a pre-albumin fraction that migrates faster than prealbumin and then sterile filtered.
The assayed constituents for this product are: protein, glucose, lactic acid, chloride, sodium, potassium, immunoglobulins and protein fractions by electrophoresis.
The Level I represents normal spinal fluid. Level II represents abnormal spinal fluid. The conditions observed in both levels of the control are most commonly seen in meningitis, multiple sclerosis, and brain trauma or injuries.
TABLE I______________________________________Constituent Targets: LEVEL LEVELPARAMETER NORMAL I II UNITS______________________________________Sodium 139-150 140-160 120-140 mmol/LPotassium 2.7-3.9 2-4 3-6 mmol/LChloride 116-127 110-130 90-110 mmol/LLactic Acid 1.1-2.8 1-3 7-9 mmol/LGlucose 45-80 45-80 25-40 mg/dLProtein 15-45 15-45 50-80 mg/dLELECTROPHORETIC SEPARATION(% of Total Protein)PREALBUMIN 2-7 2-7 2-7 %ALBUMIN 56-76 45-76 45-76 %GLOBULINS:ALPHA 1 2-7 2-7 2-7 %BETA 7-18 7-18 7-18 %GAMMA 7-14 7-19 7-19 %IMMUNOGLOBULINS(RID)IgA 0-0.2 trace trace mg/dLIgG 10-40 0-15 5-40 mg/dLIgM 0-0.6 trace trace mg/dL______________________________________ Microbiology Specs: No growth to USP procedures.
EXAMPLE 1
Prealbumin Isolation from Serum
Units of normal human serum were pooled and the volume measured to be approximately two liters. The pooled serum was diluted 50% in 50 mM potassium phosphate buffer, pH 7.5, 0.1% azide. The diluted serum was sterile filtered through a 0.22 micron filter into sterile containers. The prepared serum was then loaded on to an ion exchange column containing DEAE SEPHACEL™, diethylaminoethyl crosslinked cellulose, ion exchange chromatography media or DEAE SEPHAROSE™ , diethylaminoethyl crosslinked agarose, (Pharmacia) ion exchange chromatography media that has been previously equilibrated with 50 mM potassium phosphate buffer, pH 7.5, 0.1% azide. After completion of the sample load, the column was washed with 50 mM potassium phosphate buffer, pH 7.5, 0.1% azide until an OD at 280 nm is less than 0.2 as measured on an UV spectrophotometer. The bound proteins were eluted with a gradient from 0 to 1M NaCl in 0.5M potassium phosphate buffer, pH 7.5, 0.1% azide. 12 mL fractions were collected until the gradient was exhausted. This column removed ceruloplasmin, globulins and albumin from the sample.
The fractions are tested by immunodiffusion for the presence of prealbumin. When the fractions that contain prealbumin are identified, they are pooled, concentrated, and buffer exchanged with 20 mM potassium phosphate buffer, pH 7.1, 0.02% azide. The pooled fractions were concentrated to a total protein of approximately 4 to 5 g/dL. The fraction pool is then loaded on an affinity column containing AFFI GEL BLUE™ (Biorad) chromatography media or BLUE SEPHAROSE™, 4-((4-((4-amino-9,10-dihydro-9,10-dioxo-3-sulfo-1-anthracenyl)amino)-2-sulfophenyl)amino)-6-((3(or 4)-sulfophenyl)amino)-1,3,5-triazin-2-yl ether, trisodium salt agarose, which has been equilibrated with 20 mM phosphate buffer, pH 7.1, 0.02% azide. This chromatography media contains CIBACRON BLUE Dye F3G-A which has an affinity for albumin. After the sample was loaded, the fraction collector was started and 6 mL fractions were collected as the column was washed with 20 mM phosphate buffer, pH 7.1, 0.02% azide. As the sample was loaded, albumin binds to the blue dye and the remaining proteins passed through the column. The prealbumin containing fractions were pooled, concentrated and buffer exchanged with 50 mM potassium phosphate buffer, pH 7.5, 0.1% azide. The fractions were concentrated to a total protein of approximately 3 to 4 g/dL. The concentrated fractions were then loaded onto an ion exchange column containing DEAE SEPHACEL™ ion exchange chromatography media or DEAE SEPHAROSE™ (Pharmacia) ion exchange chromatography media which has been equilibrated with 50 mM potassium phosphate buffer, pH 7.5, 0.1% azide. The proteins were eluted using a salt gradient of 0 to 1M NaCl in 50 mM potassium phosphate buffer, pH 7.5, 0.1% azide. Fractions of 3 mL were collected until the gradient was exhausted. Fractions were tested for the presence of prealbumin using immunodiffusion.
When the prealbumin containing fractions have been identified these fractions were pooled, concentrated and buffer exchanged in 50 mM phosphate buffer with 170 mM sodium chloride, pH 7.5, 0.02% azide. The fraction pool was concentrated to a total protein of approximately 2-7 g/dL. This fraction pool was then loaded on a gel filtration column which contained ULTROGEL®, a mixture of polyacrylamide and agarose, AcA 54 (IBF Biotechnics) gel filtration media equilibrated with 50 mM phosphate buffer with 170 mM sodium chloride, pH 7.5, 0.02% azide. This column was then washed with 50 mM phosphate buffer with 170 mM sodium chloride, pH 7.5, 0.02% azide. Fractions were collected of 3 mL each. Two protein peaks were collected. The prealbumin was mostly contained in the second peak. Fractions were tested for the presence of prealbumin using immunodiffusion. The fractions that contain prealbumin were then tested by serum protein electrophoresis for the presence of other serum proteins. The purified prealbumin fractions were selected, pooled and concentrated to a total protein of approximately 1 to 4 g/dL. These pooled fractions were sterile filtered and stored at 2°-8° C.
The purified prealbumin was tested for total prealbumin content using serum protein electrophoresis, and radial immunodiffusion analysis for quantitative measurement of prealbumin. A single peak was observed and the prealbumin was found to be 90 to 100% pure by protein electrophoresis. See FIG. 3. When compared to the electrophoretic pattern of normal serum, the peak is observed in the prealbumin region and no other serum proteins are present. See FIG. 4. When spiked into normal serum, the resulting electrophoretic pattern showed a peak in the prealbumin region. See FIG. 1 and 2. SDS PAGE electrophoresis shows a single protein to be present. This protein is found in the correct molecular weight range for prealbumin (54,000). The quantity of prealbumin demonstrated yields of 80 to 100% depending on the purity of prealbumin required. A commercially available prealbumin prepared from human plasma using the method defined by Raz, A., et al., J. Biol. Chem., 244,12 (1969) was evaluated for purity. This prealbumin was found to be only 75% pure by protein electrophoresis. See FIG. 5. When compared to the electrophoretic pattern of normal serum the contaminating proteins are observed in the albumin, and alpha globulin regions. See FIG. 6.
The purified prealbumin has been monitored for stability while being stored refrigerated and frozen. The prealbumin has been tested for quantity by radial immunodiffusion and purity by protein electrophoresis. After ten months storage at these conditions, the prealbumin has remained stable.
TABLE II______________________________________STABILITY OF PREALBUMINMONTHS______________________________________ STORAGE AT 2-8° C.0 7395 mg of prealbumin/liter of solution4 7020 mg of prealbumin/liter of solution6 7879 mg of prealbumin/liter of solution10 7005 mg of prealbumin/liter of solution STORAGE AT -20° C.0 N/A4 N/A6 7724 mg of prealbumin/liter of solution10 7275 mg of prealbumin/liter of solution______________________________________
EXAMPLE 2
Preparation of Cerebrospinal Fluid Control
A clean container with a stirring device is prepared. 800 mL of distilled is placed into the container. While mixing, the following chemicals are added:
______________________________________Constituents Level I Level II______________________________________HEPES (N-2-hydroxyethyl 12.3 gm 9.2 gmpiperazine-N.sub.2 '-2-ethane sulfonic acid)Sodium HEPES 9.4 gm 7.0 gmSodium Chloride 6.6 gm 5.3 gmPotassium Chloride 0.19 gm 0.3 gmGlucose 0.57 gm 0.33 gmSodium Lactate 0.38 gm 1.5 gmHuman Serum 0.29 gm 0.63 gmPrealbumin 10.0 mg 15.0 mgSodium Azide 25% 0.8 mL 0.8 mL______________________________________
After all chemicals are dissolved, the total volume of the solution is brought to one liter with distilled water. All constituents are analyzed and adjusted within the above described specifications. A gas cylinder of oxygen is connected to a two stage regulator. Rubber tubing or equivalent is connected to the regulator and to the batching container. The first stage of the regulator is opened. The second stage is slowly opened until the gas flow through the solution is approximately 0.4 SCFH (square cubic feet per hour). While mixing, the pool is flushed in this manner at room temperature.
After flushing, a sample of the solution is removed and concentrated approximately 60 times. This concentrated sample is then evaluated by serum protein electrophoresis. If the electrophoretic pattern does not show a single peak in the prealbumin region, reflushing is necessary.
After a normal electrophoretic pattern is recovered, the solution is sterile filtered through 0.22 micron membranes into sterilized containers. The sterile solution is then filled into sterilized vials at three mL each.
These cerebrospinal fluid controls were evaluated for stability according to a protocol for the evaluation of the stability of diagnostics products. This protocol states guidelines for accelerated stability studies. According to this protocol, a product that is stored at 37° C. for one week is stable for one year at 2°-8° C. Accelerated stability studies were used to determine the performance characteristics of the product under storage conditions which stress the product in comparison to those recommended for use and handling of the product. The cerebrospinal fluid controls were analyzed after storage at 25° C. for three months and 37° C. for four weeks. Results from these analyses show the product to be stable and therefore have a predicted shelf life of greater than three years. The product has been monitored at 2°-8° C. for greater than one year. See Table III.
TABLE III______________________________________STABILITY OF CEREBROSPINAL FLUID CONTROLCON- 2-8° C. 25° C. 37° C.STITUENTS UNITS Storage Storage Storage______________________________________LEVEL IPROTEIN mg/dL 28 30 28LACTIC mM 1.2 1.1 1.2ACIDGLUCOSE mg/dL 56 56 56CHLORIDE mM 120 127 122SODIUM mM 149 150 149POTASSIUM mM 2.6 2.6 2.6IgA mg/dL 1.2 1.1 1.3IgG mg/dL 4.6 5.0 4.3IgM mg/dL 1.2 1.6 1.4ELECTRO-PHORESIS:PRE- % OF TOTAL 6.2 6.2 5.2ALBUMINALBUMIN % OF TOTAL 66 65 66ALPHA 1 % OF TOTAL 3.2 3.0 3.7ALPHA 2 % OF TOTAL 6.3 6.3 6.2BETA % OF TOTAL 7.7 8.2 8.2GAMMA % OF TOTAL 10.5 11.2 11.6LEVEL IIPROTEIN mg/dL 61 66 64LACTIC mM 7.6 7.7 7.6ACIDGLUCOSE mg/dL 31 34 33CHLORIDE mM 102 106 102SODIUM mM 127 127 127POTASSIUM mM 4.1 4.2 4.1IgA mg/dL 2.5 2.5 3.0IgG mg/dL 10.2 10.4 10.3IgM mg/dL 1.9 2.4 1.9ELECTRO-PHORESIS:PRE- % OF TOTAL 5.4 4.9 4.6ALBUMINALBUMIN % OF TOTAL 63 63 62ALPHA 1 % OF TOTAL 2.8 2.4 2.7ALPHA 2 % OF TOTAL 7.4 7.6 7.8BETA % OF TOTAL 8.6 9.6 9.6GAMMA % OF TOTAL 12.5 12.6 13.5______________________________________
The cerebrospinal fluid controls were also evaluated for open vial stability. Vials were tested after being open for two weeks. Analyses of the opened vials showed no change when compared to vials that were freshly sampled. See TABLE IV.
TABLE IV______________________________________ OPENCONSTITUENT UNITS FRESH VIAL 14 DAYS______________________________________OPEN VIAL STABILITY LEVEL IProtein mg/dL 25.5 25.7Glucose mg/dL 60.0 60.2Sodium mM 158 158Chloride mM 113 112IgG mg/dL 4.98 4.99IgA mg/dL 1.18 1.16IgM mg/dL <0.69 <0.69ELECTRO-PHORESIS:Prealbumin % of Total 3.6 4.4Albumin % of Total 65 64Alpha 1 % of Total 3.0 3.6Alpha 2 % of Total 6.8 7.1Beta % of Total 9.2 9.2Gamma % of Total 11.9 12.1OPEN VIAL STABILITY LEVEL IIProtein mg/dL 59.5 59.1Glucose mg/dL 33.3 33.2Sodium mM 127 127Chloride mM 96 97IgG mg/dL 11 11IgA mg/dL 2.59 2.58IgM mg/dL 0.89 0.91ELECTRO-PHORESIS:Prealbumin % of Total 2.5 2.6Albumin % of Total 61 62Alpha 1 % of Total 4.0 4.1Alpha 2 % of Total 8.5 7.8Beta % of Total 10.0 9.5Gamma % of Total 13.5 13.8______________________________________
EXAMPLE 3
The cerebrospinal fluid control prepared in Example 2 was used as a control in several diagnostic tests. The results of these assays are reported in TABLE V.
TABLE V______________________________________METHODS COMPARISONCON- LEVEL LEVELSTITUENT UNITS METHOD I II______________________________________Protein mg/dL DuPont aca 4 28.5 59.8 mg/dL DuPont aca 3 22 57 mg/dL Kodak Ektachem 25.6 75.6 mg/dL Abbott Spectrum 28.6 60.2Lactic Acid mM DuPont aca 3 1.2 7.0 mM Baxter Paramax 1.4 7.1Glucose mg/dL DuPont aca 4 57.2 33.5 mg/dL DuPont aca 3 57 33.8 mg/dL DuPont 56.6 33.4 Dimension mg/dL Kodak Ektachem 60.1 35.9 mg/dL Abbott Spectrum 58.5 35.4 mg/dL Baxter Paramax 60.0 36.0Chloride mM DuPont aca 3 122 104 mM Kodak Ektachem 112 93 mM Abbott Spectrum 119 101 mM DuPont 114 97 Dimension mM NOVA 119 101 Biomedical mM Baxter Paramax 113 95Sodium mM Abbott Spectrum 152 130 mM DuPont 153 128 Dimension mM NOVA 150 126 BiomedicalPotassium mM NOVA 2.7 4.1 BiomedicalIgG mg/dL RID 8.0 16 mg/dL Beckman Array 5.0 11IgA mg/dL RID 1.4 3.0 mg/dL Beckman Array 1.2 2.6IgM mg/dL RID 1.4 1.9 mg/dL Beckman Array <0.69 0.91ELECTROPHORESIS:% OF TOTALHELENAPrealbumin 7.0 5.5Albumin 63 61Alpha 1 3.8 3.9Alpha 2 6.4 7.4Beta 7.3 8.3Gamma 13.0 14.0BECKMAN PARAGONPrealbumin 5.5 3.5Albumin 66 67Alpha 1 3.7 3.7Alpha 2 6.6 7.1Beta 7.6 7.6Gamma 10.0 11.0______________________________________
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A biosynthetic cerebrospinal fluid control and method of use. Additionally, this invention relates to the isolation and purification of stable liquid human prealbumin, a component in the biosynthetic cerebrospinal fluid control.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/679,960, filed on Nov. 16, 2012, which claims the benefit of U.S. Provisional Application No. 61/587,438, filed on Jan. 17, 2012, entitled “MASTER CONTROL SYSTEM WITH REMOTE MONITORING FOR HANDLING TUBULARS,” the content of which is incorporated herein by reference in its entirety.
FIELD
The present embodiments generally relate to a master control system with remote monitoring for handling tubulars.
BACKGROUND
A need exists for a master control system that allows one or more users to remotely monitor the installation, removal, or both of one or more tubulars.
A further need exists for a master control system that allows at least partial automation of rig operation to provide a safe work environment for rig personnel.
The present embodiments meet these needs.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description will be better understood in conjunction with the accompanying drawings as follows:
FIG. 1 depicts a schematic of a master control system configured to perform an operation on a tubular according to one or more embodiments.
FIG. 2 depicts a schematic of a portion of the master control system of FIG. 1 with a retracted top drive.
FIGS. 3A and 3B depict a detailed schematic of data storage according to one or more embodiments.
FIG. 4 depicts a detailed schematic of data storage according to one or more embodiments.
FIG. 5 is a top view of an embodiment of the drilling rig, vertical pipe handler, and horizontal to vertical pipe handler that can be controlled by the master controller.
The present embodiments are detailed below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Before explaining the present system in detail, it is to be understood that the system is not limited to the particular embodiments and that it can be practiced or carried out in various ways.
The present embodiments relate to a master control system with remote monitoring for handling one or more tubulars.
The master control system can include a server with a processor connected to a data storage, which can be on a network, connectable to a computing cloud, or both, for installing tubulars connectable into a drill string into a wellbore by a drilling rig.
The master control system can include a server with a processor connected to a data storage with a plurality of computer instructions for removing tubulars from a wellbore and breaking down a drill string.
The master control system can be used to allow remote monitoring during installation of one or more tubulars in a wellbore using a drilling rig. The remote monitoring can be 100 yards from the well bore or hundreds of miles from the well bore.
The invention provides increased safety and reduced accidents around the rig.
The invention allows a home office to act quickly when a rig may be experiencing difficulty in making up tubulars into a drill string or breaking down a drill string.
The master control system can include a server. The server can be a laptop, a PC, or another type of computing processor that communicates to data storage. The data storage and the processor that form the server can be in communication with a network and a data storage.
The server can be based in a computing cloud. The server can be in the home office of a driller, on a network.
The network can be a local area network, a wireless network, a satellite network, a similar network, or combinations thereof.
The server can be in communication with multiple client devices simultaneously, or with a single client device via the network. The client devices can be cell phones, laptops, PCs, desk top processors with data storage, tablets, and similar devices that can be wired or wirelessly connected to the network or the computing cloud and be configured to present an executive dashboard of rig functions, vertical pipe handler functions, and horizontal to vertical pipe handler functions, to a user of the client device.
The server can be in communication with a second client device via the network, a computing cloud, or both.
The second client device can be a device similar to the first client device, or different than the first client device. The second client device can be configured to present an executive dashboard of rig functions, vertical pipe handler functions, and horizontal to vertical pipe handler functions to a user of the client device.
The data storage can include computer instructions to manage synchronized functions of the rig's hoist system and a top drive, as well as the functions of a vertical pipe handler, and a horizontal to vertical pipe handler which are operationally connected together in series.
The computer instructions in the data storage can receive inputs from monitoring devices connected with components of the drilling rig, and can use the received inputs to determine a location of the top drive and vertical pipe handler, a position of the horizontal to vertical pipe handler, and a speed of the hoist system.
Sensors on the rig can also be used with computer instructions in the server to count the number of tubulars that are used on the drill string and to measure the length of each tubular being connected to or removed from a drill string.
For example, one or more sensors can be placed at one or more predetermined locations on a mast to detect if the top drive is proximate to the crown, to the tubular, or to the base of the mast.
One or more sensors on the rig can measure a rotational speed of the hoist system.
One or more sensors on the rig can determine the location of the top drive and computer instructions in the server can be used to continuously calculate the location of the top drive and the depth of the tubular in the well bore based on a sensed position and rotational speed of the hoist system.
In operation, the vertical pipe handler and the horizontal to vertical pipe handler can be actuated based on the sensed location of the top drive.
The data storage of the master control system can include computer instructions to determine when one or more tubulars are disposed on the horizontal to vertical pipe handler and to instruct the horizontal to vertical pipe handler to grab the one or more tubulars.
For example, the computer instructions in the data storage can receive inputs provided to the server by one or more sensors on the horizontal to vertical pipe handler, and when a signal from the sensors indicates that tubulars are disposed thereon, the computer instructions can instruct a processor of the server to actuate one or more cylinders on the horizontal to vertical pipe handler to grip the tubular.
The data storage can include computer instructions to raise the horizontal to vertical pipe handler to a vertical position from an initial horizontal position.
For example, these computer instructions can instruct the server to initiate movement of the horizontal to vertical pipe handler from a substantial horizontal position to a substantially vertical position once a sensor detects that a gripper has fully closed about the one or more tubulars on the horizontal to vertical pipe handler.
The data storage can include computer instructions to extend arms of the vertical pipe handler to grab a tubular from the horizontal to vertical pipe handler, and to rotate and lift the tubular for positioning at a well center. For example, these computer instructions can receive inputs on the location of the horizontal to vertical pipe handler, determine when the horizontal to vertical pipe handler is in an operative position, and instruct the processor to send one or more signals to the vertical pipe handler instructing the vertical pipe handler to extend top and bottom pivoting arms of the vertical pipe handler to grab the tubular from the horizontal to vertical pipe handler.
The data storage can include computer instructions to lower the top drive to an end of the tubular. For example, these computer instructions can compare the calculated or detected location of the top drive to a predetermined location, and instruct the processor to instruct a control of the hoist system to lower the top drive until the predetermined location is reached enabling the tubular to be connected to the top drive.
The data storage can include computer instructions to engage the top drive with the tubular making up the connection. For example, these computer instructions can instruct the top drive to secure to the tubular in a manner known to one skilled in the art.
The data storage can include computer instructions to rotate the tubular with the top drive and drive the tubular into the wellbore. For example, these computer instructions can instruct the processor to instruct the hoist system to lower the top drive when a signal is received indicating that the top drive has secured to the tubular.
The data storage can include computer instructions to retract the travelling block with the top drive, and to travel the top drive to a start position. The start position can be adjacent a crown when running tubulars into the wellbore. For example, these computer instructions can instruct the processor to instruct one or more arms connected to the traveling block to move the travelling block with the top drive into a channel formed in a mast when it is determined that the top drive and traveling block are aligned with a space.
The data storage can include computer instructions to extend arms of the vertical pipe handler to grab a subsequent tubular from the horizontal to vertical pipe handler, and rotate and lift the subsequent tubular for positioning at the well center.
The master control system can retract the traveling block into a recess in the mast and actuate the vertical pipe handler simultaneously.
The data storage can include computer instructions to lower the top drive to an end of the subsequent tubular. For example, these computer instructions can instruct the server to send a signal to the hoist system to lower the top drive upon receiving a signal indicating that the subsequent tubular member is in position to be engaged by the top drive.
The data storage can include computer instructions to engage the top drive with the subsequent tubular making up the connection.
The data storage can include computer instructions to rotate the subsequent tubular with the top drive and make up a connection with the tubular using a roughneck secured to a drilling floor. For example, these computer instructions can instruct the server to initiate rotation of the top drive when a signal is received indicating that the tubular member is engaged by hydraulic power tongs, and to move the subsequent tubular member towards the roughneck.
The data storage can include computer instructions to drive the tubulars into the well bore.
The data storage can include computer instructions to retract the travelling block with the top drive to the start position.
The data storage can include computer instructions to perform the foregoing operations on any number of tubulars.
The data storage can be configured to cause any number of tubulars to be ran downhole or removed from the wellbore.
The data storage can be configured to reset the horizontal to vertical pipe handler when the horizontal to vertical pipe handler is depleted of tubulars.
The data storage can include computer instructions to lower the horizontal to vertical pipe handler to a trailer frame. For example, these computer instructions can instruct the processor to lower the horizontal to vertical pipe handler to the trailer frame when an input is received that all tubulars have been removed from the horizontal to vertical pipe handler.
The master control system with remote monitoring can be configured to aid with the removal of tubulars from the well bore.
The data storage can be configured to include computer instructions to manage synchronized functions of the hoist system, the top drive, the vertical pipe handler, and the horizontal to vertical pipe handler.
The data storage can be configured to lower the top drive to an end of a tubular disposed in the wellbore.
The data storage can be configured to engage the top drive with the tubular making up a connection.
The data storage can be configured to retract the tubular from the wellbore using the top drive.
The data storage can be configured to determine when the hydraulic power tongs have engaged the tubular, and to operate the hydraulic power tongs to break out the tubular from subsequent tubulars located in the wellbore.
The data storage can be configured to engage the tubular with the vertical pipe handler.
The data storage can be configured to retract the vertical pipe handler to place the tubular in a setback
The data storage can also include computer instructions to track how many tubulars are placed in the wellbore.
In one or more embodiments, the horizontal to vertical pipe handler can have two arms. Each arm of the horizontal to vertical pipe handler can be configured to hold independently raise the tubulars held therein to a vertical position.
Turning now to the Figures, FIG. 1 depicts a schematic of the master control system configured to perform an operation on a tubular according to one or more embodiments.
The master control system can include a server 602 a which includes a processor and communicates to data storage 610 a that is connected via a network 608 .
Similarly, the master control system can include a cloud based server 602 b which can include a processor and can communicate to cloud based data storage 610 b that is in a computing cloud 687 and can communicate with the network 608 .
The servers 602 a and 602 b can be configured to execute computer instruction in one or more data storages 610 , and to communicate with devices via the network 608 . The servers 602 a and 602 b can be a PENTIUM™ processor or similar device.
The one or more data storages 610 a and 610 b can be connected to, integrated with, or otherwise in communication with the servers 602 a and 602 b.
In embodiments, a cloud based server, a non-cloud based server, or both can be used simultaneously.
Similarly, in embodiments, a cloud based data storage, a non-cloud base data storage, or both can be used simultaneously.
A first client device 660 and a second client device 670 can be in communication with the network 608 , the computing cloud 687 or both simultaneously.
The first client device 660 is configured for receiving and presenting an executive dashboard 663 a which displays not only rig functions to a first user but also vertical pipe handler operational information and horizontal to vertical pipe handler operational information to the first user 667 .
The second client device 670 is configured for receiving and presenting the executive dashboard 663 b which is identical to the executive dashboard 663 a of the first client device. Like the executive dashboard 663 a , executive dashboard 663 b displays not only rig functions to a second user but also vertical pipe handler operational information and horizontal to vertical pipe handler operational information to the second user 669 .
The master control system can communicate with a drilling rig 680 .
The drilling rig 680 can be sequentially connected and operationally connected to a vertical pipe handler 681 , and a horizontal to vertical pipe handler 688 .
The master controller operates a hoist system 682 of the rig, which is shown sitting on a subbase trailer, as this is a portable rig.
The hoist system includes a drawworks and a drill line 218 that connects to a top drive 684 . The master control for this embodied portable rig can be used to control a winch 289 that runs a hoist line 287 for raising or lowering the mast 683 of the rig.
In this Figure, the master controller can also be used to operate hydraulic power tongs 689 .
The drill line 218 passes from the drawworks to the crown 22 and then to the top drive.
The hoist system 682 can have a rotational speed monitoring device 916 that communicates to the master controller.
The rotational speed monitoring device 916 can be any device capable of determining the rotational speed of the hoist system 682 and transmitting the rotations per minute to the server in the computing cloud or on the network outside of the computing cloud.
The vertical pipe handler 681 can have one or more vertical pipe handler monitoring devices 918 that can monitor the presence of each tubular 902 and the device and determine pressure applied to each tubular connected, to the vertical pipe handler. The vertical pipe handler monitoring device 918 then transmits the signal to the server.
The vertical pipe handler monitoring devices 918 can be configured to determine: (i) if the arms of the vertical pipe handler 681 are actuated, (ii) a position of the arms, or combinations thereof, and transmit the information to the server in the computing cloud or on the network outside of the computing cloud.
The top drive 684 can have one or more top drive monitoring devices 912 .
The top drive monitoring devices 912 can be accelerometers, radio frequency identification (RFID) tags, or any other device capable of measuring the acceleration of the top drive 684 and/or aiding in the determination thereof by sending a signal or interacting with another monitoring device to cause a signal to be sent. In embodiments, the top drive monitoring device is a device capable of measuring the location of the top drive.
For example, the top drive 684 can have a chip or device configured to interact with one or more mast monitoring devices 914 to cause a signal to be sent to the server 602 a or 602 b or both between a crown and a base to detect where a top drive is located.
The hydraulic power tongs 689 can be power tongs secured to a drill floor 690 of the drilling rig 680 . The hydraulic power tongs 689 can have one or more hydraulic power tong monitoring devices 928 configured to determine if the hydraulic power tongs 689 are in a closed position or opened position, determine forces applied to the hydraulic power tongs 689 , or combinations thereof. The hydraulic power tong monitoring devices can communicate with the servers in the computing cloud or connected via the network to enable continuous monitoring of the apparatus.
The horizontal to vertical pipe handler 688 can have one or more horizontal to vertical pipe handler monitoring devices 920 and 922 configured to detect the location of the horizontal to vertical pipe handler 688 , speed of the horizontal to vertical pipe handler 688 , force applied to the horizontal to vertical pipe handler 688 , the presence of a tubular 902 , how many tubulars are disposed on the horizontal to vertical pipe handler 688 , the like, or combinations thereof. The horizontal to vertical pipe handler monitoring devices 920 and 922 can communicate to the servers in the computing cloud or connected via the network.
The crown 22 can have a top crown 685 can have one or more top crown monitoring devices 930 to determine the speed of line passing therethrough and communicate to the servers in the computing cloud or connected via the network.
Each of the monitoring devices, including the horizontal to vertical pipe handler monitoring devices 920 and 922 , top crown monitoring devices 930 , rotational speed monitoring device 916 , hydraulic power tong monitoring devices 928 , mast monitoring devices 914 , top drive monitoring devices 912 , and vertical pipe handler monitoring devices 918 , can communicate with a server 602 through any form of telemetry, such as through the network 608 or the computing cloud 687 using individual protocols of each sensor. Illustrative telemetry can include wired, wireless, acoustic, frequency, or combinations thereof.
The drilling rig 680 can be operatively aligned with a wellbore 698 .
Also shown is a rig mounted sensor 929 that can be: used with computer instructions in the data storage 610 for counting each tubular and/or measuring the length of each tubular that enters the wellbore 698 .
FIG. 2 depicts the vertical pipe handler 681 with a tubular 902 adjacent a drilling rig 680 .
The vertical pipe handler is shown with the top pivoting arm 904 holding the tubular 902 below a top drive 684 over the well center, and the bottom pivoting arm 905 also grasping the tubular 902 . In this view the vertical pipe handler has raised the tubular from its position when grasped from the horizontal to vertical pipe handler 688 above the base of the rig.
FIG. 2 also shows a vertical pipe handler rotation and vertical motion monitor 932 . The vertical pipe handler rotation and vertical motion monitor 932 transmits to the master control system a signal indicating a degree at which the vertical pipe handler is positioned and a height at which either the top pivoting arm 904 , the bottom pivoting arm 905 , or both, are located from a base of the vertical pipe handler.
The top pivoting arm 904 can have a first arm monitor 934 , and the bottom pivoting arm 905 can have a second arm monitor 936 , which can communicate with the master control system to determine an angle of extension of each pivoting arm on a vertical pipe handler and transmit the angle of extension to the server.
Also shown in FIG. 2 are sensors that transmit signals on the location of the tubular on the horizontal to vertical pipe handler 688 .
The sensors for the horizontal to vertical pipe handler 688 include a horizontal to vertical pipe handler tubular monitoring device 921 transmitting information that a tubular is on the horizontal to vertical pipe handler 688 to the server.
The sensors for the horizontal to vertical pipe handler 688 include a horizontal to vertical pipe handler tubular rolling monitoring device 923 transmitting information that a tubular is rolling or stopped rolling on the horizontal to vertical pipe handler to the server.
The sensors for the horizontal to vertical pipe handler include a horizontal to vertical pipe handler grip monitoring device 925 transmitting information that a tubular is gripped securely by the horizontal to vertical pipe handler.
The mast 683 is also shown in this Figure.
FIGS. 3A and 3B depict a detailed schematic of data storage 610 a according to one or more embodiments.
The data storage 610 a can include computer instructions 620 to manage synchronized functions of the drilling rig a vertical pipe handler, and a horizontal to vertical pipe handler.
The data storage 610 a can include computer instructions 621 to determine when a tubular is on a horizontal to vertical pipe handler.
The data storage 610 a can include computer instructions 624 to raise the tubular from a horizontal position to a vertical position using the horizontal to vertical pipe handler.
The data storage 610 a can include computer instructions 626 to extend top and bottom pivoting arms of the vertical pipe handler.
The data storage 610 a can include computer instructions 627 to grab the raised tubular from the horizontal to vertical pipe handler using the top and bottom pivoting arms.
The data storage 610 a can include computer instructions 629 to rotate the extended pivoting arms holding the tubular to position the tubular over the well center.
The data storage 610 a can include computer instructions 629 to lift the tubular to a position proximate to the top drive for connection with the top drive.
The data storage 610 a can include computer instructions 630 to lower the top drive down a mast of the drilling rig for connection to an end of the tubular.
The data storage 610 a can include computer instructions 631 to connect the top drive to the tubular.
The data storage 610 a can include computer instructions 632 to rotate the tubular using the top drive to insert the tubular into the wellbore while lowering the top drive towards the well bore.
The data storage 610 a can include computer instructions 634 to disengage the tubular from the top drive once the tubular reaches a preset depth.
The data storage 610 a can include computer instructions 646 to retract the top drive away from the wellbore.
The data storage 610 a can include computer instructions 661 to form an executive dashboard of rig functions, vertical pipe handler functions and horizontal to vertical pipe handler functions.
The data storage 610 a can include computer instructions 638 for simultaneously drilling with the drilling rig while connecting tubulars.
The data storage 610 a can include computer instructions 1000 for measuring the length of each tubular that enters the well bore.
The data storage 610 a can include computer instructions 1002 for counting each tubular with the rig mounted sensor as the top drive inserts the tubulars into the well bore.
The data storage 610 a can include computer instructions 1004 to determine the speed of line passing there through and communicate to the servers via the web.
The data storage 610 a can include computer instructions 1006 to measure acceleration of the top drive.
The data storage 610 a can include computer instructions 1008 to measure location of the top drive.
The data storage 610 a can include computer instructions 1010 for determining a location of the top drive between the crown and the subbase.
The data storage 610 a can include computer instructions 1012 to determine a member of the group consisting of: if the hydraulic power tongs are in a closed position, if the hydraulic power tongs are in an open position, how much torque force is applied to the hydraulic power tongs, or combinations thereof.
The data storage 610 a can include computer instructions 1014 to enable transfer of a tubular between a horizontal to vertical pipe handler and an adjacent vertical pipe handler using signals from a vertical pipe handler monitoring device that can monitor the presence of each tubular and pressure applied to a tubular connected to the vertical pipe handler.
The data storage 610 a can include computer instructions 1016 for receiving signals from: a horizontal to vertical pipe handler monitoring device for transmitting positions of the horizontal to vertical pipe handler holding the tubular to the server; a horizontal to vertical pipe handler tubular monitoring device transmitting information that a tubular is on the horizontal to vertical pipe handler; a horizontal to vertical pipe handler tubular rolling monitoring device transmitting information that a tubular is rolling or stopped rolling on the horizontal to vertical pipe handler; and a horizontal to vertical pipe handler grip monitoring device transmitting information that a tubular is gripped securely by the horizontal to vertical pipe handler.
The data storage 610 a can include computer instructions 1018 for receiving signals from: a vertical pipe handler rotation and vertical motion monitor for transmitting a degree at which the vertical pipe handler is positioned and a height at which either the top pivoting arm the bottom pivoting arm, or both; are located from a base of the vertical pipe handler; and a first arm monitor and a second arm monitor to determine an angle of extension of each pivoting arm on a vertical pipe handler and transmit the angle of extension to the server.
FIG. 4 is a detailed schematic of data storage 610 b according to one or more embodiments.
The data storage 610 b can include computer instructions 620 to manage synchronized functions of the drilling rig, a vertical pipe handler and a horizontal to vertical pipe handler.
The data storage 610 b can include computer instructions 661 to form an executive dashboard of rig functions, vertical pipe handler functions and horizontal to vertical pipe handler functions.
The data storage 610 b can include computer instructions 702 to lower the top drive to an end of a tubular disposed in the well bore.
The data storage 610 b can include computer instructions 704 to engage the top drive with the tubular in the wellbore and rotating the tubular to make up a connection with the top drive.
The data storage 610 b can include computer instructions 706 to withdraw the tubular from the wellbore.
The data storage 610 b can include computer instructions 708 to grab the tubular with a top and a bottom pivoting arms of a vertical pipe handler.
The data storage 610 b can include computer instructions 710 to retract the top and bottom pivoting arms of the vertical pipe handler holding the tubular and rotate the top and bottom arms while lowering the top and bottom arms.
The data storage 610 b can include computer instructions 712 to grab the tubular from the vertical pipe handler with the horizontal to vertical pipe handler.
The data storage 610 b can include computer instructions 714 to lower the horizontal to vertical pipe handler holding the tubular and placing place the tubular in a set back or a pipe tub.
The data storage 610 b can include computer instructions 716 for simultaneously removing a drill string of connected tubulars from a well bore while breaking up tubulars from a drill string.
The data storage 610 b can include computer instructions 2000 for measuring the length of each tubular that are removed from the wellbore, and computer instructions 2002 for counting each tubular with the rig mounted sensor as the tubulars are removed from the wellbore.
FIG. 5 is a top view of an embodiment of the rig and vertical pipe handler and horizontal to vertical pipe handler that can be controlled by the master controller.
In this view can be seen the bucking machine 590 with a tubular 505 and the pipe tub 592 connected to the vertical pipe handler 681 connected to a drilling rig 680 .
While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein.
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A master control system with remote monitoring that can perform, monitor, and control operations of a portable rig with a pipe handler as the pipe handler installs tubulars into a drill string or breaks out tubulars from a drill string for a wellbore. The master control system can include a processing device communicatively coupled to a data storage. The processing device receives a communication associated with a component of a portable rig. The processing device determines a position of the component of the portable rig based on the received communication. The processing device further provides an executive dashboard that includes at least one drilling rig function associated with the component of the portable rig. The processing device also initiates the portable rig to perform the at least one drilling rig function associated with the component of the portable rig.
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FIELD OF THE INVENTION
[0001] The present invention relates to a method for incinerating combustible materials, particularly waste materials, including hazardous and bio-hazardous waste materials.
BACKGROUND OF THE INVENTION
[0002] The disposal of waste is a serious problem to governments, especially municipal governments. The waste disposal process is regulated by increasingly stricter standards since some wastes are toxic. In the case of industrial waste, there are even more problematic materials, such as petrochemicals, PCBs (polychlorinated biphenyls), etc. than in common, non-industrial waste. Additionally, medical and other biological waste is often hazardous and requires complete sterilization and decomposition.
[0003] Previously, other methods of waste disposal were more attractive than incineration. Landfills, for example, were used instead of incineration since the cost of disposing waste at a landfill was far less than that of incineration. However, increasingly more severe environmental standards have made landfills less attractive, primarily because of the increased awareness that toxic chemicals, over long periods of time, percolate through the ground contaminating aquifers. Similarly, the ever increasing quantity of waste make landfills and other methods physically impractical.
[0004] Accordingly, destructive, degradative processes such as incineration have become more popular. Destructive techniques like incineration must efficiently turn waste into innocuous end-products. This is a particularly acute problem in incineration where burning hazardous waste requires high temperatures so that the resulting decomposition products are environmentally benign. The high temperatures needed and the large quantities of waste involved require the development of incinerators that are economically and environmentally efficient. The emissions from such products are generally gaseous and must comply with standards set by international and governmental agencies. Similarly, solid and particulate wastes of incineration, such as slag, bottom ash and fly ash, must be neutered to remove harmful effects to the environment.
[0005] Examples of recently proposed incineration methods and incinerators can be found in U.S. Pat. Nos. 5,752,452 and 5,179,903 and WO 95/01809. The latter two patents describe recycled flue gases which are augmented with oxygen. U.S. Pat. No. 5,752,452 describes a system with lances which inject oxygen into a heating zone at a velocity of at least 350 ft/sec.
[0006] However, despite improvements in incinerators and incineration processes, capital and maintenance costs are still very high. In addition, effluents emitted into the environment still require further reduction.
SUMMARY OF THE PRESENT INVENTION
[0007] An object of the present invention is to provide a process which maximizes the rate of incineration and throughput in waste incinerators while minimizing gas emissions and solid waste produced.
[0008] It is a further object of the present invention to provide an economical incineration process for use with industrial, consumer and biological wastes, including hazardous waste.
[0009] It is yet another object of the present invention to minimize the size of the required incinerator and flue gas purification system, thereby minimizing the required investment and maintenance costs.
[0010] A further object of the present invention is to provide an economical, environmentally friendly process which can be applied to large industrial installations, such as electricity generating plants, which burn large quantities of fossil fuels.
[0011] There is thus provided in accordance with the present invention a process for incinerating combustible material including the step of delivering combustible material and inlet gases to a primary combustion chamber, the inlet gases having an oxygen content of at least 50 vol. %. This is followed by burning the combustible material with the oxygen of the inlet gases in a primary combustion chamber producing flue gases and solid particulates as thermal decomposition products of the burnt combustible material. The flue gases and particulates are then passed to a secondary combustion chamber where further combustion occurs. The flue gases exiting from the secondary combustion chamber are cooled. A portion of the cooled flue gases is returned to at least one of the combustion chambers where the cooled gases moderate the temperature in the at least one chamber. Finally, the remaining portion of the cooled flue gases is passed on to a flue gas purification system where pollutants in the flue gases and particulates are substantially converted to benign compounds or removed entirely before the flue gases are emitted into the atmosphere.
[0012] Additionally, there is provided in accordance with the present invention a process which further includes the step of monitoring the value of at least one parameter in at least one combustion chamber, the parameter being a function of the thermal decomposition of the combustible material in at least one combustion chamber. This is followed by comparing the value of the at least one monitored parameter with at least one predetermined value for that parameter, the comparison being effected by a control device. Finally, the result of the comparison is communicated to a means for controlling the portions of cooled flue gases returned to the at least one combustion chamber and the flue gas purification system. The means for controlling the portions adjusts the relative sizes of the two portions accordingly.
[0013] Additionally, in accordance with a preferred embodiment of the present invention the at least one parameter in the monitoring step is temperature. The temperature can be monitored in the primary combustion chamber or in the secondary combustion chamber or in both chambers.
[0014] Further, in accordance with a preferred embodiment of the present invention, the at least one parameter in the monitoring step is the concentration of carbon monoxide or the concentration of oxygen or the concentration of both simultaneously. These concentrations can be measured in the effluent of the secondary combustion chamber.
[0015] In accordance with a preferred embodiment of the present invention, the means for controlling the amount of cooled gases are valves.
[0016] Additionally, in accordance with a preferred embodiment of the present invention, the inlet gases of the delivering step are delivered in two high concentration oxygen streams, one inlet gas stream positioned adjacent to the burning waste and the other above the flames of the burning waste, the amount of oxygen from each stream controlled so that the temperature of the burning waste is maintained at a temperature that does minimal damage to the floor of the primary combustion chamber, while ensuring complete combustion of the waste and an oxygen volume % in the system's effluent within regulatory limits.
[0017] Further, in accordance with a preferred embodiment of the present invention the oxygen content of the inlet gases is at least 80 vol. %.
[0018] Additionally, in a preferred embodiment of the present invention, the oxygen content of the inlet gases is at least 90 vol. %.
[0019] Further, in a preferred embodiment of the present invention, the oxygen content of the inlet gases is between about 90 vol. % and 95 vol. %.
[0020] Additionally, in accordance with a preferred embodiment of the present invention, the burning step in the primary combustion chamber is effected at a temperature from about 1100° C. to about 2000° C.
[0021] In another preferred embodiment of the present invention, the burning step in the primary combustion chamber is effected at a temperature from about 1200° C. to about 1750° C.
[0022] Additionally, in a preferred embodiment of the present invention, the burning step in the primary combustion chamber is effected at a temperature from about 1300° C. to about 1500° C.
[0023] Further, in yet another embodiment of the present invention, combustion in the secondary combustion chamber of the first passing step is effected at a temperature from about 850° C. to about 1500° C.
[0024] In another embodiment of the present invention, combustion in the secondary combustion chamber of the first passing step is effected at a temperature from about 950° C. to about 1350° C.
[0025] Additionally, in yet another embodiment of the present invention, combustion in the secondary combustion chamber of the first passing step is effected at a temperature from about 1050° C. to about 1200° C.
[0026] In another embodiment of the present invention, the process further includes the step of adding at least one reduced nitrogen compound into the second combustion chamber to destroy nitrogen oxide gases. Typically, the at least one reduced nitrogen compound can be ammonia or urea.
[0027] Further, in a preferred embodiment of the present invention, the process further includes the step of separating solid particulates from the flue gases after the gases are cooled.
[0028] Additionally, in a preferred embodiment of the invention, the at least one combustion chamber of the returning step is the primary combustion chamber.
[0029] Finally, in a preferred embodiment of the present invention, the cooled flue gases are returned to the primary combustion chamber proximate to the flame produced by burning combustible material in that chamber. In another embodiment, the cooled flue gases are returned to the primary combustion chamber proximate to the bottom ash and slag.
[0030] In yet another preferred embodiment of the present invention, the at least one combustion chamber of the returning step is the secondary combustion chamber.
[0031] Finally, the present invention can be used with combustible material which is waste, including hazardous waste, or fuels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The present invention will be understood and appreciated more fully from the following detailed description taken in conjunction with the drawings in which:
[0033] [0033]FIG. 1 is a flow diagram illustrating a preferred embodiment of the process of the present invention;
[0034] [0034]FIG. 2A is a schematic view of an incinerator operative in accordance with the present invention;
[0035] [0035]FIG. 2B is a schematic view of a typical purification system which can be used with an incinerator operative in accordance with the present invention; and
[0036] [0036]FIG. 3 is a schematic diagram illustrating another preferred embodiment of the process of the present invention.
[0037] Similar elements in the Figures are numbered with similar reference numerals.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0038] Reference is now made to FIG. 1, which shows a flow diagram of a preferred embodiment of an incineration process generally referenced 110 , in accordance with the present invention. Process 110 is particularly preferred when used to incinerate industrial, commercial and/or biological waste. The description herein below, as well as the accompanying Figures, describe the process in terms of such waste. However, while the above process 110 has been discussed as a process for the incineration of waste, the system can also be used to burn any fuel, producing energy in a clean, cost efficient manner. In lieu of municipal or industrial waste, process 110 can be used to burn fuels such as natural gas, fuel oil, and coal. These fuels, however, are to be viewed as non-limiting examples.
[0039] Process 110 includes a primary combustion chamber (PCC) 12 into which waste is fed 51 via a conduit (not shown). Inlet gases containing at least 50 vol. %, preferably at least 80 vol. %, and most preferably at least 90 vol. % oxygen, usually between about 90 vol. % to 95 vol. % oxygen, are also passed 53 , via a conduit (not shown), into PCC 12 , typically in the region immediately proximate to the burning waste. The waste is burned in an excess of the stoichiometric amount of oxygen. The waste is burned in PCC 12 at temperatures maintained between about 1100 to 2000° C., preferably between about 1200 to 1750° C., and even more preferably between about 1300 to 1500° C. Because of the high oxygen concentrations used in primary combustion chamber 12 , a significant percentage of the material burned undergoes complete oxidation. Oxygen lancing and other methods to introduce supplementary oxygen are therefore not required.
[0040] Flue gases mixed with small solid particulates resulting from incineration rise from PCC 12 and pass 55 , via a conduit (not shown), into a secondary combustion chamber (SCC) 14 . Partially combusted flue gases are further combusted in SCC 14 to more completely oxidized gases using the residual oxygen arriving from PCC 12 . In SCC 14 , the temperature is maintained within the range of from about 850 to 1500° C., preferably from about 950 to 1350° C., and even more preferably from about 1000 to 1200° C.
[0041] Optionally, materials which destroy nitrogen oxide gases (NOx) are fed 57 , via a conduit (not shown), into SCC 14 . Typically, these materials are reduced nitrogen compounds such as ammonia or urea which convert the NOx gases formed in PCC 12 and SCC 14 into nitrogen and water. Since the amount of nitrogen comprising the inlet gases passed 53 , via a conduit (not shown), into PCC 12 is small, the amount of NOx present in the system is not great. In some embodiments, the materials which destroy nitrogen oxide gases may be employed without a catalyst; in other embodiments, a catalyst may be required. Preferably, PCC 12 and SCC 14 are contained in a single structure, but each can be located in separate structures, when necessary.
[0042] The flue gases are conveyed 59 via a conduit (not shown) to a heat exchanger 22 . Typically, heat exchanger 22 may be a boiler which removes heat from the flue gases. The energy removed, usually as steam, is conveyed 61 , via a conduit (not shown), to an energy converter 18 , often a turbogenerator. Alternatively, any heat recovery system from which electricity or steam can be withdrawn 63 can be employed. Any electricity generated or steam removed can be returned to the incineration plant or distributed to outside consumers.
[0043] After emerging from heat exchanger 22 , the flue gases have a temperature of about 230 to 270° C., preferably about 250° C. The gases are transferred 65 via a conduit (not shown) to a particulate separator 26 , typically a cyclone separator, which via a conduit (not shown), removes 69 fly ash 27 from the flue gases. The removed fly ash 27 is collected, “bagged” and sent to a toxic waste disposal site. The use of a particulate separator 26 at this stage of process 110 is optional. Alternatively, particulates can be removed exclusively in flue gas purification system 29 discussed below. As another alternative, purification system 29 can include a particulate remover which supplements particulate separator 26 .
[0044] Two valves (not shown) located between particulate separator 26 and flue gas purification system 29 divide the flue gases into two portions. The percentage of flue gas that is recycled 73 through a conduit (not shown) and the percentage of flue gas passed 71 via a conduit (not shown) directly on to a flue gas purification system 29 for further purification is determined by some parameter(s) of PCC 12 and/or SCC 14 . Typically, the parameter is its (their) temperature(s) or the concentration of carbon monoxide and/or oxygen on the downstream side of SCC 14 .
[0045] The flue gases that are passed on 71 via a conduit (not shown) for further purification reach flue gas purification system 29 , details of which are not shown. The exact nature of purification system 29 depends on the waste being incinerated, the gases and particulates emitted, and the environmental standards which must be met. Typically, flue gas purification system 29 contains a particulate remover, which supplements optional particulate separator 26 , discussed above, and sometimes serves as the sole particulate remover in process 110 . Generally, the particulate remover in purification system 29 traps finer particles than optional particulate separator 26 . Typically, purification system 29 also contains a scrubber to neutralize acid gases. Other apparatuses commonly used for purifying effluent gases can be added as needed to attain the required effluent emission standards before the gases are expelled 81 to the atmosphere.
[0046] Another portion of the flue gases is recycled 73 via a conduit (not shown) to PCC 12 . Typically, the recycled, cooled flue gases are returned 73 A via a conduit (not shown) to PCC 12 directly above the flame, thereby removing heat from PCC 12 and transferring it to heat exchanger 22 via SCC 14 . In another embodiment, the recycled flue gases can be returned 73 B via a conduit (not shown) directly to SCC 14 . In yet another embodiment, the flue gases can also be recycled 73 C via a conduit (not shown) through bottom ash and slag 17 lying at the floor of PCC 12 . Finally, in other embodiments, the cooled flue gases can be returned to both PCC 12 and SCC 14 . Because PCC 12 operates at temperatures in excess of 1300° C., the bottom ash becomes vitrified 75 when cooled. Some ash is carried 79 by convection to SCC 14 . Cooled slag and vitrified bottom ash 17 are periodically removed 77 to a slag and bottom ash receptacle (not shown) for disposal.
[0047] Reference is now made to FIG. 2A which shows a schematic view of an incinerator system 210 operated in accordance with the process 110 of the present invention shown in FIG. 1. The system 210 permits a better understanding of process 110 presented in FIG. 1. The system shown in FIG. 2A, however, is presented by way of example only and should not be considered as limiting.
[0048] System 210 includes a primary combustion chamber 12 into which waste 19 is fed from a waste feed 10 . There is an inlet gas feed array 15 which delivers inlet gases for combustion, the gases typically being composed of at least 90 vol. % oxygen. Waste 19 is burned in primary combustion chamber (PCC) 12 . The inlet gases are brought from array 15 proximate to the burning waste in PCC 12 . The high concentration of oxygen in the inlet gases fed to primary combustion chamber 12 accelerates the rate of combustion of waste 19 . The temperature in PCC 12 is also significantly higher than temperatures generated when air alone is used. The higher temperatures attained easily crack and shatter solids, facilitating their incineration. Materials that do not burn in air, or do so only incompletely, burn easily in inlet gases with a high oxygen content, often to near completion. Since the oxygen concentration used in the process of the present invention is so high, burning is much more complete and there is no need for selectively introducing lanced oxygen. Because the rate of combustion is faster than in currently used incinerators, primary combustion chamber 12 can be made smaller while throughput will be greater than in prior art incinerators.
[0049] PCC 12 has a bottom grating comprised of slats, which are preferably adapted to be rotatable or otherwise movable so as to rotate or otherwise agitate the burning waste. The grating can be made from, or covered with, ceramic materials which protect it from the elevated temperature of combustion. Typically, every other grating slat is moved periodically, turning over the burning waste, permitting more thorough and rapid combustion. The lower parts of the walls of PCC 12 must also be protected from the heat, usually using ceramic tiling as shields. Alternatively, the walls and the grating can be cooled with water flowing through adjacent water pipes. It is readily apparent to one skilled in the art that instead of grating slats at the bottom of primary combustion chamber 12 , the floor of chamber 12 can include rotating metal cylindrical rollers or any other means that can periodically move and/or rotate the burning waste.
[0050] Slag and bottom ash 17 from PCC 12 are cooled and emptied into an ash and slag receptacle (not shown) via a slag channel 16 . Because of the high temperatures (>1300° C.) in the primary combustion chamber 12 , the bottom ash 17 is vitrified when cooled and encapsulated in a glass-like crust. The encapsulation insulates and neutralizes harmful materials making them usable for civil engineering projects such as road beds without the need for further processing.
[0051] Gases and fly ash emitted from the burning waste as well as residual oxygen from PCC 12 enter a secondary combustion chamber 14 where additional combustion occurs. An array 30 of nozzles in the wall of primary combustion chamber 12 injects cooled, recycled flue gases into PCC 12 ; typically these recycled gases enter PCC 12 immediately above flames 11 . The cooled, recycled flue gases entering from array 30 have a typical temperature of approximately 250° C. and they maintain the temperature in primary combustion chamber 12 at a predetermined temperature, generally about 1300 to 1500° C. Similarly, they cool the gases rising from PCC 12 into SCC 14 to temperatures between about 1000 to 1300° C.
[0052] Optionally, ammonia or urea are added to the flue gas in SCC 14 reducing the nitrogen oxide gases produced in PCC 12 and SCC 14 to nitrogen and water. PCC 12 and SCC 14 can be constructed as any one of several types of chambers, such as rotary kiln, fixed hearth or other types of ovens.
[0053] The gases continue on from secondary combustion chamber 14 to an heat exchanger 22 , typically a boiler. Heat exchanger 22 removes heat from the flue gases, generally forming steam which is led to a turbogenerator (not shown). The turbogenerator can be connected to an electric grid from which electricity can be delivered directly to consumers or returned to the incineration plant for use within the plant. Alternatively, the steam itself, or a mixture of steam and electricity generated by the heat exchanger/boiler 22 and turbogenerator (not shown) respectively, can be sold. By the time the gases and fly ash emissions from the burnt waste reach an optional blower 24 , the temperature of the gases has been reduced to approximately 250° C.
[0054] The fly ash that passes through optional blower 24 enters an optional cyclone separator 26 which precipitates the bulk of the fly ash passing through blower 24 . The cyclone separator 26 may be any cyclone separator commercially available used to separate particulates from gases. A single cyclone or multiple cyclones can be used.
[0055] It should be noted that there is a significant reduction in the amount of fly ash produced by the process of the present invention. The reduction in fly ash is a direct consequence of the very high percentage of oxygen introduced with the inlet gases. The high percentage of oxygen reduces the total amount of inlet gases provided to primary combustion chamber 12 , which in turn leads to a smaller volume of carrier gas for ash generated by incineration. More of the ash produced remains as bottom ash. Since fly ash traps poisonous materials found in flue gases, such as dioxins and heavy metals, the law requires that fly ash be gathered and delivered to a toxic disposal dump. Any reduction in fly ash therefore results in a reduction in waste treatment expense.
[0056] The bulk of the emitted waste gases, the flue gas, is returned via a recycling line 28 to primary combustion chamber 12 . The recycled flue gas is at a temperature of approximately 250° C. and enters PCC 12 through array 30 in the wall of primary combustion chamber 12 . Generally, the gases enter the chamber proximate to and above flames 11 . The cooled recycled flue gas functions as a coolant keeping the temperature in primary combustion chamber 12 at the predetermined temperature, typically 1300-1500° C. Typically, the recycled flue gases reenter the system directly into PCC 12 above flames 11 therein; optionally they can also be recycled directly to SCC 14 or into the bottom ash and slag 17 on the floor of PCC 12 . Typically, an array of conduits is used for reintroducing the recycled flue gas, but in other embodiments, a single point of entry for the recycled flue gases may be employed.
[0057] Part of the flue gases from blower 24 enters a cleaning line 32 . Valves 31 A and 31 B determine how much, and when, flue gases enter cleaning line 32 and recycling line 28 . Using 90 vol. % oxygen and a typical mix of Israeli municipal waste, the mixture of flue gases generated and entering these lines has a typical approximate composition of oxygen 6 vol. %, nitrogen 5 vol. %, CO 2 43 vol. % and steam 46 vol. %. If the inlet gases fed to primary combustion chamber 12 had been air (approximately 21 vol. % oxygen) and not a gas mixture containing at least 90 vol. % oxygen, the nitrogen content of the flue gases entering cleaning line 32 and recycling line 28 would have risen to approximately 66 vol. %.
[0058] Valves 31 A and 31 B are connected to a control system which monitors a parameter, typically the temperature, of the gases exiting primary combustion chamber 12 and/or secondary combustion chamber 14 . If the temperature is higher than required, a larger percentage of the flue gases is recirculated to the primary combustion chamber; if the temperature in the primary combustion chamber is lower than required, the amount of flue gases that is returned is decreased. If, for example, the temperature in PCC 12 is 1750° C. and the temperature in SCC 14 is 1100° C., the approximate percentage of flue gases recycled is 60 vol. % while 40 vol. % are passed via line 32 directly to the flue gas purification system 310 shown in FIG. 2B and discussed below.
[0059] Typically, a device, for example a thermocouple, is used to measure the temperature inside PCC 12 and/or SCC 14 , while a temperature controller compares the measured PCC 12 and SCC 14 temperatures, with one or more temperature set points. The controller then opens or closes the two valves accordingly, returning the required amount of recycled flue gases to PCC 12 and/or SCC 14 . The recycling of cooled flue gases ensures better control of temperature in primary combustion chamber 12 than when recycling is absent. It also increases the degree of combustion of the flue gases.
[0060] Reference is now made to FIG. 2B, where a schematic view of an exemplary purification and scrubbing system 310 of the incinerator plant is shown. The configuration of devices in FIG. 2B are shown merely by way of example and the scope of the present invention is not intended to be limited thereby.
[0061] Cleaning line 32 continues into the purification system 310 of the plant where the amount of effluent solid and flue gases is reduced. These gases and solids are led into an electrostatic precipitator (ESP) 34 which complements or functions in place of cyclone separator 26 discussed above. In ESP 34 much of the remaining fly ash is removed. In ESP 34 , fly ash particulates are charged by a high voltage source and drawn to a conductive plate of opposite charge where the particulate's charge is dissipated. The ash is then precipitated and collected.
[0062] The flue gases are then sent via a line 42 to a scrubber heat exchanger 36 which removes heat from the system. The gases enter the lower part of a scrubber 40 where the temperature is less than 100° C. and much of the water vapor in the flue gases condenses. In scrubber 40 , drops of a basic solution containing calcium hydroxide, sodium hydroxide, sodium carbonate, potassium carbonate or some other such alkaline compound are injected. These neutralize acid gases such as sulfur dioxide and any residual nitrogen oxides not destroyed by ammonia or urea optionally added in secondary combustion chamber 14 . The scrubbed gases then reenter heat exchanger 36 , via a line 38 , where they are reheated using the heat previously withdrawn from the flue gases before these gases entered the lower part of scrubber 40 . The reheated gases then enter a line 46 , where an activated carbon injector 44 injects carbon into line 46 , so that contaminants, among them dioxins and furans, are adsorbed. The carbon also traps other contaminants including heavy metal and heavy metal oxide particulates.
[0063] The injected activated carbon and gas effluents advance through line 46 and are deposited onto a fabric filter 50 , which removes the injected active carbon from the flue gases. Residual gases such as oxygen and nitrogen are then led through a line 48 to a stack 52 where they are emitted into the air, usually with the assistance of a blower 49 located at the bottom of the stack.
[0064] When the inlet gases contain at least 90% oxygen, the amount of effluent gases emitted from stack 52 is about 5 times less than the amount emitted by currently used incinerators. Typically, approximate percentages of the emitted gases using the process of the present invention are 6 vol. % oxygen, 5 vol. % nitrogen, 20 vol. % water vapor and 70 vol. % carbon dioxide.
[0065] The reduction in nitrogen and the large amount of completely oxidized carbon in the form of carbon dioxide are a direct result of the use of inlet gases with a very high oxygen content followed by recycling of flue gases into the primary combustion chamber. The reduction in water vapor is a consequence of the condensation of a large percentage of the vapor in scrubber 40 discussed above.
[0066] It should be apparent to one skilled in the art that the exact configuration of devices used to clean the effluent after it enters cleaning line 32 is to a degree variable and/or optional. Other types of scrubbers and filters known in the art can be used. Similarly, some of the devices discussed above may be absent entirely while others not shown can be added. Cleaning devices at different plants would be expected to vary depending on the nature of the waste being burned and the environmental standards which must be met.
[0067] The inlet gases used to burn waste in primary combustion chamber 12 of the process discussed herein above should typically contain at least 80 vol. %, preferably at least 90 vol. %, but generally between 90 vol. % and 95 vol. %, oxygen. This level of oxygen content (90-95 vol. %) is readily attained by using a vapor pressure swing adsorption (VPSA) device, such as the one produced by Praxair Inc. A VPSA device absorbs nitrogen from air and passes the rest of the gases, mainly oxygen, to primary combustion chamber 12 at relatively low cost. VPSA separates nitrogen from air by molecular sieving. Nitrogen is adsorbed at low pressures in the sieve and then removed by vacuum. Presently, this method is the most economical way to obtain gas fractions having such high percentages of oxygen. Any attempt to use higher concentrations of oxygen to increase the performance of the incinerator would increase the cost of producing the inlet gas because it would require distillation of liquefied air.
[0068] The use of VPSA as discussed above or, alternatively, the related pressure swing adsorption (PSA) process to produce inlet gases containing a high percentage of oxygen should be viewed as non-limiting. Devices employing membrane technology also can be used to produce inlet gases with higher than atmospheric oxygen content but these typically are only 40 to 60 vol. %.
[0069] Since there is likely to be a reduction by a factor of about 5 in effluent gases at the incinerator's stack when the inlet gases of the incinerator include at least 90% oxygen (based on absolute amount of weight per ton of waste), there is a concomitant reduction in the size and cost of the apparatus required to clean up effluent gases. Similarly, costs of the incinerator are reduced because of the faster combustion and higher throughput. In addition, because of the reduction in fly ash and the vitrification of bottom ash in the system, waste disposal costs are reduced. Finally, because nitrogen forms a much smaller portion of the inlet gases, energy lost in heating nitrogen is reduced. This energy may be retrieved for profitable use elsewhere.
[0070] Reference is now made to FIG. 3 which schematically shows another embodiment of the present invention. FIG. 3 includes a primary combustion chamber (PCC) 12 , a secondary combustion chamber (SCC) 14 , and their control systems 120 , 122 and 124 . It also includes an inlet gas feed array 15 , an auxiliary inlet gas feed array 115 and a recycled gas flue array 30 , positioned in the aforementioned chambers.
[0071] In this, as in previous embodiments, a high oxygen concentration is fed into PCC 12 proximate to the burning waste at the floor of PCC 12 . Oxygen is delivered through inlet gas feed array 15 , which, because of the high concentration of oxygen delivered, generates very high temperatures near the burning waste 11 . These temperatures may adversely effect the structure of PCC 12 and can require different, more heat resistant, more costly materials from which to construct PCC 12 .
[0072] In order to reduce combustion temperatures in the bottom region of PCC 12 , the present embodiment contemplates limiting the total amount of oxygen supplied to the primary chamber by inlet gas feed array 15 . Limiting the oxygen introduced by array 15 , but not the high concentration of the oxygen, reduces the temperature at, or near, the floor of PCC 12 .
[0073] With the reduction in total amount of oxygen introduced through inlet gas feed array 15 , some waste, and the flue gases generated therefrom, may be incompletely oxidized. In order to ensure that all the waste and flue gases are substantially completely burned, there is positioned in PCC 12 a second gas feed array carrying a high concentration of oxygen to PCC 12 . This second array, herein denoted as an auxiliary inlet gas feed array 115 , supplies a high concentration of oxygen, typically in excess of 90%, over the burning coals and into the flue gases rising therefrom. The oxygen fed through auxiliary inlet gas feed array 115 produces substantially complete combustion of the flue gases generated by the burning waste in PCC 12 , while permitting operation of PCC 12 at lower temperatures. Even if oxygen provided by auxiliary inlet gas feed array 115 increases the temperature of the exiting flue gases, little increase in temperature results in the burning waste adjacent the floor of PCC 12 and little damage to the floor of PCC 12 occurs.
[0074] The temperature of the exiting flue gases is moderated by recycled gases introduced from an array of nozzles 30 through valves 130 , the nozzles generally located in the wall of SCC 14 or in the upper region of PCC 12 . The temperature of the exiting flue gases is measured by a thermocouple, pyrometer or other temperature monitoring instrument 142 B connected to a temperature control unit 120 which controls the operation of valves 130 .
[0075] Using two high concentration oxygen sources, inlet gas feed array 15 and auxiliary inlet gas feed array 115 , allows for substantially complete combustion of the waste at generally lower temperatures in, or proximate to, the burning waste located at, or near, the bottom of PCC 12 .
[0076] The amounts of oxygen brought into PCC 12 and needed to maintain relatively low combustion temperatures there can be controlled in several ways. Temperature control can be effected by monitoring the oxygen concentration in the effluent emerging from the system's stack 52 . As described above, flue gas concentrations entering the atmosphere must meet strict regulatory requirements. An oxygen monitoring instrument 132 can be inserted into, or positioned near, the outlet of stack 52 to monitor the oxygen vol. % of the effluent. Data relating to the concentrations thus measured are then fed to an oxygen concentration control unit 122 . When the oxygen concentration in the effluent emerging from stack 52 is lower than required by regulations, the amount of oxygen provided by auxiliary oxygen feed array 115 is increased; when the amount of oxygen is higher than required by regulations, the amount of oxygen supplied by auxiliary oxygen feed array 115 is reduced.
[0077] As an alternative to an oxygen monitoring instrument 132 positioned at the outlet of stack 52 , oxygen can be monitored by measuring oxygen content of the recycled gases delivered by recycled gas flue array 30 and entering either PCC 12 or SCC 14 . The percentage oxygen content at stack 52 is related to the oxygen content in the recycled gases arriving from recycled gas flue array 30 . Therefore, the composition of the recycled gases entering either PCC 12 or SCC 14 can be used to determine the over or under abundance of oxygen at stack 52 .
[0078] In yet other embodiments of the present invention, two oxygen monitoring instruments can be used to determine the oxygen content exiting stack 52 . One instrument 132 can be positioned at stack 52 while the other can be located at the point where recycled flue gases are delivered by array 30 .
[0079] An alternative method for controlling the system is by monitoring the temperature in PCC 12 . At least one thermocouple or pyrometer 142 A is placed near, or at, the flames 11 of the burning waste. The results of these temperature measurements then are fed into a control unit 124 , the burning waste temperature control unit, and compared to a predetermined temperature setting. The amount of oxygen provided to PCC 12 by both gas inlet arrays 15 and 115 then is adjusted to maintain a predetermined temperature setting at flames 11 by operating valves 126 and 128 , respectively. By controlling temperature, the effluent oxygen concentration at stack 52 is also kept within regulatory limits.
[0080] It should be readily apparent to one skilled in the art that there is a reciprocal relationship between the amount of oxygen being supplied through valves 126 and 128 of inlet gas feed array 15 and auxiliary inlet gas feed array 115 , respectively. When more oxygen is required at array 15 , generally less oxygen is required at array 115 for a given required flame temperature.
[0081] When the temperature of the burning material is too high, valve 126 , controlled by burning waste temperature control unit 124 , reduces the flow of oxygen from inlet gas feed array 15 above the burning coals. Control unit 124 is separate from another control unit, the temperature control unit 120 , which monitors temperature at the exit of the secondary combustion chamber (SCC) 14 . This temperature, as discussed above, is effected by means of two valves 31 A and 31 B (FIG. 2A) which determine the amount of recycled cooled flue gases returned to PCC 12 and SCC 14 or sent to stack 52 by recycling line 28 (FIG. 2A) or cleaning line 32 (FIG. 2A), respectively.
[0082] It can readily be seen that the temperature of the burning coals as measured by measuring instrument 142 A and controlled by control unit 124 through valve 126 and gas feed array 15 , the oxygen monitoring instrument 132 at stack 52 and its oxygen control unit 122 through valve 128 and auxiliary gas feed array 115 , and temperature monitoring instrument 142 B through temperature control unit 120 and valve 130 of recycled flue gas array 30 form three control loops which are functionally interconnected. Generally, changes in one have a discernible effect in the other two control loops.
[0083] The embodiment shown in FIG. 3 moderates and controls temperature better than in currently available furnaces. This embodiment with its auxiliary oxygen feed array 115 and recycled flue gas array 30 , the latter positioned either in the walls of secondary combustion chamber (SCC) 14 or the upper region of PCC 12 , permits moderation of the temperature at every stage of the combustion process. Furnace temperatures, irrespective of the type of the furnace used, can be maintained so that damage to PCC 12 is minimized.
[0084] It will be appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described herein above. Rather the scope of the invention is defined solely by the claims that follow.
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A process for incinerating combustible materials including the steps of: delivering combustible material and inlet gases to a primary combustion chamber, the inlet gases having an oxygen content of at least 50 vol %; burning the combustible material with the oxygen of the inlet gases in the primary combustion chamber producing flue gases and solid particulates as thermal decomposition products of the burnt combustible material; passing the flue gases and particulates to a secondary combustion chamber where further combustion occurs; cooling the flue gases exiting the secondary combustion chamber; returning a portion of the cooled flue gases to at least one of the combustion chambers where the cooled gases moderate the temperature in the at least one chamber; and passing the remaining portion of cooled flue gases on to a flue gas purification system where pollutants in the flue gases and particulates are substantially converted to benign compounds or removed entirely before the flue gases are emitted into the atmosphere.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method of controlling the rotational speed of the drum of program controlled laundry treatment machines such as, for instance, washing machines, washer-dryers and dryers, of the kind provided with a drum rotatable about an at least approximately horizontal axis, a drive motor for the drum, a measuring device for defining the load parameters as a function of the laundry put into the drum, and with a control device for setting the drive motor for different revolutions per minute during the various cycles of a washing or drying program, such that during part of a washing or drying program individual rotating cycles are carried out with intermittent idle periods, the drum being driven during a rotational cycle at different rotational speeds ranging between upper and lower values. Unless otherwise indicated hereinafter, machines of the kind under consideration will be referred to as laundry machines.
2. The State of the Art
When textiles are being washed, the mechanical action affecting the laundry is one of the significant factors in terms the result of the washing operation. To provide the most efficient washing action in a washing machine equipped with a horizontally or at least approximately horizontally suspended rotary drum, individual pieces of the laundry should be moved to about the 12-o'clock-position and then, upon release from the wall of the drum, drop down in consequence of gravity. This is brought about by the centrifugal force of the laundry being slightly less than the gravity of the earth. Since the centrifugal force is a function of the distance of a piece of laundry from the rotational axis of the drum, a rotational cycle implemented at a predetermined constant rotational speed is of advantage only in respect of those laundry pieces which have moved to a certain distance from the axis of the drum. The standard value of this distance is assumed to be the same as the radius of the drum. Laundry closer to the axis of the drum drops substantially sooner, i.e. it separates at the 9- or 10-o'clock-position, and instead of a dropping movement, it goes through a rolling movement.
From DE 34 36 786 A1 it is known during washing to drive the drum at a speed dependent upon the quantity of laundry such that with increasing quantities of laundry, higher rotational speeds are applied. Thus, those items of the laundry which are at a large distance from the rotational axis are subjected to strong gravitational forces and they form a ring engaging the wall of the drum. This prevents the laundry from dropping freely.
From DE 39 33 355 it is known during a laundry operation to provide cycles of alternating rotational directions with intermittent idle periods, the drum being initially rotated at an upper speed of 55 min −1 followed by a lower speed of 40 min −1 . The purpose of the higher speed is to subject the laundry to satisfactory mechanical action, and the lower speed is to ensure sufficient soaking of the laundry.
DE 100 05 991 A1 discloses a washing machine provided with a measuring sensor, such as a spring scale, for defining a load step corresponding to the weight of the laundry deposited into the drum.
A washing machine is known from DE 44 38 760 A1 in which, based on the oscillations of the signal of rotations during a reverse cycle, a measuring device defines a load step depending on the kind and quantity of the laundry placed into the drum.
In the washing machine W 487 WPS manufactured and sold by the assignee, the drum, during the “boiling-/colored laundry” cycle of a wash program, is operated in accordance with the rotational cycle known from DE 39 33 355 A1, and it is provided with the weight measuring feature in accordance with DE 100 05 991 A1. In the washing machine W 453 WPS manufactured and sold by the assignee, the drum, during the “boiling-/colored laundry” cycle of a wash program, is also rotated in accordance with the cycle known from DE 39 33 355 A1, but it is provided with the load step recognition known from DE 44 38 760 A1.
DE 100 14 718 A1 discloses a laundry dryer provided with a feature for detecting the pattern of laundry movement as a function of the laundry placed in the dryer. The dryer is equipped with controls for energizing the drive motor of the drum in response to the movement pattern of the laundry in the drum such that a desired pattern of laundry movement in the drum may be set by way of the rotational speed of the drum. Its purpose is during the drying process to move the laundry in the drum through the heated air in a predetermined trajectory. While suitable for laundry consisting of large sheets, as used in hospitals, for instance, controlling the rotational speed of the drive motor of the drum as a function of the pattern of laundry movement is unsuitable for household laundry.
OBJECT OF THE INVENTION
It is an object of the invention to provide a method of controlling the rotational speed of the drum of a program-controlled laundry machine of the kind referred to above, which provides for subjecting the laundry to improved mechanical action during a washing process or to uniform air permeation during a drying process.
SUMMARY OF THE INVENTION
This and other objects of the invention are accomplished by a method of controlling rotational speed of the drum of program-controlled laundry treatment machines of the kind provided with a drum rotatable about an at least approximately horizontal axis, a drive motor for the drum, a measuring device for defining load parameters depending upon the laundry deposited into the drum, and with a control device for setting different rotational speeds of the drive motor during the various cycles of a laundry treatment program so that during part of such a program individual rotation cycles will be carried out with intermittent idle periods, the drum being driven during a rotation cycle at different speeds ranging between upper and lower limits set by the control in response to the defined load parameter.
Other objects and advantages will in part be obvious and will, in part, appear hereinafter.
DESCRIPTION OF THE SEVERAL DRAWINGS
The novel features which are considered to be characteristic of the invention are set forth with particularity in the appended claims. The invention itself, however, in respect of its structure, construction and lay-out as well as manufacturing techniques, together with other objects and advantages thereof, will be best understood from the following description of preferred embodiments when read in connection with the appended drawings, in which:
FIG. 1 schematically depicts the structure of a washing machine;
FIG. 2 depicts a rotation-time-diagram for two rotational cycles in reverse operation at different load steps; and
FIG. 3 schematically depicts the structure of a dryer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The laundry machine shown in FIG. 1 is a washing machine provided with a suds basin 2 in which a drum 3 for receiving laundry is rotatably mounted. For washing, water and detergent are fed to the suds basin 2 by way of a drawer 4 a of a detergent flushing compartment 4 . While detergent is being dispensed, the drum 3 is alternatingly rotated in opposite directions by a drive motor 5 . The suds basin 2 is suspended for oscillatory movements by springs 6 , and, for attenuating the oscillations, it is supported at its lower section by shock absorbers 7 connected to the bottom of the housing 1 a . While the machine is in operation, the suds basin 2 is closed by a door (not shown) mounted at the front wall of the housing. The door is kept in its locked condition by an electromagnetic latching device 8 .
A microprocessor control 9 is provided for controlling the various washing programs. It is connected to a plurality of sensors and servo-elements (not shown). From time to time it issues time and condition dependent signals by way of control line 10 b to different actuators such as, for instance, the motor 5 , the latching device 8 , valves (not shown), heating elements and pumps (not shown), and it also functions as a control unit for energizing the motor to run at different rotational speeds and in alternating directions. For instance, during at least part of a washing operation, the drum 3 is rotated in alternating directions with idle periods between individual rotating cycles. The applied pattern or profile of rotations will be described hereinafter. The microprocessor control 9 is provided with read-only memories (ROM) 9 a - c.
One of the sensors of the washing machine constructed in accordance with the invention is a weight sensor 11 for determining the weight of the laundry within the drum 3 . The sensor may, for instance, be a torsion balance or spring scale 11 mounted in a well-known manner parallel to a shock absorber 7 for measuring the height or level of the suds basin as a function of the weight of the laundry. Other sensors (not shown) such as expansion strips may also be used. The microprocessor control 9 determines, and reads into memory, a load step B s on the basis of the static portion of a displacement signal from the torsion balance 11 which corresponds to the weight of the laundry within the drum 3 .
As an alternative to the weight sensor, the load step B s may be determined by a method known from DE 44 38 760 A1 on the basis of the kind and quantity of laundry, in accordance with which an evaluation circuit integrated in a microprocessor control defines the load step as a function of the oscillation pattern of the rotation signal during a rotational cycle in an initial part of the program, for instance, during a pre-wash program or during the main program.
After sensing the load step by the weight sensor or evaluation circuit the rotational cycles within a washing program are adjusted to the quantity of laundry in the drum 3 . For this purpose, the microprocessor control 9 , as the control device of the drive motor 5 , sets, as a function of the stored load step value B s , a lower value n min and upper value n max as upper and lower limits of the rotational speed of the drum 3 during the washing operation, as shown in the following table:
Load Step B s
minimum rpm n min
maximum rpm n max
1 kg
40 min −1
50 min −1
2 kg
40 min −1
55 min −1
3 kg
35 min −1
60 min −1
4 kg
30 min −1
70 min −1
5 kg
30 min −1
80 min −1
The range of rotational speeds thus set as a function of the load step is executed as the substantially trapezoidal pattern or profile shown in FIG. 2 . Alternatively, the profile of rotations may have an ascending and a descending slope, or it may assume the shape of a roof.
The structuring of the method as provided by the invention takes into consideration the fact that laundry is distributed in several layers at different radii relative to the circumference of the drum, the number of layers being dependent upon the size of the load. As a result of the load-related variation in the number of rotations during a cycle of rotations, each layer of laundry is optimally agitated. At very small loads slow rotations at a narrow range between lower and upper values of rotational speed is utilized to ensure that the laundry is released from the wall of the drum and that high washing mechanics or action are achieved nevertheless. Thus, the profile or pattern of the rotations resembles a relatively flat trapezoid (see the dash-dotted line I in FIG. 2 ). At medium loads the range of rotations may be increased up to 60 min −1 since adherence of the laundry against the wall of the drum occurs only at values higher than 60 min −1 (see the dashed line II trapezoid in FIG. 2 ). At large loads a wide band width or range of rotations is required since the laundry in the drum is stacked in several layers so that the centrifugal forces within these layers vary widely (see the solid line trapezoid III in FIG. 2 ). By initially increasing the number of rotations from 30 to 80 rpm, the laundry in the outer area is agitated strongly. By increasing the number of rotations, the laundry will be forced into engagement with the wall of the drum, and laundry disposed further inwardly, i.e. closer to the center of rotation, is lifted to the 12 o'clock position, and because of the engagement of the outer laundry with the wall of the drum, more drop-down space is available for the inwardly disposed laundry. A further increase in the number of rotations causes the effect of being displaced further towards the center of the drum. Thereafter, the laundry in the outer layer is again released from the wall of the drum by reducing the number of rotations.
The laundry machine shown in FIG. 3 is a dryer for executing the drying process in accordance with the invention and is provided with a rotatable horizontally journalled drum 12 for receiving laundry as well as with a blower for feeding drying air heated by a heating device (not shown) into the drum 12 . The drum 12 is rotated in alternating directions by a drive motor 14 connected to the drum 12 by a drive belt 13 . The dryer is additionally equipped with a device for detecting and evaluating residual wetness of the laundry as well as the quantity of the load.
A microprocessor control 9 is provided for controlling various drying programs for different loads. The microprocessor control 9 is connected to several sensors and operating elements by means of signal lines 10 . The control 9 issues signals depending upon time and condition over control lines to various actuators and thus functions as a control for setting the drive motor 14 to run at different numbers of rotations. For instance, the drum 12 is rotated in alternating directions during part of a drying program, with idle periods interspersed between individual rotary cycles.
After sensing the weight of the load and/or any residual wetness, the number of rotations within individual segments of the drying program is adjusted to the quantity or residual wetness of laundry in the drum 14 . For this purpose, the microprocessor control 9 , as the control unit for setting the drive motor 14 in accordance with dryer-specific stored load quantities and residual wetness stages, sets lower limits n min and upper limits n max for the rotational speed of the drum.
The applied profiles of the number of rotations are substantially similar to those described supra in connection with the washing program.
One of the sensors of the laundry dryer in accordance with the invention is a sensor arrangement 15 for detecting residual laundry wetness by way of a striker rib 16 disposed within the drum 12 . The residual wetness is detected in a known manner as a function of the conductivity of the laundry.
The described method is of special importance in connection with the washing and drying of cotton textiles in a boiling/colored laundry program, since large quantities of such laundry are usually deposited in the drum. It may be useful also to make use of the described rotary profiles in connection with rinsing cycles as they enhance the soaking of the laundry with rinsing water and thus lead to an improved rinsing action.
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A laundry treatment method consisting of controlling the rotational speed a program-controlled laundry machine drum between lower and upper limits as a function of at least one predetermined parameter of the laundry within the drum.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part application claiming priority under 35 U.S.C. §120 of U.S. patent application Ser. No. 11/739,089 filed Apr. 23, 2007, now abandoned, and a continuation-in-part application claiming priority under 35 U.S.C. §120 of U.S. patent application Ser. No. 12/606,519 filed Oct. 27, 2009, now U.S. Pat. No. 7,819,576, which is a continuation application of U.S. patent application Ser. No. 11/258,742, filed Oct. 26, 2005, now U.S. Pat. No. 7,628,528, the respective disclosures of which are hereby incorporated by reference.
FIELD OF INVENTION
The invention pertains to apparatus for mixing solutions. More particularly, the invention relates to methods for using pneumatically operated mixers for use in closed, sterile environments.
BACKGROUND OF THE INVENTION
Efforts of biopharmaceutical companies to discover new biological drugs have increased exponentially during the past decade-and-a-half. Bioreactors have been used for cultivation of microbial organisms for production of various biological or chemical products in the pharmaceutical, beverage, and biotechnological industry. Most biological drugs are produced by cell culture or microbial fermentation processes which require sterile bioreactors and an aseptic culture environment. An increasing number of biological drug candidates are in development. Stringent testing, validation, and thorough documentation of process for each drug candidate are required by FDA to ensure consistency of the drug quality used for clinical trials to the market. However, shortages of global biomanufacturing capacity are anticipated in the foreseeable future, particularly as production needs will increase as such new drugs are introduced to the market.
A production bioreactor contains culture medium in a sterile environment that provides various nutrients required to support growth of the biological agents of interest. Stainless steel stir tanks have been the only option for large scale production of biological products in suspension culture. Manufacturing facilities with conventional stainless bioreactors, however, require large capital investments for construction, high maintenance costs, long lead times, and inflexibilities for changes in manufacturing schedules and production capacities. Conventional bioreactors use mechanically driven impellors to mix the liquid medium during cultivation. The bioreactors can be reused for the next batch of biological agents after cleaning and sterilization of the vessel. The procedure of cleaning and sterilization requires a significant amount of time and resources, especially to monitor and to validate each cleaning step prior to reuse for production of biopharmaceutical products. Due to the high cost of construction, maintenance and operation of the conventional bioreactors, single use bioreactor systems made of disposable plastic material have become an attractive alternative.
While several mixing methods of liquid in disposable bioreactors have been proposed in recent years, none of them provides efficient mixing for large scale (greater than 1000 liters) without expensive operating machinery. For this reason, a number of non-invasive and/or disposable mixing systems that do not require an external mechanical operation have been developed. Many of these systems work well within certain size ranges, however, problems sometimes arise as larger mixing systems are attempted.
Single use disposable bioreactor systems have been introduced to market as an alternative choice for biological product production. Such devices provide more flexibility on biological product manufacturing capacity and scheduling, avoid risking major upfront capital investment, and simplify the regulatory compliance requirements by eliminating the cleaning steps between batches. However, the mixing technology of the current disposable bioreactor system has limitations in terms of scalability to sizes beyond 200 liters and the expense of large scale units. Therefore, a disposable single use bioreactor system which is scalable beyond 1000 liters, simple to operate, and cost effective will be needed as a substitute for conventional stainless steel bioreactors for biopharmaceutical research, development, and manufacturing.
It is an objective of the present invention to provide a pneumatic bioreactor that is capable of efficiently and thoroughly mixing solutions without contamination. It is a further objective to such a reactor that can be scaled to relatively large sizes using the same technology. It is a still further objective of the invention to a bioreactor that can be produced in a disposable form. It is yet a further objective of the invention to provide a bioreactor that can be accurately controlled by internal pneumatic force, as to speed and mixing force applied to the solution without creating a foaming problem. Finally, it is an objective to provide a bioreactor that is simple and inexpensive to produce and to operate while fulfilling all of the described performance criteria.
SUMMARY OF THE INVENTION
A pneumatic bioreactor providing all of the desired features can be constructed from the following components. A containment vessel is provided. The vessel has a top, a closed bottom, a surrounding wall and is of sufficient size to contain a fluid to be mixed and a mixing apparatus. The mixing apparatus includes at least one gas supply line. The supply line terminates at an orifice adjacent the bottom of the vessel. At least one buoyancy-driven mixing device is provided. The mixing device moves in the fluid as gas from the supply line is introduced into and vented from the mixing device. When gas is introduced into the gas supply line the gas will enter the mixing device and cause the device to mix the fluid.
In a variant of the invention, the buoyancy-driven mixing device further includes at least one floating plunger. The plunger has a central, gas-holding chamber and a plurality of mixing elements located about the central chamber. The mixing elements are shaped to cause the plunger to agitate the fluid as the plunger rises in the fluid in the containment vessel. In a variant, the mixing elements are generally in the shape of a disc.
In yet another variant, the buoyancy-driven mixing device further includes at least one floating impeller, which is also provided as a mixing element. The impeller has the central, gas-containing chamber and a plurality of impeller blades arcurately located about the central chamber. The impeller blades are shaped to cause the impeller to revolve about a vertical axis as the impeller rises in fluid in the containment vessel.
The central chamber has a gas-venting valve. The valve permits escape of gas as the central chamber reaches a surface of the fluid. A constraining member is provided. The constraining member limits horizontal movement of the floating plunger and/or impeller (“plunger/impeller”) as it rises or sinks in the fluid. When gas is introduced into the gas supply line, the gas will enter the gas-holding chamber and cause the floating plunger/impeller to rise by buoyancy in the fluid while agitating the fluid. When the gas-venting valve of the central chamber reaches the surface of the fluid, the gas will be released and the floating plunger/impeller will sink toward the bottom of the containment vessel where the central chamber will again be filled with gas, causing the floating plunger/impeller to rise.
In a further variant, a mixing partition is provided. The partition is located in the containment vessel adjacent the floating plunger/impeller and has at least one aperture to augment a mixing action of the floating plunger/impeller.
In another variant, means are provided for controlling a rate of assent of the floating plunger/impeller.
In still another variant, the means for controlling the rate of assent of the floating plunger/impeller includes a ferromagnetic substance attached to either of the floating plunger/impeller, the constraining member, or the outside housing, and a controllable electromagnet located adjacent the bottom of the containment vessel. The gas flow is interrupted by an on/off switch which is controlled by interactions of two magnetic substances. Therefore, the volume of gas supplied into the gas-holding chamber is determined by the strength of the electromagnetic power since the gas flow stops as the floating plunger/impeller starts to rise when the buoyancy becomes greater than the magnetic holding force.
In yet another variant, the central, gas-holding chamber further includes an opening. The opening is located at an upper end of the chamber. A vent cap is provided. The vent cap is sized and shaped to seal the opening when moved upwardly against it by buoyancy from gas from the supply line. A support bracket is provided. The support bracket is located within the chamber to support the vent cap when it is lowered after release of gas from the chamber. When the chamber rises to the surface of the fluid the vent cap will descend from its weight and the opening will permit the gas to escape, the chamber will then sink in the fluid and the vent cap will again rise due to buoyancy from a small amount of gas permanently enclosed in the vent cap, thereby sealing the opening.
In a further variant, a second floating plunger/impeller is provided. A second constraining member is provided, limiting horizontal movement of the second plunger/impeller as it rises in the fluid. At least one additional gas supply line is provided. The additional supply line terminates at an orifice adjacent the bottom of the vessel. At least one pulley is provided. The pulley is attached to the bottom of the containment vessel. A flexible member is provided. The flexible member attaches the chamber of the floating plunger to a chamber of the second floating plunger/impeller. The flexible member is of a length permitting the gas venting valve of the chamber of the floating plunger/impeller to reach the surface of the fluid while the chamber of the second floating plunger/impeller is spaced from the bottom of the containment vessel. When the floating plunger/impeller is propelled upwardly by buoyancy from the gas from the supply line the second floating plunger/impeller is pulled downwardly by the flexible member until the gas is released from the chamber of the floating plunger/impeller as its gas venting valve reaches the surface of the fluid. The chamber will then sink in the fluid as the second floating plunger/impeller rises by buoyancy from gas introduced from the second supply line.
In yet a further variant, the containment vessel is formed of resilient material, the material is sterilizable by gamma irradiation methods.
In still another variant, the pneumatic bioreactor further includes a cylindrical chamber. The chamber has an inner surface, an outer surface, a first end, a second end and a central axis. At least one mixing plate is provided. The mixing plate is attached to the inner surface of the chamber. First and second flanges are provided. The flanges are mounted to the cylindrical chamber at the first and second ends, respectively. First and second pivot points are provided. The pivot points are attached to the first and second flanges, respectively and to the containment vessel, thereby permitting the cylindrical chamber to rotate about the central axis. A plurality of gas-holding members are provided. The members extend from the first flange to the second flange along the outer surface of the cylindrical chamber and are sized and shaped to entrap gas bubbles from the at least one gas supply line. The gas supply line terminates adjacent the cylindrical chamber on a first side of the chamber below the gas-holding members. When gas is introduced into the containment vessel through the supply line it will rise in the fluid and gas bubbles will be entrapped by the gas-holding members. This will cause the cylindrical chamber to rotate on the pivot points in a first direction and the at least one mixing plate to agitate the fluid.
In yet another variant, a rate of rotation of the cylindrical chamber is controlled by varying a rate of introduction of gas into the gas supply line.
In a further variant, a second gas supply line is provided. The second supply line terminates adjacent the cylindrical chamber on a second, opposite side of the chamber below the gas holding members. Gas from the second supply line causes the cylindrical chamber to rotate on the pivot points in a second, opposite direction.
In still a further variant, the at least one mixing plate has at least one aperture to augment mixing of the fluid in the containment vessel.
In yet a further variant, the containment vessel further includes a closable top. The top has a vent, permitting the escape of gas from the gas supply line through a sterile filter.
In another variant of the invention, a temperature control jacket is provided. The jacket surrounds the containment vessel.
In a variant of the invention, an outside housing is provided. The housing is ring-shaped and surrounds the floating impeller and constrains its lateral movement. At least one supporting pole is provided. The pole extends from the bottom upwardly toward the top. The outside housing is slidably attached to the supporting pole. The floating impeller is rotatably attached to the outside housing.
In still another variant, the impeller blades are rotatably mounted to the central chamber and the central chamber is fixedly attached to the outside housing.
In a further variant, the impeller blades are fixedly mounted to the central chamber and rotatably mounted to the outside housing.
In still a further variant, the outside housing further includes a horizontal interior groove located on an inner surface of the housing. The impeller blades include a projection, sized and shaped to fit slidably within the groove.
In yet another variant, the vent cap further includes an enclosed gas cell. The cell causes the cap to float in the fluid and thereby to reseal the opening after the gas has been released when the chamber reached the surface of the fluid.
In a further variant, wherein the pneumatic bioreactor further includes a second floating impeller, a second outside housing surrounding the second floating impeller is provided. At least one additional supporting pole is provided. At least one additional gas supply line is provided. The additional supply line terminates at an orifice at the bottom of the vessel. The second outside housing is slidably attached to the additional supporting pole. The second floating impeller is rotatably attached to the second outside housing. At least one pulley is provided. The pulley is attached to the bottom of the containment vessel.
An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of the invention illustrating floating impellers and their control mechanisms.
FIG. 2 is a top view of the FIG. 1 embodiment illustrating the floating chamber affixed to the constraining member with the impeller blades rotating upon the chamber.
FIG. 2A is a top view of the FIG. 1 embodiment illustrating the floating chamber rotating within the constraining member with the impeller blades fixed to the chamber.
FIG. 3 is a side elevational view of the FIG. 1 embodiment.
FIG. 4 is a side elevational view of the FIG. 2A embodiment of the floating impeller.
FIG. 4A is a side elevational view of the FIG. 2 embodiment of the floating impeller.
FIG. 5 is a perspective view of a second embodiment of the invention illustrating floating plungers and their control mechanisms.
FIG. 6 is a top view of the FIG. 5 embodiment illustrating the floating plungers.
FIG. 7 is a perspective view of the gas supply line and magnetic assent control mechanism.
FIG. 8 is a cross-sectional side elevation of the floating chamber illustrating the vent cap in a closed position.
FIG. 9 is a cross-sectional side elevation of the floating chamber illustrating the vent cap in an open position.
FIG. 10 is a perspective view of a third embodiment of the invention illustrating a rotating drum mixer with gas supply line.
FIG. 11 is an end view of the FIG. 10 embodiment illustrating a single gas supply line.
FIG. 12 is an end view of the FIG. 10 embodiment illustrating a pair of gas supply lines.
FIG. 13 is a side elevational view of the FIG. 10 embodiment illustrating a containment vessel.
FIG. 14 is a perspective view of the FIG. 5 embodiment illustrating a closable top and sterile filters.
FIG. 15 is a perspective view of the FIG. 5 embodiment illustrating a temperature control jacket surrounding the vessel.
FIG. 16 is a perspective view of a pneumatic bioreactor shown through a transparent housing and containment vessel for clarity.
FIG. 17 is a front view of the pneumatic bioreactor of FIG. 16 .
FIG. 18 is top view of the pneumatic bioreactor of FIG. 16 .
FIG. 19 is a perspective view of the top and mixing apparatus of the pneumatic bioreactor of FIG. 16 .
FIG. 20 is a perspective view of one wheel of the pneumatic bioreactor of FIG. 16 .
FIG. 21 is a perspective view of the top and mixing apparatus of a modified bioreactor of FIG. 16 .
DETAILED DESCRIPTION OF THE INVENTION
A pneumatic bioreactor 10 , as illustrated in FIGS. 1-3 , providing all of the desired features can be constructed from the following components. A containment vessel 15 is provided. The vessel 15 has a top 20 , a closed bottom 25 , a surrounding wall 30 and is of sufficient size to contain a fluid 35 to be mixed and a mixing apparatus 40 . The mixing apparatus 40 includes at least one gas supply line 45 . The supply line 45 terminates at an orifice 50 adjacent the bottom 25 of the vessel 15 . At least one buoyancy-driven mixing device 55 is provided. The mixing device 55 moves in the fluid 35 as gas 60 from the supply line 45 is introduced into and vented from the mixing device 55 . When gas 60 is introduced into the gas supply line 45 the gas 60 will enter the mixing device 55 and cause the device to mix the fluid 35 .
In a variant of the invention, the buoyancy-driven mixing device 55 further includes at least one floating mixer 65 . The mixer 65 has a central, gas-holding chamber 70 and a plurality of mixing elements 75 located about the central chamber 70 . The mixing elements 75 are shaped to cause the mixer 65 to agitate the fluid 35 as the mixer 65 rises in the fluid 35 in the containment vessel 15 . The central chamber 70 , as illustrated in FIGS. 8 and 9 , has a gas-venting valve 80 . The valve 80 permits escape of gas 60 as the central chamber 70 reaches a surface 85 of the fluid 35 . A constraining member 90 is provided. The constraining member 90 limits horizontal movement of the floating mixer 65 as it rises or sinks in the fluid 35 . When gas 60 is introduced into the gas supply line 45 , the gas 60 will enter the gas holding chamber 70 and cause the floating mixer 65 to rise by buoyancy in the fluid 35 while agitating the fluid 35 . When the gas venting valve 80 of the central chamber 70 reaches the surface 85 of the fluid 35 , the gas 60 will be released and the floating mixer 65 will sink toward the bottom 25 of the containment vessel 15 where the central chamber 70 will again be filled with gas 60 , causing the floating mixer 65 to rise.
In another variant, means 95 , as illustrated in FIG. 7 , are provided for controlling a rate of assent of the floating mixer 65 .
In still another variant, the means 95 for controlling the rate of assent of the floating mixer 65 includes a ferromagnetic substance 100 attached to either of the floating mixer 65 or the constraining member 90 and a controllable electromagnet 105 located adjacent the bottom 25 of the containment vessel 15 .
In yet another variant, as illustrated in FIGS. 8 and 9 , the central, gas-holding chamber 70 further includes an opening 110 . The opening 110 is located at an upper end 115 of the chamber 70 . A vent cap 117 is provided. The vent cap 117 is sized and shaped to seal the opening 110 when moved upwardly against it by buoyancy from gas 60 from the supply line 45 . A support bracket 120 is provided. The support bracket 120 is located within the chamber 70 to support the vent cap 115 when it is lowered after release of gas 60 from the chamber 70 . When the chamber 70 rises to the surface 85 of the fluid 35 the vent cap 115 will descend from its weight and the opening 110 will permit the gas 60 to escape, the chamber 70 will then sink in the fluid 35 and the vent cap 115 will again rise due to buoyancy from a small amount of gas 60 permanently enclosed in the vent cap 115 , thereby sealing the opening 110 .
In a further variant, as illustrated in FIGS. 1-3 , a second floating mixer 125 is provided. A second constraining member 130 is provided, limiting horizontal movement of the second mixer 125 as it rises in the fluid 35 . At least one additional gas supply line 135 is provided. The additional supply line 135 terminates at an orifice 143 adjacent the bottom 25 of the vessel 15 . At least one pulley 140 is provided. The pulley 140 is attached to the bottom 25 of the containment vessel 15 . A flexible member 145 is provided. The flexible member 145 attaches the chamber 70 of the floating mixer 65 to a chamber 150 of the second floating mixer 125 . The flexible member 145 is of a length permitting the gas venting valve 80 of the chamber 70 of the floating mixer 65 to reach the surface 85 of the fluid 35 while the chamber 70 of the second floating mixer 125 is spaced from the bottom 25 of the containment vessel 15 . When the floating mixer 65 is propelled upwardly by buoyancy from the gas 60 from the supply line 45 the second floating mixer 125 is pulled downwardly by the flexible member 145 until the gas 60 is released from the chamber 70 of the floating mixer 65 as its gas venting valve 80 reaches the surface 85 of the fluid 35 . The chamber 70 will then sink in the fluid 35 as the second floating mixer 125 rises by buoyancy from gas 60 introduced from the second supply line 135 .
In yet a further variant, the containment vessel 15 is formed of resilient material 155 , the material is sterilizable by gamma irradiation methods.
In still a further variant, as illustrated in FIGS. 5 and 6 , the buoyancy-driven mixing device 10 further includes at least one floating plunger 160 . The plunger 160 has a central, gas-holding chamber 70 and at least one disk 165 located about the central chamber 70 . The disk 165 is shaped to cause the plunger 160 to agitate the fluid 35 as the plunger 160 rises in the fluid 35 in the containment vessel 15 . The central chamber 70 has a gas-venting valve 80 . The valve 80 permits escape of gas 60 as the central chamber 70 reaches a surface 85 of the fluid 35 . A mixing partition 170 is provided. The partition 170 is located in the containment vessel 15 adjacent the floating plunger 160 and has at least one aperture 175 to augment a mixing action of the floating plunger 160 . A constraining member 180 is provided. The constraining member 180 limits horizontal movement of the plunger 160 as it rises or sinks in the fluid 35 . When gas 60 is introduced into the gas supply line 45 the gas 60 will enter the gas holding chamber 70 and cause the floating plunger 160 to rise by buoyancy in the fluid 35 while agitating the fluid 35 . When the gas venting valve 80 of the central chamber 70 reaches the surface 85 of the fluid 35 , the gas 60 will be released and the floating plunger 160 will sink toward the bottom 25 of the containment vessel 15 where the central chamber 70 will again be filled with gas 60 , causing the floating plunger 160 to rise.
In another variant of the invention, a second floating plunger 185 is provided. A second constraining member 190 is provided, limiting horizontal movement of the second plunger 185 as it rises in the fluid 35 . At least one additional gas supply line 135 is provided. The additional supply line 135 terminates at an orifice 143 adjacent the bottom 25 of the vessel 15 . At least one pulley 140 is provided. The pulley 140 is attached to the bottom 25 of the containment vessel 15 . A flexible member 145 is provided. The flexible member 145 attaches the chamber 70 of the floating plunger 160 to a chamber of the second floating plunger 185 . The flexible member 145 is of a length permitting the gas venting valve 80 of the chamber 70 of the floating plunger 160 to reach the surface 85 of the fluid 35 while the chamber 70 of the second floating plunger 185 is spaced from the bottom 25 of the containment vessel 15 . The mixing partition 170 is located between the floating plunger 160 and the second floating plunger 185 . When the floating plunger 160 is propelled upwardly by buoyancy from the gas 60 from the supply line 45 the second floating plunger 185 is pulled downwardly by the flexible member 145 until the gas 60 is released from the chamber 70 of the floating plunger 160 as its gas venting valve 80 reaches the surface 85 of the fluid 30 . The floating plunger 160 will then sink in the fluid 35 as the second floating plunger 185 rises by buoyancy from gas 60 introduced from the second supply line 135 .
In still another variant, as illustrated in FIGS. 10-13 , the pneumatic bioreactor 10 further includes a cylindrical chamber 195 . The chamber 195 has an inner surface 200 , an outer surface 205 , a first end 210 , a second end 215 and a central axis 220 . At least one mixing plate 225 is provided. The mixing plate 225 is attached to the inner surface 200 of the chamber 195 . First 230 and second 235 flanges are provided. The flanges 230 , 235 are mounted to the cylindrical chamber 195 at the first 210 and second ends 215 , respectively. First 240 and second 245 pivot points are provided. The pivot points 240 , 245 are attached to the first 230 and second 235 flanges, respectively and to the containment vessel 15 , thereby permitting the cylindrical chamber 195 to rotate about the central axis 220 . A plurality of gas holding members 250 are provided. The members 250 extend from the first flange 230 to the second flange 235 along the outer surface 205 of the cylindrical chamber 195 and are sized and shaped to entrap gas bubbles 255 from the at least one gas supply line 45 . The gas supply line 45 terminates adjacent the cylindrical chamber 195 on a first side 260 of the chamber 195 below the gas holding members 250 . When gas 60 is introduced into the containment vessel 15 through the supply line 45 it will rise in the fluid 35 and gas bubbles 255 will be entrapped by the gas holding members 250 . This will cause the cylindrical chamber 195 to rotate on the pivot points 240 , 245 in a first direction 262 and the at least one mixing plate 225 to agitate the fluid 35 .
In yet another variant, a rate of rotation of the cylindrical chamber 195 is controlled by varying a rate of introduction of gas 60 into the gas supply line 45 .
In a further variant, as illustrated in FIG. 12 , a second gas supply line 135 is provided. The second supply line 135 terminates adjacent the cylindrical chamber 195 on a second, opposite side 265 of the chamber 195 below the gas holding members 250 . Gas 60 from the second supply line 135 causes the cylindrical chamber 195 to rotate on the pivot points 240 , 245 in a second, opposite direction 270 .
In still a further variant, as illustrated in FIGS. 10 and 13 , the at least one mixing plate 225 has at least one aperture 275 to augment mixing of the fluid 35 in the containment vessel 15 .
In yet a further variant, as illustrated in FIG. 14 , the containment vessel 15 further includes a closable top 280 . The top has a vent 285 , permitting the escape of gas 60 from the gas supply line 45 through a sterile filter 290 .
In another variant of the invention, as illustrated in FIG. 15 , a temperature control jacket 295 is provided. The jacket 295 surrounds the containment vessel 15 .
In yet another variant, as illustrated in FIGS. 1-3 , a pneumatic bioreactor 10 includes a containment vessel 15 . The vessel 15 has a top 20 , a closed bottom 25 , a surrounding wall 30 and is of sufficient size to contain a fluid 35 to be mixed and a mixing apparatus 40 . The mixing apparatus 40 includes at least one gas supply line 45 . The supply line 45 terminates at an orifice 50 at the bottom 25 of the vessel 15 . At least one floating impeller 300 is provided. The impeller 300 has a central, gas-containing chamber 70 and a plurality of impeller blades 305 arcurately located about the central chamber 70 . The impeller blades 305 are shaped to cause the impeller 300 to revolve about a vertical axis 310 as the impeller 300 rises in fluid 35 in the containment vessel 15 .
The central chamber 70 has a gas-venting valve 80 . The valve 80 permits escape of gas 60 as the central chamber 70 reaches a surface 85 of the fluid 35 . An outside housing 315 is provided. The housing 315 is ring-shaped and surrounds the floating impeller 300 and constrains its lateral movement. At least one supporting pole 320 is provided. The pole 320 extends from the bottom 25 upwardly toward the top 20 . The outside housing 315 is slidably attached to the supporting pole 320 . The floating impeller 300 is rotatably attached to the outside housing 315 . When gas 60 is introduced into the gas supply line 45 the gas 60 will enter the gas containing chamber 70 and cause the floating impeller 300 to rise in the fluid 35 while rotating and mixing the fluid 35 . When the gas venting valve 80 of the central chamber 70 reaches the surface 85 of the fluid 35 , the gas 60 will be released and the floating impeller 300 will sink toward the bottom 25 of the containment vessel 15 where the central chamber 70 will again be filled with gas 60 , causing the floating impeller 300 to rise.
In still another variant, as illustrated in FIGS. 2 and 4A , the impeller blades 305 are rotatably mounted to the central chamber 70 and the central chamber 70 is fixedly attached to the outside housing 315 .
In a further variant, as illustrated in FIGS. 2A and 4 , the impeller blades 305 are fixedly mounted to the central chamber 70 and rotatably mounted to the outside housing 315 .
In still a further variant, the outside housing 315 further includes a horizontal interior groove 322 located on an inner surface 325 of the housing 315 . The impeller blades 305 include a projection 330 , sized and shaped to fit slidably within the groove 322 .
In yet a further variant, as illustrated in FIG. 7 , means 95 are provided for controlling a rate of assent of the floating impeller 300 .
In another variant of the invention, the means 95 for controlling a rate of assent of the floating impeller 300 includes a ferromagnetic substance 100 attached to either the floating impeller 300 or the outside housing 315 and a controllable electromagnet 105 located adjacent the bottom 25 of the containment vessel 15 .
In still another variant, as illustrated in FIGS. 8 and 9 , the central, gas-containing chamber 70 further includes an opening 110 located at an upper end 115 of the chamber 70 . A vent cap 115 is provided. The vent cap 115 is sized and shaped to seal the opening 110 when moved upwardly against it by pressure from gas 60 from the supply line 45 . A support bracket 120 is provided. The support bracket 120 is located within the chamber 70 to support the vent cap 115 when it is lowered after release of gas 60 from the chamber 70 . When the chamber 70 rises to the surface of the fluid 35 the vent cap 115 will descend from its weight and the opening 110 will permit the gas 60 to escape. The floating impeller 300 will then sink in the fluid 35 and the vent cap 115 will again rise due to pressure from gas 60 introduced into the chamber 70 from the gas line 45 , thereby sealing the opening 110 .
In yet another variant, the vent cap 115 further includes an enclosed gas cell 310 . The cell 310 causes the cap 115 to float in the fluid 35 and thereby to reseal the opening 110 after the gas 60 has been released when the chamber 70 reached the surface 85 of the fluid 35 .
In a further variant, as illustrated in FIGS. 1 and 3 , the pneumatic bioreactor 10 further includes a second floating impeller 317 . A second outside housing 324 surrounding the second floating impeller 317 is provided. At least one additional supporting pole 326 is provided. At least one additional gas supply line 135 is provided. The additional supply line 135 terminates at an orifice 143 at the bottom 25 of the vessel 15 . The second outside housing 324 is slidably attached to the additional supporting pole 325 . The second floating impeller 317 is rotatably attached to the second outside housing 324 . At least one pulley 140 is provided. The pulley 140 is attached to the bottom 25 of the containment vessel 15 .
A flexible member 145 is provided. The flexible member 145 attaches the chamber 70 of the floating impeller 300 to a chamber 70 of the second floating impeller 317 . The flexible member 145 is of a length to permit the gas venting valve 80 of the chamber 70 of the floating impeller 300 to reach the surface 85 of the fluid 35 while the chamber 70 of the second floating impeller 317 is spaced from the bottom 25 of the containment vessel 15 . When the floating impeller 300 is propelled upwardly by pressure from the gas 60 from the supply line 45 the second floating impeller 315 will be pulled downwardly by the flexible member 145 until the gas 60 is released from the chamber 70 of the floating impeller 300 as its gas venting valve 80 reaches the surface 85 of the fluid 35 , the floating impeller 300 will then sink in the fluid 35 as the second floating impeller 315 rises under pressure from gas 60 introduced from the second supply line 135 .
FIGS. 16 through 20 illustrate a bioreactor positioned in a housing, generally designated 410 . The housing 410 is structural and preferably made of stainless steel to include a housing front 412 , housing sides 414 and a housing back 416 . The housing back 416 does not extend fully to the floor or other support in order that access may be had to the underside of the bioreactor. The housing 410 includes a housing bottom 418 which extends from the housing sides 414 in a semi-cylindrical curve above the base of the housing 410 . One of the front 412 or back 416 may act as a door to facilitate access to the interior of the housing 410 .
The bioreactor includes a containment vessel, generally designated 420 , defined by four vessel sides 422 , 424 , 426 , 428 , a semi-cylindrical vessel bottom 430 , seen in FIG. 17 , and a vessel top 432 . Two of the vessel sides 424 , 428 which are opposed each include a semicircular end. The other two vessel sides 422 , 426 join with the semi-cylindrical vessel bottom 430 to form a continuous cavity between the two vessel sides 424 , 428 . All four vessel sides 422 , 424 , 426 , 428 extend to and are sealed with the vessel top 432 to form a sealed enclosure. The vessel top 432 extends outwardly of the four vessel sides 422 , 424 , 426 , 428 so as to rest on the upper edges of the structural housing front 412 , sides 414 and back 416 . Thus, the containment vessel 420 hangs from the top 432 in the housing 410 . The vessel, with the exception of the vessel top 432 , is of thin wall film which is not structural in nature. Therefore, the housing front 412 , sides 414 , back 416 and bottom 418 structurally support the containment vessel 420 depending from the vessel top 432 when filled with liquid. All joints of the containment vessel 420 are welded or otherwise sealed to provide the appropriate sealed enclosure which can be sterilized and closed ready for use.
The vessel top 432 includes access ports 434 for receipt or extraction of liquids, gases and powders and grains of solid materials. The access ports 436 in the vessel top 432 provide for receipt of sensors to observe the process. Two orifices 438 , 440 are shown at the vessel bottom 430 slightly offset from the centerline to receive propellant gas for driving the rotational mixer as will be discussed below. The semi-cylindrical vessel bottom 430 defining a semi-cylindrical concavity within the containment vessel 420 also includes a temperature control sheet 442 which may include a heater with heating elements, a cooler with cooling coils, or both as may be employed to raise or lower the temperature of the contents of the containment vessel 420 during use. Sealed within the enclosure defining the containment vessel 420 , struts 444 extend downwardly from the vessel top 432 to define a horizontal mounting axis at or close to the axis of curvature defined by the semi-cylindrical bottom 430 .
A mixing apparatus includes a rotatably mounted rotational mixer, generally designated 448 . The rotational mixer 448 is a general assembly of a number of functional components. The structure of the rotational mixer 448 includes two parallel wheels 450 , 452 which are displaced from one another. These wheels are tied to an axle 454 by spokes 456 . Additional stabilizing bars parallel to the axle 54 may be used to rigidify the rotational mixer 448 .
Each wheel 450 , 452 is defined by two parallel plates 460 , 462 . These plates 460 , 462 include buoyancy-driven mixing cavities 464 there between. These cavities 464 operate to entrap gas supplied from below the wheels 450 , 452 through the gas supply at orifices 438 , 440 . The orifices 438 , 440 are offset from being directly aligned with the horizontal axis of rotation to insure that the buoyancy-driven cavities 464 are adequately filled with gas to power the rotational mixer 448 in rotation. In the embodiment of FIGS. 16 through 20 , the buoyancy-driven cavity 464 in each one of the wheels 450 , 452 are similarly oriented to receive gas from the orifices 438 , 440 at the same time.
Outer paddles 466 are equiangularly placed to extend axially outwardly from the outer parallel plates 460 where they are attached. These outer paddles 466 can mix the liquid between the rotational mixer 448 and either side 424 , 428 . The outer paddles 466 are formed in this embodiment with a concavity toward the direction of rotation of the rotational mixer 448 and are inclined toward the direction of rotation as well such that they are disposed to induce flow entrained with constituents of the mix in the vessel inwardly toward the axis for flow through each wheel 450 , 452 with the rotation of the rotational mixer 448 . The outer paddles 466 may exhibit an inclined orientation on each of the outer parallel plates 460 such that any induced axial flow through each wheel 450 , 452 will flow toward the center of the rotational mixer 448 in opposite directions. The number of outer paddles 466 may be increased from the four shown, particularly when the constituents of the mix in the vessel are not easily maintained in suspension. The outer paddles 466 may extend close to the vessel bottom 430 to entrain constituents of the mix in the vessel which may otherwise accumulate on the bottom. Such extensions beyond the wheels 450 , 452 preferably do not inhibit rotation of the rotational mixer 448 through actual or close interaction with the vessel wall.
Inwardly of the two wheels 450 , 452 , vanes 468 may be employed in some embodiments as can best be seen in FIG. 20 . These vanes 468 extend axially inwardly from the inner parallel plates 462 to span the distance there between. The vanes 468 can also extend to induce flow radially outwardly from the rotational mixer 448 and beyond the rotational mixer 448 so as to impact and mix liquid outwardly of the rotational mixer. As with the outer paddles 466 , the vanes 468 can be used to entrain constituents that tend to fall and collect on the vessel bottom 430 . These vanes 468 may, in some instances not be preferred because of flow resistance or disruption of circulating flow. Empirical analysis is necessary in this regard depending on such things as rotational mixer speed, liquid viscosity, space to the vessel walls and the like. Four vanes 468 are illustrated on each wheel 450 , 452 but the number can, as with the outer paddles 466 , be increased or decreased with the performance of the mix.
Inner paddles 470 also extend axially inwardly from the inner parallel plates 462 . These inner paddles 470 are convex facing toward the rotational direction and are inclined to draw flow axially through the wheels 450 , 452 . The inner paddles 470 can enhance radially outward flow with rotation of the rotational mixer 448 as well at the location shown inside of the wheels 450 , 452 . There can be any practical number of inner paddles 470 , four being shown. Such paddles 470 , if configured to extend past the perimeter of the wheels 450 , 452 , can urge flow off of the bottom as well and direct that flow axially outwardly to either side.
Located inwardly of each wheel 450 , 452 is an impeller having blades 472 . The two impellers provide principal axial thrust to the flow through the wheels 450 , 452 . The thrust resulting from these blades 472 both flow inwardly toward one another in this embodiment. This is advantageous in creating toroidal flow about the wheels and balance forces which would otherwise be imposed on the mountings. The placement of the blades 472 may be at other axial locations such as at either of the plates 460 , 462 . Where the impellers act alone, the blades 472 can be located anywhere from exterior of to interior to the rotational mixer with appropriate reconfiguration in keeping with slow speed impeller practice.
The mixing apparatus defined principally by the rotating rotational mixer 448 is positioned in the containment vessel 420 such that it extends into the semi-cylindrical concavity defined by the vessel bottom 430 and is sized, with the outer paddles 466 , vanes 468 and inner paddles 470 , to fill the concavity but for sufficient space between the mixing apparatus and the vessel sides 424 , 428 and bottom 430 to avoid inhibiting free rotation of the rotational mixer 448 . In one embodiment, the full extent of the mixing apparatus 426 is on the order of 10% smaller than the width of the cavity in the containment vessel 420 and about the same ratio for the diameter of the rotational mixer 448 to the semi-cylindrical vessel bottom 430 . This spacing is not critical so long as the mixing apparatus is close enough and with commensurate speed to effect mixing throughout the concavity. Obviously, empirical testing is again of value. The liquid preferably does not extend above the mixing apparatus and the volume above the rotational mixer 448 will naturally be mixed as well.
In operation, the liquid, nutrients and active elements are introduced into the containment vessel 420 through the ports 434 , 436 . The level of material in the vessel 420 is below the top of the rotational mixer 448 to avoid the release of driving gas under the liquid surface which may cause foam. Gas is injected through the orifices 438 , 440 to become entrapped in the buoyancy-driven cavity 464 in the rotational mixer 448 . This action drives the rotational mixer 448 in a direction which is seen as clockwise in FIG. 17 .
The blades 472 act to circulate the liquid within the containment vessel 420 with toroidal flow in opposite directions through the wheels 450 , 452 , radially outwardly from between the wheels 450 , 452 and then radially inwardly on the outsides of the rotational mixer 448 to again be drawn into the interior of the rotational mixer 448 . Mixing with turbulence is desired and the outer paddles 466 , the vanes 468 and the inner paddles 470 contribute to the mixing and to the toroidal flow about each of the wheels 450 , 452 . The target speed of rotation is on the order of up to the low tens of rpm to achieve the similar mixing results as prior devices at 50 to 300 rpm. The difference may reduce shear damage in more sensitive materials. Oxygen may be introduced in a conventional manner as well as part of the driving gas to be mixed fully throughout the vessel 420 under the influence of the mixing apparatus.
FIG. 21 illustrates a variation on the embodiment of FIGS. 16 through 20 . In this embodiment, the buoyancy-driven mixing cavities 464 are reversed in one of the wheels 450 , 452 for driving in the opposite direction. Similarly, the orifices 438 , 440 are offset to either side of the horizontal axis of rotation. The gas through the orifices 438 , 440 is independently controlled to allow selection of rotation of the rotational mixer in either direction.
Thus, an improved pneumatic bioreactor is disclosed. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
An appreciation of the other aims and objectives of the present invention and an understanding of it may be achieved by referring to the accompanying drawings and the detailed description of a preferred embodiment.
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A pneumatic bioreactor includes a vessel containing a fluid to be mixed and at least one mixing device driven by gas pressure. A first embodiment includes a floating impeller that rises and falls in the fluid as gas bubbles carry it upward to the surface where the gas is then vented, permitting the impeller to sink in the fluid. The floating impeller may be tethered to a second impeller with a flexible member and pulley. The mixing speed is controlled with electromagnets in the vessel acting upon magnetic material in the impeller or its guides. In another embodiment, floating pistons mix the fluid, pushing it through a mixing plate with one or more apertures. In a third embodiment, the mixing device is a rotating drum with bubble-catching blades and rotating mixing plates with apertures. The top of the vessel for these mixers may include a closed top and sterile filters.
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FIELD OF THE INVENTION
The present invention relates to a semiconductor device equipped with a conductivity modulation MISFET, and more particularly to the structure of a drain electrode in a conductivity modulation MISFET that can be formed in an integrated circuit.
BACKGROUND OF THE INVENTION
In the output circuit of display drive integrated circuits shown in FIG. 10, it has conventionally been advantageous to use the parasitic diode existing in a double diffusion MOSFET as diode D2, which is connected in parallel to an FET, if a double diffusion MOSFET (DMOS) is used as transistor N2 in the A region of this output circuit.
However, if an attempt is made to use a conductivity modulation MOSFET (IGBT) as transistor N2, diode D2 becomes inoperative because of the existence of a parasitic diode D4 serially connected to transistor N2 in addition to parasitic diode D2, as shown in FIG. 11. To make D2 operative, a parallel resistance R5 can be connected in parallel with diode D4 as shown in FIG. 12. A conductivity modulation MOSFET of anode short type that contains said type of circuitry is shown in FIG. 13.
In this conductivity modulation MOSFET, a p-type base region (23) and an n-type source region (24) are formed on the front surface of n-type conductivity modulation layer (22) by means of a double diffusion process, with an insulation layer (25), a gate electrode (28), and a source electrode (29) being disposed thereon. A minority carrier injection region (26) is formed by means of a diffusion process on the rear surface of the conductivity modulation layer (22). This rear surface is entirely covered by a drain electrode (27). In this case, the drain electrode (27) is structured so as to be in direct contact with the conductivity modulation layer (22), other than the minority carrier region (26), in order to shorten the time needed for the conductivity modulation MOSFET to transit to a low state of conductivity. Thus, a parallel circuit having parallel resistance R5 is formed. Parts D2 and D4, shown by dotted lines in FIG. 13, are parasitic diodes.
In this conductivity modulation MOSFET, when positive potential is applied to the gate electrode (28), electrons flow from the source region (24) to the conductivity modulation layer (22) via an inversion layer, resulting in holes to flow from the minority carrier injection region (26) into the conductivity modulation layer (22) as a result of the forward potential difference generated from a voltage drop in parallel resistance R5. This raises the conductivity of the conductivity modulation layer (22), and thus allows a large current to flow. Removal of the positive potential in the gate electrode (28) causes the inversion layer to disappear, the electrons to stop flowing in, the carrier to discharge, and the conductivity modulation layer (22) to become high in resistance again.
The circuit in region B of the circuit in FIG. 12 is called an "open-drain structure", and the circuit in region B can also be structured by a conductivity modulation MISFET of anode short type. If a conductivity modulation MISFET is used in a circuit of this type, a bonding pad or bump electrode is formed as an external connecting electrode at terminal DO in the figure, a multi-output drive circuit can be made that contains a large number of open-drain circuits (80 circuits, for example), and an equal number of DO terminals. Furthermore, each of the DO terminals is connected with a bonding pad or bump electrode.
In the above conductivity modulation MISFET of anode short type, conductivity modulation may become impossible if the value for parallel resistance R5 is too small. On the other hand, the effect of parallel resistance R5 cannot be obtained if the value for parallel resistance R5 is too large. Therefore, the resistance value of this parallel resistance R5 must be set at an adequate value and can be adjusted by changing the depth of the minority carrier injection region (26). However, if a diffusion process is used, diffusion to a great depth may reduce the accuracy of the shape of the diffusion region, thus making it difficult to obtain an accurate resistance value for controlling the minority carrier injection region (26) in the depth direction.
In addition, when this conductivity modulation MISFET of anode short type is incorporated in an integrated circuit, the element current is generally reduced, as is the voltage drop of parallel resistance R5. Therefore, to ensure an operation that will induce a conductivity modulation by applying a forward bias voltage (˜0.7 V) between the minority carrier injection layer and the conductivity modulation layer, the value of parallel resistance R5 must be increased. However, increasing the resistance value is difficult because the setting range of the resistance value is restricted by the resistance factor of the conductivity modulation layer (22) and the element size. Thus separate resistance layers were heretofore required.
Furthermore, the existence of the drain electrode on the rear surface made it difficult to form an integrated circuit. It also became difficult to make the element separation technology and made the wiring arrangement more complex.
Moreover, connecting the drain electrode to a junction pad or bump electrodes on a large number of DO terminals causes many wirings to cross the elements. The wiring potential affects the elements, possibly causing a reduction in the breakdown voltage. In addition, the inability to form elements beneath the bonding pad or bump electrodes, in order to improve reliability, prevented a higher integration of the circuit.
SUMMARY OF THE INVENTION
It is an object of the present invention to solve the above problems by producing a conductivity modulation MISFET in which a parallel resistance can be efficiently formed in a small installation area without requiring additional manufacturing processes, and which can be incorporated into an integrated circuit by forming a drain electrode on the front surface of the conductivity modulation layer, as well as by using the characteristics of the drain electrode junction face, or by defining the relations among the regional structures.
More specifically, to solve the above problems, the present invention provides a semiconductor device equipped with a conductivity modulation MISFET, comprising an MIS part containing a second conductive region and a first conductive region formed, e.g., by a double diffusion process on the outer surface of a first conductive conductivity modulation layer, and a second conductive minority carrier injection region formed in an insulation region opposite to said MIS part on the outer surface of said conductivity modulation layer. Said semiconductor device has a drain electrode that conductively contacts said minority carrier injection region on the outer surface of said conductivity modulation layer, with said drain electrode having an electrode junction face of a predetermined area that contacts said conductivity modulation layer. Means taken by the present invention includes disposing a drain electrode in contact with a minority carrier injection region on the front surface of a conductivity modulation layer, with the drain electrode forming an electrode junction face of a predetermined area conductively contacting the conductivity modulation layer. This drain electrode may be integrated with an external fetch electrode.
The electrode junction face may be farther isolated from the MIS part than from said minority injection region. In this case, the electrode junction face may be formed in a region other than the lower layer of the conductivity modulation layer beneath the electrode junction face.
In the above means, the minority carrier injection region may be formed so as to surround the region beneath the electrode junction face in the conductivity modulation layer.
Beneath this electrode junction face, a first contact region conductively contacting the conducivity modulation layer may be formed later. In this case, the minority carrier injection region may be formed such that it is subsumed by said contact region, or such that it surrounds said contact region on the surface of the conductivity modulation layer, or may be arranged such that it sandwiches the contact region by the minority carrier injection regions and juxtaposes the contact region and the minority carrier injection regions on both sides opposite to the MIS part. The edge of the contact region on the side of the MIS part may be formed at a deep position that is isolated farther from said MIS part than from the edge of said minority injection region opposite the MIS part. Furthermore, in each of the above means, a conductivity modulation layer may be formed on a second conductive layer, such as a second conductive semiconductor substrate, an embedded layer, and so become a conductive layer formed in a higher carrier concentration.
According to the first means described above, because the drain electrode conductively contacts the minority carrier injection region as well as the conductivity modulation layer at the electrode junction face of a predetermined area, the contact resistance at this electrode junction face forms a resistance connected in parallel with parasitic diodes existing at the junction of the minority carrier injection region and the conductivity modulation layer. This parallel resistance is set at a predetermined value by means of adjusting the area of the electrode junction face while taking the contact resistance value into account. Therefore, this arrangement requires neither a separate resistance layer nor any additional manufacturing processes, and it reduces the installation space. In addition, because the drain electrode and minority carrier injection region are formed on the front surface of the conductivity modulation layer, the manufacturing process is simplified, thus reducing the number of production processes, facilitating the wiring arrangement and element separation, and making the structure suitable for formation in an integrated circuit.
Integrating the drain electrode and an external fetch electrode will eliminate the need for wiring between the drain electrode and the external fetch electrode, remove the problem of a drop in the breakdown voltage of the elements under wiring, and offer a possibility of integrating the circuits. In this case, because the area of the external fetch electrode is sufficiently larger than the element, the contact part of the drain electrode with the minority carrier region can be formed on the side of the MIS part. On the other hand, the electrode junction face can be isolated further from said MIS part than from this contact part. In this case, when current flows from the MIS part through the conductivity modulation layer, a parasitic resistance exists in parallel with the parasitic diodes between the minority carrier region and the conductivity modulation layer because the electrode junction face is farther isolated from the minority carrier region. In this case, resistance of the conductivity modulation layer itself can be applied to the contact resistance of the electrode junction face without causing an increase in the installation area of the elements, thus facilitating the setting of the parallel resistance. If a structure is selected in which a region beneath the electrode junction face of the conductivity modulation layer is surrounded by the minority carrier injection region, the cross-section of the region beneath the electrode junction face is limited by the minority carrier injection region, hence generating a pinch resistance corresponding to the cross-section and length of the region. This allows the pinch resistance value to be changed by changing the shape of the minority carrier injection region, thus making possible the optimization of the parallel resistance value. If the electrode junction of the drain electrode and the conductivity modulation layer is connected via the first conductive contact region, formation can be made with good ohmic character between the drain electrode and the contact region by controlling the concentration of impurities in the contact region, and the formation of a Schottky junction on the electrode junction face is prevented. In addition, the parallel resistance value can be optimized by changing the concentration of impurities in the contact region, its shape, or the ratio of the area of the contact region and the minority carrier region that contact the drain electrode.
If a minority carrier injection region is formed in a contact region, the contact region can function as a stopper for a depletion layer formed in the conductivity modulation layer as a result of a junction with the base region. When forming a flat pattern in which the minority carrier injection regions surrounds the contact region on the front surface of the conductivity modulation layer, the resistance value of said parallel resistance can be changed to a wider range based on the relation between the depth of the contact region and that of the minority carrier injection region. In addition, if the contact region is sandwiched between the minority carrier injection regions, and the contact region and the minority carrier injection regions on both their sides are juxtaposed opposite to the MIS part, and the edge of the contact region on the side of MIS part is formed at a deep opposition isolated farther from the said MIS part than from the edge of said minority injection region on the side of the MIS part, then the contact region can be connected to a narrow band of the conductivity modulation layer sandwiched by the minority carrier injection regions that are situated in a direction toward the MIS part, whereas a pinch resistance is generated that corresponds to the width and length of this narrow band. In this case, because the width and length of the narrow band are formed with high accuracy only from a mask shape formed by diffusion, the resistance value of the parallel resistance can be controlled easily and more precisely.
If a conductivity modulation layer is formed on the second conductive layer, applying a source potential to this second conductive layer will cause the drain voltage to rise, and a depletion layer to expand from an interface of the second conductive layer and the conductivity modulation layer to the inside of the conductivity modulation layer. In this case, the depletion layer will meet with the depletion layer expanding from an interface of the base region and the conductivity modulation layer, and thereafter, the depletion layer in the second conductive layer will expand. Hence, the depletion electric field will be alleviated in the base region, making it more difficult for a punch-through to occur, and making it possible to obtain high breakdown voltage elements. In this case, if the second conductive layer is formed so as to make its carrier concentration high, its resistance factor will be decreased, whereby the current will flow either out or in an on state even if it flows through the second conductive layer, thus allowing an increase in the current carrying capacity of the elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to a first embodiment of the present invention.
FIG. 2 is a longitudinal sectional drawing illustrating a conducivity modulation MISFET according to a MISFET second embodiment of the present invention.
FIG. 3 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to a third embodiment of the present invention.
FIG. 4 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to a forth embodiment of the present invention.
FIG. 5 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to a fifth embodiment of the present invention.
FIG. 6 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to a sixth embodiment of the present invention.
FIG. 7 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to a seventh embodiment of the present invention.
FIG. 8 is a longitudinal sectional drawing illustrating a conductivity modulation MISFET according to an eighth embodiment of the present invention.
FIG. 9 is an equivalent circuit diagram of a conductivity modulation MISFET according to an embodiment MISFET of the present invention.
FIG. 10 is a circuit diagram illustrating the use of a double diffusion MOSFET in a display driver output circuit.
FIG. 11 is a circuit diagram illustrating the use of a conductivity modulation MOSFET in a display driver output circuit.
FIG. 12 is a circuit diagram illustrating the use of a conductivity modulation MOSFET of the anode short type in a display driver output circuit.
FIG. 13 is a cross section illustrating the structure of a conventional conductivity modulation MOSFET of the anode short type.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the first embodiment of the present invention, an n-type embedded layer (1) is formed on the bottom surface of an island-shaped region p-n junction and is separated by a p-type isolation region (41) on a p-type substrate (42). Also, an n-type conductivity modulation layer (2) is formed on the embedded layer (1), and a p-type base region (3) and an n-type source region (4) are formed on the front surface of the conductivity modulation layer (2) through a diffusion process. These are covered by an insulation layer (5), on which a polysilicon gate electrode (8) is disposed to construct the MIS parts that use the source region (4) as their source, the conductivity modulation layer (2) as their drain, and the surface part of the base region (3) disposed directly below the gate electrode (8) via the insulation layer (5) as their channel region. Furthermore, a p-type source contact region (15) is formed in the base region (3), the source contact region (15) and the source region (4) conductively contacting the source electrode (9) (not shown except for the connection).
A p + -type minority carrier injection region (6) is diffusively formed on the front surface of the conductivity modulation layer (2) and located away from its MIS part. A drain electrode (7), conductively contacting the minority carrier injection region (6), is also in direct contact with junction face (10). Furthermore, on the side of the minority carrier injection region (6) in the base region (3), a p - -type graft base (16) is disposed to prevent any electric field concentrations. The drain electrode (7) is formed integrally with the bonding pad that is an external fetch electrode. The drain electrode (7) is connected to drain D, the source electrode (9) is connected to source S, and the gate electrode (8) is connected to gate G.
In this conductivity modulation MISFET, when a positive potential is applied to gate G, with a bias voltage (hereinafter called the drain voltage) applied across drain D and source S, electrons flow from the source region (4) into the conductivity modulation layer (2) through the inversion layer formed on front surface of the base region (3), resulting in the injection of holes from the minority carrier injection region (6) into the conductivity modulation layer (2). The solid lines in FIG. 1 represent the electron path, while the dotted lines represent the hole path. These carriers flow in to induce a high conductivity state in the conductivity modulation layer (2), and cause a large current to flow between the drain D and source S. The activity realizing a transition to this high conductivity state is caused by a voltage drop based on the parallel resistance Rc, as shown in FIG. 9. FIG. 9 shows a circuit similar to this embodiment. In the figure, part Rs is a short circuit resistance parasitically existing between the base region (3) and the source region (4), N2 is a MOSFET, and D2 and D4 are parasitic diodes. In this embodiment, the parallel resistance Rc is secured by a contact resistance at the electrode junction section (10), while a voltage drop in the parallel resistance Rc caused by an electron current flowing through N2 generates a forward bias voltage between the conductivity modulation layer (2) and the minority carrier injection region (6). This, in turn, causes the holes to be injected from the minority carrier injection region (6) to the conductivity modulation layer (2), and a transition to a high conductivity state. At the same time, the wiring section possessing this parallel resistance Rc enables the parasitic diode D2, connected in parallel with the MOSFET N2, to operate.
This embodiment, in which the minority carrier injection region (6) can be formed simultaneously when forming the MIS part, or, for example, when diffusing the source contact the conductivity modulation layer, offers an advantage during the manufacturing process, facilitates the wiring arrangement, and is suitable for being formed into an integrated circuit. In addition, the drain electrode structure is very simple, and the increase of the element installation area can be minimized. Using contact resistance to obtain the parallel resistance Rc of the drain electrode requires no additional manufacturing process during formation. In addition, changing the area of the electrode junction section (10) enables a formation which adjusts the value of the parallel resistance Rc to some extent.
If the electrode junction face (10) is so structured that it surrounds the minority carrier injection region (6) while the cross section of a region in the conductivity modulation layer (2) located beneath the electrode junction face (10) is limited by the minority carrier injection region (6), a pinch resistance created in this region will be added to the contact resistance to form the parallel resistance Rc. Because changing the depth of the minority carrier injection region (6) enables its length to be changed, the pinch resistance value can also be changed, making it possible to change the value of the parallel resistance Rc over a wider range.
The drain electrode (7) formed integrally with the bonding pad as an external fetch electrode eliminates the need to connect wiring between the drain and the external fetch electrode, thereby preventing a breakdown voltage drop resulting from the wiring potential at the element section formed beneath the wiring, and eliminating the need for the space required by the wiring region. Moreover, the region beneath the bonding pad, which has not been used conventionally, can be used effectively because the bonding pad is used for the drain electrode (7), and the space occupied by the elements can be reduced further. In this embodiment, the drain electrode (7) can also be formed as underground wiring for the bump electrode. Furthermore, it is also possible to form it as a single drain electrode similar to the conventional type, and to connect it to other components by wiring.
While this conductivity modulation layer MISFET has an embedded layer (1) beneath the conductivity modulation layer (2) to assure the current carrying capacity, the layer (1) may not be formed to improve the breakdown voltage.
FIG. 2 shows a second embodiment of the conductivity modulation MISFET according to the present invention. In this embodiment, those parts identical to the first embodiment have the same numerals, and the explanation thereof is omitted. While the minority carrier region (6) and the electrode junction face (10), which are identical to those in the first embodiments, are integrally formed on the drain electrode (7) with the bonding pad in this embodiment, on the MIS part side, while the electrode junction face (10) is formed in a region far from the MIS part. This means that the drain electrode (7) has a parasitic resistance corresponding to the distance L connected in the embedded layer (1) in parallel with the parasitic p-n junction conductivity modulation layer (2). Therefore, the value of the parallel resistance can be set not only by the contact resistance at the electrode junction face (10), but also by the distance L between electrode junction face (10) and the minority carrier region (6). Thus, in this embodiment the parallel resistance is secured by the distance between the electrode contact face and the minority carrier region. However, because the drain electrode (7), which is integrated with the bonding pad, is formed originally with a sufficient size compared with the size of the elements, it is not necessary to increase the size of the drain electrode (7).
In the first and second embodiments, if the impurity concentration of the conductivity modulation layer (2) is low, the electrode junction face (10) may form a Schottky junction, allowing for the possibility that the parasitic diode D2, as shown in FIG. 9, will become inoperative. Therefore, in the third embodiment, shown in FIG. 3, a contact region (11) is formed on the front surface of the conductivity modulation layer (2), and the drain electrode (7) is conductively connected with the contact region (11). In FIG. 3, the parts identical to those in the first embodiment are provided with the same numerals and their explanation is omitted. The minority carrier injection region (6) is embedded in the contact region (11), and the drain electrode (7) is connected to the minority carrier region (6) at its center, with its periphery also connected to the contact region (11). The graft base (16) described in the first embodiment is not formed.
This embodiment limits the impurity concentration of the contact region (11) to 10 18 cm -3 or higher, allowing the attainment of reliable ohmic contact with the drain electrode (7). Therefore, the impurity concentration in the conductivity modulation layer (2) can be set optionally without the need to consider the possibility of the formation of a rectifier junction. The contact region (11) subsuming the minority carrier region (6) prevents a punch-through between the base region (3) and the minority carrier region (6), allowing for a rise in the breakdown voltage. In other words, the contact region (11) also serves as a stopper to prevent the expansion of a depletion layer formed in the conductivity modulation layer (2) by the junction of the conductivity modulation layer (2) with the base region (3). If the drain electrode (7) is disposed in the vicinity of a p-type separation band for p-n junction and separation, its function as a depletion layer stopper will have the effect of preventing a punch-through between this p-type separation band and the minority carrier region (6).
The value of the parallel resistance Rc can be changed, other than by resorting to changing the area of the electrode junction (10), by changing the impurity concentration in the contact region (11) to within a range that does not impair the ohmic junction with the drain electrode (7), and by changing the shape of the contact region (11).
Next, a fourth embodiment of the present invention is explained with reference to FIG. 4. This embodiment has the same structure as the first embodiment, except for the shape of the contact region (11) and the minority carrier injection layer (6). The identical parts are given the same numerals, and their explanation is omitted.
The minority carrier injection layer (6) surrounds the contact region (11) on the front surface of the conductivity modulation layer (2), and the parallel resistance Rc can be varied by changing the ratio of the contact area of the drain electrode (7) with the minority carrier injection region (6) to the area of the electrode junction face (10). Moreover, if the depth of the minority carrier injection region (6) is increased so that it is greater than the contact region (11), a parasitic pinch resistance beneath the contract region (11) will be formed. In this case, therefore, it is possible to make the depth of the minority carrier injection region (6) shallower than that of the contact region (11) and thereby reduce the resistance value. Therefore, it is possible to change the value of the parallel resistance Rc reliably over a wider range.
Also in this embodiment, the drain electrode (7) is formed integrally on the bonding pad, thereby a sufficient surface area can be assumed for impurity diffusion, thereby deepening the minority carrier injection region (6) and increasing the pinch resistance value.
Next, a fifth embodiment of the present invention is explained with reference to FIG. 5. In this embodiment, the contact region (11) is also formed beneath the electrode junction face (10), thus making it possible to prevent the formation of a Schottky junction when the impurity concentration in the conductivity modulation layer (2) is low.
In addition, the electrode junction face (10) in the drain electrode (7) is formed in a region further from the MIS part than from the minority carrier injection region (6), as in the case of the second embodiment. However, unlike the second embodiment, the embedded layer (1) is not formed beneath the electrode junction face (10). For this reason, in this embodiment, a parasitic resistance exists corresponding to the distance L in the figure of the conductivity modulation layer (2). Since the conductivity modulation layer (2) has a high resistance because this parasitic resistance becomes part of the parallel resistance Rc, it is very easy to obtain a high resistance. In addition, because the drop in the parasitic resistance value is compensated by an increase in the current amount even if the conductivity modulation MISFET transfers to an on-state, giving the conductivity modulation layer (2) low resistance, it is possible to assure sufficient resistance for the transition to the on-state condition and its maintenance also from the parasitic resistance in the conductivity modulation layer (2).
The embedded layer (1) is formed only beneath the MIS part, and is not formed beneath the electrode junction face (10), nor is it formed beneath the minority carrier injection region (6). As a result, a punch-through may be generated between the minority carrier injection region (6) and the substrate, causing the breakdown voltage in the elements to be decreased. To prevent this, an n-type buffer layer (17) is formed in such a way that it will subsume the surrounding area of the minority carrier injection region (6).
Unlike this embodiment, if the embedded layer (1) is formed and extended to beneath the minority carrier injection region (6), the same parasitic resistance as in the above case may be obtained, and the buffer layer (17) will no longer be necessary.
FIG. 6 shows a sixth embodiment of the present invention, which is identical with the second embodiment except for the structure around the drain electrode. The identical parts are given the same numerals, and their explanation is omitted. In this embodiment, the surfaces of the minority carrier region (6) and the contact region (11) are both rectangular in shape. They are juxtaposed alternately in parallel in the direction along which the MIS part extends, and the contact region (11) is formed sandwiched by the minority carrier injection region (6) with a narrower width. The edge (11a) of the contact region (11) on the MIS part side is located deeper than the edge (6a) of the minority carrier injection region (6) on the MIS part side. Therefore, the region of the conductivity modulation layer (2) at which the edge (11a) of the contact region (11) makes contact forms a narrow band (12) sandwiched within the minority carrier injection region (6). The narrow band (12) generates a pinch resistance in the direction toward the MIS part. In this case, because both the length and width of the narrow band (12) are determined by the surface shape of both the minority carrier injection region (6) and the contact region (11), it is possible to accurately obtain the pinch resistance value, which is determined approximately according to the length and width. In this way, it is possible to set the parallel resistance Rc accurately.
When the minority carrier injection region (6) and the contact region (11) are formed by the diffusion process, the size of the mask used in the diffusion process can set the length and width of the narrow band (12), and can precisely control the pinch resistance, hence improving the reproducibility and uniformity of the value in the parallel resistance. It is possible as a matter of course to control the value of the parallel resistance Rc by changing the area, depth and width of the minority carrier injection region (6) and the contact region (11).
In this embodiment, a narrow band is also formed on the opposite side of the MIS part. Therefore, the minority carrier injection region (6) is sectioned into various parts, but only the structure forming the narrow band on the MIS part side may be adopted.
The seventh embodiment of the present invention is explained with reference to FIG. 7. In this embodiment, the structure of the conductivity modulation layer (2) on the front surface side and on the surface is identical with that in the third embodiment shown in FIG. 3. However, it is different in that the conductivity modulation layer (2) is formed on a p-type silicon substrate (18). This is the so-called RESURF (Reduced Surface Field) structure, in which, since the silicon substrate (18) is connected to the source S, the p-n junction formed on the contact face of the silicon substate (18) with the conductivity modulation layer (2) is in a reverse bias state when the MOSFET is in an off-state, with the drain voltage being applied, and the depletion layer expands from the p-n junction face to the inside of the conductivity modulation layer (2), while at the same time, forming also within the silicon substrate (18).
At the same time, because a source voltage is applied to the base region (3) through the source contact region (15), depletion layers are formed from the interface of the base region (3) with the conductivity modulation layer (2) into the conductivity modulation layer (2) and the base region (3). When the drain voltage is increased under these conditions the depletion layer in the base region (3) will expand to reach the source region (4), thereby possibly generating a punch-through. However, in this embodiment which adopts a RESURF structure, the depletion layer expanding from the base region (3) partly meets with the depletion layer expanding from the silicon substrate (18) at a high electric field region within the conductivity modulation layer (2) as the drain voltage is raised. As a result, the increase of the space-charge amount in the depletion layers at the subsequent meeting part is depressed. The expansion of the depletion layer in the base region (3) is also depressed, thereby making it more difficult for a punch-through to occur between the conductivity modulation layer (2) and the source region (4) and assuring a high breakdown voltage for the elements.
The n-type embedded layer (1) disposed in the third embodiment is not formed in this embodiment. However, it is possible to assure an on-current value by increasing the conductivity in the conductivity modulation layer (2) when the MOSFET is in an on-state. No drop in the current-carrying capacity, because of the non-existance of the embedded layer (1), has been experimentally verified.
The eighth embodiment of the present invention is explained, with reference to FIG. 8. This embodiment has a structure nearly the same as that of the first embodiment shown in FIG. 1, except that a p-type embedded layer (19) is formed beneath the conductivity modulation layer (2) and is connected with an isolation (41), by allowing a potential of the source S to be applied to the embedded layer (19) through the isolation (41).
In this embodiment, which adopts a RESURF structure, as does the seventh embodiment, it is possible to secure a high breakdown voltage in the elements. Furthermore, as the structure allows the positive drawing of the holes of the embedded layer (19) into the conductivity modulation layer (2) in the on-state, and since the embedded layer (19) is kept at a high carrier concentration, it is possible to increase the on-current as well as the current-carrying capacity.
In addition, because the embedded layer (19) is applied with the source voltage through the isolation (41), it is not necessary to separately dispose the structure to apply the source voltage from the rear of the conductivity modulation layer (2), allowing a one-side total electrode structure to be maintained.
As described above, the present invention, which is characterized by having a one-side total electrode structure with a drain electrode disposed on the surface side of a conductivity modulation layer, and by having an electrode junction face with a predetermined area disposed on the drain electrode, conductively contacts the conductivity modulation layer either directly or through a contact region and provides the following effects.
(1) In the case where the electrode junction face conductively contacts directly with the conductivity modulation layer, a parallel resistance is formed as a result of the contact resistance at the electrode junction face with a predetermined area. Therefore, drain short-type elements with adequate parallel resistance can be formed without requiring an additional manufacturing process. The increase in the area occupied by the elements resulting from the transfer of the drain electrode to the surface side can be minimized as a result of its structural simplicity. Moreover, the one-side total electrode structure allows for the formation of an integrated circuit.
(2) If the drain electrode is formed integrally with an externally disposed electrode, it is not necessary to fix wiring between the drain electrode and the externally disposed electrode. This allows for a reduction of the element area, thus preventing a drop in the breakdown voltage of the elements. In particular by using the externally disposed electrode occupying a large area, a parasitic resistance can be formed based on the distance between the electrode junction face and the minority carrier injection region making it a part of the parallel resistance, without having to increase the element area by keeping the electrode junction face and the minority carrier injection region isolated from each other. Furthermore, since it is possible to assure a sufficient diffusion area when diffusing the minority carrier injection region and contact region beneath the drain electrode, it is possible to set the area and depth of these diffusion regions over a wider range, thereby enhancing the element function.
(3) By surrounding the electrode junction face with the minority carrier injection region, it is possible to form a parallel resistance with the above contact resistance added to a pinch resistance. It is also possible to change the parallel resistance by changing the depth of the minority carrier injection region.
(4) If the electrode junction conductivity contacts with the conductivity modulation layer via the contact region, it will be possible to freely set an impurity concentration of the conductivity modulation layer according to the required element characteristics, since it will be possible to reliably prevent a rectifier junction even if the impurity concentration in the conductivity modulation layer is low. Also, by controlling the impurity concentration and the shape of the contact region, it will be possible to optimize the parallel resistance value, thereby enhancing the element function.
(5) If the minority carrier injection region is formed within the contact region, the contact region will function as a depletion layer stopper to prevent a punch-through between the base region and the minority carrier region. Therefore, it will be possible to increase the breakdown voltage of the elements without forming another layer, such as a graft base.
(6) If the contact region is surrounded by the minority carrier injection region, it will be possible to change the parallel resistance value over a wider range, and optimize the parallel resistance value more easily, by changing the ratio of the area over which the minority carrier injection region contacts the drain electrode to the area of the electrode junction face, and by changing the difference of the depths of the minority carrier injection region and the contact region.
(7) If the contact region and the minority carrier injection region are alternately juxtaposed to the MIS part, and the sides of the contact region are located further from the MIS section than from the minority carrier injection region, a narrow band will be formed within the minority carrier injection region on the side of MIS sections in the contact region, thereby forming a pinch resistance. Since the values of this pinch resistance can be controlled easily and precisely according to the surface shape of the diffusion region, it is then possible to form a parallel resistance having an optimum value with high accuracy and good reproducibility.
(8) Because, by adopting the so-called RESURF structure, it is possible to stop the expansion of a depletion layer from the base region using a depletion layer formed from an interface with the second conductive layer; and, to depress an increase of the depletion electric field in the electric field concentration, thus electric field in the base region can be alleviated, thus increasing the breakdown voltage of the elements.
(9) If the carrier concentration in the second conductivity layer is set high in the case of the above RESURF structure, the second conductive layer can be used as a path for the on-current to flow out (or flow in), thereby increasing the current carrying capacity of the elements.
Although specific embodiments of the present invention have been illustrated and explained, it is easy to carry out many changes and variations other than the embodiments described above. For example, it is possible to reverse the conduction type of respective parts or to adopt different production methods for the MISFET provided on the device.
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A semiconductor device including a conductivity modulating MISFET comprising a conductvitiy modulation layer of a first conductive type, a base region of a second conductive type, a source region of the second conductive type in the base region, a gate electrode on an insulating layer on the base region, an injection region of the second conductive type, and a drain electrode coupled to the injection region and the conductivity modulation layer. Wherein, the semiconductor device has a one-side electrode structure and the drain electrode coupled to the conductivity modulation layer provides a resistance parallel to a parasitic diode between the injection region and the conductivity modulation layer sufficient to forward bias the parasitic diode.
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REFERENCE TO RELATED APPLICATION
This application is divisional application of nonprovisional patent application, Ser. No. 10/944,344, filed Sep. 17, 2004 which is a continuation of nonprovisional patent application, Ser. No. 10/319,962, filed Dec. 16, 2002, now U.S. Pat. No. 6,891,202 and entitled, OXYGEN-DOPED Al-CONTAINING CURRENT BLOCKING LAYERS IN ACTIVE SEMICONDUCTOR DEVICES and published on Dec. 25, 2003 as Pub. No. 2003/0234969 and claiming priority of provisional patent application Ser. No. 60/340,319, filed Dec. 14, 2001; and nonprovisional patent application Ser. No. 10/267,331, filed Oct. 8, 2002 and entitled, TRANSMITTER PHOTONIC INTEGRATED CIRCUITS (TxPIC) AND OPTICAL TRANSPORT NETWORKS EMPLOYING TxPICs and published on May 22, 2003 as Pub. No. 2003/0095737 and claiming priority of provisional patent application Ser. No. 60/328,207, filed Oct. 9, 2001, all which patent applications are incorporated herein by their reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to active semiconductor devices, such as photonic, electronic or optoelectronic devices, and more particularly to photonic integrate circuits (PICs) that include active semiconductor devices, such as buried heterostructure active devices, such as Group III-V buried heterostructure semiconductor lasers, LEDs, modulators, photodiodes, heterojunction bipolar transistors, field effect transistors or other active devices for preventing current flow through designated regions of the device, such as high resistance current blocking layers on adjacent sides of the active region of such devices to provide for current confinement to the active region to enhance device efficiency.
2. Description of the Related Art
It is well known in the art to provide blocking layers for current confinement to the active region in buried heterostructure (BH) lasers or other such semiconductor active devices employed, for example, as an optical transmitter source, modulator or optical amplifier in optical telecommunication systems. Such a BH device employs junction blocking or reverse bias layers or blocking junctions, such as combinations of p-InP/n-InP layers. An example of such a blocking layer combination is disclosed in U.S. Pat. Nos. 4,470,143 and 5,148,439. However, due to intrinsic capacitance, these types of blocking junctions may not be readily adaptable for bit rates higher than 2.5 Gb/s. The particular problem with respect to these types of blocking layers is that the reverse biased p-n blocking junction possess a significant junction capacitance, limiting the high speed characteristics of such devices. Also, the reverse biased p-n junction in these devices may possess leakage paths leading to high thresholds in the case of laser diodes as well as low quantum efficiencies in all such devices.
Another type of blocking layer is made semi-insulating through the addition of one or combinations of Fe, Co, Ni, as a dopant, for example, in AlGaInAs, AlInAs, InP or InGaAsP. In particular, Fe is employed as a high resistance blocking layer such as disclosed in U.S. Pat. Nos. 4,660,208 and 4,888,624. Combination layers of Fe doped InP layers with p or n doped InP layers may be employed as illustrated in European Patent Application No. 0314372. As illustrated in these patents and publications, InP:Fe layers are utilized as blocking layers in BH lasers for current confinement to the active region of a semiconductor active device. Other Group III-V alloys, such as, for example, InGaAsP:Fe, may be employed as a blocking layer as illustrated in U.S. Pat. No. 6,028,875. The use of Fe doped Group III-V blocking layers is a well established current blocking technology but plagued by problems. In particular, Fe doped layers have poor stability so that Fe readily diffuses into adjacent semiconductor layers or materials, particularly the active region of a device. This diffusion process can occur more particularly during subsequent high temperature processing steps. European Patent Application No. 0208209 suggests a solution to this problem with the provision of an undoped spacer layer formed between the active region and adjacent layers and a second-growth InP:Fe, current blocking layer. Such a spacer layer prevents contamination of the active region by the impurity Fe in the adjacent, high resistive current blocking layer since the spacer layer functions as a diffusion inhibitor. Also, the spacer layer is made thin so that the leakage current outside of the buried active region is small. However, there is no mention in this publication of what the material might be for such a spacer layer.
A more recent approach for providing resistive layers to function as current blocking layers has been reported by S. Bouchoule et al. in an article entitled, “New Buried Heterostructure using MOVPE Selective Regrowth of Semi-Insulating (SI-) InAlAs for Low Capacitance Optical Sources”, Proceedings of The 14 TH Annual Meeting of the IEEE Lasers & Electro - Optics Society (LEOS), La Jolla, San Diego, Calif., pp. 883–884, Nov. 14–15, 2001. SI-InAlAs layers were grown by MOVPE under growth conditions to obtain high resistivity with low capacitance and lattice matched to InP substrates. Under optimized conditions, a resistivity of 2×10 7 Ωcm was achieved. Similar results are reported in U.S. Pat. No. 5,679,603, in particular, in the discussion of embodiments 1–3 of that patent where the oxygen forms a deep donor level which is naturally taken into the crystal from residual oxygen and H 2 O in the MOCVD reactor and/or contamination of their source materials with oxygen utilized to growth Group III-V materials. Resistivity values of 5×10 4 Ωcm are indicated. However, for good quantum efficiencies with low current leakage, the resistivity required for the current blocking layer must be much higher than these values, preferably at least about 10 6 to 10 7 Ωcm or higher. U.S. Pat. No. 5,679,603 reports values in the range of a resistivity of 10 3 Ωcm to 10 8 Ωcm for InAlAs and indicates this to be a sufficiently high resistance compound semiconductor for current blocking layers. However, it would be desirable to obtain repeatable, maintained high resistivity values with even lower current leakage values in a narrow, upper resistivity range, e.g., about 10 6 to 10 8 Ωcm.
Generally, the resistivity for semi-insulating Group III-V or SI-III-V epitaxial growths can be achieved through background doping using low growth temperatures, such as below 550° C. As an example, in U.S. Pat. No. 5,804,840 to Ochi et al., high resistance or SI-InAlAs layers were achieved with growth temperatures of about 500° C. where background oxygen acts as a deep donor compensating the shallow acceptor, such as carbon, having a higher concentration than that of a shallow donor, such as background silicon. By controlling the relationship of deep and shallow donors and acceptors, a SI-layer, for example, of InAlAs, can be achieved. In this case, a resistivity “exceeding” 5×10 4 Ωcm was achieved, which is significantly lower than the desirability for a resistivity range of about 10 6 to 10 8 Ωcm or higher. The dependence on background doping levels in a reactor or other growth apparatus to achieve a desired level of resistivity is a difficult approach to form current blocking layers having uniform characteristics on continuous and repeatable fabrication basis. Background doping levels are a function of many variables, e.g., hydride source oxygen purity, metalorganic source purity, carrier gas purity, integrity of the vacuum seals in the MOCVD reactor, previously deposited materials within the confines of the MOCVD reactor chamber as well as on the susceptor, injector(s), etc. As a result, background doping levels can substantially vary from reactor run to reactor run, resulting in significant variations in the current blocking properties of the compounds and materials formed when utilizing this technique and approach.
U.S. Pat. No. 6,019,840 to Hartmann et al. does disclose SI-layers with resistances in the range of 10 9 Ωcm for SI-InGaP lattice-matched to GaAs. However, the greater need is for materials lattice-matched to InP for producing light emitting devices emitting and functioning at wavelengths (e.g., 1270 nm to 1650 nm) suitable for optical telecommunication applications, such as InAlAs latticed-matched to InP. As previously indicated relative to U.S. Pat. No. 5,804,840, SI-InAlAs, via low growth temperatures and background impurities, does not provide sufficiently high resistive values or well controlled active semiconductor devices employed particularly in optical telecommunication applications where the active semiconductor devices are integrated as a photonic integrated circuit (PIC) with close device spacing encountered so that the highest achievable levels of low current leakage in such devices are required, e.g., resistivities in a range of about 10 6 to 10 8 Ωcm or more.
Studies of higher resistivity materials of InAlP lattice-matched to GaAs and InAlAs lattice matched to InP suggested the possibility of achieving high resistance or semi-insulating materials through intentional oxygen doping, such as indicated in the paper of J. C. Chen et al., “Effects of Trimethylindium on the Purity of In 0.5 Al 0.5 P and In 0.5 Al 0.5 As Epilayers Grown by Metalorganic Chemical Vapor Deposition”, Journal of Electronic Materials , Vol. 6(4), pp. 362–365, 1997, although this paper was not directed to such intentional oxygen doping. The paper only relates to the study of background doping and impurities of carbon, silicon and oxygen. There has been increasing interest in intentional oxygen doping in MOCVD processing, as illustrated in the patent of U.S. Pat. No. 5,909,051 to Stockman et al., which teaches oxygen doping of p-type confinement layers (e.g. AlGaInP) in LEDs which improves device stability and, therefore, long term device reliability. Also in the case of AlGaInP lattice matched to GaAs, oxygen doping has been studied as indicated the paper of J. S. McCalmont et al., “The Effect of Oxygen Incorporation in Semi-Insulating (Al x Ga 1−x ) y In 1−y P”, Journal of Applied Physics , Vol. 71(2), pp. 1046–1048, Jan. 15, 1992. In the case here, besides being lattice matched to GaAs, the source of oxygen was an O 2 flow into the reactor and not from an oxygen source, such as diethyl aluminum ethoxide (DEALO), which has been found to compensate silicon donors due to oxygen-induced multiple deep levels in InGaAs:Si:O. See the article of J. W. Huang et al., “Controlled Oxygen Incorporation in Indium Gallium Arsenide and Indium Phosphide Grown by Metalorganic Vapor Phase Epitaxy”, Journal of Electronic Materials , Vol. 24(11), (7 TH Biennial Workshop on Organmetallic Vapor Phase Epitaxy, Fort Myers, Fla., Apr. 2–5, 1995), pp. 1539–1546, November 1995. Also, previous mentioned U.S. Pat. No. 5,679,603 includes examples where the oxygen concentration in the crystal is controlled by the intentional doping of oxygen in AlInAs via an oxygen gas. However, in the embodiments reported, there is no indication of the resistivity levels except for the previously mentioned statement that high resistance semiconductor compounds fall in the range of 10 3 to 10 8 Ωcm. As indicated earlier, this large range is not acceptable for current blocking applications in demanding applications. Furthermore, using O 2 as an oxygen source has the disadvantage of pre-reacting with the Group III-V growth source materials in the MOCVD reactor chamber. These pre-reactions make the controlled incorporation of oxygen difficult and cause other detrimental problems such as undesired deposits in the reactor chamber and problems with composition or constituent control of the epitaxial deposition of Group III-V components comprising the compounds or layers that are being epitaxially grown in the reactor.
Still another approach for forming semi-insulating blocking layers is to employ lateral oxidation techniques such as disclosed in U.S. Pat. Nos. 5,262,360 and 5,400,354 by exposing Al-containing layers to a wet oxidation process to form a native oxide in such layers or a diffusion process where oxide layer is formed on the surfaces to be oxidized and diffusion of water molecules or oxygen occurs from the oxide surface layer into the aluminum-containing layers to form its native oxide. A similar method may also be employed herein to produce the novel devices contemplated by this invention. In the utilization of this native oxide processing, the lateral oxidation to form the native oxide of the aluminum-containing layers can be controlled so as not enter the defined current flow region by utilizing Al-containing blocking layers containing a higher Al mole fraction than the Al mole fraction of any of the layers formed in the current flow region so that the lateral oxidation can be easily terminated at the lower mole fraction Al-containing layers in the current flow region as taught in U.S. Pat. No. 6,201,264, or by forming a mesa or groove current confinement region where the Al-containing layers are stepped so that the oxidation extends only to layer step region as taught in U.S. Pat. No. 6,287,884. Both of these patents are incorporated herein by their reference.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a photonic integrated circuit having at least one active semiconductor device containing current blocking layers which are intentionally doped with oxygen.
SUMMARY OF THE INVENTION
According to this invention, active semiconductor devices of the type disclosed herein are employed in photonic integrated circuits (PICs) such as disclosed in U.S. patent application, Ser. No. 10/267,331, filed Oct. 8, 2002, supra.
Further, according to this invention, an Al containing group III-V compound semi-insulating layer is formed during MOCVD growth using an oxygen source to from a current blocking layer or region that defines a current channel or region in active semiconductor devices incorporated in a photonic integrated circuit (PIC), examples of such devices comprising buried heterostructure semiconductor lasers, LEDs, modulators, photodiodes, heterojunction bipolar transistors, field effect transistors or other active devices and for preventing current flow through designated regions of the device.
An important aspect of this invention is the provision of current blocking layers formed in such active semiconductor devices that are formed from intentional oxygen doping during their epitaxial growth. The deployment of intentional oxygen doping provides for better control and greater oxygen incorporation during layer growth over a wider range of growth parameters so that higher, repeatable resistivity values can be achieved under those conditions, such as 10 6-8 Ωcm or higher. These current blocking layers particularly contained Al and are lattice matched to the substrate, such as InAlGaP latticed matched to GaAs or InAlGaAs latticed matched to InP. The oxygen doping may be provided via an O 2 flow into the MOCVD reactor or provided via an oxide source where the oxide is cracked, i.e., the oxygen is dissociated from other gas constituents. However, an oxide source is preferred over an O 2 gas source because the latter provides a higher cracking temperature and reduced pre-reactions as described earlier. The preferred source for intentional oxygen doping is with a low vapor pressure oxide source such as, for example, a nitrogenous oxide (NO x ) or dialkylaluminum aloxides or diethyl aluminum alkoxide (DEALO). An ideal oxygen source is one that has a low cracking temperature without any tendency of pre-acting in the reactor with other source constituents prior to epitaxial wafer deposition. The material regime of particular interest is InAlAs/InP for achieving wavelengths of interest in optical telecommunication systems. Instead of InAlAs:O as a blocking layer material, InAlGaAs:O or AlGaAsSb:O or alternating layers of or alternating monolayers of AlAs:O/InAs or AlGaAs:O/InAs or InAlGaAs:O/InAs may be utilized or substitute InGaAs, InAlAs, InGaAsP for any of the InAs layers here. Also, combinations of the ternary layers and the quaternary layers may be employed, such as alternating layers of InAlAs:O and InAlGaAs:O. In the case of all the embodiments disclosed in this application, Fe can be co-doped with O since the oxygen at donor sites provides a strong holding bond for the out-diffusion of Fe from the material as well as prevention of the in-diffusion of other dopants, such as Zn, into the formed current blocking layer. Furthermore, O-doped layers can bond other layers with mobile elements (e.g., Fe) to prevent the indiffusion or out-diffusion of impurities into or out of these layers.
It should be understood that with respect to the foregoing Al-containing Group III-V blocking layer materials, there is no Group V phosphor or P. However, it is within the scope of this invention that small amounts of P can be present in these Al-containing Group III-V blocking layer materials.
To enhance the effect of oxygen doping of the Al-III-V current blocking layer or region and the resulting resistivity level, the Al content in the deposited layer is preferably 0.5 mole fraction or greater.
In another embodiment of this invention, the current confining channel of the active semiconductor device in such circuits may be a plurality of Al containing layers formed adjacent to the active region with a current channel formed through the Al containing layers by means of impurity induced disordering (IID) or vacancy induced disordering (VID). Regions of the deposited Al containing layers adjacent to the disordered current channel region are laterally oxidized from a water vapor source to form an Al-bearing native oxide defining current blocking regions on adjacent sides of the disordered current channel region. An example of such a device material regime is an InP substrate with Al containing layers comprising or InAlGaAs or alternating layers of InAlAs and InAlGaAs.
According to this invention, active semiconductor devices of the type disclosed herein in photonic integrated circuits (PICs) as disclosed in U.S. patent application, Ser. No. 10/267,331, filed Oct. 8, 2002, and published on May 22, 2003 as Pub. No. 2003/0095737, which nonprovisional application is incorporated herein by its reference.
Other objects and attainments together with a fuller understanding of the invention will become apparent and appreciated by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like reference symbols refer to like parts:
FIG. 1 is schematic side view of a first embodiment of this invention.
FIG. 2 is a schematic side view of a second embodiment of this invention.
FIG. 3 is a schematic side view of a third embodiment of this invention.
FIG. 4 is a schematic side view of a fourth embodiment of this invention.
FIG. 5 is a schematic side view of a fifth embodiment of this invention.
FIG. 6 is a schematic side view of a sixth embodiment of this invention.
FIG. 7A is a schematic side view of a seventh embodiment of this invention.
FIG. 7B is a schematic side view of a first modified version of the seventh embodiment of this invention.
FIG. 7C is a schematic side view of a second modified version of the seventh embodiment of this invention.
FIG. 8 is a schematic side view of a eighth embodiment of this invention.
FIG. 9A is a schematic side view of a ninth embodiment of this invention.
FIG. 9B is a schematic side view of a modified version of the ninth embodiment of this invention.
FIG. 10 is a schematic side view of a tenth embodiment of this invention.
FIG. 11 is a schematic side view of an eleventh embodiment of this invention.
FIG. 12 is a schematic side view of a twelfth embodiment of this invention.
FIG. 13 is a schematic side view of a thirteenth embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1 illustrating the first embodiment of this invention in a generally generic form. Active semiconductor device 10 A may be, for example, any such semiconductor device that is rendered operative through the establishment of a current channel through the device, such as, a semiconductor laser diode, semiconductor optical amplifier (SOA), LED or EA modulator, just to name a few such devices. Device 10 A comprises a substrate 12 , for example, n-InP, upon which is grown lattice-matched or pseudomorphic strained active layer or layers comprising active region 16 . To provide for carrier recombination under applied bias conditions, Group III-V epitaxially grown layers may be provided with an n-type dopant, such as Si or S, or with a p-type dopant such as Zn or Mg, as is well known in the art. Substrate 12 could also be GaAs but for wavelengths useful in present optical telecommunication systems, the preferable material system for these devices are InP material systems, such as, but not limited to, InGaAsP/InP.
Device 10 A, as well as most other embodiments of this invention, involves a multi-step growth process employing metalorganic chemical vapor deposition (MOCVD), also known as or organometallic vapor-phase epitaxy (OMVPE) which is well known in the art as documented by Professor Stringfellow in his book entitled, Orgaometallic Vapor - Phase: Theory and Practice, 1999, Academic Press. As a specific example, in the first growth process, a buffer layer (not shown) may be grown on substrate 12 followed by the growth of a confinement layer 14 of n-InP, such as doped with Si or S. Next, an active region 16 is grown. Active region may be a single layer or multiple layers or a plurality of quantum well (QW) layers. For example, active region 16 may be InGaAsP or a plurality of quantum wells and barriers of different mole fractions of InGaAsP lattice matched to substrate 12 or pseudomorphic strained as is known in the art. These layers include separate confinement layers with a bandgap lower than the adjacent confining region but higher than layers in the active region that are responsible for the emission or absorption of light. These layers or region provide carrier confinement and/or favorable waveguiding characteristics and are well known in the art. The growth of active region 16 is followed by the growth of confinement layer 18 of p-InP, such as with Zn or Mg as the p-type dopant. At this point in time in the MOCVD process, the first growth processing is completed and a selective etch is then performed on the InP wafer via an SiO 2 or SiN mask through the use of patterned photolithography. The etch is performed backed to the region of substrate 12 or n-InP containing layer 14 employing, for example, a dry etching process, reactive ion etching (IRE) or plasma enhance reactive ion etching (PE-IRE), forming a ridge or mesa structure 28 (comprising epitaxial layers 14 , 16 and 18 ) in regions covered by the mask as illustrated in FIG. 1 . The etch may alternatively comprise a wet chemical etch process. The mask can then be retained for the second growth process with MOCVD wherein a high resistance Al-containing Group III-V layer 30 (hereinafter referred to as Al-III-V) is epitaxially deposited. Layer 30 functions a current blocking layer to limit the primary flow of applied current through device 10 A through mesa 28 which defines a current confinement channel for device 10 A.
As previously mentioned in the background, Al-III-V layer 30 may be grown as an in-situ, non-doped layer due to background doping, such as from background hydrogen, carbon and oxygen due to sources of contamination in the epitaxial process, such as from sources providing the growth material gases to the MOCVD process, or due to leaks or deposits in the reactor from past runs in the reactor itself. This type of background doping, therefore, is not controllable since the resulting resistance of the layer depends on the previous growth history, the particular background doping available from growth to growth in the reactor as well as particular growth conditions, particularly temperature, which is conducted at a low temperature compared to the higher growth temperatures in the epitaxial deposition of other semiconductor Group III-V layers of device 10 A. Moreover, consistently high resistance values to achieve the lowest values of current leakage are not obtainable by means of this approach. A better approach is to intentionally dope rather than depend upon unintentional doping via the MOCVD reactor, i.e., via background doping or related schemes in an attempt to achieve desired background doping levels which are not reliable or stable from growth to growth.
As also mentioned in the background, others have employed Fe doped Al-III-V for SI, current blocking layer 30 . However, Fe has high mobility in the as-grown material and has a high tendency to migrate into other adjacent layers of the as-grown structure, such as the mesa structure 28 , thereby changing the layer conductivity property or quantum efficiency which is, of course, not desirable. In addition, dopants from the mesa structure 28 may also outdiffuse into the Al-III-V:Fe layers, which will degrade device performance. We intentionally dope layer 30 with oxygen to form the current blocking layer. Oxygen, in particular, provides a diffusion block against the diffusion of other dopants either into or through current blocking layer 30 and also render the material of layer 30 semi-insulating (Si) so that effectively no current flow will exist through this region. The oxygen dopant retards or restricts the diffusion of dopants and/or other crystal point defects which can result in deleterious effects on device performance. Thus, as will be seen in later embodiments, the codoping with Fe:O in Al-III-V compounds, such as InAlAs, provides for tying up Fe from diffusing out of current blocking layer 30 as well as preventing the in-diffusion of other dopants, such as Zn which has high volatility for diffusion, into blocking layer 30 . Thus, the use of oxygen as a dopant to form for a high resistivity layer 30 significantly retards the diffusion of impurities, such as Zn or Fe and/or other crystal point defects into or out of current blocking layers 30 . As a result, a spacer layer, as taught in the prior art previously mentioned in the background, is not required or necessary, i.e., the current blocking layer 30 may be in direct contact with mesa 28 as shown in FIG. 1 . In other words, it is possible to eliminate the requirement for any separation or spacer layer between mesa 28 and current blocking layer 30 .
While the prior art cited in the background discussed the use oxygen doping, the source generally employed is oxygen gas (O 2 ). This type of source does not provide good oxygen incorporation in a continuous and controlled manner. It is preferred that a low vapor pressure oxygen source, such as, nitrogenous oxide (NO x ) or diethyl aluminum ethoxide (DEALO) be employed for best controlled results to achieve the highest, consistent levels of oxygen incorporation at deep level donor sites in the bandgap of the blocking layer material.
Referring now again to the description of FIG. 1 and the completion of device 10 A, after the growth of the current blocking layers 30 and removal of the SiO 2 or SiN etch mask, the active semiconductor device 10 A is completed by the growth of an additional cladding layer 32 of p-InP followed by a cap or contact layer 20 , such as p ++ -InGaAs. A metal contact 22 is formed in a SiO 2 passivation layer 24 , comprising, for example, AuZn under Au, which is aligned with mesa 28 , all of which is well known in the art. The device is completed with a bottom contact 26 comprising, for example, AuGe under Au as is known in the art.
It should be noted that in the case of the embodiment of FIG. 1 as well as in all other embodiments, the oxygen doped current blocking layer or layers may include other conductivity type dopants, such as Zn or Mg in the case of p-type, or Si or S in the case of n-type, and/or other SI-dopants such as Fe, Co, Ni or Ti. A principal feature of this invention is the deployment of oxygen for high resistivity, insulating current blocking layer(s), taking advantage of the strong bonding properties of oxygen to hold these other dopants and/or crystal point defects, whether of the insulating type or of the conductivity type, from out-diffusing from the oxygen doped layer(s) or in-diffusing into the oxygen doped layers.
Reference is now made to FIG. 2 which discloses a second embodiment of this invention. In this embodiment as well as in all subsequent embodiments, the previous description relative to elements and components in FIG. 1 equally apply to all of the same elements and components having the same numerical identification in figures of the subsequent embodiments. FIG. 2 is the same as FIG. 1 except there is, in addition, the deposited layers 34 and 36 between which is formed current blocking Al-III-V layer 30 . These layers 34 and 46 are optionally added in the case where, for example, the close proximity of the Al-III-V:O layer to the mesa 28 or active region 16 may induce deleterious device effects (e.g., high interface recombination). In these cases, it may be desirable to set-back the Al-III-V:O layer with a layer of InP or InP:O. This layer should be in the range of about 100 Å to 2 μm thick, preferably about 500 Å to 5,000 Å thick. In the case of layer 34 , this lower set-back layer may comprise InP, InGaAs or InGaAsP that is doped n-type, unintentionally doped, oxygen doped, or any combinations thereof. Likewise, for layer 36 , this upper set-back layer may comprise InP, InGaAs or InGaAsP that is doped n-type, p-type, unintentionally doped, or oxygen doped. Upper set-back layer 36 provides the utility of an Al-free cap layer after the growth of the current blocking layer. Without this cap layer 36 , the underlying, exposed Al-III-V layer would form a “hard” oxide at its surface making it extremely difficult to grow high-quality single crystal material on this layer. Thus, cap layer 36 prevents the formation of such a “hard” oxide since all of the Al containing layers are buried and facilitates subsequent processing and regrowth of layers 32 and 20 . It is essential that cap layer 36 bury or cover all Al-III-V material originally existing at the growth surface. This is true relative to subsequent embodiments herein as shown in FIGS. 3–9 . The sandwiching layers 34 and 36 may be respectively doped to form added current blocking properties, such as a reverse biased junction as is known in the art.
Reference is made to FIG. 3 illustrating a third embodiment of this invention comprising the same layers as shown in FIG. 2 except that here, the material of choice for current blocking layer 30 is InAlAs:O sandwiched between layers 34 A and 36 A of n-InP and p- or n-InP, respectively. Alternatively, layer 36 A can be doped as InP:O. While InAlAs:O is illustrated in this embodiment for blocking layer 30 , it should be understood that blocking layer 30 may also be InAlGaAs:O or alternating layers or monolayers of AlAs:O/InAs, the latter of which will be described in more detail later, such as relative to the embodiment shown in FIG. 6 .
Reference is now made to the fourth embodiment comprising this invention shown in FIG. 4 . Active semiconductor device 10 D is the same as that in the embodiment of FIG. 3 except that current blocking layer 38 is co-doped with oxygen (O) and iron (Fe) to provide enhanced current-blocking characteristics. Both of these dopants are deep level impurities and, in combination, the O donors do not allow any Fe mobility as well as any mobility for impurity in-diffusion by other dopants such as Zn. While InAlAs:O:Fe is shown in this embodiment, it should be understood that layer 38 may also be InAlGaAs:O:Fe or alternating layers or alternating monolayers of AlAs:O:Fe/InAs. It should be noted that the presence of Fe as an additional deep level impurity can be provided relative to any of the embodiments of this invention. Note that the controlled introduction of oxygen from an oxide source is suitable for this embodiment. In order to incorporate high levels of active Fe, specific growth conditions are required such as, for example, higher growth temperatures. These conditions are not necessarily consistent with the incorporation of high levels of oxygen from the background. Thus, intentional oxygen doping can enable simultaneously high levels of both active Fe and O in the current blocking layers. Boundary layer 34 B may be comprised of InP, InGaAs or InGaAsP and O-doped and undoped (unintentionally doped) or n-doped or combinations thereof, and boundary layer 36 B may be comprised of InP, InGaAs or InGaAsP and O-doped and undoped (unintentionally doped) or n-doped or p-doped or combinations thereof.
Reference is now made to the fifth embodiment shown in FIG. 5 illustrating active semiconductor device 10 E. This embodiment is the same as the previous embodiment of FIG. 4 except that a pair of current blocking layers 40 and 42 is employed and upper boundary layer 36 A may be n-InP or n-InP:O where the latter prevents indiffusion or out-diffusion of impurities or crystal point defects. In the case here, one of the two layers 40 and 42 carries more Al content than the other layer in a set of layers 40 , 42 . For example, layer 40 may be comprised of In x Al 1−x As:O and layer 42 comprises In y Al 1−y As:O where x>y and preferably x may be greater than about 0.5 (Al-rich). The Al-rich alloy layer 40 provides for heightened concentration of oxygen in the grown crystal while the In y Al 1−y As layer 42 provides strain balance or lattice matching to InP substrate 12 . Note that either layer 40 or 42 may be Al-rich. Furthermore, it is only critical that the Al-rich layer be oxygen doped. Thus, in the case here, layer 42 need not be doped.
In the sixth embodiment shown in FIG. 6 , device 10 F is the same as that device shown in FIG. 5 except that there are multiple Al-rich alloy layers 40 interposed with other Al containing layers 42 . For example, alternate layers 40 may be comprised of In x Al 1−x As:O and alternate layers 42 are In y Al 1−y As:O where x>y and preferably x may be greater than about 0.5. These layers are preferably pseudomorphic or strain compensated. Such a current blocking layer combination provides a high resistance, SI-region with very little current leakage.
In both embodiments of FIGS. 5 and 6 , layers 40 and 42 are very thin layers. The InAlAs layers 42 provide for strain balance or compensation relative to the Al-rich layers 40 that will not be lattice matched to InP. Thus, layers 40 and 42 are only grown to a thickness not to exceed the critical thickness, i.e., the thickness does not exceed the point where threading dislocations appear in the material. The strain compensating layers 42 relax the lattice strain brought about by the lattice mismatched, Al-rich layers 40 . As an example, the strain compensating layers 42 may be In 0.7 Al 0.3 As: and the Al-rich layers 40 may be In 0.3 Al 0.7 As:O. The thickness of layers 40 , 42 may roughly be in the range about 30 Å to about 1,000 Å, depending upon their compositional mole fractions of the layer constituents.
As stated previously, only the Al-rich layer or layers 40 are required to be O-doped. Furthermore, the position of layers 40 and 42 may be interchanged. Also, in the embodiment of FIG. 6 , spacer layers are arbitrary lattice matched or pseudomorphic material may be placed between each pair of layers. Note that in the employment of FIG. 6 , Fe-doping may be utilized in the Al-rich or Al-poor layers 40 and 42 , respectively, for enhanced current blocking characteristics, i.e., In x Al 1−x As:O:Fe and/or In y Al 1−y As:O:Fe. In this connection, it should be further noted that not all of the layers need to have the same Fe-doping level. For example, it may be desirable to have the outmost layers free of Fe. A further extension of the embodiments of FIGS. 5 and 6 is to utilize InAlGaAs layers for InAlAs layers 40 and 42 . Note that the lower Al-content layers, such as layers 42 , may contain no aluminum all; for example, they may be InGaAs.
FIG. 7A illustrates a further embodiment of the structure shown in FIG. 3 except in active semiconductor device 10 G of FIG. 7A , multiple alternate layers are employed where layers 44 may be InAlAs:O or InAlAs:O:Fe and layers 46 may be InAlAs:O or InAlAs:O:Fe. In this example, the Fe-doped layers may or may not be co-doped with oxygen. Also, Fe may be placed with any deep-level mobile impurity. Furthermore, the Group III-V alloy that is Fe-doped may be InP, InGaAs, InGaAsP or InAlGaAs beside InAlAs. The purpose of the oxygen co-doping is to retard the movement of deep-level impurities and/or enhance the current blocking capabilities of the layers. The adjacent O-doped layers serve to further impede any out-diffusion or in-diffusion of impurities into the Fe or other deep-level impurity doped blocking layer. In this respect, a preferred embodiment would be to utilize InAlAs:O boundary layers that bound a core comprising an InAlAs (or InP):Fe layer or an InAlAs (or InP):Fe:O layer. This device 10 H is shown in the modified embodiment of FIG. 7B relative to core layer 44 . Note that it may be possible to omit the upper layer 46 above layer 44 or, alternatively, layer 36 A or both layers 44 and 36 A. One could omit one or both of these layers provided that out-diffusion or in-diffusion to or from p-InP layers 32 or 18 is not problematic.
Also, in order to eliminate upper boundary layer 36 A, layer 44 (or layer 46 , if present) should not contain sufficiently high Al content to form a “hard” oxide upon exposure to O-doping, as previously described. An example of this embodiment is device 101 shown in FIG. 7C where layer 44 is InP:Fe or InP:Fe:O.
In any of these embodiments shown in FIGS. 7A , 7 B or 7 C, InAlGaAs may be substituted where InAlAs is utilized in layers 44 or 46 . Also, in connection with these layers 44 or 46 , there may be ten or more alternating layers of InAlAs: Fe[O] and InAlAs:O. Furthermore, layers 44 may be Al-rich layers such as (Al x Ga 1−x ) y In z As:Fe[O] and layers 46 are Al x′ Ga y′ In z′ As:O where x>x′. Optionally, layers 44 may also be co-doped with an n- or p-type impurity or impurities.
FIG. 8 illustrates a further embodiment comprising active semiconductor device 10 J where the current blocking layers in device 10 J are modulated alloy layers 48 which may be alternating layers or alternating monolayers of AlAs:O/InAs or AlGaAs:O/InAs or InAlGaAs:O/InAs. It is desirable to utilize these layers where high oxygen content is required. Thus, not all O-doped layers in device 10 J need to contain these alternating layers. Also, any of these layers may also be doped or co-doped with Fe.
FIG. 9A illustrates a further embodiment comprising active semiconductor device 10 K where the current blocking layers do not contain an Al-content layer as is the case of all of the previous embodiments. In the case here, the non-Al containing material comprises InP doped with oxygen, The bond of oxygen atoms to InP, however, is not as strong as the bond of oxygen atoms with aluminum atoms in Al-III-V compounds. As a result, the insulating properties are not as good either, i.e., the achievable resistivity will not be as high. However, these O-doped layers may still provide reasonable ability for impeding the out-diffusion or in-diffusion of impurities or crystal point defects. Such a device 10 K has utility where Al-III-V compounds are not desired in the fabrication of the active semiconductor device.
Active semiconductor device 10 K comprises a current blocking region 50 of oxygen doped InP:O or InP:O:Fe sandwiched between blocking current confinement layers 34 A and 52 respectively comprising n-InP and n-InP or n-InP:Fe. It should be noted that bottom boundary layer 34 A is optional. Moreover, upper boundary layer 52 can also be doped with Fe to provide additional resistance to current flow in combination with current blocking layer 50 . Also, since layer 50 is doped with O, the out-diffusion of Fe into the layers in mesa 28 will be minimized. Alternatively, one can utilize InP:O boundary layers to impede the out-diffusion of sandwiched Fe-doped layers. Such a modified structure is shown in FIG. 9B comprising active semiconductor device 10 L. In the structure here, layers 50 are InP:Fe or InP:Fe:O and outer layers 49 and 53 of the blocking region are InP undoped or n-doped. These outer layers 49 and 53 are optional. Layers 51 of InP:O are also optional in the case where layer 50 is co-doped Fe:O. In any case, the boundary layers 51 of doped O-InP help prevent the out-diffusion of Fe from layer 50 .
The foregoing embodiments are oxygen doped preferably with a low vapor pressure oxide source, such as DEALO. It is also possible to prepare the oxygen-diffuse current blocking layers by means of the wet oxide approach as mentioned in the background section or from a deposited layer comprising an oxide layer as a diffusion source for oxygen to form a native oxide. Embodiments employing these types of sources for semiconductor active devices are illustrated in FIGS. 10–12 .
In FIG. 10 , active semiconductor device 10 M is similar to the structure shown in FIG. 3 except that the oxygen doping of Al-containing, current blocking layer 30 is brought about by native oxide diffusion. In the case here, at least after the deposition of cladding layer 32 of p-InP in the second epitaxial growth process, trenches 60 are formed by selective etching after which a wet-oxidation process is applied, as is known in the art. Then, as taught in U.S. Pat. No. 5,262,360 to Professor Holonyak and associates and other later patents dealing with this process, which patent is incorporated herein by their reference, a wet oxide process is conducted, such as by bubbling nitrogen through H 2 O. As a result, layer 30 is transformed into its native oxide by lateral diffusion via trenches 60 . Core layer 30 may, for example, be InAlAs, AlGaAs or AlAs.
Reference is now made to the embodiment shown in FIG. 11 comprising active semiconductor device 10 N which comprises a substrate 12 of n-InP upon which is deposited in a first growth process the following layers: n-InP buffer layer 13 ; confining layer 14 A of n-InAlAs or n-InAlGaAs; active region 16 , such as InGaAsP or multiple quantum wells and barriers of InGaAsP; confining layer 18 A of p-InAlAs or p-InAlGaAs; and InP layer 70 to protect the underlying Al containing layer 18 A from oxidation when the device is removed or otherwise exposed to the ambient prior a second growth process. The surface of the wafer containing device 10 N is then covered with a SiO 2 or SiN x mask layer, which is patterned via photolithography as is known in the art. The exposed portions of the photolithographic pattern are removed and an etching process is performed in the exposed regions to produce troughs 60 , as in the case illustrated in FIG. 10 , employing an anisotropic dry etching process such as reactive ion etching (IRE) or plasma enhance reactive ion etching (PE-IRE), forming a ridge or mesa structure 28 A (comprising epitaxial layers 14 A, 16 and 18 A), as shown in FIG. 11 . This is followed with the performance of the second epitaxial growth process and the deposition of current blocking layer 77 comprising a Al-containing layer, such as, for example, InAlAs, followed by the epitaxial growth of protection layer 72 of InP, cladding layer 74 of p-InP and cap or contact layer 76 of p ++ -InGaAs. Layer 77 can be a Al-rich InAlAs layer where the Al content in the layer is greater than 0.5 mole fraction. Next, trenches 71 are formed in the regions of the second growth between mesas 28 A of adjacent devices 10 N in the wafer employing a mask and selective etching process as known in the art. This is followed by the formation of an oxide source layer 78 on InAlAs layer 77 , such as SiO 2 or spin-on-glass (SOG) which is deposited in troughs 71 employing sputter or other such process to form this layer on the side surfaces of troughs 71 . This is followed further by a heat treatment process where an oxide diffusion is generated from layer 78 forming an oxide of InAlAs in layer 77 . The temperature of such a process may be, for example, around 750° C. This oxide process may proceed through layer 77 to mesa 28 A. On the other hand, additional control can be achieved by forming Al-rich layer 77 , i.e., more than 0.5 mole fraction of Al, so that the native oxide of layer 77 is readily formed without oxidizing the Al containing layers within mesa 28 A.
FIG. 12 shows the twelfth embodiment of this invention where active semiconductor device 10 P comprises a fabricated planer structure rather than a ridge or mesa structure. In the case here, a n-InP wafer is provided upon which is epitaxially grown the following exemplifying layers: n-InP confining layer 14 , active region 16 such as InGaAsP, a confining layer 18 of InP or InAlGaAs, a group 80 of layers 82 , 84 , 86 respective, for example, of InAlGaAs, InAlAs and InAlGaAs where at least one of these layers is Al-rich for purposes of conversion to a high native oxide content, a p-InP layer 32 and cap layer 22 of p ++ -InGaAs. SiO 2 SiN x layer 24 provides a mask for performing impurity induced disordering (IID) via opening 82 formed in mask 24 A, which opening later receives a metal contact. IID is taught in U.S. Pat. Nos. 4,378,255; 4,594,603; 4,511,408 and 4,639,275, all of which are incorporated herein by their reference. Next, either by trenching or by dicing into chips, the lateral side surfaces of layer group 80 are exposed to an oxide source treatment, as discussed in the preceding embodiments of FIG. 10 or 11 , to form Si-layers through native oxide formation in regions 88 of the group 80 of layers 82 , 84 , 86 via the oxide diffusion 91 . The advantage of the pre-formed IID region 90 is that the diffusion of Zn in this region interdiffuses the Al containing layer constituents, as is known in the art, and functions, in part, as a barrier to oxygen diffusion extending from regions 88 into region 90 , i.e., the oxidation proceeds through regions 88 but not significantly into the interdiffused region 90 because the Al-containing layers 82 , 84 , 86 have been disordered via IID to render region 90 , as disordered, generally more Al-poor compared to non-disordered regions 88 . Thus, region 90 is substantially resistant to oxidation compared to oxidized regions 88 so that region 90 functions as a current channel to active region 16 of device 10 P.
An alternative approach to the IID Zn diffusion region 90 in FIG. 12 is shown in FIG. 13 , where the active semiconductor device 10 Q is the same as device 10 P in FIG. 12 except that selective delta doped regions 90 , such as with zinc delta-doping, are formed relative to each of the layers 82 , 84 , 86 , via masking during epitaxial growth to form a interdiffused region 92 upon subsequent annealing after completion of device growth. Region 92 is substantially resistant to oxidation compared to subsequently oxidized regions 88 because, in region 92 , layers 82 , 84 , 86 have been disordered so that the overall Al content of the disordered layers in this region have low Al content compared to at least one of the same layers in regions 88 . The annealing temperature to form this diffusion may be, for example, around 850° C. This is followed by the oxide diffusion employing, for example, a wet oxide treatment, illustrated at 91 . The conversion to native oxide of layers 82 , 84 , 86 , via the oxide diffusion 91 , will significantly terminate at the interface 94 of these layers formed between regions 88 and region 92 due to the previously preformed IID treatment in region 92 .
While the invention has been described in conjunction with several specific embodiments, it will be evident to those skilled in the art that many further alternatives, modifications and variations will be apparent in light of the foregoing description. For example, instead of InAlAs:O current blocking layers, they can also be comprised of AlGaAsSb or (AlGaIn)AsSb. Thus, the invention described herein is intended to embrace all such alternatives, modifications, applications and variations as may fall within the spirit and scope of the appended claims.
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In photonic integrated circuits (PICs) having at least one active semiconductor device, such as, a buried heterostructure semiconductor laser, LED, modulator, photodiode, heterojunction bipolar transistor, field effect transistor or other active device, a plurality of semiconductor layers are formed on a substrate with one of the layers being an active region. A current channel is formed through this active region defined by current blocking layers formed on adjacent sides of a designated active region channel where the blocking layers substantially confine the current through the channel. The blocking layers are characterized by being an aluminum-containing Group III-V compound, i.e., an Al-III-V layer, intentionally doped with oxygen from an oxide source. Also, wet oxide process or a deposited oxide source may be used to laterally form a native oxide of the Al-III-V layer. An example of a material system for this invention useful at optical telecommunication wavelengths is InGaAsP/InP where the Al-III-V layer comprises InAlAs:O or InAlAs:O:Fe. Other materials for the blocking layers may be InAlGaAs or alternating layers or alternating monolayers of AlAs/InAs. Thus, the O-doped blocking layers may be undoped, impurity doped or co-doped with Fe.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to medical diagnostic systems to provide diagnostic image maps of lumens within the body.
2. Discussion of Prior Art
It is desirable to acquire an indication of the inside of lumens of a body of a subject to diagnose different medical dysfunctions.
X-ray methods bombard the subject with ionizing radiation, and may require addition of contrast agents which are uncomfortable to the subject. While X-ray methods can show blockage, they do not differentiate between different types of tissue which may be blocking the lumen.
Magnetic Resonance methods can differentiate between tissue types better than X-ray, but are relatively slow and expensive. Perhaps the most useful method for tissue differentiation is a visual examination. Unfortunately, this typically requires the surgical removal of tissue for diagnosis.
Currently there is a need for a method of examining the inside of lumens of a subject which provides visible coloration information without surgical excision.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, both as to organization and method of operation, together with further objects and advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawing in which:
FIG. 1 is a simplified block diagram of the present invention employing an MR tracking system used to follow an invasive device in real-time.
FIG. 2 is a simplified block diagram of the present invention employing an RF tracking system used to follow an invasive device in real-time.
FIG. 3 is a schematic representation of a system according to the present invention for the acquisition of a visible spectrum luminal map indicating health of luminal tissue.
SUMMARY OF THE INVENTION
A system for creating 3D tissue maps of a selected lumen within a subject employs an optical spectrum acquisition device in an insertion end of the invasive device, inserted into a lumen of the subject.
The optical spectrum acquisition device operates to create a light beam and directs it to intersect the lumen at several angular displacement θ around the invasive device. The outgoing light beam O is reflected from the lumen wall as a reflected light beam R having a spectrum characteristic of the tissue type at that location of the lumen at the reflection point.
A device locating means is attached to the insertion end of the invasive devce and is tracked by a tracking means, preferably in real time, which passes the location of the device locating means to a look up device.
A rotation sensor measures the angular displacement θ of the irradiating beam and also passes this to look up device 365. It is beneficial to rotate the outgoing beam O to acquire radial measurements before the invasive device moves significantly.
Look up device 365 converts the tracked location of the device locating means 261, and the angular displacement of the irradiating beam to estimate a 3D location of the lumen reflecting the irradiating beam. The look up device also correlates the reflected light spectrum with a known, stored tissue type.
The 3D location and the tissue type are stored in a storage device for later retrieval.
The look up device can also be operated to display the 3D locations and corresponding tissue type as a tissue map on a display according to operator defined input.
A user interface may be incorporated which is operated to receive operator defined input from the operator and provide this input to the lookup device.
In an alternative embodiment, an interferometer device may be connected to the fiber optic cable to receive the reflected light. It will then determine a distance D from the lumen to the optical spectrum acquisition device, thereby allowing accurate measurements of radii and diameter of the lumen at various locations. When this information is provided to the look up device, the 3D location on the lumen reflecting the irradiating beam may be determined, resulting in tissue maps incorporating actual measured lumen diameters. This results in actual 3D maps with tissue types superimposed upon it.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a diagnostic luminal map of the visual characteristics of a lumen wall of a subject.
It is another object of the present invention to provide a luminal map of tissue types from the visual light reflected from an internal lumen wall of a subject.
DETAILED DESCRIPTION OF THE INVENTION
Typically, vascular disease progresses in a somewhat predictable (although usually hidden) manner. Healthy arteries, such as those found in a newborn baby have three well defined layers: the endothelium, media and adventitia. The endothelium is located on the inner surface of the vessel, the media forms the internal structure of the vessel wall and the adventitia defines the outer wall. The endothelium is formed by a porous layer of tissue which is sensitive to the blood moving in the vessel. The adventitia is formed of fibrous material and has the ability to stretch somewhat.
The first step in the progression of arterial disease is the deposition of fatty material in the media layer of the vessel wall. Frequently the location of these deposits is associated with regions of low shear stress associated with vessel bifurcations. These deposits slowly increase in size and cause a thickening of the vessel wall. Because of the pressure of the arterial blood, however, the initial thickening of the wall does not result in a constriction of the internal lumen of the vessel. Rather, the adventitia is stretched and the internal lumen is maintained. At some point in the progression of the disease, however, the adventitia is stretched to its limit and further expansion is impossible. When this occurs, further increases in wall thickening result in a decrease in the caliber of the internal lumen. As the lumen caliber decreases, the local blood velocity increases and damage to the endothelial layer begins to occur. The simultaneous occurrence of a damaged endothelial layer, increased blood velocity and altered flow patterns due to a reduced internal lumen can result in the creation of ulcerations in the vessel wall. If these ulcers become large enough, they can create regions of slow or stagnant flow. Consequently, blood clots can form within the ulcers. Blood clots are not stable, however, and it is possible for portions to break away and become lodged downstream in the vascular system, causing a stroke or heart attack.
There are several variations to the typical progression of arterial disease. For example, if the disease progresses slowly enough, some of the fatty material deposited as a plaque in the wall of the vessel can be converted to a calcified material. Unlike fatty tissue, a calcified plaque is hard and brittle. It is also possible for a plaque to develop its own blood supply, with the formation of microscopic vasculature within the wall of the vessel.
Identification of plaques and differentiation among the types of plaques plays an important role in the diagnosis and treatment of vascular disease. Because they are relatively soft, fatty plaques tend to respond better to mechanical treatment such as balloon angioplasty than brittle calcified plaques. Hemorrhagic plaques, however, respond better to surgical interventions.
Optical spectroscopy has the potential to differentiate the different types of plaques and provide useful diagnostic information. Healthy arterial walls have a smooth pink appearance. Fatty plaques, on the other hand, appear somewhat bumpy and have a yellowish hue. Calcified plaques appear white while hemorrhagic plaques appear red or brownish-red.
Systems for creating a tissue map according to the present invention are shown in FIGS. 1, and 2. These track the real-time location of an invasive device 320, such as a catheter, within a subject 1.
An operator 3, typically a Physician, inserts invasive device 320 into a lumen of subject 1. Invasive device 320 has an element which is tracked by a tracking means. For magnetic resonance (MR) tracking, the tracked element may be an MR coil, or a plurality of MR coils. These coils may be either receive or transmit coils. The tracked element may also be a quantity of a material which is imaged well in an MR image, such as Gadolinium chelate solution.
The tracking means for MR tracking includes a magnet assembly 101 having RF and gradient coils, and system electronics 340. An MR signal is acquired in magnet assembly 101 and passed to system electronics 340 which interpret the signal into a location, or plurality of locations which are tracked in real-time, or near real-time, and displayed on a monitor 380.
In RF tracking, as shown in FIG. 2, the tracked element may be an RF coil, or a plurality of RF coils attached to the invasive device 320. An external coil 201 operates to transmit an RF signal which is received by the RF coils attached to the invasive device 320.
RF tracking system electronics 350 interpret the signals to determine the location and orientation of invasive device 320 in real-time, and display the location on a monitor 380.
In an alternative embodiment, external coil 201 may be a receive coil and the RF coils attached to invasive device 320 may be transmit coils.
In FIG. 3, a system for tissue mapping 300 is shown. Tissue mapping system 300 includes an optical spectrum acquisition device 200 which is intended for the spectral analysis of tissue. An invasive device 320 is shown in a lumen 310 of subject 1. Lumen 310 may be a vessel, intestine, esophagus, stomach, or other opening within the subject to be imaged. This may also include cavities such as the abdominal cavity which are only accessible through an incision.
Invasive device 320, inserted in lumen 310, is tracked by a device tracking means 360 which may be magnetic resonance (MR) tracking, or radio frequency (RF) tracking.
Invasive device 320 may be moved further in, or retracted out of luminal cavity 310, and therefore its displacement D along the luminal cavity can be measured.
A fiber optic cable 240 connects a white light source 330 to an exit port 241. A white light outgoing beam O is passed down fiber optic cable 240, exits at exit port 241, and impinges upon a fixed parabolic mirror 220.
Outgoing beam O is then reflected back to a rotating planar mirror 230. Rotating planar mirror 230 reflects outgoing beam O to impinge on lumen wall 310.
Lumen wall 310 absorbs portions and reflects portions of the white light beam being the return beam R, with its spectrum indicating morphology of lumen wall at the impingement point.
Return beam R is reflected off of rotating planar mirror 230 and fixed mirror 220 and back into port 241. From port 241 it is passed back down fiber optic cable 240.
Return beam R is then passes to a detector 341 which converts the reflected light into an electronic signal which is passed to a spectrum analyzer 353.
Spectrum analyzer 353 determines the spectral content of the electronic signal representing the reflected light spectrum.
A look up device 365 receives the spectral information from spectrum analyzer 353 and correlates this with known, stored, morphological information. For example, if the lumen is a vessel wall and the reflected signal has an amplitude which is high in the yellow frequency band, this may indicate plaque buildup on the inside of the artery. Spectral signals with a high amplitude in the red frequencies may indicate hemorrhaging.
A first device locating means 261 and a second locating means 263 are tracked by conventional MR tracking or RF tracking to determine translational displacement D of invasive device 320. The translational displacement D from tracking device 360 is provided to look up device 365.
Two device locating means are shown 261, 263, however, only one is required to determine the location of invasive device 320. By using two device locating means, the orientation of invasive device 320 may also be determined.
A rotation sensor 395 determines the angular rotation θ of fiber optic cable 240, and therefore the angular displacement θ of rotating mirror 230 and the optical beam. Angular rotation θ from rotation sensor 395 is also provided to look up device 365
The morphology information is then associated with the translational displacement D and angular displacement θ of the optical beam in a look up device 365 to create a morphology map in three dimensions. The 3D morphological map may then be stored in a storage device 370 for later retrieval.
Operator 3 may interact with a user interface 390 to request images of portions of lumen 310. Operator 3 may also specify how to view lumen 310, and set the viewpoint from which it is to be viewed.
Images may be color coded to distinguish between different tissue morphology. Look up device 365 receives the user defined input and provides images on a display 380 to operator 3.
Operator 3 may manually rotate or move invasive device 320 to acquire information and images of different portions of lumen 310.
In an alternative embodiment, a detector 341 is a conventional interferometer which receives the reflected light beam R.
If it is desired to measure distance between rotating mirror 230 and the lumen wall 310, light source 330 should have a monochromatic output and detector 341 should be an interferometer. Instantaneous distances can then be determined. The measured distances would be provided to look up device 365, and stored with the other information in storage device 370. This would provide radii and diameters at different locations in subject 1. This would allow look up device 365 to create 3D maps of the lumen. These maps may be used alone, or to supplement the morphology maps.
Another alternative embodiment would pass a clear fluid through the inside of invasive device 320 when the optical beams are operating and the system is acquiring data. The fluid would squirt through a plurality of ports 235 in invasive device 320 to facilitate transmission of the outgoing and reflected beams when the lumen is full of a fluid which attenuates or scatters light. For example, if invasive device 320 was inserted into a vessel of subject 1, sterile saline solution could be squirted through ports 235 to temporarily displace blood in a local region allowing transmission of the optical beam. This would greatly facilitate beam transmission and produce more accurate morphology maps.
The present invention may be employed for a number of different diagnostic procedures. For example, invasive device 320 may be used to determine the biochemical makeup of a blood vessel wall within a living patient. Other embodiments of the present invention could be used to diagnose abnormal tissue in the walls of other body structures such as the colon, small intestines, stomach or esophagus. It should be noted, however, that the present invention could also be employed in non-medical application if desired.
The present invention can also employ ultra-violet, visible, or infra-red light.
In still another embodiment, fluorescent tracers which accumulate in specific types of tissue may be used. The present invention can then easily accurately map the tissue by monitoring the fluorescence.
Conventional spectroscopy methods, such as Raman Spectroscopy, may be employed with the present invention.
While several presently preferred embodiments of the novel invention have been described in detail herein, many modifications and variations will now become apparent to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and variations as fall within the true spirit of the invention.
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An invasive probe for determining the morphological characteristics of walls of a lumen employs a real-time tracking means and an optical spectral measurement means. As the probe is advanced within the lumen, the real-time tracking means provides three-dimensional coordinates of the probe's position and orientation. Concurrent with probe localization, measurement of the spectral properties of the lumen wall are made by detecting the reflectance and/or absorption of light at the lumen wall. Both the probe position and the spectral measurement are sent to a data acquisition system which in turn provides an graphic or numeric display to the operator. Probe tracking can be performed with radio-frequency, magnetic resonance, ultrasonic techniques or the like. If desired, spectral measurements can be made in the visible, ultra-violet or infra-red spectral bands to provide optimized detection of chemical species of interest.
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This invention was made with Government support under contract F33615-92-C-2258 awarded by the Department of the Air Force, Air Force Systems Command. The Government has certain rights in the invention.
This application is a division of application Ser. No. 08/134,429, filed on Oct. 8, 1993, now U.S. Pat. No. 5,393,617.
FIELD OF THE INVENTION
The present invention relates to a packaging method, electrode formulations, and fabrication techniques for making electrochemical cells and multi-cell batteries. In particular, this invention relates to electrochemical cell constructions useful for rechargeable bipolar battery structures that have a high energy storage capacity and that are capable of many recharging cycles without substantial deterioration of the battery's performance. More specifically, this invention relates to flat nickel and metal hydride electrode structures and methods of making nickel and flat metal hydride electrode structures that are capable of being stacked in a multi-cell battery construction.
BACKGROUND OF THE INVENTION
Multi-cell batteries that are constructed in a broad range of electrochemical systems are typically packaged in cylindrical or prismatic housings. Individual cells are connected in series by conductive links to make the multi-cell batteries. Such construction approaches provide for good sealing of the individual cell compartments and for reliable operation. However, such constructions allocate a large fraction of the multi-cell battery's weight and volume to the packaging and, thus, do not make full use of the potential energy storage capacity of the active components of the cell. For improving battery energy storage capacity on a weight and volume basis, packaging approaches are sought that reduce packaging weight and volume and that provide stable battery performance and low internal resistance.
These objectives have led to the pursuit of a bipolar construction in which an electrically conductive bipolar layer serves as the electrical interconnection between adjacent cells as well as a partition between the cells. In order for the bipolar construction to be successfully utilized, the bipolar layer must be sufficiently conductive to transmit current from cell to cell, chemically stable in the cell's environment, capable of making and maintaining good electrical contact to the electrodes and capable of being electrically insulated and sealable around the boundaries of the cell so as to contain electrolyte in the cell. These requirements are more difficult to achieve in rechargeable batteries due to the charging potential that can accelerate corrosion of the bipolar layer and in alkaline batteries due to the creep nature of the electrolyte. Achieving the proper combination of these characteristics has proved very difficult.
For maintenance-free operation it is desirable to operate rechargeable batteries in a sealed configuration. However, sealed bipolar designs typically utilize flat electrodes and stacked-cell constructions that are structurally poor for containment of the gases present or generated during cell operation. In a sealed cell construction, gases are generated during charging that need to be chemically recombined within the cell for stable operation. To minimize weight of the structures used to provide the gas pressure containment, the battery should operate at relatively low pressure. The pressure-containment requirement creates additional challenges on designing a stable bipolar configuration.
Despite a number of patents and considerable effort at making a bipolar construction for the lead-acid and nickel-cadmium systems such batteries are not commercially available, (U.S. Pat. No. 4,098,967). Construction of a flat metal hydride battery is even more difficult because many of the metal hydride alloys used to make metal hydride batteries operate at elevated hydrogen pressures.
The bipolar construction has been successfully employed in the flat plate construction of the Leclanche MnO 2 --Zn system as a primary battery, U.S. Pat. No. 4,098,965. Since a primary battery is non-rechargeable, the materials-stability problem is less severe and the aqueous chloride electrolyte may be contained without unreasonable difficulty.
Another problem of prior art electrochemical cells relates to the material problems encountered with metal hydride electrodes. Electrochemically reversible metal hydride electrodes operate by the absorption of hydrogen in the lattice of the metal hydride alloy during electrochemical charging of the cell. A number of alloy formulations have been identified of the so-called AB 5 and AB 2 structure that can function in this manner, for example, as disclosed in U.S. Pat. Nos. 4,487,817 and 4,728,586. To insure reasonable rates of reaction and transport of hydrogen, such electrodes may be prepared from alloy powders typically having an average particle size of about 50 microns. Fabricating an electrode structure from the alloy powders may be accomplished by sintering the metal powders or by using polymeric binders. However, conventional techniques do not yield electrodes that make good and stable contact to the cell face of the conductive outer layer in a bipolar construction. Metal hydride alloys can fragment during repeated cycling as the alloy undergoes expansion and contraction each time the hydrogen enters and leaves the lattice. It is also recognized that oxygen and or the electrolyte can react with the hydride alloy and cause deterioration of the hydrogen storage capacity of the hydride alloy.
The present invention provides a method for achieving the packaging benefits of bipolar construction for rechargeable multi-cell batteries and of overcoming the materials and construction problems of previous approaches. Although the materials of construction for each type of cell are specific to each battery chemistry, the generic bipolar construction disclosed herein may be used for many types of electrochemical cells. In particular, the descriptions and approaches that follow relate specifically to the rechargeable nickel-metal hydride chemistry but may generally be adaptable to other chemistries.
ADVANTAGES AND SUMMARY OF THE INVENTION
An object of the present invention is to provide a bipolar battery construction for rechargeable multi-cell batteries that overcomes the above-cited problems of prior art bipolar constructions.
More specifically, an object of the present invention is to provide bipolar designs that have improved energy storage capacity while still providing stable and efficient battery performance.
Another object of the present invention is to provide bipolar battery constructions using flat electrochemical cells having a sealed configuration.
Still another object of the present invention is to provide bipolar battery constructions wherein metal hydride electrodes may be used.
Yet another object of the present invention is to provide improved metal hydride electrode structures.
Still another object of the present invention is to provide a method of preparing flat metal hydride structures that may be used in rechargeable bipolar battery constructions.
These and still other objects, benefits and advantages may be achieved by making a bipolar electrochemical battery comprising:
a stack of at least two electrochemical cells electrically arranged in series with the positive face of each cell contacting the negative face of the adjacent cell, wherein each of the cells contains
(a) a metal hydride electrode;
(b) a nickel electrode;
(c) a porous separator between the electrodes, wherein the separator contains an electrolyte;
(d) a first electrically conductive outer layer in electrical contact with the outer face of the metal hydride electrode; and
(e) a second electrically conductive outer layer in electrical contact with the outer face of the nickel electrode; wherein the outer layers are sealed peripherally to an electrically non-conductive polymeric material such as to form a sealed enclosure containing the electrodes, the separator and the electrolyte.
The present invention further relates to a method of making electrodes comprising:
dry mixing a combination of an electrochemically active material and polytetrafluoroethylene particles in a blending mill to form a mixture;
dry rolling the mixture into a thin layer;
dry kneading the thin layer by sequentially folding and rolling the thin layer such that the polytetrafluoroethylene particles form an interconnected network in which the electrochemically active material is embedded;
calendaring the folded and rolled thin layer to form a substantially flat porous sheet; and
cutting a substantially flat electrode from the porous sheet.
Further objects and advantages of the subject invention will be apparent to those skilled in the art from the following detailed description of the disclosed bipolar electrochemical battery and the methods for producing bipolar electrochemical batteries, and to the metal hydride electrodes used therein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an overview of a wafer cell.
FIG. 2A shows a three-dimensional view of a multi-cell stack of wafer cells and FIG. 2B shows a two-dimensional side view of a multi-cell stack of wafer cells.
FIG. 3 shows a side view of a sealed battery housing.
FIG. 4 shows a side view of a sealed battery housing containing a hydraulic fluid.
FIG. 5 shows a side view of a multi-electrode configuration in a single wafer cell.
FIG. 6 shows a wafer cell having a back side oxygen recombination arrangement.
FIG. 7A shows the strip chart recording of the cell voltage of cell #113 for cycle numbers 104, 112, 242, 250, 368 and 376.
FIG. 7B shows the strip chart recording of the cell voltage of cell #113 for cycle numbers 480, 488, 608, 616, 680 and 688.
FIG. 8 shows the strip chart recording of the cell voltage of cell #121 for cycle numbers 4, 5, 128, 136, 288 and 296.
FIG. 9 shows the strip chart recording of the cell voltage of cell #144 for cycle numbers 101, 102, 103, 942, 943,944, 1509, 1510 and 1511.
FIG. 10 shows the strip chart recording of the cell voltage of cell #134 for cycle numbers 168, 176, 296, 304, 408 and 416.
FIG. 11 shows the strip chart recording of the cell voltage of cell #170 for cycle numbers 98, 99, 100, 298, 299, 300, 398, 399 and 400.
FIG. 12 shows the strip chart recording of the voltage of a stack of five cells for cycle numbers 2 and 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the following description of preferred embodiments of the present invention is intended to provide detailed instructions that would enable one of ordinary skill in the art to practice the invention, the scope of the invention is not to be limited to the scope of the specific product or process details hereinafter provided.
The bipolar electrochemical battery of the subject invention first involves preparing a single electrochemical cell. FIG. 1 shows a schematically illustrative embodiment of a wafer cell 1 comprised of a pair of electrodes contained between two conductive, carbon-filled outer layers 2 and 3 that make electrical contact to the positive and negative electrodes, 4 and 5, respectively. The electrodes are prevented from coming into direct physical electrical contact by a separator 6 that typically is porous so as to contain an electrolyte. The electrolyte typically comprises an aqueous solution of one or more alkali hydroxides such as lithium hydroxide, sodium hydroxide and potassium hydroxide. The separator material typically comprises synthetic resin fibers such as polyamide or polypropylene fibers. In order to enhance the electrical contact, a conductive paste or cement may be used between each of the carbon-filled outer layers and the respective electrode with which it is in contact. In the preferred embodiment of the present invention, the negative electrode 5 is a bonded metal hydride alloy powder that can electrochemically and reversibly store hydrogen. Such alloys may include materials disclosed in U.S. Pat. Nos. 4,487,817 and 4,728,586 but the subject invention is not limited to the formulation of materials disclosed therein. These alloy formulations may include what are commonly referred to as Mischmetal hydride alloys, which may be comprised of an alloy of hydride-forming metals such as MnNi 3 .5 Co 0 .7 Al 0 .83. The positive electrode 4 of the present invention is preferably what is typically referred to as a nickel-type electrode, or more simply, as a nickel electrode. Nickel hydroxide is the active component of a nickel electrode. Prior art nickel electrodes are illustrated in German Patent No. 491,498 and British Patent No. 917,291.
As indicated in FIG. 1, the preferred construction of the present invention comprises an electrochemical cell wherein the electrodes, the separator between the electrodes and the two outer layers are each substantially flat and in tight physical and electrical contact with the adjacent component. The design illustrated in FIG. 1 permits construction of a thin cell that is referred to herein as a wafer cell.
In order for the electrodes, the separator between the electrodes and the electrolyte to be contained within an enclosed wafer cell, the flat outer layers 2 and 3 have a larger physical area than the electrodes, such that each outer layer extends beyond the electrode around the entire perimeter of the adjacent electrode. A non-conductive material 7 may be sealed peripherally to the outer layers to form a border material around the entire perimeter of the electrodes such as to form a sealed enclosure containing the pair of electrodes, the separator and the electrolyte within the wafer cell. The border material is preferably of a polymeric material that may be heat sealed to the outer layers. The polymeric material of the subject invention is preferably a vinyl polymer.
The enclosed wafer cell may be completely sealed or it may be provided with vents for release of excess pressure that may build up in the cell during charging. Since the flat cell construction is a poor physical configuration for a pressure-containment vessel, the use of hydride alloys that operate at atmospheric pressure are preferred. If a completely sealed configuration is used, a design that is electrochemically limited by the capacity of the positive electrode is preferred. For this type of design, oxygen gas is generated at the end of the charging cycle at the positive electrode before the total available hydrogen storage capacity of the hydride electrode is fully utilized. Oxygen produced at the positive electrode may migrate to the negative hydride electrode and chemically recombine with the hydrogen in the hydride electrode so as to help prevent excessive build-up of pressure. The chemical recombination of oxygen and hydrogen is referred to herein as the oxygen recombination reaction.
The present invention further relates, as described in more detail hereinafter, to providing means for enhancing the migration of oxygen gas to the negative electrode and for promoting efficient chemical recombination of the oxygen with hydrogen at the hydride electrode surface. In addition to helping prevent excessive hydrogen build-up, the efficient migration and removal of the oxygen by chemical recombination with hydrogen also helps reduce the tendency for deterioration of the negative hydride electrode by oxidation after many charging cycles.
The separator between the electrodes typically has a porous structure for absorbing and containing the electrolyte within the cell. In a preferred embodiment of the present invention the separator is comprised of two layers of non-woven nylon and the electrolyte is comprised of an alkaline solution. Preferably the alkaline electrolyte is a mixed hydroxide of potassium and lithium hydroxide. The separator extends beyond the edge of the electrodes so as to prevent direct electrical contact between the electrodes.
The individual electrodes each may be connected to current collectors for carrying current between the adjacent cells. Preferably, the current collectors are not necessary since the current path between adjacent electrodes is relatively short and the area of physical and electrical contact between the adjacent cells is large relative to the total area of the adjacent components. In addition, the electrodes are typically conductive enough for cell operation without having current collectors that add weight and complexity to the cell.
FIG. 2A and FIG. 2B show a multi-cell battery 8 made by stacking several wafer cells 1. The wafer cells are electrically arranged in series with the positive face of each cell contacting the negative face of the adjacent cell. The end cells have metal foil contacts, 9 and 10, respectively, to conduct the electric current from the battery stack to the battery terminals. The cell-to-cell contact or the contact between the end cells and the metal foil contacts may be enhanced by use of a conductive paste or cement. The compact stack assembly is held in compression to insure uniform physical contact between the adjacent cells and between the respective layers within each cell, The stack compression can be achieved by means of ridged end plates 11 and 12 having external tie rods 13 and 14 wrapped around the perimeter of the stack, as shown in FIG. 2B, or by having internal tie rods 16, as shown in FIG. 3, that penetrate through sealed holes provided in the individual electrochemical cells. The holes are sealed such as to prevent electrical contact between the tie rods and the electrically conductive components of the cell.
Alternatively, the stack may be contained in an outer battery housing that serves as the battery housing 8. To allow for electrode expansion and irregularities in the stack, the stack may beheld in compression by means of a layer of sponge rubber 15 between one or both of the metal foil contacts 9 and 10 and the end plates, 11 and 12, respectively, of the outer housing. FIG. 2B is shown with only one layer of sponge rubber, 15. Alternatively, a spring or a gas-filled compressible pad may be used instead of the sponge rubber. If the cell stack is contained in an enclosed outer housing, the outer housing can serve to provide stack compression and the housing may be sealed or vented.
FIG. 3 shows an embodiment of the invention in which multiple cells each have small vent ports 17 and the cells are contained in a sealed container which serves as the battery housing 8. The battery housing can be provided with a pressure measuring device. Such a device may be a pressure gauge, a transducer and/or a pressure switch 19. The pressure measuring device may be used for monitoring the battery pressure and for regulating the magnitude and duration of the charging current during the charge cycle. Such regulation of the charging current is herein referred to as charge control. The stack may contain internal tie rods 16 to insure uniform compression and contact over the entire plane of the cells. The sealed container may have a pressure relief valve 18 to vent internal gases. The individual wafer cells 1 may be made according to the methods disclosed herein and the remaining components shown in FIG. 3 may be made using known methods or obtained from supply sources known to one skilled in the art.
FIG. 4 shows a similar arrangement as above in which the individual cells are sealed in an outer housing 8 and the void space around the cells is filled with an electrically non-conductive fluid 20. The fluid may be one of many different hydraulic fluids than are known and available. The outer housing contains a pressure switch and/or a pressure indicator 21. If gas pressure is generated within any cell, the cell envelope expands slightly and exerts pressure on the fluid. Since the fluid is non-compressible, the pressure is transmitted to the pressure switch which can be used for charge control. This technique provides for individual sealed cell operation and allows for the first cell that generates pressure to control the battery charge. This avoids reaching an excessive pressure in any cell and eliminates formation of a gas or a liquid interface between individual cells during operation.
FIG. 5 shows an embodiment of a single wafer cell that contains multiple electrodes to increase cell capacity and/or electrode area. In this case the positive and negative electrodes, 4 and 5, respectively, contain current collectors, 22 and 23, respectively, which are folded to provide electrical contact with the entire surface of each electrode.
FIG. 6 shows an embodiment of a single wafer cell having an improved means for chemically recombining the oxygen gas produced during sealed cell operation. In this case, there is a porous spacer 24 between the back side of the hydride electrode and the conductive, carbon-filled outer layer. The spacer is electrically conductive so as to provide electrical contact of the electrode with the cell face. Preferably, the spacer is porous graphite paper. This back side recombination configuration provides a path 25 for migration of oxygen to the back side of the hydride electrode where it can recombine with the hydrogen. The back side of the hydride electrode can be wet proofed and/or provided with a catalyst to enhance oxygen recombination. Wet proofing may be carried out using known methods for increasing the hydrophobic nature of the surface. The catalysts may be selected from those known to enhance the oxygen recombination reaction. The porous spacer can also be wet proofed and/or provided with a catalyst to enhance the recombination reaction. These approaches can increase the rate of cell overcharge and keep the cell pressure at acceptable levels during overcharge. The back side recombination configuration allows for use of dense separator materials and an increased quantity of electrolyte in the separator since the oxygen generated during overcharge has an alternative path to reach the negative electrode and thereby prevent excessive oxygen build-up.
Another important aspect of the subject invention relates to a method for the fabrication of electrodes and to techniques for insuring good electrical contact of the active electrodes with the conductive cell faces of the wafer cell and with the electrolyte. In particular, an electrode fabrication method is herein disclosed in which an electrochemically active material is held together with a fibrous lace-like network of a polymeric binder. The term "electrochemically active material" is a term that would be readily understood by one of ordinary skill in the art. In particular, the term relates to materials that may be used as the active component in an electrode of an electrochemical cell. Such materials typically comprise a metal or a metal-containing material that readily participates in an electrochemical reaction. For example, for alkaline storage batteries, the electrochemically active material used in the positive electrode may be made from the oxides or hydroxides of nickel, silver, manganese, copper or mercury, and from oxygen. The electrochemically active material used in the negative electrode of an alkaline storage battery may be fabricated from various geometric forms of cadmium, iron or zinc and from hydrogen. Preferably, the electrochemically active material of the negative electrode of the subject invention comprises a metal hydride alloy powder. Metal hydride alloy powders are well known in the art and such powders are readily available from known commercial suppliers. Preferably, the metal hydride powders comprise particles having an average particle size from about 20 to about 50 microns. Most preferably, the metal hydride particles have an average particle size of about 50 microns.
As an example of a preferred embodiment of the subject method, a combination of a metal hydride alloy powder and a powder of the polytetrafluoroethylene polymer known as Teflon® is first dry mixed in a high speed blending mill. The mixture is rolled into a thin layer and the layer is then dry kneaded by sequentially rolling and folding in a shearing action that causes the discrete Teflon® binder particles to fibrillate into a fibrous, lace-like network that has a cohesive structure. The subject invention is directed to the discovery that by sequentially folding and rolling a layer including Teflon® particles, wherein the direction of the folding and rolling is turned about 90 degrees from the direction of the immediately preceding step, a continuously interconnected, fibrous and lace-like structure can be produced in a manner such as to form a cohesive structure in which the electrochemically active particles are embedded. The subject invention is specifically directed to the discovery that Teflon® particles are particularly suitable for use in forming this fibrous, lace-like structure. After the mixture is sufficiently worked by the folding and rolling steps, it is then calendared to the desired electrode thickness.
The subject method differs from that described in U.S. Pat. No. 3,898,099 in that the subject method uses Teflon® having a finer particle size and, furthermore, the subject method is a dry method that is accomplished without a lubricating fluid. In particular, the particle size of the Teflon® powder is preferably less than about 20 microns. Using this dry method it is possible to prepare cohesive porous sheets of a metal hydride powder with unexpectedly small quantities of the Teflon® binder in the range, for example, of about 0.5 to about 5 weight percent. This quantity of binder is sufficient to prepare battery electrodes that do not disintegrate during operation. A significant feature of the subject method is that small quantities of binder may be used without the binder completely overcoating the electrochemically active material as happens with other solvent-binder methods. The subject method results in achieving the two competing objectives of providing particles that have good inter-particle contact and of producing particles that are capable of being uniformly wettable with the electrolyte. The subject dry-processing method eliminates the hazard of a working fluid and, thus, eliminates the need to remove the working fluid from the electrode strip before assembly of the electrode in the cell.
Even though this method yields a bonded porous sheet of good structural integrity, metal hydride electrodes fabricated in this manner still perform very poorly due to poor particle-to-particle electric contact as a result of an oxide film that is typically present on hydride powders. It was discovered that incorporation of additive particles such as cupric oxide powder into the mixture can overcome this problem. Although the theory of how the additive particles of cupric oxide improve the cell performance has not been confirmed or proven, it is believed that the improvement is provided in the manner as described below. The scope of the subject invention is, however, not to be limited to the theory hereinafter described.
Cupric oxide is slightly soluble in the alkaline electrolyte used in the cell. By allowing the electrode containing the cupric oxide particles to soak in the electrolyte prior to the first charge cycle, the cupric oxide may enter into solution. During the first charge cycle of the cell the cupric oxide in solution and in the pores of the electrode may be electrochemically reduced and converted to metallic copper. It is believed that the metallic copper deposits on the metal hydride particles throughout the electrode structure as well as on the interface between the electrode layer and the conductive outer layer, such that an interconnected metallic copper layer is produced throughout the electrode structure. If properly and uniformly deposited, the interconnected metallic copper layer would not be expected to retard the metal-hydrogen reaction at the hydride surface, but could create a conductive network that would improve the overall electrical integrity of the electrode structure and, thus, its conductivity. The interconnected metallic copper layer produced in this manner may be formed uniformly throughout the porous electrode structure, but the metallic layer is preferably present only to the extent required to give adequate electrical contact throughout the electrode.
The interconnected metallic-copper layer may also serve as a protective layer to reduce alloy oxidation as well as to enhance the oxygen recombination reaction for sealed cell operation. By enhancing the chemical recombination of hydrogen and oxygen, the incorporation of cupric oxide particles in the electrode, which are converted into an interconnected metallic copper layer, may also assist in balancing the charge of the nickel and the metal hydride electrode for sealed cell operation. Furthermore, the deposited metallic copper layer may also serve as a lower voltage reserve capacity in the metal hydride electrode, if the electrode is discharged completely, thereby avoiding reversal of the metal hydride electrode.
Although the subject method is described in terms of using cupric oxide particles as the additive particles that are believed to be electrochemically converted into an interconnected metallic layer, it is to be understood that other additive particles comprising a material that is capable of being electrochemically converted into a metal layer also fall within the scope of the present invention. The term "additive particles" is herein defined to refer to such particles that are capable of enhancing the electrical contact in the manner described.
Another aspect of the present invention relates to a preparation technique for formulation of the nickel electrode. Nickel electrodes for rechargeable nickel alkaline batteries may be of the sintered, pasted or plastic-bonded type. However, it is necessary that the nickel electrode makes effective and stable contact with the conductive polymeric cell face of the wafer cell. One approach employed herein is, by the dry technique described above, to fabricate a Teflon®-bonded layer from a mixture of nickel hydroxide and graphite and cobalt monoxide and of the Teflon® powder. During the initial electrolyte-soak period a portion of the cobalt monoxide enters into solution and redeposits as a conductive layer at the electrode-conductive polymeric interface. This mechanism is described in U.S. Pat. No. 4,844,999.
The nickel electrode may also be prepared by pasting a mixture of carboximethylcellulose binder ("CMC"), nickel hydroxide and cobalt monoxide in a nickel foam. This pasted, foam-nickel electrode makes good electrical contact to the conductive polymeric face of the wafer cell.
EXAMPLES OF THE INVENTION
Example 1
A single cell was fabricated which consisted of one positive nickel electrode and one negative metal hydride electrode assembled in an arrangement as shown in FIG. 1. The hydride electrode was prepared by blending a mixture consisting of 45 grams of a Mischmetal hydride alloy, 0.5 grams of Teflon® powder and 4.5 grams of CuO. The Mischmetal hydride alloy used herein was comprised of an alloy of Mn Ni 3 .5 Co 0 .7 Al 0 .8. The hydride alloy, received as about 1/8 to 1/4 inch particles, was fragmented by dry pressure hydrating five times between vacuum and 200 psi to produce an average particle size of about 50 microns. The mixture was blended in a high speed blender for two 30-second periods. The mixture was then rolled out to a layer approximately 0.060 inch thick, and then folded and rolled to a 0.060 inch thickness in a direction about 90 degrees from the original direction. The above folding and rolling in the rotated direction was sequentially repeated seven times to a point wherein the Teflon® powder was fibrillated to form a fibrous, lace-like network which contained and bonded the other ingredients. For each step, the folding and rolling was carried out in a direction about 90 degrees from the folding and rolling direction of the immediately preceding step. The strip was then calendared to a final thickness of 0.020 inches. A 3×3 inch electrode, weighing 11 grams, was cut from the strip and assembled in the cell.
The nickel electrode was prepared using a method similar to that described for the hydride electrode. The mixture contained 1 gram of Teflon® powder, 1.5 grams of cobalt monoxide, 15 grams of graphite powder and 32.5 grams of nickel hydroxide powder. The final strip was calendared to a thickness of about 0.040 inches. A 3×3 inch electrode weighing 10 grams was cut from the strip. The electrode was then pressed at about 2,000 psi in a hydraulic press to a thickness of about 0.033 inches prior to assembly in the cell. Two layers of a non-woven nylon separator were placed between the electrodes. The outer layers of the cell were constructed from a conductive, carbon-filled polymeric film manufactured by Graphics Inc. A frame border of non-conductive vinyl polymer was sandwiched between the inner faces of the outer layers and heat sealed on three sides. Nickel foil layers with a thickness of 0.002 inches were placed on the outer faces of the outer layers. The cell assembly was then placed between two rigid acrylic plates which contained peripheral bolts to hold the assembly together. The cell was filled with 30% KOH-1% LiOH electrolyte, allowed to soak for 24 hours and then subjected to three formation cycles. A formation cycle is comprised of 15 hours charge at 150 mA and discharge at 500 mA to 0.8 volts. The cell was life tested on a three-hour cycle, corresponding to two hours of charging at about 0.55 amps and one hour of discharging at about 1 amp. Water was added to the cell to make up for losses. FIG. 7A and 7B show strip chart recordings of the cell voltage of cell #113 at periodic intervals through cycle 688. The results obtained show the cell voltages were surprisingly stable during the charge/discharge cycle for more than 500 cycles.
Example 2
A cell was constructed as above except that the nickel electrode was of the sintered type and was obtained from a commercial supplier. The 3×3 electrode weighed 12 grams and was 0.028 inches thick. The cell was life tested and showed stable cell voltages for more than 200 cycles as shown in FIG. 8 (cell #121).
Example 3
A cell was assembled as described above with the exception that the nickel electrode was of the pasted foam type and the separator was a plastic bonded inorganic pigment. Commercially available electroformed nickel foam obtained from Eltek Inc. was pasted with a mixture consisting of a 1% solution of CMC in water which had been added to a dry blended mixture of 10% cobalt monoxide and 90% nickel hydroxide. After drying, the 3×3 inch electrode was pressed to a final thickness of 0.040 inches. The finished electrode weight was 14 grams. The cell exhibited stable performance for over 1500 cycles as shown in FIG. 9 (cell #144).
Example 4
A cell was assembled as described in Example 1 with a hydride electrode comprised of 19% nickel powder (#210 powder obtained from INCO), 1% Teflon®, and 80% hydride alloy. The cell was life tested and showed stable cell voltages for more than 416 cycles as shown in FIG. 10 (cell #134).
Example 5
A cell was assembled as described in Example 1 with one layer of a an inorganic composite separator material. The quantity of electrolyte was 8 cc and after the 24 hour soak period all excess free electrolyte was drained from the cell. A layer of porous, wet proofed, graphite paper was placed on the back side of the hydride electrode. The cell was assembled between two acrylic plates with a peripheral rubber gasket. The cell was contained in a sealed compartment and operated in the sealed condition. The cell was life tested and showed stable cell voltages for more than 400 cycles as shown in FIG. 11 (cell #170). A pressure gauge connected to a sensor located in the cell compartment showed no indication of pressures above 20 psi during the cycle operation.
Example 6
A stack of five vented cells in an arrangement as shown in FIG. 2 was assembled to make a 6 volt battery. The cell construction was similar to Example 1, except the separator was an inorganic composite material. FIG. 12 shows the discharge voltage of cycle 2 and 5.
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The subject invention relates to electrode structures that are adaptable for primary and electrically rechargeable electrochemical wafer cells. A flat wafer cell is disclosed that includes conductive, carbon-filled polymeric outer layers that serve as electrode contacts and as a means of containment of the cell. Multi-cell, higher voltage batteries may be constructed by stacking individual cells. Specially formulated electrodes and processing techniques that are compatible with the wafer cell construction are disclosed for a nickel-metal hydride battery system. The cell design and electrode formulations provide for individual operation of a vented or low pressure sealed cell and/or for operation of these cells in a stacked array in an outer battery housing.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to and incorporates by reference provisional patent application Ser. No. 60/881,660 filed Jan. 22, 2007.
FIELD OF THE INVENTION
This invention related to cup holders and food trays, particularly including such devices used in motor vehicles.
BACKGROUND OF THE INVENTION
Trays for holding food, beverages, condiments and the like in or on motor vehicles have long been used. Such prior devices do not provide all desirable functionality and are not well adapted for use in current motor vehicles.
SUMMARY OF THE INVENTION
This invention is a system of multifunctional food and beverage holders for use in motor vehicles and other locations. The components of this system facilitate safe and convenient handling of food and beverages in automobiles and other vehicles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of a cup holder adaptor of this invention.
FIG. 2 is a first embodiment of a tray/plate of this invention.
FIG. 3 is a bottom perspective view of the tray/plate shown in FIG. 2 .
FIG. 4 is a perspective view of the top of a second embodiment of a tray/plate of this invention.
FIG. 5 is a bottom perspective view of the tray/plate shown in FIG. 4 .
FIG. 6 is a perspective view of a support handle for the tray/plates of this invention.
FIG. 7 is a perspective view of a support wall for a cup holder adaptor of this invention.
FIG. 8 is a turn buckle for use with the cup holder adaptors of this invention.
FIG. 9 is a perspective view of an inner rod or turn buckle barrel for the turn buckle of this invention.
FIG. 10 is a perspective view of a gap filler for cup holders having a gap in their side wall.
FIG. 11 is a perspective view of the second embodiment of the tray/plate of this invention (shown in FIGS. 4 and 5 ) attached to the embodiment of cup holder adaptor of this invention shown in FIG. 1 .
FIG. 12 is a bottom perspective view of the embodiments of the present invention shown in FIG. 11 .
FIG. 13 is a perspective view of nested support handles and tray/plates of this invention.
FIG. 14 is a perspective view of the first embodiment of the tray/plate of this invention attached to one embodiment of the cup holder adaptor of this invention and one embodiment of a support handle of this invention.
FIG. 15 is a top perspective view of the cup holder adaptor of this invention shown in FIG. 1 together with two of the first embodiment of the tray/plate components of this invention shown in FIG. 2 .
FIG. 16 is a perspective view of the side of an assembly of the second embodiment of the tray/plate of this invention mounted on a handle of this invention that is in turn mounted on the first embodiment of the cup holder adaptor of this invention shown in FIG. 1 .
FIG. 17 is a top perspective view of the second embodiment of the tray/plate of this invention shown attached to the cup holder adaptor embodiment of FIG. 1 with support walls as of the type depicted in FIG. 7 .
FIG. 18 depicts multiple support handles and the first embodiment of the tray/plate of this invention nested together.
FIG. 19 is a perspective view of a second embodiment of a cup holder adaptor of this invention.
FIG. 20 is a perspective view showing attachment of the support wall of this invention showing in FIG. 7 to the cup holder adaptor shown in FIG. 20 .
DETAILED DESCRIPTION
The first embodiment of the cup holder adaptor 30 of this invention, depicted in FIG. 1 , comprises generally a cup holder sleeve 40 attached to a platform 42 in the form of generally rectangular plate penetrated by a central hole and supporting, at each of two ends, an upright 44 attached to a tray support 46 from which there protrudes an upstanding tab 48 . A horizontal upper bore 50 penetrates the base of tab 48 and a portion of tray support 46 , and a lower horizontal bore 52 is positioned in a boss on the lower side of tray support 46 . Opposite sides of cup holder sleeve 40 are penetrated by a generally round turn buckle-receiving opening 54 . There are two opposed protrusions 56 within each turn buckle receiving opening 54 .
A first embodiment of a tray/plate 32 of this invention is depicted in FIG. 2 . The generally planar tray/plate 32 has a large recess 72 for receiving food adjacent to a circular cup receiving opening 74 . Pins 70 protrude generally co-planar with the top of tray/plate 32 and may be used, as will be appreciated by reference to the figures, by insertion of one of the pins 70 into one of the above-described upper bore 50 or lower bore 52 in cup holder adaptor 30 .
FIG. 3 depicts the underside of tray/plate 32 and makes it possible to see the handle engaging rail 78 and handle receiving groove 80 adapted to cooperate with the handle 38 described below.
FIG. 4 illustrates an alternative tray/plate 34 of this invention. Tray/plate 34 is generally planar with protruding components as described below. A large circular recess 82 receives food or a plate or other container containing food, and a relatively large circular cup opening 84 provide a location for a beverage cup. Two smaller condiment recesses 86 receive condiments, and a small round condiment cup opening 90 can receive a cup of ketchup or another food condiment or item such as mustard, barbecue sauce or cheese dip. A pin 70 in tray/plate 34 serves the same function as pins 70 in tray/plate 32 , and tab receiving slots 88 receive tab 110 of support walls 36 as depicted in FIG. 17 .
Slots 35 in the tray/plates 32 and 34 can receive and retain eating utensils.
FIG. 5 shows the underside of tray/plate 34 and makes it possible to see supports 76 under the condiment recesses 86 and recess 82 . Handle engaging rail 78 are part of an attachment structure of support 76 and are positioned below handle 38 receiving grooves 80 that receive the handle 38 as described below.
FIG. 6 is a perspective view of such a support handle 38 that comprises generally a planar base 92 to which there is attached a riser 94 that supports a platform 96 generally parallel to the base 92 . Platform 96 has two arms 97 comprising a groove cover 102 above parallel grooves 100 for receiving tray/plate rails such as handle engaging rails 78 shown in FIG. 5 . A pin 70 can be received, for instance, in a cup holder adaptor 30 upper bore 50 or lower bore 52 , and riser 94 defines parallel bores 98 also adapted to receive pins 70 .
The tray/plates 32 and 34 can be used with the handle 38 (shown in FIG. 6 ) for any occasion involving standing and eating or as a lap tray when sitting and eating without a table.
A turn buckle 112 shown in FIG. 8 having wing 114 may be used to lock cup holder adaptor 30 within a vehicle cup holder as is depicted in FIG. 11 . Tray/plate holder 34 is shown attached to cup holder adaptor 30 by inserting pin 70 in bore 50 in adaptor 30 . The handle 38 only partially visible in FIG. 11 can be more clearly seen in FIG. 12 that depicts attachment of handle 38 to tray/plate 34 .
Nesting of support handle 38 and tray/plate 34 is depicted in FIG. 13 . An alternative configuration of exemplary embodiments of the components of the present system is depicted in FIG. 14 , which shows a support handle 38 attached to a single cup/tray/plate 32 that is, in turn, attached to adaptor 30 by insertion of one of the attachment pin 70 in one of the bores 50 in adaptor 30 .
Attachment of two single cup holder tray/plates 32 to an adaptor 30 utilizing side pins 70 of tray/plate 32 is depicted in FIG. 15 .
In another alternative configuration, depicted in FIG. 16 , tray/plate 34 is attached to a handle 38 , which, in turn, attaches to adaptor 30 by positioning base 92 on top of platform 42 and between uprights 44 of holder adaptor 30 . Support wall 36 are attached to cup holder adaptor 32 but are folded down and not in use.
FIG. 17 depicts attachment of the tray/plate embodiment 34 to two support walls 36 by inserting tabs 110 through tab receiving slots 88 and engaging a portion of the tray/plate 34 in slots 108 in support wall 36 .
As will be appreciated by reference to all of the drawings in the above description, numerous alternative embodiments of the present invention are possible. One such embodiment of an alternative cup holder adaptor 60 is depicted in FIGS. 20 and 21 . As may be seen by reference to those figures, platforms 46 and associated upper bores 50 and lower bores 52 are positioned on all four sides of the square cup holder adaptor 60 .
The components of the multifunctional, reconfigurable vehicle food and beverage holders system for mounting in motor vehicle beverage holders of this invention can be molded or otherwise formed of plastic. Such plastic should have suitable stiffness, durability, strength, cost and other properties for these components, and such plastic may include fillers, reinforcement fibers or other components as appropriate. Pins 70 can be integrally formed or attached like or dissimilar materials, as appropriate in consideration of the cost, strength, manufacturing difficulty and other relevant factors. Sleeves can optionally be used in the bores to receive pins. Portions or all of the components can be machined, forged, stamped, cast, molded or otherwise formed of steel, aluminum or other metal alloys or other metallic materials and could be constructed of wood. System components can be coated, anodized, tempered, hardened or otherwise finished or treated as appropriate in light of the nature, properties and surface quality of the material from which the component is made.
The figures depict merely exemplary embodiments of this invention, which can be fabricated of numerous alternative materials and manufacturing techniques in myriad configurations. The figures well communicate the cup-holder engaging, component inter-connecting, and food and beverage accommodating configurations of this invention, enabling persons skilled in the relevant arts to practice this invention in both the illustrated and numerous alternative embodiments, all within the spirit of this invention and the scope of the following claims.
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A system of multifunctional food and beverage holders for use in motor vehicles and other locations. The components of this system facilitate safe, convenient and flexible handling of food and beverages in automobiles and other vehicles utilizing tray/plates for holding food that can attach to a handle, rest on a flat surface or be secured in the vehicle by attachment to a cup holder adaptor that can be temporarily locked in a vehicle cup holder.
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RELATED APPLICATION
[0001] The present application claims priority to, and the benefits of, U.S. Ser. No. 60/662,063, filed Mar. 15, 2005, the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to safety helmets, in particular a headband for adjusting and securing the helmet to a wearer's head.
BACKGROUND OF THE INVENTION
[0003] Helmets for head protection are worn in a variety of environments and for various purposes. Protective helmets generally have a spherically shaped rigid outer shell which covers the head and is secured to the user's head by means of a flexible chin strap. Various approaches have been used to adapt helmets to fit the variety of head shapes and sizes of different users. One such approach is to suspend a flexible headband within the interior of the helmet and provide a way to adjust the girth of the band to fit the user's head. While this approach adapts easily to different head shapes and sizes, it cannot absorb impact energy and therefore provides little protection against trauma, especially from the side of the helmet. Because of the importance of protecting the head against blunt trauma, recent refinements in helmets have replaced the headband with pads or a liner made of a compressible material, such as foam, situated between the user's head and the helmet shell. In these designs, however, it is difficult to provide both a comfortable and secure fit because low-density material, which has benefits with respect to comfort, allows the helmet to move too easily and provides less impact protection. Higher-density materials can absorb impact energy but do not adapt well to different head sizes and shapes. There remains a need, therefore, to fit a helmet to the user's head in a manner that is adjustable, comfortable, secure, stable, yet which provides protection against trauma.
SUMMARY OF THE INVENTION
[0004] The present invention improves on conventional approaches to fitting a safety helmet by providing a flexible headband that can be adjusted to fit the shape and size of the wearer's head and which also provides stand-off from the inner surface of the helmet shell. The stand-off provides space within which impact-absorbing materials may be situated in order to absorb blunt impact energy.
[0005] The headband generally comprises a flexible (e.g., plastic) band that may be fabricated as a thin, flat component which is curved into a circular shape by, for example, joining its ends together. In a preferred embodiment, the band is fabricated by injection molding to create and control the features described below, but alternative fabrication techniques as are well known in the art can also be used. The ends of the band are desirably joined at the back of the wearer's head in a manner that allows adjustment of the circumference of the headband. This may be accomplished, for example, by providing one or more tabs molded on one end which snap into any of two or more spaced slots in the other end, thereby providing multiple positions for joining the ends, each of which corresponds to a smaller or larger circumference for the headband. Other well-known means for adjusting the circumference of the headband, such as frictional engagement, hook-and-loop fasteners, clasps, etc., may also be used.
[0006] The headband further comprises a plurality of connecting arms to facilitate joining the headband to the helmet shell at multiple positions. For example, in embodiments with four connecting arms, two are positioned on each side, one is in front and the other is in back. In a preferred embodiment the connecting arms are molded with thin bands oriented to provide bending lines, sometimes referred to as “living hinges.” These bending lines allow the arms to flex horizontally and vertically. Each connecting arm has an aperture for engaging a fastener to join the headband to the helmet shell. The connecting arm may, for example, be joined to the helmet using an anchor having an off-round (e.g., square or angular) post that allows the connecting arm to resist rotation. The connecting arm so connected is constrained to flex in a direction approximately perpendicular to the surface of the helmet shell. When at least two of the connecting points are oriented so that the directions of flexure intersect at a point inside the diameter of the circular headband, the headband resists displacement toward the helmet shell.
[0007] As noted above, impact liner materials may be to be placed in the top of the helmet and optionally in the space between the headband and the helmet shell. Softer “comfort” pads may be positioned between the impact liner and the wearer's head to provide a cushioned surface in contact with the wearer's head. The positional security provided by the improved headband of the present invention means that the impact liner and comfort pads need not play a significant role in the fit or retention of the helmet. This allows greater choice of materials and shapes than is the case with helmets that rely on the energy absorbing materials to also provide positional security.
[0008] Accordingly, in a first aspect, the invention comprises an interior head-retention element for use in connection with a safety helmet. The retention element comprises an adjustable-size headband for engaging a wearer's head, and a plurality of stand-off attachment elements, disposed about the headband, for facilitating spaced-apart attachment of the headband to the helmet. The stand-off elements yieldably resist movement of the helmet toward the wearer's head. The resistance is yieldable in the sense that impact energy is at least partially absorbed rather than transmitting the energy, through excessive resistance, to the wearer.
[0009] In preferred embodiments, the stand-off attachment elements each comprise a generally U-shaped member. For example, as described above, each U-shaped member may be folded over a plurality of bending lines that accommodate at least horizontal, and desirably some vertical flexure. The stand-off attachment elements desirably have directions of horizontal flexure that intersect within the headband.
[0010] In another aspect, the invention comprises a helmet incorporating the head-retention element described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
[0012] FIG. 1 is a front elevational view of a user with safety helmet in place;
[0013] FIG. 2 is a cross-section of the safety helmet shown in FIG. 1 , taken along the line 2 - 2 ;
[0014] FIG. 3 is a cross-section of the safety helmet shown in FIG. 1 , taken along the line 3 - 3 ;
[0015] FIG. 4 is a perspective view of the headband of the present invention removed from the helmet; and
[0016] FIG. 5 is an exploded view of a portion of the headband and other components of a helmet retention system.
DETAILED DESCRIPTION
[0017] With reference to FIGS. 1 and 2 , a helmet 10 is shown secured to the wearer's head by a pair of flexible straps 13 a , 13 b secured to the helmet 10 by respective screws 15 a , 15 b . The flexible straps 13 a , 13 b at the front of the helmet join with straps 13 c , 13 d from the back of the helmet and are secured at the chin by means of a flexible strap 16 , which scoops beneath and may cup the chin. A detachable buckle comprising a male component 19 a and a female component 19 b may be used to secure the straps. When the buckle is detached, separating the components 19 a , 19 b , the chin strap 13 is released, allowing the wearer to remove the helmet 10 .
[0018] With reference to FIG. 2 , which shows the helmet from the right side of the wearer (including an outline of the wearer's head for reference), the left half of the headband 22 of the present invention is shown secured at the front left side of the helmet 10 by a screw 15 b , and at the back left side by another screw 15 c . An impact-absorbing liner 28 may be positioned between the wearer's head and the helmet shell 10 . The impact liner can be formed from conventional materials such as expanded polypropylene (EPP), expanded polyethylene (EPE), expanded polystyrene (EPS), or visco-elastic foam. Other impact-absorbing structures taught in U.S. Pat. Nos. 6,777,062 and 6,032,300 may also be used to advantage.
[0019] Softer pads (representatively shown at 31 a , 31 b , 31 c ) may be positioned between the wearer's head and the impact material 28 to provide a cushioned surface in contact with the wearer's head. By way of example, such comfort pads may be made from urethane foam or EVA foam.
[0020] FIG. 3 shows the headband 22 of present invention attached to the helmet shell 10 by a pair of screws 15 a , 15 b in front and another pair of screws 15 c , 15 d in back. The impact liner 28 and the comfort pads 31 a - 31 e are positioned at the top of the helmet.
[0021] FIG. 4 shows the headband 22 removed from the helmet. The headband is preferably fabricated from a flexible plastic such as nylon or polypropylene and molded as a flat band that may be curved into a circular shape with the narrowed end 34 a passing through a slot 35 in the other end 34 b to join the two ends of the headband at the back of the wearer's head. Headband end 34 a is molded with tabs (not shown) sized and spaced appropriately to match a series of slots 36 formed in headband end 34 b . Providing more slots 36 than tabs in the headband allows the wearer to select from multiple positions for joining the ends 34 a , 34 b , each position corresponding to a smaller or larger circumference for the headband, thus allowing the wearer to select a position that is comfortable yet secure.
[0022] The headband 22 further has a pair of front connecting arms 37 a , 37 b and a pair of rear connecting arms 40 a , 40 b . The connecting arms 37 may be shaped to have preferred bending lines or “living hinges” (as indicated, for example, at 43 a , 43 b ), which allow the corresponding arm 37 to be bent approximately 90 degrees (e.g., from vertical to horizontal), and another set of bending lines (as indicated, for example, at 46 a , 46 b ) which allow the corresponding arm 37 to be bent approximately a further 90 degrees (e.g., from horizontal to vertical) to join the headband 22 to the helmet shell.
[0023] As best seen in FIG. 5 , the connecting arm 37 b is joined through a hole 49 to the helmet shell 10 in the manner explained below, thereby allowing the connecting arm 37 b to resist rotation. The headband 22 so connected is able to flex a small amount vertically, which brings the wearer's head into contact with the comfort pads 31 (see FIG. 3 ). In the horizontal plane, the headband 22 flexes only in the direction shown by the arrows in FIG. 4 , i.e., approximately perpendicular to the shell at the points where the headband is joined to the shell. It is desirable that no two connecting arms have directions of flexure that are substantially parallel; in a headband configuration with four connecting arms, for example, the opposing arms are oriented so that the directions of flexure are not aligned with one another. In the preferred embodiment, at least two such connecting points are oriented so that the directions of flexure intersect at a point within the contour defined by the headband. This helps the headband resist displacement toward the helmet shell, keeping the wearer's head centered and therefore providing space for impact absorption.
[0024] FIG. 5 illustrates details of an exemplary mode of attaching connecting arm 37 b to the helmet shell 10 ; connecting arms 37 a , 40 a and 40 b have the same assembly components. The headband 22 is mounted to the shell 10 by passing the post 52 of an anchor 55 through hole 49 in the connecting arm 37 b , and also through the hole 58 in the helmet shell 10 , then securing it using the screw 15 b . The off-round (e.g., polygonal—square, for exmaple—or angular) shape of the post 52 and the matching shape of the hole 49 allow the connecting arm to resist rotation within the hole 49 . The anchor 55 may also include a contour 61 formed to match a complementary recession 64 molded into the connecting arm 37 b to further aid in resisting rotation.
[0025] The attachment of the energy absorbing liner 28 to the helmet shell 10 may be accomplished by providing a tab 67 having a hole 70 therethrough. The tab 67 may be formed directly as part of the liner 28 if a material such as polypropylene is used for the liner 28 , or co-molded if a softer material such as EPE is used. The attachment is made by passing the anchor post 52 through hole 70 , thereby capturing the tab 67 between the connecting arm 37 b and the helmet shell 10 . A chin-strap component may be attached to the anchor 55 by passing the strap 13 b through slot 73 . A comfort band 76 made of a soft material, such as compressible urethane or EVA foam, may be added on the side of the headband 22 facing the wearer's head and secured using, for example, hook-and-loop fasteners to improve comfort.
[0026] Having described certain embodiments of the invention, it will be apparent to those of ordinary skill in the art that other embodiments incorporating the concepts disclosed herein may be used without departing from the spirit and scope of the invention. The described embodiments are to be considered in all respects as only illustrative and not restrictive.
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An improved headband provides adjustment to fit the shape and size of the wearer's head as well as stand-off from the inner surface of the helmet shell. When the wearer's head is fitted properly in the headband, the headband desirably resists displacement toward the helmet shell in all directions.
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BACKGROUND OF THE INVENTION
The invention concerns the domain of charges which can be released, for example, from an aircraft to which they are fixed, and in particular a munition containing an incendiary gel made of hydrocarbons and gelatinizing agents, intended to have an incendiary effect on various targets on the ground.
Munitions containing incendiary gels constituted of a mixture of volatile hydrocarbons (kerosene, gasoline, . . . ) and gelatinizining agents (fatty acid derivatives) enable these gels, after the impact on the ground, to be distributed and to adhere to various objectives on the ground. Since these munitions are generally not aerodynamically stable, their precision is poor. On impact with the ground, the distribution of the incendiary gel is random since the munition breaks up from the shock, thus provoking ejection of the incendiary gel in splashes. This impact also triggers an ignition fuze which generally ignites phosphorus whose projection, after the impact, ignites only some of the splashes of incendiary gel. The ballistic precision, the dispersion of the incendiary gel and the reliability of ignition of the gel are the major problems encountered with this type of munition.
SUMMARY OF THE INVENTION
The aim of the invention is to remedy these disadvantages and to create a munition in which an incendiary gel is distributed, before the impact on the ground, to ensure better dispersion of the said incendiary gel, the latter being ignited preferably by a means of ignition operating as soon as break-up occurs but also after the impact on the ground.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood on reading the following description, given as a non-restrictive example and illustrated by the drawings which represent:
FIG. 1, a diagram of a munition equipped according to the invention;
FIG. 2, a transverse section AA' of the munition represented in FIG. 1;
FIG. 3, a transverse section BB' of the munition represented in FIG. 1;
FIG. 4, a transverse section CC' of the munition represented in FIG. 1;
FIG. 5, a diagram of a pyrotechnic tube surrounded by these different parts.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 represents the diagram of the munition equipped according to the invention. This munition is composed of the following main parts:
a nose cone A with a fuze and a proximity detector;
a reservoir B in the strict sense of the term with its equipment;
a tapered tail end C with a fixed tail-fin unit and a parachute.
Each of its parts comprises various elements which will be described below. The nose cone A, for example of a composite material so that no metal affects the proximity detector, comprises:
A fuze 3 already used on other munitions, mounted on a support which is made to rotate by a propeller 4; this fuze 3 is constituted mainly of parts not represented on this figure:
a turbo-generator supplying the electrical energy;
a proximity module, for example, using electromagnetic radiation, enabling the break-up to be triggered at a given height above the ground;
an ignition pyrotechnic chain;
a barrel for disalignment of the chain;
a safety device preventing operation within a certain distance from the aircraft;
A fuze holder 1 positioning the fuze 3 in such a way that the radiation from the antenna of the proximity module is not disturbed by the presence of the mass of metal;
A fairing 2, for example, of a plastic material inside which is fixed a retracting device 5 of a nose cone releasable safety cable SLO which after release enables rotation of a propeller 4 and of the turbo-generator, and at the center of which is positioned, between one end of an ignition pyrotechnic tube 7 and the fuze holder 1, a shield 6 which ensures the interruption of the pyrotechnic chain.
The reservoir B is connected, for example by a threaded joint, to the nose cone A. Its structure is made, for example, of an aluminium alloy and includes means of dislocation, for example weakened parts as shown in FIG. 2 which represents a transverse section AA' of FIG. 1. These thin parts (29) facilitate the break-up of the reservoir when a pressure generated, for example, by a powder charge placed in the reservoir is exerted inside the reservoir. The reservoir B represented in FIG. 1 comprises:
An internal beam 8, for example, of aluminium alloy of given length having, for example, the form of the quarter of a circular tube; this beam receives rings 9, for example, screwed into holes 30 to enable the munition to be fixed under an aircraft, and support places 31, for example, of steal, reinforcing the reservoir where it is fixed under the aircraft. These are intended to bear the forces during transport. At the fixing point two safety cables emerge, a nose-cone releasable safety cable SLO and a base releasable safety cable SLC, enabling both triggering of the ignition fuze for the SLO and the locking of the parachute to the reservoir structure and the triggering of the parachute release command delay for the SLC. Each of these safety cables is operational only during release of the munition: after fixing of the munition under the aircraft, the traction of each of the cables (SLO, SLC) cannot trigger the operation of the different stages mentioned above, as each of these cables is equipped with a safety device located at the point where the cable emerges, in such a way as to prevent any movement of the cables. This safety device is equipped, for example, with a plate 32 held in closed position before fixing under the aircraft by a safety pin 11 and a ball not represented on this FIG. 1 positioned around each of the cables so as to be able to strike the plate when a tension is applied to one of the cables and thus to dislodge the plate and allow movement of the cable. When the munition is positioned under the aircraft, the safety pin 11 is removed. The plate can therefore swing on the ball fixed to the cable, but its movement is blocked by the aircraft's strut which immobilizes the plate. The slack of the cable is not sufficient to trigger one of the operations mentioned above and its action is effective only during release of the munition, when a traction is exerted on the cable. The two safety cables SLO and SLC slide in channels 10 and 12 respectively up to retracting devices 5 and 26 situated in the nose cone A and the tapered tail end C;
a filler hole 13 adapted to the means of in-flight fuelling in service in NATO;
reinforcing frames 14 some of which are designed to catch the slipstream;
an automatic level 15 enabling filling to be stopped;
a depressurization valve 16;
a pump 17 with a pressure line 18 which can be activated from the outside, for example, by an electric motor M, intended to agitate the mixture (hydrocarbon+gelatinizing liquid) to homogenize the components thanks to the swirling generated by the outlet nozzle. Under the action of the electric motor the pump outlet creates a spiral whirlpool which facilitates the mixing of the hydrocarbon and the gelatinizing agent. The use of such a pump facilitates the manipulation of the munition before it is fixed under the aircraft, by enabling the hydrocarbon to be loaded after fixing of the munition under the aircraft, while giving a mixture as good as one prepared before its insertion in the reservoir of the munition;
a pyrotechnic tube 19 which traverses the reservoir from one end to the other on its axis of symmetry XX'. It includes, first, a detonating cord 20 which enables ignition of the gas-generating grains 21 and 22 placed at the front and back of the munition and illustrated in FIG. 3 which represents a transverse section BB' of FIG. 1; these gas generators 21 generate the internal pressure ensuring break-up of the reservoir; their weight and position are optimized in order to obtain an opening in the shape of petals (weight of grains greater at the front than at the rear); these grains 21 are placed, for example, in a circular arrangement within an envelope 33 in liaison with the detonating cord 20 constituted of three parts via the holes 34 inside the pyrotechnic tube 19 enabling the transmission of the ignition orders to the various gas-generating grains. Secondly, the pyrotechnic tube includes the gel ignition capsules represented in FIG. 4 which illustrates a transverse section CC' of FIG. 1; these ignition capsules 23 are ignited by the detonating cord and are expelled from the pyrotechnic tube 19 on which they were fixed, for example by a threaded joint; the ignition capsules 23 possess means of guidance, for example, fins 35 represented by dashed lines in FIG. 4; they also contain elements of combustion 36 ignited by the detonating cord and whose duration of combustion, a few seconds, enables the mixture to be ignited during the formation of the cloud, during the fall of the particles and after scattering on the ground, if necessary. The number, size and location of these capsules 23 are defined to obtain perfect ignition of the mixture scattered after break-up of the reservoir. These capsules are made, for example, of a light alloy. Inside the pyrotechnic tube 19, as represented in FIGS. 1, 2, 3, 4 and 5 is situated a rod 24 to the back of which is attached a parachute 27; this rod 24 is connected, at the front, to the mechanism used to remove the shield 6 which interrupts the pyrotechnic ignition chain and which prevents the ignition of the pyrotechnic cord 20. The rod 24 is immobilized in the pyrotechnic tube 19 by a shear pin 39 which prevents any movement of the shield 6, to which it is connected by a lever 37, before a traction is exerted on the rod 24 after the deployment of the parachute 27; this traction enables the rod 24 to slide in the pyrotechnic tube 19 and causes the shield 6 to pivot around a point 38. At this instant the pyrotechnic chain of the fuze 40 is aligned with the detonating cord 20 and the ignition operations of the various parts can proceed normally. In FIG. 5, the shield 6 is represented in dashed lines after sliding of the rod 24. There is therefore no further obstacle to the transmission of the ignition signal when the pyrotechnic chain is initiated.
The tapered tail end C comprises:
a fixed tail-fin unit (25) fixed to the structure of the reservoir B, which is constituted for example of four fins whose span corresponds to the diagonals of a square whose side is equal to the diameter of the body of the reservoir;
a parachute 27 contained in a cup 41 connected to the structure of the reservoir B by a device for locking and release of the parachute which is initialized by sufficient traction on the base releasable safety cable SLC;
a device to retract the SLC 26 which, after shearing of the pin holding the SLC to the aircraft thanks to a sufficient traction force, enables any part of the SLC not flush with the outside of the munition, which could disturb the operations, to be retracted.
These various major parts are assembled in a simple way, for example by a threaded joint, to facilitate inspection and if necessary replacement of certain parts during specific controls
Having described the munition, we shall now explain its operation. After having taken care to fill the munition with the mixture before or after the munition is fixed, as described above, and after fixing of the munition to the aircraft, the rings of the releasable safety cables SLO and SLC are simply fixed to the corresponding devices of the aircraft and the safety pins 11 are removed to make the munition ready for operation. When the munition is released, the plates 32 pivot and the SLO and SLC cables are placed under traction. The munition separates from the aircraft. The SLO unlocks the turbo-alternator and the rotating fuze support. The rotation of the fuze enables a proximity measurement which is independent of the roll of the reservoir. The turbo-alternator supplies power to the proximity detector which does not yet detect the ground. The safety device coupled to the turbo-alternator begins to turn the barrel which assures pyrotechnical chain disalignment. Meanwhile the SLC enables the parachute to be unlocked to the munition structure and triggers the parachute release command delay. At the end of the delay, the parachute is deployed; this brakes the munition to distance it from the aircraft. When the force supplied by the parachute is sufficient, it pulls the rod 24. The rod shears its pin 39 and slides in the pyrotechnic tube and, in front, displaces the shield 6 which interrupted the pyrotechnic chain at the back of the fuze. A few seconds after the release of the munition, the safing device finishes moving the barrel of the fuze and the pyrotechnic chain becomes aligned. At a height of a few meters, for example, the proximity module detects the ground and triggers the ignition of the pyrotechnic chain. The detonating cord for transmission of ignition burns inside the pyrotechnic tube and, after a few milliseconds, initiates the gas-generating grains and the gel ignition capsules. The pressure generated by the gas generation breaks up the munition. The mixture is subjected to aerodynamic pressure which disperses it in small drops. The burning ignition capsules are expelled in this cloud and pursue their trajectory to the ground where they continue to burn for several seconds. The small drops of the mixture burn continuously during their fall and after scattering on the ground. If by any chance the proximity module should fail, a backup device incorporated in the fuze initiates the pyrotechnic chain on impact on the ground.
On release without traction of the safety cables SLO and SLC, the fuze is not activated, the pyrotechnic chain is disaligned (barrel) and interrupted (shield). Moreover, the parachute is not locked to the structure and it is not liberated.
The munition according to the invention applies particularly to releasable charges intended to have an incendiary effect on various targets on the ground but it can be applied for uniform scattering of any product in a determined location.
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The invention concerns the domain of a charges which can be released, for example, from an aircraft to which they are fixed, and in particular a munition containing an incendiary gel made of hydrocarbons and gelatinizing agents, intended to have an incendiary effect on various targets on the ground.
The invention enables the munition to be broken up above the ground thanks to means of distribution constituted of a detonating cord, gas-generating grains, a shield and a rod. These means of distribution ensure regular scattering of the incendiary gel before the impact on the ground. The invention also enables ignition of the incendiary gel on break-up of the munition thanks to means of ignition composed of ignition capsules.
Application to munitions containing an incendiary gel, also to munitions containing a product to be scattered.
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FIELD OF THE INVENTION
The present invention relates to a printer, and particularly, but not exclusively to a portable printer which can print on a variety of surfaces.
BACKGROUND TO THE INVENTION
In the state of the art, a number of printers capable of “direct” printing is known. Direct printing in the context of the present invention means that the printer is placed on the image receiving medium, usually manually, and the printing means of the printer or the entire printer then scans over the image receiving medium in the printing operation. Thus, the medium is not fed through the printer—as in most office printers—but the printer moves over the medium.
Such a printer is known from EP 564297-A. The printer has an ink jet print head which scans in two orthogonal directions over the image receiving medium, onto which the printer is placed manually. The printer is connected to a computer and capable, e.g of printing addresses onto envelopes, but can also be used separately from the computer for printing data downloaded from the computer to the printer.
Another ink jet printer to be placed on a printing medium is disclosed in U.S. Pat. No. 5,634,730. This printer is provided with a keyboard for data inputting, but can also print images downloaded from a computer. The print head scans over the image receiving medium along a special path, e.g. helically or like a pendulum. DE 3142937-A refers to a so-called hand stamp which is placed manually on the image receiving medium. It can print data downloaded from an accounting machine, or images consisting of user-selected fixed phrases. The hand stamp has a thermal print head and an ink ribbon for printing.
The direct printers known in the prior art are thus capable of printing an image onto an image receiving medium, and make use of a scanning print head. JP-6286227 discloses an electronic stamping apparatus which includes a pressure detection means that detects whether the pressure applied to an object is in a prescribed range, and a control means that controls scanning of a thermal transfer head based on the detection by the pressure detection means. This requires contact between the print head and the surface to be printed, in contrast to the printers described herein where the print head is spaced from the image receiving medium.
SUMMARY OF THE INVENTION
It is an aim of the present invention to improve the quality of images which are printed by the so-called direct printers. According to various aspects of the invention, this can be done in a number of different ways.
According to one aspect of the invention there is provided a printer comprising:
a housing arranged to be manually positioned on an image receiving medium at a printing location and defining an area over which printing is effected; a printing mechanism operable to effect printing over said area with the housing at said printing location; means for detecting relative movement between the image receiving medium and the housing during printing; and a controller for inhibiting printing when such relative movement is detected.
The means for detecting relative movement may be for example a scanner head, mouse ball etc. Thus, any relative motion detected during the print cycle may be used to interrupt or terminate the print cycle.
According to another aspect of the invention there is provided a printer comprising: a housing arranged to be manually position on an image receiving medium at a printing location and defining an area over which printing is effected; a printing mechanism operable to effect printing over said area with the housing at said printing location; means for detecting orientation of the housing with respect to the image receiving medium during printing; and a controller for inhibiting printing when an orientation other than a correct predetermined orientation is detected.
The means for detecting orientation of the housing can be for example a tilt sensor. Thus, the tilt sensor enables the print cycle to be inhibited unless the printer is positioned in the correct orientation.
According to a further aspect of the invention there is provided a printer comprising: a housing arranged to be manually positioned on an image receiving medium and defining an area over which printing is effected; a print head having a plurality of ink jet nozzles and mounted in said housing for travel within said housing relative to the image receiving medium to effect printing, said print head having an extent of travel which extends in a region outside the printing area; a controller for actuating said ink jet nozzles in said region as a maintenance procedure; and a set of absorbent strips arranged in said region for receiving ink ejected from the jet nozzles during the maintenance procedure.
By using the unprintable area for interim “spitting”, the print function can be maintained by preventing individual jets from blocking. The absorbent strips which are used to catch any drops of ink spat out may be replaceable.
According to a further aspect of the present invention there is provided a printer comprising: a housing arranged to be manually positioned on an image receiving medium at a printing location and defining an area over which printing is effected; a print head mounted in said housing for travel within said housing relative to the image receiving medium to effect printing; a motor for driving said print head under the control of a drive signal; and a controller for generating the drive signal for the motor wherein the controller includes fault condition detecting means which are operable to detect when the drive signal exceeds a predetermined limit and to inhibit printing in said fault condition.
In the described embodiment, the drive signal is an electric current which is supplied to the motor for causing movement of the print head. For an X-Y movement, there are two motors, one for moving the print head along an axis in an X direction and the other for moving the axis itself in a Y direction. Under normal printing loads, the drive current to the X-Y drive motors will follow a repeatable profile. Should the printing mechanism jam or encounter a higher resistance than normal, for example when printing on an uneven surface, the drive motor current will rise. By setting the boundaries that encompass the normal operating currents, current outside these boundaries may be detected as a fault condition and used to inhibit printing.
In another aspect, the invention provides a printing system comprising: a printing unit; a base station configured to receive the printing unit when not in use and having means for detecting return of the printing unit to the base station; and wherein a maintenance sequence for the printing unit is initiated on detection of return of the printing unit to the base station.
In another aspect the invention provides a printer comprising: a housing arranged to be manually positioned on an image receiving medium and having an opening defining an area over which printing is effected; a print head having a plurality of ink jet nozzles and mounted in said housing for travel within said housing relative to the image receiving medium to effect printing, said print head travelling at least within said opening and over said area to effect printing; and a cover removably attachable to said housing to close said opening when said printer is not in use.
For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made by way of example to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing a printer, a base station and a computer;
FIG. 2 shows the print mechanism of the printer;
FIG. 3 a shows the underside of the printer with absorbent strips;
FIG. 3 b is a perspective view illustrating the use of absorbent strips;
FIG. 4 a is a view of a mechanism for fixing the print head in the printer;
FIGS. 4 b and 4 c illustrate how the arrangement of FIG. 4 a functions as a detector;
FIG. 4 d illustrates an embodiment of a motion detector;
FIG. 5 illustrates the operation mode of the printhead;
FIGS. 6 a and 6 b illustrate a tilt sensor; and
FIG. 7 illustrates the printer with a dust cover.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a printing system consisting of a computer 10 , a computer controlled display 12 , which is in the described embodiment of the invention a CRT, a keyboard 14 linked to the computer 10 by means of a cable 16 , another cable 18 , connecting the computer 10 with a base station 20 , which is connected to a printer 24 by means of a cable 22 . Thus, the printer 24 is linked to the computer 10 via the cables 18 , 22 and the base station 20 .
As known in the prior art, the computer 10 comprises a processor on which a software is running, comprising an operating system, a printer driver to enable printing with the printer 24 from the operating system, and a software application by which data can be created, selected and formatted on the PC, for defining image patterns to be printed by the printer 24 . The software application can be activated in a number of ways:
selected by the user at start-up or from the desktop: the user places the software application in the start-up directory or creates an icon on the desktop;
from within another application: the user invokes the software application from a button (displayed on the display 12 ) in the toolbar of another software application;
from the handheld printer 24 itself: if the application is not running, the user presses a print button 34 on the handheld printer 24 , which will automatically invoke the software application in the first instance.
Another possibility to activate the software application on the computer 10 for controlling the printer 24 is to lift the printer 24 off the base station 20 . A switch 32 is provided in the base station 24 sensing the presence or absence of the printer 24 by means of a pin 30 . When the printer 24 is placed upon the base station, the pin 30 is depressed, and the switch 32 is open. In the case that the printer 24 is removed from the base station 20 , the pin 30 which is biased in the vertical direction moves upwardly and the switch 32 opens. The switch is connected via some electronic circuits to the computer 18 and activates the software application for printing.
The base station 20 is connected to the computer 10 by means of the cable 18 , which can be a parallel or a USB cable. Electric power is supplied to the base station 20 by a separate mains transformer, but could also be supplied from the computer via the cable 18 , preferably when the cable 18 is a USB cable. The cable 18 can be hard wired to the base station 20 , or connected to a socket of the base station, which is preferably provided at the rear thereof. When the printer 24 is not in use, the handheld printer will be placed in the base station 20 . The base station 20 will ensure that the ink jet print head of the printer 24 is protected when not in use by a capping device that will be automatically triggered whenever the printer is inserted into the base station 20 . The base station 20 will also cause the print head of the printer 24 to eject ink into a reservoir and mechanically clear the surface of the print head. These measures are necessary to maintain optimum print quality.
The umbilical cable 22 connects the base station 20 to the hand held printer 24 , providing both power and data. A LED on the printer will indicate that power is on. The printer 24 is removed from the base station 24 and positioned on the surface to be printed. The length of the cable 22 limits the distance of travel from the base station.
In another embodiment of the invention, the printer is arranged to be disconnected from the base station by unplugging the umbilical cable 22 and moved to another location where printing of the contents of on-board memory, i.e. downloaded image data, can be effected. The user will employ scroll buttons on the printer to select the required print data, which appear in a small LCD. Once a selection has been made, pressing the print button 34 will activate printing. Having selected the data to print using the software application (or the scroll buttons on the printer), the user will activate printing from the print button 34 on the hand held printer 24 itself.
Print alignment is achieved visually through a transparent window 36 in the printer casing. This window 36 can also be opened for inserting an ink cartridge into the printer 24 before use. The cartridge is then clamped in a carriage of the printer 24 . The window 36 must be closed before printing. The user can choose from a range of coloured and special inks. Changing a cartridge is achieved by lifting a retaining lever and extracting the cartridge in use and replacing this with a new or different colour cartridge in the way described above. If the removed cartridge still contains ink and is to be reused it must be capped to avoid the ink drying out.
Alternatively a Think jet type head from Hewlett Packard may be used which utilises a different type of ink which does not dry out in the print head.
The printer 24 contains a print mechanism with the ink jet print head having a number of print nozzles, and an ink supply. The print head is moved by means of motor driven scanning means within the housing in two (generally orthogonal) directions such that a rectangular area can be imprinted through an aperture of the printer 24 at the bottom of its housing. Thus, the printer 24 is placed manually on an image receiving medium and—when the print button 34 is depressed—the print head scans over the medium and imprints it by spitting ink droplets onto it.
FIG. 1 shows the printer 24 , base station 20 and computer 10 linked by cables. In an embodiment, it is possible to replace one or all of these links by a wireless link such as a low power RF link or an infra-red link. FIG. 1 also shows the presence of a “Smart Card” reader 28 in the base station 20 . Smart cards 26 , i.e. memory cards, may be used for storing data or images or as a substitute for additional RAM in the base station. Spare cards may be stored within the base station where a storage compartment is provided (not shown).
In the case that the printer 24 is powered only by batteries, rather than having the cable 22 transmitting power from the base station 20 , the amount of charge remaining in the batteries may be monitored an displayed on a display of the printer 24 , and/or on the display 12 of the computer 10 . If rechargeable batteries are used, the battery monitoring system could also be used to control the charge/discharge cycle of the battery pack to maximise battery life. This could also enable rapid recharging of the batteries. Such a battery management system could also indicate that there was sufficient energy remaining in the battery pack to complete the current task.
The print mechanism of the printer will now be described with reference to FIG. 2 . The printer 24 has a housing 200 , the underside of which can be abutted against the surface of the image receiving medium to be printed. A print face 11 is defined by the scanning range of an ink jet print head cartridge 126 which can be replaced using the cartridge release mechanism described above. The ink jet print head cartridge 126 is mounted for movement along a write axis 128 by virtue of cooperating lead screw 130 and nut 132 . The movement is controlled by a motor 134 (stepper or DC depending on the nature of the print head). The position of the write axis 128 can be altered by an indexing axis lead screw and bush 136 controlled by a further stepper motor 138 . Reference numeral 140 designates a stability bar which extends parallel to the write axis 128 , the ink jet print head cartridge 126 being mounted between the write axis 128 and the stability bar 140 . Reference numeral 142 designates an indexing axis stability bar and bush.
If a Think jet print head is used, a DC motor and encoder may be used in place of a stepper motor.
The printer also includes an electronic controller 100 having a microprocessor for controlling movement of the motor 34 and generating signals for controlling the print head and having a buffer memory for storing data. The microprocessor is capable of converting data from a computer to which the device is connected into a format suitable for driving the print head. The buffer memory can store information in a variety of formats to enable the printer to work with a variety of computer equipment.
In FIG. 2, the line 120 defines the extent of travel of the print cartridge 126 in the X and Y directions. Referring now to FIG. 3, a print area 122 which is denoted inside the dotted lines 122 a is defined which does not use up the full extent of travel of the print head cartridge 126 . Additional travel is required so that the print head can be accelerated/decelerated to and from optimum print speed and hence firing frequency. If print occurs during acceleration/deceleration, it is necessary to deviate from the print head specified firing frequency and print quality will deteriorate.
FIG. 3 a shows the underside of the printing apparatus with all of the drive features removed for the sake of clarity. Thus, it discloses only the travel area 120 , the print area 122 and absorbent strips 124 . These absorbent strips are placed along the edges of the area of travel of the print head and outside the printing area 122 . These absorbent strips allow maintenance of the print head cartridge 126 by allowing ink to be ejected outside the print zone in order to purge the print nozzles and reduce the risk of clogged nozzles. Thus, the unprinted region between lines 120 and 122 a is used for interim spitting to maintain the print cartridge function by preventing individual jets from blocking. The strips of absorbent material may be replaced and are attached to the base of the printer and used to collect any drops of ink spat out to help maintain the print cartridge print quality. The strips should extend beyond the print head travel area to increase their effective ink capacity. Ink will wick out from the actual “spit” position to the extreme edges of the strips.
FIG. 3 b illustrates the concept in more detail, with extraneous components removed for the sake of clarity. That is, in FIG. 3 b reference numeral 124 denotes a rectangular absorbent strip. Reference numeral 230 denotes a thin fixed guide mounted on the bottom face of the printer 24 in the centre of which a rectangular aperture is provided. The print face is defined within the rectangular aperture. The guide is shown on the substrate in FIG. 3 b to illustrate its function to allow the print cartridge 126 to pass over it to print to the edge of the print area defined by it.
FIG. 4 a illustrates how a print cartridge 72 is mounted in the printer 24 . A metal (or plastics) base plate 60 is mounted for scanning motion along the direction indicated by arrow A. The necessary mechanism for scanning in this direction is not shown in FIG. 4 a , for the sake of clarity. On the base plate 60 , a first guide rail 62 is provided, and a second guide rail 64 . Both guide rails 62 , 64 extend in a direction which is orthogonal to the direction of movement of the plate 60 . Additionally, two wheels 78 are provided, around which a drive belt 66 is located. The drive belt 66 is preferably toothed and extends parallel to the guide rails 62 , 64 . Further, a pin 70 is provided on a pin holder 68 , the latter being fixed to the drive belt 66 . The print cartridge 72 provided with an ink supply and nozzles for depositing the ink onto an image receiving medium is provided with three snap-on bearings 80 , 82 , 84 . The bearings 80 and 82 are arranged to be snapped (or clipped) into the first guide rail 62 , and the bearing 84 is arranged to be snapped into the second guide rail 64 . Thus, the cartridge 72 can be slidably fixed to the guide rails 62 , 64 and travel along the longitudinal axis of the guide rails. The pin 70 engages in a hole 86 of the cartridge, such that a driving connection between the drive belt 66 and the cartridge 72 is established. An electrical connector is incorporated in the pin 70 so that the drive signals can be transmitted to the print head. A dynamic cable (not shown) links the electrical connector with the drive circuitry elsewhere in the product. When the belt is driven (by means of a corresponding motor, not shown in FIG. 4 a for the sake of clarity, but it could drive the belt 66 through the rectangular window in the base plate 60 ), the cartridge 72 travels along the guide rails 62 , 64 . In order to control the print head of the cartridge 72 , the printer's control electronic requires information on the position of the print head. Thus, a pinwheel 74 engaging the printed medium is provided on the cartridge. The pinwheel 74 rotates when the cartridge 72 moves along the guide rails 62 , 64 and its rotation is detected by means of a motion detector 76 .
The pinwheel 74 allows for the detection of the flatness of a substrate to help maintain print quality. As the pinwheel rotates, its rotation is detected by the motion detector 76 and a signal is produced. The pinwheel only rotates when the print cartridge is the correct distance from the substrate and the wheel is in contact with the substrate. At the end of each print pass, when the print cartridge is indexed forward ready to print the next pass, the pinwheel is held clear of the substrate to prevent damage. Alternatively a castor or track ball which can rotate about two orthogonal axes could be used. If the pinwheel loses contact with the substrate during the normal printing pass, the wheel no longer rotates, the signal is lost and the print cycle is inhibited.
The base plate 60 and the pins on which the wheels 78 are mounted, and the guide rails 62 , 64 are unitary. Thus, the base plate 60 is produced as a unitary unit, e.g. by die casting, in order to simplify constructions and minimise component cost. It should be noted that a movement along the direction indicated by the arrow A is not necessary when the cartridge 72 contains a print head having a width sufficient to print the entire image receiving medium in one scan.
FIGS. 4 b and 4 c illustrate in more detail how the arrangement of FIG. 4 a operates to implement “no contact, no printing”. In FIGS. 4 b and 4 c , the first position of the print cartridge 72 is shown outlined in a full black line and denoted position A. The second position is denoted by a dotted line and is denoted position B. The second position is shown to be over a small dip in the substrate such that the pinwheel 74 loses contact. FIG. 4 b illustrates how, in moving from position A to position B, the pinwheel 74 loses contact with the substrate over the small dip. FIG. 4 c illustrates the detector 76 in more detail. Each detector comprises a light emitter 76 a and a light sensor 76 b . In position A, light from the emitter 76 a reaches the sensor 76 b . In position B, it can be seen that the small dip in the substrate causes light from the emitter 76 a to be reflected at an angle such that it does not reach the light sensor 76 b . Thus, a fault condition is detected.
Thus, although the primary function of the pinwheel 74 and motion detector 76 is to monitor surface contact, it can also be used to detect movement of the printer relative to the substrate. In particular this may be achieved by comparing the actual signal received from the detector with a reference signal, the reference being generated by a calibration operation where the printer is held in contact with a substrate and not allowed to move while the printer prints a test pattern.
An alternative arrangement could be to mount at least two separate pinwheel sensors orthogonally with respect to one another within the body of the printer. When the printer is in contact with the substrate and in the printing position, no movement signal will be generated by these sensors. If relative movement occurs between the printer and the substrate, a signal will be generated by one or both of the sensors and a fault condition flagged.
A further movement detection technique could be to use a two dimensional detection system as illustrated in FIG. 4 d . A heavy ball 210 has a high friction outer surface against which rests two orthogonal shafts 212 , 214 . Attached to these shafts are respective rotary encoders 216 , 218 . When the printer contacts the substrate, the ball rests on the substrate and any movement of the printer relative to the substrate is converted to a movement of one or other or both of the encoders.
FIG. 5 illustrates how scanning is performed over the image receiving medium. Most ink jet printers known in the prior art accelerate the print cartridge from rest to normal printing speed prior to firing the ink droplets. This simplifies the control of ink droplet spacing and allows the print head to be fired at a optimum frequency, but the additional space required to accelerate the print cartridge increases the overall size of the product. The printer described here is hand held and thus requires that the overall dimensions are minimised. The control system of the print cartridge 72 thus provides the ability to print as the print cartridge assembly is accelerating—during printing of the left margin 90 of the image receiving medium 48 ′—and decelerating—during print of the right margin 90 ′ of the image receiving medium 48 ′—at the start and finish of each sweep of the mechanism thus enabling the product dimensions to be minimized for a given size of the print area on the image receiving medium.
The drive signals issued by the controller 100 to the DC motors 134 and 136 thus follow a repeatable profile under normal printing loads. Should the mechanism jam or encounter a higher resistance than normal, the drive motor current requirement for the motors will rise. If boundaries are set that encompass the normal operating currents, then currents outside this area may be detected as a fault condition and the appropriate action taken to stop printing. Thus, reverting to FIG. 2, the DC motor 134 is controlled by drive signal 154 and the DC motor 138 is controlled by drive signal 158 . Feedback signals 164 and 168 respectively return the back EMF conditions of the motor to the controller 100 . This allows the controller to monitor the profile boundary and to detect the fault condition.
It is important when the printer 24 has been aligned at a print location and is executing printing that the printer is correctly oriented while printing is being effected. That is, it is important that the printer 24 is placed squarely at the print location and is not tilted at an angle. That is, the print head 126 should desirably move in a plane parallel to the plane on which printing is to be effected. The tilt sensor of FIGS. 6 a and 6 b allows this to be achieved. The tilt sensor comprises a housing 200 which defines therein a part-spherical or “bowl-shaped” surface 202 . As can be seen, FIG. 6 b is a section taken along lines VI—VI of FIG. 6 a , but with the tilt sensor in a different position in each figure. At the lower-most point of the part-spherical surface 202 , a microswitch 204 is located. A ball 206 rolls freely on the part-spherical surface 202 and can roll in any radial direction. In FIG. 6 a , the tilt sensor is shown in its properly oriented position, with the ball 206 located over the microswitch 204 . This state is detected as a safe state, and printing is allowed to continue while the ball remains in that position. If however the unit moves, the ball will roll away from the centralised position over the microswitch, allowing the microswitch 204 to detect the absence of the ball 206 , as illustrated for example in FIG. 6 b . This is detected as a fault condition, and printing is inhibited. This allows movement of the printer during printing to be detected and printing to be inhibited accordingly.
It will also be apparent that if the printer is placed at the printing location in anything other than the correct orientation, the ball 206 will not be over the microswitch 204 and thus the fault condition will immediately be detected even prior to printing. The printer must be properly aligned vertically before printing can be effected.
FIG. 7 illustrates the printer 24 with a sealing lid or dust cover 300 attachable to the printer 24 to close the print face 11 in the base of the printer. In addition, a window 302 is hinged to the housing of the printer 24 whereby the window can be releasably hinged or fixed to the printer 24 .
In accordance with one embodiment, when the printer 24 is returned to the base station 20 , the printer 24 automatically cycles through a service routine to maintain the print cartridge performance. This sequence is triggered by a switch 304 (FIG. 1) in the base station which senses return of the printer to the base station 20 . The service routine can be determined by the supplier of the ink jet cartridge such as to maintain the print cartridge performance.
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A portable printer which can print on a variety of surfaces is disclosed. The printer has a number of failsafe features which improve its operation and the quality of print. In particular, printing is inhibited in a certain number of situations. Alternatively or additionally, a maintenance sequence can be implemented when the printing unit is removed from a base location. A set of absorbent strips additionally or alternatively allow for the ink jet nozzles to be discharged within the print area.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 61/186,871, filed Jun. 14, 2009, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates in general to plastic pipe, and more particularly to bell designs for plastic pipe and methods of making bell designs for plastic pipe.
BACKGROUND OF THE INVENTION
[0003] Bell and spigot joints are commonly used to join pipes, including extruded plastic pipes. Bell and spigot joints typically have three components; a bell on an end of a pipe, a spigot on an end of another pipe, and a gasket. These systems typically form a water tight joint.
[0004] Typical extruded multi-wall pipe includes a corrugated layer made using an extrusion process including corrugators. Bell and spigot joints are formed during the extrusion process using pipe corrugators incorporating pipe molds and a bell blocks. For example, see U.S. Pat. No. 5,405,569. The preferred process is to apply a heated gas or fluid between the outer shell and inner liner extrusion layers to form the bell and spigot.
[0005] There are two well known methods for forming a bell on the end of an extruded multi-wall corrugated pipe during the extrusion process. The first is a single extrusion layer bell, which is formed from the outer shell extrusion layer. Single layer bell extrusion processes often include complicated corrugators and extruder controls to help thin or thicken the bell, slowing down the pipe extrusion process.
[0006] The second method for forming a bell on the end of an extruded multi-wall corrugated pipe during the extrusion process results in a bell comprised of two plastic layers formed from the outer shell and an inner liner extrusion layer being fused together. In this process, the bell is formed by evacuating the air from between the two layers during the extrusion process. This process is complicated and is also known to slow down the extrusion speed of the corrugators.
[0007] Bell design involves several issues which have caused problems in the past. Control of the bell finish diameter is significant in the performance of a bell and spigot joint. For example, the bell must have adequate strength, through reinforcement or otherwise, to maintain a cylindrical shape during transportation and usage. The bell must be able to hold its shape during spigot and gasket insertion and subsequent pressurization of the pipe assembly.
[0008] One method used in the past to add strength to a pipe bell was to use reinforcing stiffeners, such as annular ribs molded into the bell. These stiffeners add strength and help maintain roundness, but typically create undulations in the inner surface of the bell. Undulations or irregularities have been known to cause problems of gasket rolling when a bell and spigot joint are assembled, as the gasket may be caught on the reinforcing ribs.
[0009] It is well known that plastic materials can have numerous variables affecting the shrinkage rates during processing. In both of the known methods of forming an inline bell discussed above, the sealing surface of the inner bell is subject to the shrinkage variability. This can cause significant dimensional control issues. For example, rapid cooling of the bell may create internal thermal stresses which may result in deformation. Differential deformation between the bell and spigot of the pipe joint may also result in leakage of a pipe joint.
[0010] Controlling the circumferential strain in the bell is important to prevent deformation of the bell during the pipe joining process. Controlling bell strain is also important for bells subjected to internal pressure. Bell expansion caused by sustained internal hydraulic pressure, for example, may result in loss of gasket seating pressure and of a water tight seal.
[0011] In the past, hose clamps and other external devices have been used to reinforce bell and spigot joints as a field fix for problem or leaking joints. It is desirable to eliminate the need for such external sealing aids.
SUMMARY OF THE INVENTION
[0012] A multi-layer bell is formed from the outer shell of a multi-layer pipe in a secondary process, thereby allowing the extrusion process to be conducted at normal speeds. The bell is designed with increased hoop or circumferential stiffness to alleviate deformation during the installation process. This invention may be used for dual wall, triple wall, or other multiple layer pipes. The bell design may include a strain limiting membrane mechanically secured between the outer shell extrusion layer and the inner liner extrusion layer, thereby enabling the use of a wider range of high strength membrane materials that are not necessarily compatible with the base resin of the pipe. This invention allows the extrusion process to be in its simplest form, with no adjustments to the corrugator or extruder speeds in an effort to control bell wall thickness. Production speeds may be increased by allowing a thinner outer shell extrusion layer at the pipe bell. The present invention may be used in conjunction with existing pipe extruding technology, minimizing the capital investment and reducing complexity of the pipe corrugating process as compared to current multi-layer bell forming technologies performed as part of the pipe extrusion corrugating process.
[0013] Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a cross-sectional view of a typical prior art watertight bell and spigot pipe joint.
[0015] FIGS. 2A-D are cross-sectional views of a pipe bell of the present invention during various stages of the forming process.
[0016] FIG. 3 is a cross-sectional view of mold blocks used to form the pipe bell of FIG. 2 .
[0017] FIG. 4 is a cross-sectional view of a first alternative embodiment of the present invention.
[0018] FIGS. 5A and 5B are cross-sectional views of a second alternative embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] FIG. 1 shows a typical multi-layer extruded plastic pipe bell and spigot joint 10 . The watertight joint is formed from two pipe sections 12 , 14 having a bell 16 and spigot 18 , respectively. Bell pipe 12 includes an outer shell 20 and an inner liner 22 . A bell 16 is formed from the outer shell extrusion layer. The bell 16 includes annular stiffening ribs 17 near the pipe end to maintain roundness. The bell 16 also includes annular stiffening ribs 19 on its outer surface which are relatively small to avoid deforming the inner surface of the bell. Spigot pipe 14 includes an outer shell 20 and an inner liner 26 . A hollow polyisoprene or thermoplastic elastomer gasket 28 provides a watertight seal between the bell and spigot. When assembled, the inner layers 22 and 26 preferably abut to provide a smooth inner surface, but this is not essential for most applications.
[0020] Referring to FIG. 2A , a two-layer corrugated pipe 30 having an outer layer 32 fused to an inner liner 34 is extruded in a typical manner well known in the art. Preferably the pipe is made of high density polyethylene, but other materials may be used as well, such as polyvinyl chloride or polypropylene. A bell and spigot section is formed in the extruded pipe using a traveling mold block, again as is well known in the art. However, the mold block of the present invention ( FIG. 3 ) has cavities for forming the bell section with reinforcing or stiffening rings 36 adjacent the end of the bell section, and an annular reinforcing bell membrane recess 38 inward of the reinforcing rings 36 .
[0021] A typical pipe has a forty-eight inch inside diameter, an outer shell wall thickness of about 0.100 inches, and an inner liner wall thickness of about 0.030 inches. Such a pipe may be extruded at a rate of about one foot/minute. The bell section length of a forty eight inch diameter pipe is about ten inches. With the present invention, there is no need to slow the extrusion process to thicken the outer shell bell section.
[0022] The extrusion process is conducted with the material at a temperature of 270 to 425 degrees Fahrenheit. The material must be cooled to the glass transition temperature of the base resin material of the pipe so that the outer shell will release from the mold and hold its shape. For example, a temperature of about 225 degrees Fahrenheit may allow the outer shell bell section to release from its mold. The exact temperature may vary depending on the base resin material of the pipe. Once the pipe is cooled and removed from the mold, a secondary bell reinforcing process takes place.
[0023] FIG. 2B shows a high tensile strain limiting annular band or membrane 40 positioned in the bell membrane recess 38 . The membrane 40 may be inserted into the recess 38 without difficulty when the outer layer 32 is still pliable from the molding process. The membrane 40 is preferably formed from a fiber reinforced polymer. Preferred fibers include but are not limited to nano carbon fibers, glass fibers, propylene fibers, and polyester fibers. Preferred polymers include but are not limited to high density polyethylene, polypropylene and polyvinylchloride (PVC). The preferred fiber reinforcement is long strand glass fiber. The membrane preferably is 10% glass fiber content by weight, but can be 5% to 25% of the membrane by weight for certain applications, with the remainder being the polymer resin. The reinforcing membrane has a relatively high tensile strength, with a preferred modulus of elasticity of 1.5 to 15 times the modulus of elasticity of the base polymer used to make the pipe. The glass fiber membrane has little to no creep, which is important in maintaining the circumference and diameter of the bell and in keeping associated gasket compression for long term water tightness.
[0024] The preferred embodiment of the reinforcing membrane is an extruded polypropylene. It can be extruded in eight inch wide strips having thicknesses varying from 0.05 to 0.25 inches and cut into a preferred width for various applications. The membrane strips are also cut to proper length, with the ends fused or mechanically joined together to form an annular membrane. Of course, the membrane may be formed of many other materials which are not necessarily fusible with the pipe resin. For example, a steel membrane could be used in certain applications.
[0025] The width and thickness of the membrane may vary depending on the strength needed for any particular application, but it is preferred that the membrane width is about 40% of the bell length, or 4 inches in the present example. The membrane 40 provides a precise diameter, not subject to the shrinkage variability of the pipe bell during the extrusion process and minimizes bell strain during spigot and gasket insertion. The reinforcement membrane 40 will have significantly closer tolerances than that which can be achieved by manufacturing a single layer bell. When the membrane 40 is compressed between the outer shell and inner liner, closer tolerances can be achieved than what is capable with currently known processes.
[0026] FIG. 2C shows the inner liner 34 reformed to the outer shell 32 in a secondary process. After the strain limiting membrane 40 is inserted, the inner liner extrusion layer 34 is heated and formed to the contour of the outer shell extrusion layer 32 . The inside diameter of the reinforcing membrane 40 is generally identical to the inside diameter of the outer layer adjacent to the recess 38 to provide a consistent inside diameter of the ring/outer layer assembly, and a smooth inside diameter of the inner liner after it is formed to the outer layer, even under the reinforcing ribs 36 .
[0027] The inner liner 34 is heated until its surface reaches a temperature above the glass transition temperature and below the melt temperature of the inner liner's thermoplastic resin material. The heating process will allow the reforming of the inner liner extrusion layer as shown in FIG. 2D . Reforming the inner liner 34 is accomplished by applying radial force to the inner liner during or after the secondary heating process, forming the inner liner 34 to the outer layer 32 . Alternatively, the pipe ends can be temporarily capped as is well known in the art, and pressure or vacuum can be applied to radially force the inner liner outwardly to engage and form with the outer shell. In any event, reforming the inner liner 34 in close contact with the outer layer 32 traps the strain limiting membrane 40 between the two layers in the bell recess.
[0028] If the outer shell 32 is also heated until its inner surface reaches a temperature above the glass transition temperature and below the melt temperature of the outer shell's thermoplastic resin material, the reforming of the inner liner 34 to the outer layer 32 may result in a binding or fusion of the two layers. This is preferred for certain applications, but is not necessary. Alternatively, the inner layer 34 and outer shell 34 may be attached together by a bonding agent or adhesive, but this too is not necessary in all applications.
[0029] It is clear from FIG. 2D that the inner liner conforms to the shape of the inside surface of the outer layer/reinforcing ring assembly, except for the region under the reinforcing ribs 36 . During the step of forming the inner liner to the outer layer, the force applied to the inner layer 34 to expand it against the outer shell 32 is not great enough under the stiffening ribs 36 to conform the inner liner to the shape of the reinforcing ribs.
[0030] It is not essential that the inner liner 34 retains a perfect cylindrical shape underneath the reinforcing ribs 36 . Even a small smoothing out the reinforcing ribs will alleviate previously known gasket rolling problems when a bell and spigot joint are assembled. The inner liner bridging the gaps formed by the stiffener ribs will enable the gasket to pass under the bell stiffener profiles, allowing bells to be designed with additional or more pronounced reinforcing stiffeners than previously used without affecting the inner gasket sliding and sealing surface.
[0031] FIG. 3 shows the traveling mold 41 comprised of mold blocks 41 a, 41 b, and 41 c. Mold blocks 41 and 41 c include convolutions 42 for forming corrugations on the outer pipe layer. Mold block 41 b includes a bell shaping section 44 having annular or spiral recesses 46 for forming annular stiffening ribs in the outer pipe layer, and an annular recess 48 for forming a reinforcing membrane recess. The continuously extruded pipe will be cut in the region generally near the abutment of mold blocks 41 b and 41 c.
[0032] FIG. 4 shows an alternative embodiment of the present invention. In this embodiment, the process is the same, except that the portion of the inner liner 34 ′ adjacent the bell is trimmed or removed and replaced by a separate plastic cylinder 50 made of the same or similar material as the inner liner 34 ′ which is bondable with the outer shell 32 ′. The process of heating, expanding and attaching the plastic cylinder 50 to the outer shell 32 ′ may be accomplished in the same manner as previously described when the inner liner is used. The cylinder 50 will maintain a cylindrical shape after being joined to the outer shell 32 ′ even below the reinforcing ribs 38 ′ as previously described. Optionally, a reinforcing recess such as 38 may be formed in the cylinder 50 or the outer shell 32 ′ and a reinforcing ring 40 may be applied as previously described.
[0033] FIG. 5A shows a triple wall composite bell 60 having an outer layer 62 , an inner liner 64 , and an intermediate corrugated layer 66 . In this alternative embodiment, after the initial extrusion process and after cooling of the pipe and removal from the mold, the intermediate layer 66 is trimmed or cut near an end of the pipe section 68 as shown in FIG. 4B . The outer shell 62 is then heated and formed in the shape of a bell, optionally with reinforcing stiffeners or ribs and a reinforcing ring recess similar to those shown in FIG. 2A . The bell may then be finally formed by expanding inner liner 64 to conform to the outer shell in the same manner as previously described, with or without a reinforcing ring.
[0034] This invention is useful for pipe diameters of 4 to 120 inches, although pipes having diameters of 60 to 120 inches are typically made by extruding flat multi-layer strips which are helically or spirally wound and bonded to form what is commonly referred to as profile wall pipe. The bells for profile wall pipe is generally roll formed, and such bells are commonly called roll formed bells.
[0035] The outer shell of pipe may range in thickness from 0.070 to 0.250 inches, depending on pipe diameter, with the inner liner generally about 30% of the thickness of the outer shell. The reinforcing membrane of can vary in thickness from 10% of the outer shell thickness to 100% of the outer shell thickness and width from 10% of the bell length to 100% of the bell length depending on the pipe diameter and strength requirements.
[0036] The bell design of this invention may be used with manufacturing methods other than those of the preferred embodiments. For example, the design may be used with injection molded bells, and with non-corrugated pipe.
[0037] The principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
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A multi-layer bell is formed from the outer shell of a multi-layer pipe in a secondary process, thereby allowing the extrusion process to be conducted at normal speeds. The bell may include a strain limiting membrane fused or mechanically secured between the outer shell extrusion layer and the inner liner extrusion layer, increased hoop or circumferential stiffness. This invention allows the extrusion process to be in its simplest form, with no adjustments to the corrugator or extruder speeds.
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BACKGROUND
The present invention relates generally to chemical mechanical polishing of substrates, and more particularly to an apparatus and method for supplying slurry to a polishing pad.
Integrated circuits are typically formed on substrates, particularly silicon wafers, by the sequential deposition of conductive, semiconductive or insulative layers. After each layer is deposited, the layer is etched to create circuitry features. As a series of layers are sequentially deposited and etched, the outer or uppermost surface of the substrate, i.e, the exposed surface of the substrate, becomes increasingly non-planar. This non-planar surface presents a photolithography problem for the integrated circuit manufacturer. Therefore, there is a need to periodically planarize the substrate surface to provide a flat surface.
Chemical mechanical polishing (CMP) is one accepted method of planarization. This planarization method typically requires that the substrate be mounted on a carrier or polishing head. The exposed surface of the substrate is placed against a moving polishing pad. The polishing pad may be either a “standard” pad or a fixed-abrasive pad. A standard pad has a durable roughened surface, whereas a fixed-abrasive pad has abrasive particles held in a containment media. The carrier head provides a controllable load, i.e., pressure, on the substrate to push it against the polishing pad. A polishing slurry, including at least one chemically-reactive agent, and abrasive particles, if a standard pad is used, is supplied to the surface of the polishing pad.
An effective CMP process not only provides a high polishing rate, but also provides a substrate surface which is finished (lacks small-scale roughness) and flat (lacks large-scale topography). The polishing rate, finish and flatness are determined by the pad and slurry combination, the relative speed between t.-ie substrate and pad, and the force pressing the substrate against the pad.
One problem in CMP is coagulation of the polishing slurry. Specifically, small abrasive particles in the slurry tend to conglomerate to form larger particulates. These large particulates create scratches, e.g., shallow grooves on the order of 300 angstroms (A) deep, in the substrate surface. These scratches render the substrate finish unsuitable for integrated circuit fabrication, decreasing process yield.
SUMMARY
In one aspect, the invention is directed to an apparatus for supplying a slurry to a polishing surface. The apparatus has a slurry source, a slurry supply line, and a slurry return line. The slurry supply line extends from the slurry source and has an outlet that may be fluidly coupled to a dispensing port positionable over the polishing surface to deliver slurry thereto during a chemical mechanical polishing operation. The slurry return line extends between the dispensing port and the slurry source, and has an inlet that may be fluidly coupled to the outlet of the slurry supply line to direct slurry away from the dispensing port and to the slurry supply.
In another aspect, the slurry supply line extends from the slurry source and has an outlet located at or proximate to a slurry dispensing point. The slurry return line extends from the slurry source and has an inlet. The slurry supply line and slurry return line are configured so that slurry may be directed from the outlet of the slurry supply line onto the polishing surface during a chemical mechanical polishing operation, and from the outlet of the slurry supply line into the inlet of the slurry return line after the polishing operation is stopped to return slurry to the slurry supply. This substantially eliminates deadleg from the slurry supply line.
Implementations of the invention may include the following. A pump may provide a flow of slurry through the slurry supply line, e.g., during the polishing operation. The pump may also direct slurry through the slurry supply line and the slurry return line, e.g., after the polishing operation is stopped. Thus, the pump may operate to provide a substantially continuous flow of slurry through the slurry supply line. A filter may be located between the slurry source and the pump.
A valve, e.g., a ball valve or a plunger valve, at the outlet of the slurry supply line may be operable between a first position in which the outlet of the slurry supply line is fluidly coupled to the port to dispense slurry onto the polishing pad and a second position in which the outlet of the slurry supply line is fluidly coupled to the inlet of the slurry return line. A portion of the slurry supply line may be flexible and moveable between a first position in which the outlet of the slurry supply line dispenses slurry to the polishing surface and a second position in which the slurry supply line is fluidly coupled to the supply return line.
The inlet of the slurry return line may be located adjacent to the polishing surface to receive slurry from the slurry supply line. The outlet of the slurry supply line may be movable between a first position in which it is positioned over the polishing surface and a second position in which it positioned over the inlet of the slurry return line.
An arm may extend over the polishing surface and support at least a portion of the slurry supply line. The outlet of the slurry supply line may be located at the end of the arm. The slurry supply line can be a passage in the arm or tubing supported by the arm. A machine base may support the polishing surface, and the arm may be pivotally connected to the base.
A second slurry supply line may extend from the slurry source and have a second outlet proximate to a second slurry dispensing point. A second slurry return line may extend from the slurry source and have an inlet. The second slurry supply line and second slurry return line may be configured so that slurry may be directed from the outlet of the slurry supply line to a second polishing surface during a chemical mechanical polishing operation, and into the inlet of the slurry return line after the polishing operation is stopped to return slurry to the slurry supply. This substantially eliminates deadleg from the second slurry supply line.
In another aspect, the invention is directed to a method of chemical mechanical polishing. In the method, slurry is pumped from a slurry source to an outlet of a slurry supply line that is positionable over a polishing surface. The slurry is directed from the outlet to the polishing surface. The outlet of the slurry supply line is fluidly coupled to an inlet of a slurry return line after the polishing operation has stopped to return the slurry to the slurry source.
Implementations of the invention may include the following. The pumping may create a flow of slurry through the slurry supply line and the slurry return line after polishing operation has stopped. The pumping may create a substantially continuous flow of slurry through the slurry supply line.
Advantages of the invention may include the following. Coagulation of slurry is reduced or eliminated, thereby reducing scratch defects and increasing process yield.
Other features and advantages will be apparent from the following description, including the drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic exploded perspective view of a chemical mechanical polishing apparatus.
FIG. 2 is a schematic diagram of a prior art slurry delivery system.
FIG. 3A is a schematic diagram of a slurry delivery system according to the present invention.
FIGS. 3B and 3C are enlarged views of a valve from the slurry delivery system of FIG. 3 A.
FIG. 4 is a schematic diagram of a slurry delivery system having a flexible slurry supply line.
FIG. 5 is a schematic diagram of a slurry delivery system having a plunger valve.
FIG. 6 is a schematic diagram of a slurry delivery system having a slurry catch inlet.
DETAILED DESCRIPTION
Referring to FIG. 1, one or more substrates 10 will be polished by a chemical mechanical polishing apparatus 20 . A description of polishing apparatus 20 may be found in U.S. Pat. No. 5,738,574, the entire disclosure of which is incorporated herein by reference. Polishing apparatus 20 includes a lower machine base 22 with a table top 23 mounted thereon and a removable outer cover (not shown). Table top 23 supports a series of polishing stations, including a first polishing station 25 a , a second polishing station 25 b , a final polishing station 25 c , and a transfer station 27 . Transfer station 27 forms a generally square arrangement with the three polishing stations 25 a , 25 b and 25 c . Transfer station 27 serves multiple functions, including receiving individual substrates 10 from a loading apparatus (not shown), washing the substrates, loading the substrates into carrier heads, receiving the substrates from the carrier heads, washing the substrates again, and finally, transferring the substrates back to the loading apparatus.
Each polishing station includes a rotatable platen 30 on which is placed a polishing pad. The first and second stations 25 a and 25 b may include a relatively hard polishing pad 32 , whereas the final polishing station may include a relative soft polishing pad 34 . If substrate 10 is an “eight-inch” (200 millimeter) or “twelve-inch” (300 millimeter) diameter disk, then the platens and polishing pads will be about twenty inches or thirty inches in diameter, respectively. Each platen 30 may be a rotatable aluminum or stainless steel plate connected to a platen drive motor (not shown). For most polishing processes, the platen drive motor rotates platen 30 at thirty to two hundred revolutions per minute, although lower or higher rotational speeds may be used.
Each polishing station 25 a - 25 c may further include an associated pad conditioner apparatus 40 . Each pad conditioner apparatus 40 has a rotatable arm 42 holding an independently-rotating conditioner head 44 and an associated washing basin 46 . The pad conditioner apparatus 40 maintains the condition of the polishing pad so that it will effectively polish substrates.
At each polishing station, a polishing slurry 50 containing deionized water, abrasive particles (e.g., silica particles for oxide polishing) and a chemically reactive component (e.g., potassium hydroxide for oxide polishing) is supplied to the polishing pad surface by a slurry delivery system 200 . As described in greater detail below, the slurry delivery system is designed to prevent coagulation of the slurry.
Two or more intermediate washing stations 55 a and 55 b may be positioned between neighboring polishing stations. The washing stations rinse the substrates as they pass from one polishing station to another.
A rotatable multi-head carousel 60 is positioned above lower machine base 22 . Carousel 60 is supported by a center post 62 and is rotated thereon about a carousel axis 64 by a carousel motor assembly located within machine base 22 . Center post 62 supports a carousel support plate 66 and a cover 68 . Carousel 60 includes four carrier head systems 70 a , 70 b , 70 c , and 70 d . Three of the carrier head systems receive and hold substrates, and polish them by pressing them against the polishing pads on the platens of the polishing stations. One of the carrier head systems receives a substrate from and delivers a substrate to transfer station 27 .
The four carrier head systems 70 a - 70 d are mounted on carousel support plate 66 at equal angular intervals about carousel axis 64 . Center post 62 allows the carousel motor to rotate carousel support plate 66 and to orbit carrier head systems 70 a - 70 d and the attached substrates thereto about carousel axis 64 .
Each carrier head system 70 a - 70 d includes a carrier or carrier head 80 . A carrier drive shaft 74 connects a carrier head rotation motor 76 (shown by the removal of one quarter of cover 68 ) to carrier head 80 so that each carrier head 80 can independently rotate about its own axis. There is one carrier drive shaft and motor for each head. In addition, each carrier head 80 independently laterally oscillates in a radial slot 72 formed in carousel support plate 66 . A slider (not shown) supports each drive shaft in its associated radial slot. A radial drive motor (not shown) may move the slider to laterally oscillate the carrier head.
The carrier head 80 performs several mechanical functions. Generally, the carrier head holds the substrate against the polishing pad, evenly distributes a downward pressure across the back surface of the substrate, transfers torque from the drive shaft to the substrate, and ensures that the substrate does not slip out from beneath the carrier head during polishing operations.
The carrier head 80 may include a flexible membrane (not shown) which provides a substrate receiving surface. A description of a suitable carrier head 80 may be found in U.S. patent application Ser. No. 08/745,679, entitled a CARRIER HEAD WITH a FLEXIBLE MEMBRANE FOR a CHEMICAL MECHANICAL POLISHING SYSTEM, filed Nov. 8, 1996, by Steven M. Zuniga et al., assigned to the assignee of the present invention, the entire disclosure of which is incorporated herein by reference.
In order to more clearly explain the invention, a conventional slurry delivery system will first be described. Referring to FIG. 2, a conventional slurry delivery system 100 includes a slurry reservoir 102 , a pump 104 , a coarse filter 106 located upstream of pump 104 , and a point-of-use (POU) filter 108 located downstream of pump 104 . Slurry is pumped through filters 106 and 108 by pump 104 , and returned to reservoir 102 through a slurry manifold 110 . Pump 104 may be operated so that slurry from reservoir 102 is continuously circulated through the slurry line and the filters. The continuous motion of the slurry helps prevent coagulation, and filters 106 and 108 remove slurry particle conglomerates from slurry manifold 110 .
A plurality of peristaltic pumps 112 a , 112 b and 112 c , associated with polishing stations 25 a , 25 b and 25 c , respectively, are fluidly coupled to slurry manifold 110 by intake lines 114 a , 114 b and 114 c , respectively. Three supply lines 116 a , 116 b and 116 c deliver slurry from peristaltic pumps 112 a , 112 b and 112 c , respectively, to the polishing pads at the polishing stations. Each supply line extends through a combined slurry/rinse arm 118 that extends over platen 30 . Although arm 118 is illustrated with only one supply line, the arm may include two or more supply lines to distribute multiple slurries to the surface of the polishing pad. The arm 118 also includes several spray nozzles (not shown) which provide a high pressure rinse of the polishing pad at the end of each polishing and conditioning cycle.
Unfortunately, the portion of the slurry delivery system extending between slurry manifold 110 and each polishing pad, e.g., intake line 114 a , peristaltic pump 112 a and supply line 116 a , constitutes a so-called “deadleg”. When slurry is not required at one of the polishing stations, e.g., polishing station 25 a , the peristaltic pump associated with that polishing station is stopped, and the slurry in the deadleg sits stagnant and coagulates. When the peristaltic pump is restarted, coagulated slurry will be delivered to the polishing pad, where it can scratch the substrate and cause defects.
Referring to FIGS. 3A-3C, a slurry delivery system 200 is constructed without a deadleg. Slurry delivery system 200 includes a slurry reservoir 202 , a primary pump 204 , and a coarse filter 206 located between primary pump 204 and reservoir 202 . Reservoir 202 , primary pump 204 and coarse filter 206 may be located in machine base 22 or in a separate slurry supply module 220 . Three peristaltic pumps 208 are connected to primary pump 204 by a slurry supply manifold 210 . A slurry/rinse arm 218 extends over each polishing pad, and a three-way valve 214 is located at the end of the each arm. Each peristaltic pump 208 is fluidly coupled to a first port 228 a of the three-way valve by a slurry supply line 212 . A point-of-use filter 216 may be located in each slurry supply line 212 between the peristaltic pump and the three-way valve. A slurry return line 222 extends back through the arm to fluidly couple a second port 288 b of each valve 214 to a slurry return manifold 224 , which returns the slurry to reservoir 202 . A third port 228 c of valve 214 is connected to an exit port 226 (see FIGS. 3A and 3B) in the arm to dispense slurry onto the polishing pad.
In the configuration illustrated in FIGS. 3A-3C, valve 214 is a ball valve rotatable between a first position (shown in FIG. 3A) in which slurry supply line 212 is fluidly coupled to exit port 226 , and a second position (shown in FIG. 3B) in which slurry supply line 212 is fluidly coupled to exit port 226 . Thus, when the valve is in the first position, slurry is directed through slurry supply line 212 and exit port 226 and onto the polishing pad. In contrast, when the valve is in the second position, slurry is pumped out to the end of arm 218 via slurry supply line 212 and returned to reservoir 202 via slurry return line 222 . Pumps 204 and 208 are operated to provide a substantially continuous, i.e., both during and between polishing operations (but not when slurry delivery system 200 is shut down for maintenance and the like), flow of slurry through the slurry supply line, thereby reducing coagulation and substrate defects.
The slurry supply line 212 may be a passageway formed integrally through arm 218 , or it may be a flexible or rigid tube supported by the arm (either inside or outside the arm housing). Alternately, the slurry supply line may be sufficiently rigid that an arm is not required. Similarly, slurry return line 222 may be a passage formed through the arm, a flexible tube supported by the arm, or a rigid self-supporting tube.
FIG. 4 illustrates a slurry delivery system 200 ′ in which the ball valve is replaced with a moveable tubing. For clarity, only the portion of the slurry delivery system associated with a single polishing station is illustrated. Additionally, the slurry reservoir, the coarse filter, the primary pump, the peristaltic pump and the point-of-use filter are not shown. A slurry/rinse arm 218 ′ supports a slurry supply line 230 having an outlet 234 near the end of the arm. The slurry supply line 230 includes a flexible portion 232 located adjacent an aperture 238 in the arm 218 ′. The flexible portion of slurry supply line 230 is moveable between a first position in which the outlet of the slurry supply line dispenses slurry onto the polishing pad via outlet 234 , and a second position (shown in phantom) in which the outlet of the slurry supply line is connected to an inlet 239 of a slurry return line 236 . Inlet 239 may be provided with a seal (not shown) to prevent leakage of the slurry when the slurry supply line is connected to the slurry return line. Alternately, inlet 239 may be slightly wider than outlet 234 . The flexible portion 232 of slurry supply line 230 may be actuated between the first and second positions by a pneumatic actuator 237 . Between polishing operations at this particular polishing station, slurry supply line 230 is fluidly coupled to slurry return line 236 so that the pumps continuously recirculate slurry through the slurry delivery system. On the other hand, during polishing operations, flexible portion 232 is shifted so that slurry flows through outlet 234 and aperture 238 onto the polishing pad.
Referring to FIG. 5, in another configuration, a slurry delivery system 200 ″ includes a slurry supply line 240 to transport slurry to a plunger valve 242 located adjacent an aperture or port 244 at the end of a slurry/rinse arm 218 ″. The plunger valve may be operated between a first position in which a first valve passage 250 directs slurry from slurry supply line 240 onto the polishing pad, and a second position (shown in phantom) in which a second valve passage 252 fluidly couples slurry supply line 240 to a slurry return line 248 . Thus, during polishing at this particular polishing station, the plunger valve is in the first position to dispense slurry onto the pad. On the other hand, between polishing operations, the plunger valve is in the second position so that slurry is continuously circulated through the slurry delivery system. The plunger valve may be equipped with a lip-seal (not shown) to prevent leakage of the slurry from slurry supply line 240 and slurry return line 248 . Plunger valve 242 may be actuated by a pneumatic actuator 246 in such a fashion as to minimize particle generation.
Referring to FIG. 6, in another embodiment (illustrated for a single polishing station 25 ), a slurry delivery system 300 includes a slurry reservoir 302 , a primary pump 304 , a coarse filter 306 , a peristaltic pump 308 and a POU filter 310 . Slurry delivery system 300 also includes a generally funnel-shaped slurry catch cup 322 located adjacent platen 30 . The slurry catch cup 322 is fluidly coupled to reservoir 302 by a slurry return line 324 . A slurry supply line 314 extends through a moveable slurry/rinse arm 318 to direct slurry onto polishing pad 32 . The arm 318 is pivotally connected to table top 23 and may be moved between a first position in which an outlet 320 at the end of slurry supply line 314 is located over polishing pad 32 , and a second position (illustrated in phantom) in which outlet 320 is positioned over slurry catch cup 322 . A motor or pneumatic actuator 316 may be connected at the base of arm 318 to pivot the arm. Thus, during polishing, slurry delivery system 300 may position arm 318 over polishing pad 32 , whereas between polishing operations, pneumatic actuator 316 may rotate or pivot arm 318 over slurry catch cup 322 so that slurry is continuously recirculated though slurry supply line 314 and slurry return line 324 .
The invention is not limited to the embodiments depicted and described. Rather, the scope of the invention is defined by the appended claims.
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An apparatus for supplying a slurry to a polishing surface has a slurry source, a slurry supply line, and a slurry return line. The slurry supply line and slurry return line are configured so that slurry may be directed from the outlet of the slurry supply line onto the polishing surface during a chemical mechanical polishing operation, or into an inlet of the slurry return line after the polishing operation is stopped. This permits continuous circulation of slurry through the slurry supply line to prevent coagulation.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application (under 35 U.S.C. §371) of PCT/EP2009/000445, filed Jan. 23, 2009, which claims benefit of German applications 10 2008 005 983.8, filed Jan. 24, 2008 and 10 2008 022 313.1, filed May 6, 2008.
TECHNICAL FIELD
[0002] The invention relates to an end cap for a drive cable that is used especially in motor vehicles, for example, in sliding and/or tilting sunroofs, or in roller blinds such as, for instance, sun blinds. The invention also relates to a drive cable having such an end cap, as well as to a method for the production of an end cap and to a method for the production of a drive cable.
BACKGROUND ART
[0003] Drive cables or transmission cables of the above-mentioned type are disclosed, for example, in European patent applications EP 0 409 103 A2 and EP 0 181 995 A2. Such drive cables are preferably employed for sliding and/or tilting sunroofs of motor vehicles, whereby the drive cables can usually be axially adjusted by means of a motor-driven screw and whereby the drive cables are attached to a part that is to be adjusted, for example, the sunroof.
[0004] Drive cables are usually manufactured as a continuous product made of metal strands consisting of several braids having an applied pitch helix, and they have to be subsequently cut to the required length. The ends of the drive cables created in this process tend to splay because of the loose individual wires of the cable.
[0005] Another problem of the prior-art drive cables is that their ends tend to rattle once they have been installed.
[0006] In order to solve these problems, a procedure known from the state of the art consists of providing the end of the drive cable with a metal sleeve. This metal sleeve is normally hammered in place. It has been found that this approach can effectively prevent splaying of the end of the drive cable but, because of the metal used, the end of the drive cable still tends to rattle once it has been installed.
[0007] In order to remedy the rattling problem encountered with metal sleeves, the alternative approach was put forward to provide a sleeve made of plastic instead of a metal sleeve. Since it is not easy to attach such prefabricated plastic sleeves to the ends of the drive cable by means of mechanical methods, an attempt was made to injection-mold the plastic sleeves directly onto the end of the drive cable. However, it was found that, during the cutting, the ends of the drive cable can acquire very sharp burrs that can damage the injection-molded sleeve. This is why the drive cable has to be polished in order to remove the burrs. This additional work step increases the cost of such drive cables.
[0008] Furthermore, it has been found that a directly injection-molded plastic sleeve frequently does not adhere well since it is often the case that oil residues from the production process adhere to the drive cable. For this reason, it must be ensured that at least the ends of the drive cable are free of oil, which can be done by changing the production process of the strands or by performing additional work steps to remove the oil.
[0009] Another problem of the injection-molded end sleeves made of plastic is that, due to the requisite high injection-molding pressure, the injection-molded plastic material tends to migrate along the applied pitch helix(es), where it hardens. The plastic material present on the pitch helix can chip off and the chipped material, in turn, can likewise give rise to rattling noises.
[0010] German utility model DE 88 10 699 U1 discloses a connecting piece for control cables having a connecting tube to establish a connection to a wire cable and to an injectio n-molded eyelet m ade of hard-elastic plastic affixed thereto, which can be used to operate gears.
[0011] German patent application DE 10 2005 006 432 A1 discloses a holding arrangement for lifting and lowering a component, especially a cargo compartment cover of a vehicle having a first holding element that is joined to a pulling element that can be non-positively clamped with a second holding element in such a manner that the clamping connection between the holding elements can be released at a predefined load.
[0012] Therefore, it would be desirable to put forward an end cap for a drive cable, a drive cable, a method for the production of an end cap as well as a method for the production of a drive cable, which, taken together, allow an end of the drive cable to be effectively protected against splaying while, at the same time, effectively reducing the tendency of the drive cable to rattle. It would also be desirable to have an end cap and a drive cable that are cost-efficient to produce.
SUMMARY OF THE INVENTION
[0013] According to the first inventive idea, an end cap for a drive cable is provided which can especially be employed in motor vehicles, particularly for sliding and/or tilting sunroofs, or roller blinds, especially sun blinds. The end cap has two sections, namely, a cold-formable connecting section for connecting the end cap to the drive cable, as well as an end section made of plastic adjacent to the connecting section. Therefore, the end section and the connecting section together form the end cap.
[0014] The connecting section has an opening facing the end section, whereby the end section preferably partially penetrates the connecting section through the opening, thus allowing a positive connection between the connecting section and the end section. The opening is preferably configured and arranged so as to be radially symmetrical. Attaching the end section to the connecting section is facilitated by such an opening.
[0015] Such an end cap makes it possible to effectively and simultaneously safeguard a drive cable from splaying and rattling, whereby the cold-formable connecting section achieves an excellent joining of the end cap to the drive cable since a positive and frictional connection is made between the end cap and the drive cable. The connection can be, for instance, hammered, soldered or crimped. However, the end section made of plastic also reduces the tendency of the drive cable to rattle since plastic is known to be a good sound insulator.
[0016] Furthermore, such an end cap can also be cost-effectively produced employing the method according to the invention described below. Another advantage of the end cap according to the invention is that the end of the drive cable created by the cutting does not require a pretreatment such as grinding or degreasing, since the end cap can be easily pulled over the untreated end of the drive cable.
[0017] Within the scope of the invention, instead of plastic, the end section can also be made of other materials known from the state of the art that do not tend to rattle very much, for example, natural materials such as cork or rubber and the like, or other materials, e.g. foams, elastomers, etc.
[0018] An especially preferred material for the connecting section of the end cap is metal. Metal is particularly easy to process, for instance, by means of deep-drawing, in addition to which it is also inexpensive. Furthermore, metal can be shaped by means of hammering, which facilitates the assembly of the end cap.
[0019] Another advantageous embodiment provides that the end section is made of a thermoplastic, for example, polyacetal (POM), polyamide (PA) or polypropylene (PP). Thermoplastics can be processed very well by means of injection-molding methods.
[0020] It is likewise preferred for the end cap to be configured so as to be essentially radially symmetrical. In this context, the connecting section as well as the end section can be configured so as to be radially symmetrical and can be attached to each other along a shared axis of symmetry. This facilitates the attachment of the end cap to the drive cable, particularly by means of hammering.
[0021] As an alternative, the connecting section, especially the end section, can have radially distributed webs. This can reduce the tendency of the drive cable to rattle and can simplify the installation of the drive cable.
[0022] According to another advantageous embodiment, it is provided that the end section is injection-molded onto the connecting section. In this manner, the end cap can be produced very simply and inexpensively, while also ensuring the reliable and dimensionally accurate production of the end cap.
[0023] Furthermore, it can be advantageously provided that the connecting section is configured so as to be tapered towards the end section. On the one hand, this allows the end section to be installed on or affixed to the connecting section without the end section circumferentially protruding substantially beyond the diameter of the connecting section, which would cause the end cap to acquire an inconveniently large diameter, and, on the other hand, this allows a particularly secure connection between the connecting section and the end section, even when the connecting section is deformed in order to attach the connecting section to the end of the drive cable.
[0024] Preferably, it can be provided that the end cap is configured so as to widen at one end of the connecting section facing away from the end section. This makes it easier to insert the end of the drive cable into the end cap.
[0025] According to another advantageous embodiment of the invention, the end section is configured in two pieces, and it is integrally joined to form a one-piece end section when the end cap is assembled. This facilitates the assembly of the end section.
[0026] Another embodiment of the end cap according to the invention advantageously provides that the end section is configured so as to be slotted towards the connecting section. This make it very easy to attach the end section to the connecting section in that the end section is inserted into the connecting section and the slotted area of the end section is bent apart and permanently deformed in such a way that a positive connection is created between the end section and the connecting section.
[0027] If the end section has a front area and a rear area, whereby the rear area is intended to be inserted into the connecting section, the end section can be better secured in the connecting section if the connecting section has an opening that serves to allow the insertion of the end section and that has a diameter that is smaller than the diameter of the rear part of the end section. This causes the rear part of the end section to be firmly clamped in the connecting section. In this context, a constriction that allows latching can be provided in the rear part of the end section. By hammering the connecting section after insertion of the end section, the bond between the connecting section and the end section can be further improved.
[0028] Another aspect of the invention relates to a drive cable that has an end cap in accordance with the invention described above. Such drive cables can be produced cost-effectively, and they combine high quality with a low tendency to rattle.
[0029] Another aspect of the invention relates to a method for the production of an end cap in accordance with the invention described above. The method according to the invention provides for the preparation of a connecting section and for the attachment of an end section to the connecting section. An end cap produced according to this method is very sturdy, can be easily and reliably attached to the end of the drive cable, does not tend to rattle and can also be produced cost-effectively.
[0030] Particularly advantageously, the end section can be attached to the connecting section by means of insertion, ultrasound welding, thermal upsetting, plastic cold-forming, driving in or by means of direct injection molding. These methods allow a particularly cost-effective production of the end caps while attaining a high level of quality.
[0031] Moreover, it can be advantageously provided that the end section and the connecting section are manufactured separately and then clipped together. This translates into a particularly easy assembly.
[0032] Furthermore, it can be provided that the end section and the connecting section are manufactured separately and that the end section is then latched into the connecting section. This accounts for a particularly easy attachment of the end section in the connecting section.
[0033] According to a last aspect of the invention, a method for the production of a drive cable is provided that is especially used in motor vehicles, particularly for sliding and/or tilting sunroofs, or roller blinds, especially sun blinds. In the method according to the invention, a cable section is provided and an end cap that is configured in accordance with the above-mentioned invention is attached to one end of the drive cable. This method can be executed particularly easily and allows the production of particularly high-grade drive cables.
[0034] An advantageous embodiment of the method according to the invention provides that the end cap is attached to the end of the drive cable by means of hammering. In comparison to other conceivable means of attachment, hammering is easy to carry out and ensures a reliable connection of the connecting cap to the end of the drive cable.
[0035] Advantageously, the connecting section is attached to the end of the drive cable and the end section is injection-molded onto the already attached connecting section. This allows production with very few rejects since the connecting section has already acquired its final shape before the end section is attached by means of injection-molding. Otherwise, it can happen in rare cases that the deformation of the end section causes the end section to break off, especially if the end cap has not been properly inserted into the hammering device.
[0036] Additional objectives, advantages, features and application possibilities of the present invention ensue from the description below of an embodiment on the basis of the drawings. In this context, all of the described and/or depicted features, either on their own or in any meaningful combination, constitute the subject matter of the present invention, also irrespective of their compilation in the claims to which they refer back.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The following is schematically shown:
[0038] FIG. 1 an end cap according to the invention;
[0039] FIG. 2 a cross section through the end cap from FIG. 1 along the sectional line A-A;
[0040] FIG. 3 a cross section through an alternative embodiment of the end cap according to the invention;
[0041] FIG. 4 an end section of an end cap according to the invention;
[0042] FIG. 5 a third embodiment of an end cap according to the invention;
[0043] FIGS. 6 a to 6 c a drive cable having a conventional metal sleeve in a top view ( FIG. 6A ), in a cross section ( FIG. 6B ) through a drive cable, as well as in a cross section through a prior-art sleeve ( FIG. 6C );
[0044] FIG. 7 a drive cable according to the state of the art, with an injection-molded end section, as well as
[0045] FIGS. 8 A,B a fourth embodiment of an end cap according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0046] FIG. 1 shows an end cap 2 according to the invention, comprising a connecting section 4 as well as an end section 6 . The end cap 2 according to the invention is configured so as to be essentially rotationally symmetrical and tapers gradually towards the side facing away from the drive cable.
[0047] The connecting section 4 is made of metal that is easy to cold-form. The connecting section 4 serves to allow the insertion of an end of the drive cable (not shown here) into the end cap 2 and to fasten the end cap 2 onto the end of the drive cable. The visible part of the connecting section 4 is configured so as to be primarily cylindrical, as a result of which the connecting section 4 can be properly fastened, for instance, by being hammered onto the end of the drive cable.
[0048] The end section 6 is made of plastic and it is configured with a round tip so as to taper conically in the front end, thus facilitating the installation of a drive cable that is provided with such an end cap 2 .
[0049] FIG. 2 shows a cross section through an end cap 2 according to the invention, along the sectional line A-A from FIG. 1 .
[0050] Towards the end section 6 , the connecting section 4 has an opening 8 that is configured so as to be essentially circular and axially symmetrical. The connecting section 4 has a front area 10 that is tapered towards the front with respect to the diameter of an essentially cylindrical rear section 12 . The opening 8 and the tapering front area 10 make it possible that the end section 6 is merely bent and not sheared when the connecting section 4 is hammered so that the end cap 2 can be attached to the drive cable. The deformation of the connecting section 4 takes place over the entire connecting section 4 and causes compression of the front area 10 that has not been hammered. As a result, the reject rate during the attachment of the end caps 2 onto the cables can be reduced since the plastic of the end area 6 has more of a tendency to rupture than to be deformed when exposed to shear forces.
[0051] The connecting section 4 has a widened area 14 at the end facing the cable, facilitating the insertion of the drive cable into the connecting section 4 .
[0052] In the embodiments shown in FIGS. 1 and 2 , the connecting section 4 and the end section 6 can be joined to each other by means of various methods. One possibility is to directly injection-mold the plastic onto the connecting element 4 that has already been produced, for instance, by means of deep-drawing. For this purpose, the connecting element 4 is placed onto a punch and then injection-molded with the thermoplastic from the top through the opening 8 , so that the plastic assumes the shape of the end section 6 during the forming procedure and, at the same time, a reliable, positive connection is always attained, irrespective of any possible tolerances of the connecting section 4 .
[0053] Other possibilities are explained on the basis of FIG. 4 in conjunction with separately prefabricated end sections 6 made of plastic or the like.
[0054] FIG. 3 shows a cross-sectional view of an alternative embodiment to the embodiment depicted in FIGS. 1 and 2 . The end cap 22 has a connecting section 24 as well as an end section 26 , whereby the connecting section 24 is not configured so as to be conically tapered towards the front in the area facing the end section as was the case with the embodiment first described, but rather, it is configured so as to be continuously cylindrical and to have a collar that protrudes into the end section 26 and that has a circular opening 28 . The end section 26 is injection-molded directly onto the connecting section 24 .
[0055] FIG. 4 shows a conceivable embodiment of the end section 6 of the kind that can be used for the first variant ( FIGS. 1 , 2 ) if the end section 6 is going to be prefabricated separately.
[0056] The end section 6 comprises a front conical area 16 and a rear cylindrical area 18 . The front area 16 widens to a diameter that is greater than the diameter of the rear area 18 and it makes the transition to the rear area 18 with an undercut 20 . This undercut 20 has essentially the contour of the tapered area 10 of the associated connecting element 4 . The end section 6 can then be inserted into the opening 8 of the connecting element and can subsequently be permanently deformed in order to create a positive connection with the connecting section. The deformation of the rear area 18 can be carried out by means of ultrasound welding, thermal upsetting, riveting or cold-forming employing a punch.
[0057] FIG. 5 shows another alternative of an end cap 52 according to the invention. In contrast to the first embodiment shown in FIGS. 1 and 2 , a front end section 56 that is injection-molded onto a connecting section 54 is positively fastened by means of a slotted and shaped rear area 58 . In this embodiment, the end section 56 can be joined to the connecting section 54 by clipping them together.
[0058] FIGS. 6 a to 6 c show a drive cable 32 known from the state of the art. FIG. 6 a depicts a side view of the drive cable 32 . The drive cable 32 is closed on its front end by a sleeve 34 in order to prevent the drive cable 36 from splaying. The prior-art sleeve 34 is made of metal and is fastened to the end of the drive cable 36 by means of hammering.
[0059] FIG. 6 b shows a cross section through the cable from FIG. 6 a . The end of the drive cable 32 protrudes into the end cap 34 all the way to the conically tapered area of the end cap 34 .
[0060] FIG. 6 c shows a cross section of the end cap 34 known from the state of the art. The end cap 34 is configured so as to be conically tapered towards the front. Such end caps can be produced, for example, by means of the deep-drawing method.
[0061] FIG. 7 shows another possibility known from the state of the art for purposes of capping a drive cable. A plastic cap 44 is injection-molded directly onto the end 42 of the cable. For this purpose, the end 42 of the drive cable has to be pre-treated, particularly de-burred; if applicable, it might also be necessary to carry out a cleaning and/or degreasing procedure.
[0062] FIG. 8A shows an end section 66 of an end cap according to a fourth embodiment. The end section 66 has a front section 66 . 1 as well as a rear section 66 . 2 that is inserted into a connecting section 64 shown in FIG. 8B into an opening 68 provided for this purpose.
[0063] The opening 68 of the connecting section 64 has a diameter Z that is smaller than the largest diameter X of the end section 66 . 2 . During the insertion, it can be achieved here that the end section 66 fits securely in the opening 68 of the connecting section 64 provided for this purpose, so that it cannot fall out. In the fourth embodiment, the assembly can be carried out by a simple insertion. The secure fit can be additionally improved by hammering the connecting section 64 after the end section 66 has been inserted, as a result of which the diameter Z of the opening 68 of the connecting section 64 is further reduced in the manner described above, thus achieving an additional clamping effect.
[0064] Of course, the appertaining components do not have to be configured so as to be radially symmetrical. They can also have different shapes such as, for example, oval, angular or the like. This is easily determined within the scope of the concrete requirements.
[0065] The rear section 66 . 2 of the end section 66 can have a constriction 70 towards the front section 66 . 1 , thus improving the secure fit of the end section 66 in the connecting section 64 . The end section 66 then latches into the connecting section 64 . For this purpose, the constriction 70 has a diameter that corresponds approximately to the diameter Z of the opening 68 of the connecting section 64 , or that is even somewhat smaller than that of diameter Z. Such a constriction 70 , however, is not absolutely necessary for the fourth embodiment.
[0066] While preferred embodiments of the invention have been described and illustrated here, various changes, substitutions and modifications to the described embodiments will become apparent to those of ordinary skill in the art without thereby departing from the scope and spirit of the invention.
LIST OF REFERENCE NUMERALS
[0000]
2 end cap
4 connecting section
6 end section
8 opening
10 front area of the connecting section 4
12 rear area of the connecting section 4
14 widened area
16 front area of the end section 6
18 rear area of the end section 6
20 undercut
22 end cap
24 connecting section
26 end section
28 opening
32 drive cable
34 sleeve
36 end of the drive cable
40 drive cable
42 end of the drive cable
44 plastic cap
52 end cap
54 connecting section
56 end section
58 slotted rear area
62 end cap
64 connecting section
66 end section
66 . 1 front section
66 . 2 rear section
68 opening
70 constriction
x diameter of the end section
z diameter of the connecting section
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A terminus cap ( 2; 22; 52; 62 ) for a drive cable has a connection section ( 4; 24; 54; 64 ), which can be cold-formed, on the drive cable, and an end section ( 6; 26; 56; 66 ) made of plastic. The connection section ( 4; 24; 54; 66 ) has an opening ( 8; 28; 68 ) pointing toward the end section ( 6; 26; 56; 66 ), and the end section ( 6; 26; 56; 66 ) engages partially in the opening ( 8; 28; 68 ). An end section ( 6; 26; 56; 66 ) of the terminus cap ( 2; 22; 52; 62 ) may be fastened on the connection section ( 4; 24; 54; 64 ) of the drive cable. The drive cable with terminus cap can be used in pop-up and/or sliding roofs or sunscreen roller blinds of motor vehicles.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods of installing foundation systems and particularly to methods of installing foundation systems for modular type construction.
2. Description of the Prior Art
Constructing shelters has been an essential part of human development since the beginning of civilization. In the last century, buildings have been developed beyond the ordinary “stick-frame” construction into new modular designs. Both types of construction, however, use the same types of foundation, which consists of a concrete footing and some type of concrete or block walls. The building is built upon these walls typically by bolting a bottom sill plate to the top of the foundation wall using “J” bolts that have been embedded in the concrete.
Although these walls have been proven to be strong and reliable, they require quite a lot of site preparation, including surveying, grading, excavating, rebar install, setting concrete forms, pouring concrete (or building wall of block), and then back filling around the foundation. Additionally, in many areas, the foundation wall is waterproofed, which adds additional costs and time.
BRIEF DESCRIPTION OF THE INVENTION
The instant invention eliminates all of the problems associated with conventional concrete type foundations. It consists of a modular structure that requires no heavy equipment, a fraction of construction time, minimal site preparation, bagged concrete, and can be easily assembled by a small crew. The foundation system is hurricane proof and tornado proof. It can be assembled and dismantled, for either emergency housing or permanent construction. It allows additions to be added at any time, simply and easily. Moreover, it allows parts of the building to be removed if desired. The foundation system allows an owner or contractor to build it quickly and easily.
The foundation consists of a number of box bar joists that are square units that are assembled based on a grid layout. The box bar joists are supported by foundation steel tube columns that are embedded into the ground. While installing the foundation columns does require bag concrete and crushed rock, no forms or other complex structures are needed for the installation. Once the columns are installed, the box bar joists are installed using a unique leveling system. Once the box bar joists are level and secured to the columns, the foundation is complete. The use of the box bar joists also allows for expansion or contraction as additional box bar joists can easily be added or removed from the foundation. Once the box bar joists are in place, the foundation is ready for building.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a layout grid (LG) used in installing the foundation system.
FIG. 2 is a detail view of a connection node bolt (CNB) in the layout grid (LG) of the foundation system.
FIG. 3 is a detail view of an auger end post and turnbuckle used in the layout grid (LG) of the foundation system.
FIG. 4 is an exploded view of the connection node bolt (CNB) used in the layout grid (LG) of the foundation system.
FIG. 5 is an expanded detail view of the major components used in the foundation system.
FIG. 6 is a top plan view of a portion of the foundation system.
FIG. 7 is a top perspective view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 8 is a front elevation view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 9 is a side elevation view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 10 is a top plan view of one of the box bar joists (BBJ) used in the foundation system.
FIG. 11 is a front elevation view of two box bar joists (BBJ) used in the foundation system.
FIG. 12 is a perspective detail section view of an alignment of 4 box bar joists (BBJ) used in the foundation system.
FIG. 13 is a top perspective view of one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 14 is a bottom perspective view of one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 15 is an enlarged detail view of the leveling toggle bolts (LTB) on one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 16 is an enlarged side view of one of the leveling toggle bolts (LTB) on one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system.
FIG. 17 is a perspective view of one of the steel tube columns (STC) used in the foundation system.
FIG. 18 is a side elevation view of one of the steel tube columns (STC) used in the foundation system.
FIG. 19 is a top detail view of one of the steel tube columns (STC) used in the foundation system.
FIG. 20 is a perspective view of the components used as part of the aligning bar connector (ABC) system.
FIG. 21 is a detail perspective view of the various aligning bar connector (ABC) systems.
DETAILED DESCRIPTION OF THE INVENTION
The first step in the construction of the foundation is to prepare the site and lay out the grid. Referring now to FIGS. 1-4 , the grid system 100 is shown. Prior to erecting the grid, it is good practice to ensure the site is surveyed by a licensed surveyor to confirm the location of all property lines. In the preferred embodiment, the best site is one that is nearly flat with no more than a six (6) inch rise (slope) from one side of the building exterior to the other in both directions, ensuring all the foundation poles are the same length; slopes greater than six inches will require longer foundation poles. As an alternative, the site can be graded prior to construction. In the next step, level any grade high points greater than six inches or fill areas lower than six inches with crushed rock or fill material and compact so that the area is reasonably smooth and free from irregular surface changes. Next, install wood stakes at the corners of the exterior walls, tie string between the wood stakes six inches above the construction site high point and ensure it is horizontal with a line level. The string may also be run diagonally to each stake to better view the highpoints of the site and make leveling adjustments accordingly.
Once the site is prepared, the next step is to unroll the site layout grid (LG) in the location where the foundation is to be assembled. The assembled grid is shown in FIG. 1 . The grid is made up of lengths of coated wire rope. In the preferred embodiment, this is stainless steel vinyl coated wire rope, ⅛″ Bare OD, 7/32″ Coated OD. The wire rope is cut into sections and secured to end posts.
The grid may be assembled prior to deployment in the field. Note that for the system, the grid 100 has rows 101 and columns 102 of wire rope to make up the grid. The intersections 103 are fitted with special bolts and other hardware called connection nodes, which ensure that the intersections are properly spaced. The foundation poles are placed at these intersections so it is important to make sure they are properly positioned. Once the site is ready the grid is prepared; stretch the grid so that it is flat on the ground. The grid is anchored at the corners with two augers 104 at each of the corners. The augers are installed twelve (12) inches below grade to ensure the wire is taught, and laid directly on grade.
FIG. 2 shows details of the grid 100 showing one of intersections 103 and the hardware for making up the corners, of the rope grid 100 . Note that the ends of the rope are folded over to make thimbles 105 using clips 106 in the ordinary manner. The thimbles are placed on all lines leading to each auger. At each of the intersections 103 formed by the rows and columns are bolt assemblies 110 that hold the grid together.
FIG. 3 is a detail view of an auger and turnbuckle used in the layout grid (LG) of the foundation system. In this view, the actual attachments are shown. As shown, an auger 104 is shown with a thimble 105 on it. A length of wire rope is run out to a turnbuckle 108 . At the other end of the turnbuckle, the main row of the wire rope is attached. This rope runs the width of the foundation area, where it meets another turnbuckle assembly and another auger. Note the bolt assembly 110 at the intersection.
FIG. 4 is an exploded view of the connection node bolt (CNB) assembly 110 . At the bottom of the assembly is a ¾″-10 hex bolt 111 . This bolt is an ASTM A307 grade A bolts that is zinc plated. Note that it also had two grooves 112 formed in it as shown. These grooves 112 are used to hold the wire ropes that form the grid. The grooves allow the wire ropes 102 and 103 to fit within the bolt to produce a compact assembly. The wire ropes 101 and 102 , with the intersection 103 , are positioned between two flat washers 113 . Above the top washer 113 is a lock washer 114 and hex nut 115 as shown (or hex nylon lock nut replacing lock washer and nut).
As noted, the grid can be assembled prior to field layout. Once the augers are set and the grid stretched on them and properly tightened, the outline of the wire four-foot grid pattern is transferred using white pavement marking paint (or its equivalent) sprayed onto the surface of the ground. Next, orange color marking flags are installed at all connector node bolt (CNB) locations; i.e., at all four-foot wire spacing's. These flags are pushed deep into the soil so each flag is just visible to avoid pulling out the flag during construction. Once the flags are set, the layout grid (LG) can be rolled up and removed as the site is now prepared for the foundation installation.
This system uses rigid box bar joists (BBJ) set on plies. Unlike conventional pile foundations, however, the piles (called steel tube columns (STC) here) are attached to a leveled set of box bar joists (BBJ) before they are cemented into place. To do this, the following components are used, as shown in the following figures.
FIG. 5 is an expanded view of the major components used in the foundation system. FIG. 6 is a top plan view of a portion of the foundation system. At the top of the figure are four box bar joists (BBJ) 10 . Below them are four crawlspace leveling lifts (CLL) 20 . Below them are four columnar supports called steel tube columns (STC) 30 that are shown embedded in the ground 1000 . Note that the steel tube columns (STC) 30 , crawlspace leveling lifts (CLL) 20 and box bar joists (BBJ) 10 are the same for a flat site. The installations directions listed below are for a flat site setup. A sloped site setup is the same except that the steel tube columns (STC) are different lengths to accommodate the uneven ground.
Each of the components is discussed in detail below, along with complete installation details.
FIG. 7 is a top perspective view of one of the box bar joists (BBJ) 10 used in the foundation system. Each BBJ 10 has a top chord 11 that is made up of four pieces of angle iron that are welded together as shown. In the preferred embodiment, each of the top angle iron pieces is a 4″ by 4′ by 0.25″ with two 48″ long and two 40″ long pieces of angle iron. Four ⅞″ inch holes 12 are drilled to receive four ½″-13 bolts 1″ long 12 a , bolt head height is ¼″. The bottom chord 13 of the BBJ 10 is made up of smaller angle iron. In the preferred embodiment, the loner frame is made up of four pieces of 2″ by 2″ by 0.25″ by 40½″ long angle. Additionally, in the preferred embodiment, four ½″-13 studs 14 , 1-inch long are attached as shown to each corner with ¼″ steel plate tabs 14 a . Between the top and bottom chords is a web 15 of #3 rebar, or equivalent, this is welded to the top and bottom chords. Note that the overall height h (see FIGS. 8 and 9 ) of the BBJ 10 can range from 12 to 30 inches. In the example shown the height h is 18 inches.
FIG. 8 is a front elevation view of one of the box bar joists (BBJ) 10 used in the foundation system. FIG. 9 is a side elevation view of one of the box bar joists (BBJ) used in the foundation system. In these views, the top chord 11 , the bottom chord 13 and the web 15 are shown along with the tabs 14 a , studs 14 , ⅞″ hole 12 , and ½″ hex head bolt 12 a . Note here, the height h is also 18″ and overall length of the top chord is 4′ and overall length of the bottom cord is 40½″ (dimensions may vary per structural calculations).
FIG. 10 is a top plan view of one of the box bar joists (BBJ) used in the foundation system. Here, the top chord 11 is shown. Note that the corners 11 a are notched. This is to facilitate the assembly, as discussed below. Note here, that the holes 12 and bolts 12 a are also shown adjacent to the studs 14 and tabs 14 a.
FIG. 11 is a front elevation view of two box bar joists (BBJ) used in the foundation system. Here, two sections of BBJ 10 are shown placed adjacent. This is how the BBJs are aligned during the construction. FIG. 12 is a perspective detail section view of an alignment of four BBJs used in the foundation system. In this view, note how the holes 12 and the studs 14 are aligned. Note too, that the notched corners 11 a come together to form a hole in the center of the assembled BBJs, as shown. This hole is used to secure the aligning bar connectors (ABC), as described below. All BBJs are galvanized and are coated with a bitumen coating.
As discussed above, the BBJs 10 must be arranged and leveled prior to attaching the steel tube columns (STC). To do this, a number of crawlspace leveling lifts (CLLs) 20 are used to support and level the BBJs. Referring now to FIGS. 13-16 , details of the crawlspace leveling lifts (CLLs) 20 are shown. FIG. 13 is a top perspective view of one of the foundation crawlspace leveling lifts (CLL) 20 used in installing the foundation system. FIG. 14 is a bottom perspective view of one of the foundation crawlspace leveling lifts (CLL) used in installing the foundation system. Each of the CLLs 20 consists of a base plate 21 that has four spikes 22 attach that extend downwardly from the base plate 21 as shown. Four angle braces 23 extend upward from the base plate (one is placed at each corner of the base plate). The braces 23 are attached to a top plate 24 as shown. Two leveling toggle bolts (LTB) 25 assemblies are attached to the top plate as shown.
FIG. 15 is an enlarged detail view of the leveling toggle bolt assemblies 25 on one of the foundation crawlspace leveling lifts. FIG. 16 is an enlarged side view of one of the leveling toggle bolt assemblies. These assemblies are temporarily installed, as described below, and are used to level the BBJs and to support the BBJs and the STCs while the concrete for the STCs is curing. Each leveling toggle bolt assembly 25 has a long bolt 25 a that is threaded through two nuts 25 b that are welded to the top plate 24 as shown. A leveling nut 25 c welded and fixed to the bolt is provided as a measuring device to move bolt 25 a to the desired height, as discussed below. At the top of each of the toggle bolts 25 a is a “C” holder and toggle clamp 25 d that is riveted (and free turning) to the top of the bolt 25 a . In use, the bottom frame angle of a BBJ is placed in the “C” holder of the toggle bolt and clamped into place. Then, the toggle bolt height can be adjusted as needed, as described in the installation section below. Referring now to FIGS. 17-19 , details of the steel tube columns (STC) 30 are disclosed. FIG. 17 is a top perspective view of one of the steel tube columns (STC) used in the foundation system. FIG. 18 is a side elevation view of one of the steel tube columns (STC) used in the foundation system. Each STC 30 consists of a top cap 31 and a lower column 32 . The top cap gas a 7″ square×¼″ thick flange 33 that is secured to a 6″ long, 2½ inch OD round bar 34 . In the preferred embodiment, the cap is galvanized; the top cap secures the BBJs top chord hex bolt 12 a . Below the cap is a lower column 32 . This column is a 3″ diameter steel tube 35 , 3/16″ thick and is between 6 and 8 feet long. In the preferred embodiment it is galvanized and covered with a bitumen covering. The column has four ¼″×2″×2′ hurricane fins 36 attached as shown. Below the fins, four 2″ shear studs 37 are attached. Two steel angles 38 , 3″×3″×0.25″, 4″ long are attached on opposite sides of the column. These angles have 9/16″ diameter holes 39 drilled in them (see also FIG. 19 ). The angles secure the BBJs stud 14 , tighten with a ½″ hex net and washer.
FIG. 19 is a top detail view of one of the steel tube columns (STC) used in the foundation system. Here, the top cap 31 is shown. Note that the top cap has four 9/16″ perimeter holes 33 a formed in it as shown, and a center hole 33 b that is tapped at 1″-12 NC threads, 2″ deep. The cap 31 is placed into the lower column 32 and is welded to the lower column assembly.
Finally, another temporary component is shown on FIGS. 20 and 21 . FIG. 20 is a perspective view of the components used as part of the aligning bar connector (ABC) system. The aligning bar connectors (ABCs) 40 are made up of ⅛″ steel plates 41 that from a square perimeter and are reinforced by plates 42 that cross in the center as shown. At the four corners are steel tubes 42 , 1½ inch (nominal) milled ID, as shown. Four 1½ inch shoulder bolts 43 are placed in the tubes 42 . In addition, a number of spacers 44 , made from 2″ round stock and having 1½ inch (nominal) milled holes are used to support the ABCs when installed to the steel tube columns (STC) aligning them to the modular grid system.
FIG. 21 is a detail perspective view of various aligning bar connectors (ABC) to be used to align the steel tube columns (STCs). In this view, a single ABC is overlaid with 2 ABCs, followed by three, and so on. The ABCs 40 provide a locking overlay to secure all of the foundation components from above as part of the curing process, as discussed below. In practice, referring to FIG. 6 , the first ABC is placed atop the first BBJ. The four shoulder bolts are then secured to the center holes 33 b on the top caps. Once this is done, the second ABC is secured to the adjacent BBJ. Note that this ABC overlaps the first at one edge. Thus, two of the bolts used in the first installation are removed and then fed through the steel tubes 42 on both of the ABCs. Obviously, spacers 44 are used to support the other end of the second ABC. In a similar manner additional ABCs are installed overlapping them as needed until the entire foundation is covered.
To install the foundation, the following steps are used:
First, set up a laser level at a far corner of the grid that has been laid out as described above. Ensure the laser level is placed in an unobstructed sight line of all marking flags. This corner is opposite of where the first BBJ 10 is to be placed. The start location may be at any corner. In the preferred embodiment, the laser level height is 27″ above grade.
Next, the grid area is inspected to remove debris, vegetation, large rocks and tripping hazards. All paint markings and marking flags are verified as being visible. Note that as described above, the marking flags and paint stripes are on a four (4) foot grid.
Beginning with the first grid square, (opposite diagonal end from laser) auger two rows of STC holes (Depth varies per location). These holes should start at the short length of the building and next row over.
Next, tamp down and compact the exposed earth at the bottom of each hole. Then pour 1 cubic foot of crushed rock into the hole and tamp and compact the rock.
Once the rock has been compacted, place a paver (stone or plastic) cover over each hole. In this example, these holes are called row one (1) and two (2).
Next, place four CLLs 20 in the starting corner of the grid (herein called square # 1 ). As shown in FIG. 6 , place each of the CLLs centered between the holes drilled for the STCs around the perimeter of the first starting corner square # 1 .
Place the perimeter CLLs 20 with the screw hold up toggle lock bracket on the inside of the square (one toggle lock will be unused at the perimeter, as shown in FIG. 6 ).
Note, the bottom plate stakes are not pushed into soil more than an inch at this time. Place a BBJ 10 on the first square CLLs 20 into the channel next to the toggle bolt clamps again as shown in FIG. 6 . Ensure that the CLLs are in a near vertical position. Then, the bottom plate stakes are hammered into the ground.
Next, the leveling/toggle bolts are adjusted (up or down) until the welded leveling nut is centered in the laser level beam. (Note: in the preferred embodiment, the leveling nut is welded to the leveling/toggle bolt.
These steps are repeated for each CCL. When first CCL is level (i.e., when all leveling nuts at the same height), this is the height of all the BBJs 10 used in the system.
Next, after ensuring that the laser level is perfectly level at all times, begin working in the second grid square. As before, the next three CLLs are placed in the adjacent grid square. Similarly, the next BBJ is placed atop the three new CLLs, next to the installed BBJ.
Next, an STC 30 is placed in each of the four holes at square # 1 . (Note: STC may need to be placed earlier, depending on depth of hole from structural analysis). Each STC is raised up and the column cap is bolted to the BBJ hand tight. See FIG. 6 for the position of these components. Next four STC are installed in the grid square # 2 , as before.
Next, an aligning bar connector (ABC) is bolted into the center of each column cap 33 a . See FIG. 6 . Next, the bolts on the column cap are wrench tightened on each BBJ. Then concrete is poured into each STC hole.
The remaining grid squares for the foundation assembly are completed using the same process as in grid squares #1 and #2.
After seven (7) days from the last concrete pour, the CLLs are removed, and earth is pushed back into the holes in eight-inch lifts. Leach lift is compacted. Compact a small amount of earth two inches high around the top of each STC hole.
At this point, the foundation system is complete and ready for building upon.
Note that the ABCs are not removed at this time. They are removed only when floor joists assemblies (FJA not part of this system) are installed. Note: an alternate method of construction uses the floor joists assemblies (FJA) in place of the ABCs.
Finally, a crawlspace vapor barrier may be installed later in the construction process, for example, after installation of roofing.
The present disclosure should not be construed in any limited sense other than that limited by the scope of the claims having regard to the teachings herein and the prior art being apparent with the preferred form of the invention disclosed herein and which reveals details of structure of a preferred form necessary for a better understanding of the invention and may be subject to change by skilled persons within the scope of the invention without departing from the concept thereof.
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A method of installing a modular structure foundation system that requires no heavy equipment, minimal site preparation, and can be easily assembled by a small crew. The foundation consists of a number of box bar joists that are square units which are assembled based on a grid layout. The box bar joists are supported by foundation steel columns that are embedded into the ground. No forms or other complex structures are needed for the installation. Once the columns are installed, the box bar joists are installed using a unique leveling system. Once the box bar joists are level and secured to the columns, the foundation is complete. The use of the box bar joists also allows for expansion or contraction as additional box bar joists can easily be added or removed from the foundation. Once the box bar joists are in place, the foundation is ready for building.
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RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/694,107, filed Mar. 30, 2007, which is a continuation of U.S. application Ser. No. 11/006,409, filed Dec. 6, 2004, now U.S. Pat. No. 7,217,219, which is a continuation of U.S. Application No. 10/418,509, filed Apr. 16, 2003, now U.S. Pat. No. 6,945,903, which is a continuation of U.S. application Ser. No. 10/141,652, filed May 7, 2002, now U.S. Pat. No. 6,551,210, which is a continuation of U.S. application Ser. No. 09/695,757, filed Oct. 24, 2000, now U.S. Pat. No. 6,419,608, which issued Jul. 16, 2002. Each of the above identified applications is incorporated by reference in its entirety.
[0002] The U.S. application Ser. No. 10/418,509 is also a continuation-in-part of U.S. application No. 10/016,116, filed on Oct. 30, 2001, now U.S. Pat. No. ,676,559, which is a continuation of U.S. application Ser. No. 09/823,620, filed Mar. 30, 2001, now U.S. Pat. No. 6,322,475, which is a continuation of U.S. application Ser. No. 09/133,284, filed Aug. 12, 1998, now U.S. Pat. No. 6,241,636, which in turn claims priority to U.S. provisional application No. 60/062,860, filed on Oct. 16, 1997; U.S. provisional application No. 60/056,045, filed on Sep. 2, 1997; U.S. provisional application No. 60/062,620, filed on Oct. 22, 1997 and U.S. provisional application No. 60/070,044 filed on Dec. 30, 1997.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The field of the invention relates to transmissions. More particularly the invention relates to continuously variable transmissions.
[0005] 2. Description of the Related Art
[0006] In order to provide an infinitely variable transmission, various traction roller transmissions in which power is transmitted through traction rollers supported in a housing between torque input and output discs have been developed. In such transmissions, the traction rollers are mounted on support structures which, when pivoted, cause the engagement of traction rollers with the torque discs in circles of varying diameters depending on the desired transmission ratio.
[0007] However, the success of these traditional solutions has been limited. For example, in U.S. Pat. No. 5,236,403 to Schievelbusch, a driving hub for a vehicle with a variable adjustable transmission ratio is disclosed. Schievelbusch teaches the use of two iris plates, one on each side of the traction rollers, to tilt the axis of rotation of each of the rollers. However, the use of iris plates can be very complicated due to the large number of parts which are required to adjust the iris plates during shifting the transmission. Another difficulty with this transmission is that it has a guide ring which is configured to be predominantly stationary in relation to each of the rollers. Since the guide ring is stationary, shifting the axis of rotation of each of the traction rollers is difficult. Yet another limitation of this design is that it requires the use of two half axles, one on each side of the rollers, to provide a gap in the middle of the two half axles. The gap is necessary because the rollers are shifted with rotating motion instead of sliding linear motion. The use of two axles is not desirable and requires a complex fastening system to prevent the axles from bending when the transmission is accidentally bumped, is as often the case when a transmission is employed in a vehicle. Yet another limitation of this design is that it does not provide for an automatic transmission.
[0008] Therefore, there is a need for a continuously variable transmission with a simpler shifting method, a single axle, and a support ring having a substantially uniform outer surface. Additionally, there is a need for an automatic traction roller transmission that is configured to shift automatically. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission.
SUMMARY OF THE INVENTION
[0009] The present invention includes a transmission for use in rotationally or linearly powered machines and vehicles. For example the present transmission may be used in machines such as drill presses, turbines, and food processing equipment, and vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft.
[0010] In one embodiment of the invention, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is centrally located within each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, at least one platform for actuating axial movement of the support member and for actuating a shift in the axis of rotation of the power adjusters, wherein the platform provides a convex surface, at least one stationary support that is non-rotatable about the axis of rotation that is defined by the support member, wherein the at least one stationary support provides a concave surface, and a plurality of spindle supports, wherein each of the spindle supports are slidingly engaged with the convex surface of the platform and the concave surface of the stationary support, and wherein each of the spindle supports adjusts the axes of rotation of the power adjusters in response to the axial movement of the platform.
[0011] In another embodiment, the transmission comprises a rotatable driving member; three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis of rotation that is respectively central to the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, a rotatable driving member for rotating each of the power adjusters, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a coiled spring for biasing the rotatable driving member against the power adjusters, at least one lock pawl ratchet, wherein the lock pawl ratchet is rigidly attached to the rotatable driving member, wherein the at least one lock pawl is operably attached to the coiled spring, and at least one lock pawl for locking the lock pawl ratchet in response to the rotatable driving member becoming disengaged from the power adjusters.
[0012] In still another embodiment, the transmission comprises a rotatable driving member, three or more power adjusters, wherein each of the power adjusters respectively rotates about an axis that is respectively central to each of the power adjusters, a support member providing a support surface that is in frictional contact with each of the power adjusters, wherein the support member rotates about an axis that is centrally located within the support member, a bearing disc having a plurality of inclined ramps for actuating the rotation of the driving member, a screw that is coaxially and rigidly attached to the rotatable driving member or the bearing disc, and a nut that, if the screw is attached to the rotatable driving member, is coaxially and rigidly attached to the bearing disc, or if the screw is rigidly attached to the bearing disc, coaxially and rigidly attached to the rotatable driving member, wherein the inclined ramps of the bearing disc have a higher lead than the screw.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a cutaway side view of the transmission of the present invention.
[0014] FIG. 2 is a partial perspective view of the transmission of FIG. 1 .
[0015] FIG. 3 is a perspective view of two stationary supports of the transmission of FIG. 1 .
[0016] FIG. 4 is a partial end, cross-sectional view of the transmission of FIG. 1 .
[0017] FIG. 5 is a perspective view of a drive disc, bearing cage, screw, and ramp bearings of the transmission of FIG. 1 .
[0018] FIG. 6 is a perspective view of a ratchet and pawl subsystem of the transmission of FIG. 1 that is used to engage and disengage the transmission.
[0019] FIG. 7 is partial perspective view of the transmission of FIG. 1 , wherein, among other things, a rotatable drive disc has been removed.
[0020] FIG. 8 is a partial perspective view of the transmission of FIG. 1 , wherein, among other things, the hub shell has been removed.
[0021] FIG. 9 is a partial perspective view of the transmission of FIG. 1 , wherein the shifting is done automatically.
[0022] FIG. 10 is a perspective view of the shifting handlegrip that is mechanically coupled to the transmission of FIG. 1 .
[0023] FIG. 11 is an end view of a thrust bearing, of the transmission shown in FIG. 1 , which is used for automatic shifting of the transmission.
[0024] FIG. 12 is an end view of the weight design of the transmission shown in FIG. 1 .
[0025] FIG. 13 is a perspective view of an alternate embodiment of the transmission bolted to a flat surface.
[0026] FIG. 14 is a cutaway side view of the transmission shown in FIG. 13 .
[0027] FIG. 15 is a schematic end view of the transmission in FIG. 1 showing the cable routing across a spacer extension of the automatic portion of the transmission.
[0028] FIG. 16 is a schematic end view of the cable routing of the transmission shown in FIG. 13 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the inventions herein described.
[0030] The present invention includes a continuously variable transmission that may be employed in connection with any type of machine that is in need of a transmission. For example, the transmission may be used in (i) a motorized vehicle such as an automobile, motorcycle, or watercraft, (ii) a non-motorized vehicle such as a bicycle, tricycle, scooter, exercise equipment or (iii) industrial equipment, such as a drill press, power generating equipment, or textile mill.
[0031] Referring to FIGS. 1 and 2 , a continuously variable transmission 100 is disclosed. The transmission 100 is shrouded in a hub shell 40 covered by a hub cap 67 . At the heart of the transmission 100 are three or more power adjusters 1 a , 1 b , 1 c which are spherical in shape and are circumferentially spaced equally around the centerline or axis of rotation of the transmission 100 . As seen more clearly in FIG. 2 , spindles 3 a , 3 b , 3 c are inserted through the center of the power adjusters 1 a , 1 b , 1 c to define an axis of rotation for the power adjusters 1 a , 1 b , 1 c . In FIG. 1 , the power adjuster's axis of rotation is shown in the horizontal direction. Spindle supports 2 a - f are attached perpendicular to and at the exposed ends of the spindles 3 a , 3 b , 3 c . In one embodiment, each of the spindles supports have a bore to receive one end of one of the spindles 3 a , 3 b , 3 c . The spindles 3 a , 3 b , 3 c also have spindle rollers 4 a - f coaxially and slidingly positioned over the exposed ends of the spindles 3 a , 3 b , 3 c outside of the spindle supports 2 a - f.
[0032] As the rotational axis of the power adjusters 1 a , 1 b , 1 c is changed by tilting the spindles 3 a , 3 b , 3 c , each spindle roller 4 a - f follows in a groove 6 a - f cut into a stationary support 5 a , 5 b . Referring to FIGS. 1 and 3 , the stationary supports 5 a , 5 b are generally in the form of parallel discs with an axis of rotation along the centerline of the transmission 100 . The grooves 6 a - f extend from the outer circumference of the stationary supports 5 a , 5 b towards the centerline of the transmission 100 . While the sides of the grooves 6 a - f are substantially parallel, the bottom surface of the grooves 6 a - f forms a decreasing radius as it runs towards the centerline of the transmission 100 . As the transmission 100 is shifted to a lower or higher gear by changing the rotational axes of the power adjusters 1 a , 1 b , 1 c , each pair of spindle rollers 4 a - f , located on a single spindle 3 a , 3 b , 3 c , moves in opposite directions along their corresponding grooves 6 a - f.
[0033] Referring to FIGS. 1 and 3 , a centerline hole 7 a , 7 b in the stationary supports 5 a , 5 b allows the insertion of a hollow shaft 10 through both stationary supports 5 a , 5 b . Referring to FIG. 4 , in an embodiment of the invention, one or more of the stationary support holes 7 a , 7 b may have a non-cylindrical shape 14 , which fits over a corresponding non-cylindrical shape 15 along the hollow shaft 10 to prevent any relative rotation between the stationary supports 5 a , 5 b and the hollow shaft 10 . If the rigidity of the stationary supports 5 a , 5 b is insufficient, additional structure may be used to minimize any relative rotational movement or flexing of the stationary supports 5 a , 5 b . This type of movement by the stationary supports 5 a , 5 b may cause binding of the spindle rollers 4 a - f as they move along the grooves 6 a - f.
[0034] As shown in FIGS. 4 and 7 , the additional structure may take the form of spacers 8 a , 8 b , 8 c attached between the stationary supports 5 a , 5 b . The spacers 8 a , 8 b , 8 c add rigidity between the stationary supports 5 a , 5 b and, in one embodiment, are located near the outer circumference of the stationary supports 5 a , 5 b . In one embodiment, the stationary supports 5 a , 5 b are connected to the spacers 8 a , 8 b , 8 c by bolts or other fastener devices 45 a - f inserted through holes 46 a - f in the stationary supports 5 a , 5 b.
[0035] Referring back to FIGS. 1 and 3 , the stationary support 5 a is fixedly attached to a stationary support sleeve 42 , which coaxially encloses the hollow shaft 10 and extends through the wall of the hub shell 40 . The end of the stationary support sleeve 42 that extends through the hub shell 40 attaches to the frame support and preferentially has a non-cylindrical shape to enhance subsequent attachment of a torque lever 43 . As shown more clearly in FIG. 7 , the torque lever 43 is placed over the non-cylindrical shaped end of the stationary support sleeve 42 , and is held in place by a torque nut 44 . The torque lever 43 at its other end is rigidly attached to a strong, non-moving part, such as a frame (not shown). A stationary support bearing 48 supports the hub shell 40 and permits the hub shell 40 to rotate relative to the stationary support sleeve 42 .
[0036] Referring back to FIGS. 1 and 2 , shifting is manually activated by axially sliding a rod 11 positioned in the hollow shaft 10 . One or more pins 12 are inserted through one or more transverse holes in the rod 11 and further extend through one or more longitudinal slots 16 (not shown) in the hollow shaft 10 . The slots 16 in the hollow shaft 10 allow for axial movement of the pin 12 and rod 11 assembly in the hollow shaft 10 . As the rod 11 slides axially in the hollow shaft 10 , the ends of the transverse pins 12 extend into and couple with a coaxial sleeve 19 . The sleeve 19 is fixedly attached at each end to a substantially planar platform 13 a , 13 b forming a trough around the circumference of the sleeve 19 .
[0037] As seen more clearly in FIG. 4 , the planar platforms 13 a , 13 b each contact and push multiple wheels 21 a - f . The wheels 21 a - f fit into slots in the spindle supports 2 a - f and are held in place by wheel axles 22 a - f . The wheel axles 22 a - f are supported at their ends by the spindle supports 2 a - f and allow rotational movement of the wheels 21 a - f.
[0038] Referring back to FIGS. 1 and 2 , the substantially planar platforms 13 a , 13 b transition into a convex surface at their outer perimeter (farthest from the hollow shaft 10 ). This region allows slack to be taken up when the spindle supports 2 a - f and power adjusters 1 a , 1 b , 1 c are tilted as the transmission 100 is shifted. A cylindrical support member 18 is located in the trough formed between the planar platforms 13 a , 13 b and sleeve 19 and thus moves in concert with the planar platforms 13 a , 13 b and sleeve 19 . The support member 18 rides on contact bearings 17 a , 17 b located at the intersection of the planar platforms 13 a , 13 b and sleeve 19 to allow the support member 18 to freely rotate about the axis of the transmission 100 . Thus, the bearings 17 a , 17 b , support member 18 , and sleeve 19 all slide axially with the planar platforms 13 a , 13 b when the transmission 100 is shifted.
[0039] Now referring to FIGS. 3 and 4 , stationary support rollers 30 a - l are attached in pairs to each spindle leg 2 a - f through a roller pin 31 a - f and held in place by roller clips 32 a - l . The roller pins 31 a - f allow the stationary support rollers 30 a - l to rotate freely about the roller pins 31 a - f . The stationary support rollers 30 a - l roll on a concave radius in the stationary support 5 a , 5 b along a substantially parallel path with the grooves 6 a - f . As the spindle rollers 4 a - f move back and forth inside the grooves 6 a - f , the stationary support rollers 30 a - l do not allow the ends of the spindles 3 a , 3 b , 3 c nor the spindle rollers 4 a - f to contact the bottom surface of the grooves 6 a - f , to maintain the position of the spindles 3 a , 3 b , 3 c , and to minimize any frictional losses.
[0040] FIG. 4 shows the stationary support rollers 30 a - l , the roller pins, 31 a - f , and roller clips 32 a - l , as seen through the stationary support 5 a , for ease of viewing. For clarity, i.e., too many numbers in FIG. 1 , the stationary support rollers 30 a - l , the roller pins, 31 a - f , and roller clips 32 a - l , are not numbered in FIG. 1 .
[0041] Referring to FIGS. 1 and 5 , a concave drive disc 34 , located adjacent to the stationary support 5 b , partially encapsulates but does not contact the stationary support 5 b . The drive disc 34 is rigidly attached through its center to a screw 35 . The screw 35 is coaxial to and forms a sleeve around the hollow shaft 10 adjacent to the stationary support 5 b and faces a driving member 69 . The drive disc 34 is rotatively coupled to the power adjusters 1 a , 1 b , 1 c along a circumferential bearing surface on the lip of the drive disc 34 . A nut 37 is threaded over the screw 35 and is rigidly attached around its circumference to a bearing disc 60 . One face of the nut 37 is further attached to the driving member 69 . Also rigidly attached to the bearing disc 60 surface are a plurality of ramps 61 which face the drive disc 34 . For each ramp 61 there is one ramp bearing 62 held in position by a bearing cage 63 . The ramp bearings 62 contact both the ramps 61 and the drive disc 34 . A spring 65 is attached at one end to the bearing cage 63 and at its other end to the drive disc 34 , or the bearing disc 60 in an alternate embodiment, to bias the ramp bearings 62 up the ramps 61 . The bearing disc 60 , on the side opposite the ramps 61 and at approximately the same circumference contacts a hub cap bearing 66 . The hub cap bearing 66 contacts both the hub cap 67 and the bearing disc 60 to allow their relative motion. The hub cap 67 is threaded or pressed into the hub shell 40 and secured with an internal ring 68 . A sprocket or pulley 38 is rigidly attached to the rotating driving member 69 and is held in place externally by a cone bearing 70 secured by a cone nut 71 and internally by a driver bearing 72 which contacts both the driving member 69 and the hub cap 67 .
[0042] In operation, an input rotation from the sprocket or pulley 38 , which is fixedly attached to the driver 69 , rotates the bearing disc 60 and the plurality of ramps 61 causing the ramp bearings 62 to roll up the ramps 61 and press the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . Simultaneously, the nut 37 , which has a smaller lead than the ramps 61 , rotates to cause the screw 35 and nut 37 to bind. This feature imparts rotation of the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . The power adjusters 1 a , 1 b , 1 c , when rotating, contact and rotate the hub shell 40 .
[0043] When the transmission 100 is coasting, the sprocket or pulley 38 stops rotating but the hub shell 40 and the power adjusters 1 a , 1 b , 1 c , continue to rotate. This causes the drive disc 34 to rotate so that the screw 35 winds into the nut 37 until the drive disc 34 no longer contacts the power adjusters 1 a , 1 b , 1 c.
[0044] Referring to FIGS. 1 , 6 , and 7 , a coiled spring 80 , coaxial with the transmission 100 , is located between and attached by pins or other fasteners (not shown) to both the bearing disc 60 and drive disc 34 at the ends of the coiled spring 80 . During operation of the transmission 100 , the coiled spring 80 ensures contact between the power adjusters 1 a , 1 b , 1 c and the drive disc 34 . A pawl carrier 83 fits in the coiled spring 80 with its middle coil attached to the pawl carrier 83 by a pin or standard fastener (not shown). Because the pawl carrier 83 is attached to the middle coil of the coiled spring 80 , it rotates at half the speed of the drive disc 34 when the bearing disc 60 is not rotating. This allows one or more lock pawls 81 a , 81 b , 81 c , which are attached to the pawl carrier 83 by one or more pins 84 a , 84 b , 84 c , to engage a drive disc ratchet 82 , which is coaxial with and rigidly attached to the drive disc 34 . The one or more lock pawls 84 a , 84 b , 84 c are preferably spaced asymmetrically around the drive disc ratchet 82 . Once engaged, the loaded coiled spring 80 is prevented from forcing the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . Thus, with the drive disc 34 not making contact against the power adjusters 1 a , 1 b , 1 c , the transmission 100 is in neutral and the ease of shifting is increased. The transmission 100 can also be shifted while in operation.
[0045] When operation of the transmission 100 is resumed by turning the sprocket or pulley 38 , one or more release pawls 85 a , 85 b , 85 c , each attached to one of the lock pawls 81 a , 81 b , 81 c by a pawl pin 88 a , 88 b , 88 c , make contact with an opposing bearing disc ratchet 87 . The bearing disc ratchet 87 is coaxial with and rigidly attached to the bearing disc 60 . The bearing disc ratchet 87 actuates the release pawls 85 a , 85 b , 85 c because the release pawls 85 a , 85 b , 85 c are connected to the pawl carrier 83 via the lock pawls 81 a , 81 b , 81 c . In operation, the release pawls 85 a , 85 b , 85 c rotate at half the speed of the bearing disc 60 , since the drive disc 34 is not rotating, and disengage the lock pawls 81 a , 81 b , 81 c from the drive disc ratchet 82 allowing the coiled spring 80 to wind the drive disc 34 against the power adjusters 1 a , 1 b , 1 c . One or more pawl tensioners (not shown), one for each release pawl 85 a , 85 b , 85 c , ensures that the lock pawls 81 a , 81 b , 81 c are pressed against the drive disc ratchet 82 and that the release pawls 85 a , 85 b , 85 c are pressed against the bearing disc ratchet 87 . The pawl tensioners are attached at one end to the pawl carrier 83 and make contact at the other end to the release pawls 85 a , 85 b , 85 c . An assembly hole 93 (not shown) through the hub cap 67 , the bearing disc 60 , and the drive disc 34 , allows an assembly pin (not shown) to be inserted into the loaded coiled spring 80 during assembly of the transmission 100 . The assembly pin prevents the coiled spring 80 from losing its tension and is removed after transmission 100 assembly is complete.
[0046] Referring to FIGS. 1 , 11 , 12 , and 15 , automatic shifting of the transmission 100 , is accomplished by means of spindle cables 602 , 604 , 606 which are attached at one end to a non-moving component of the transmission 100 , such as the hollow shaft 10 or the stationary support 5 a . The spindle cables 602 , 604 , 606 then travel around spindle pulleys 630 , 632 , 634 , which are coaxially positioned over the spindles 3 a , 3 b , 3 c . The spindle cables 602 , 604 , 606 further travel around spacer pulleys 636 , 638 , 640 , 644 , 646 , 648 which are attached to a spacer extension 642 which may be rigidly attached to the spacers 8 a , 8 b , 8 c . As more clearly shown in FIGS. 11 and 12 , the other ends of the spindle cables 602 , 604 , 606 are attached to a plurality of holes 620 , 622 , 624 in a non-rotating annular bearing race 816 . A plurality of weight cables 532 , 534 , 536 are attached at one end to a plurality of holes 610 , 612 , 614 in a rotating annular bearing race 806 . An annular bearing 808 , positioned between the rotating annular bearing race 806 and the non-rotating annular bearing race 816 , allows their relative movement.
[0047] Referring to FIG. 15 , the transmission 100 is shown with the cable routing for automatic shifting.
[0048] As shown in FIGS. 1 , 9 , 11 , and 12 , the weight cables 532 , 534 , 536 then travel around the hub shell pulleys 654 , 656 , 658 , through holes in the hub shell 40 , and into hollow spokes 504 , 506 , 508 (best seen in FIG. 12 ) where they attach to weights 526 , 528 , 530 . The weights 526 , 528 , 530 are attached to and receive support from weight assisters 516 , 518 , 520 which attach to a wheel 514 or other rotating object at there opposite end. As the wheel 514 increases its speed of rotation, the weights 526 , 528 , 530 are pulled radially away from the hub shell 40 , pulling the rotating annular bearing race 806 and the non-rotating annular bearing race 816 axially toward the hub cap 67 . The non-rotating annular bearing race 816 pulls the spindle cables 602 , 604 , 606 , which pulls the spindle pulleys 630 , 632 , 634 closer to the hollow shaft 10 and results in the shifting of the transmission 100 into a higher gear. When rotation of the wheel 514 slows, one or more tension members 9 positioned inside the hollow shaft 10 and held in place by a shaft cap 92 , push the spindle pulleys 630 , 632 , 634 farther from the hollow shaft 10 and results in the shifting of the transmission 100 into a lower gear.
[0049] Alternatively, or in conjunction with the tension member 9 , multiple tension members (not shown) may be attached to the spindles 3 a , 3 b , 3 c opposite the spindle pulleys 630 , 632 , 634 .
[0050] Still referring to FIG. 1 , the transmission 100 can also be manually shifted to override the automatic shifting mechanism or to use in place of the automatic shifting mechanism. A rotatable shifter 50 has internal threads that thread onto external threads of a shifter screw 52 which is attached over the hollow shaft 10 . The shifter 50 has a cap 53 with a hole that fits over the rod 11 that is inserted into the hollow shaft 10 . The rod 11 is threaded where it protrudes from the hollow shaft 10 so that nuts 54 , 55 may be threaded onto the rod 11 . The nuts 54 , 55 are positioned on both sides of the cap 53 . A shifter lever 56 is rigidly attached to the shifter 50 and provides a moment arm for the rod 11 . The shifter cable 51 is attached to the shifter lever 56 through lever slots 57 a , 57 b , 57 c . The multiple lever slots 57 a , 57 b , 57 c provide for variations in speed and ease of shifting.
[0051] Now referring to FIGS. 1 and 10 , the shifter cable 51 is routed to and coaxially wraps around a handlegrip 300 . When the handlegrip 300 is rotated in a first direction, the shifter 50 winds or unwinds axially over the hollow shaft 10 and pushes or pulls the rod 11 into or out of the hollow shaft 10 . When the handlegrip 300 is rotated in a second direction, a shifter spring 58 , coaxially positioned over the shifter 50 , returns the shifter 50 to its original position. The ends of the shifter spring 58 are attached to the shifter 50 and to a non-moving component, such as a frame (not shown).
[0052] As seen more clearly in FIG. 10 , the handlegrip 300 is positioned over a handlebar (not shown) or other rigid component. The handlegrip 300 includes a rotating grip 302 , which consists of a cable attachment 304 that provides for attachment of the shifter cable 51 and a groove 306 that allows the shifter cable 51 to wrap around the rotating grip 302 . A flange 308 is also provided to preclude a user from interfering with the routing of the shifter cable 51 . Grip ratchet teeth 310 are located on the rotating grip 302 at its interface with a rotating clamp 314 . The grip ratchet teeth 310 lock onto an opposing set of clamp ratchet teeth 312 when the rotating grip 302 is rotated in a first direction. The clamp ratchet teeth 312 form a ring and are attached to the rotating clamp 314 which rotates with the rotating grip 302 when the grip ratchet teeth 310 and the clamp ratchet teeth 312 are locked. The force required to rotate the rotating clamp 314 can be adjusted with a set screw 316 or other fastener. When the rotating grip 302 , is rotated in a second direction, the grip ratchet teeth 310 , and the clamp ratchet teeth 312 disengage. Referring back to FIG. 1 , the tension of the shifter spring 58 increases when the rotating grip 302 is rotated in the second direction. A non-rotating clamp 318 and a non-rotating grip 320 prevent excessive axial movement of the handlegrip 300 assembly.
[0053] Referring to FIGS. 13 and 14 , another embodiment of the transmission 900 , is disclosed. For purposes of simplicity, only the differences between the transmission 100 and the transmission 900 are discussed.
[0054] Replacing the rotating hub shell 40 are a stationary case 901 and housing 902 , which are joined with one or more set screws 903 , 904 , 905 . The set screws 903 , 904 , 905 may be removed to allow access for repairs to the transmission 900 . Both the case 901 and housing 902 have coplanar flanges 906 , 907 with a plurality of bolt holes 908 , 910 , 912 , 914 for insertion of a plurality of bolts 918 , 920 , 922 , 924 to fixedly mount the transmission 900 to a non-moving component, such as a frame (not shown).
[0055] The spacer extension 930 is compressed between the stationary case 901 and housing 902 with the set screws 903 , 904 , 905 and extend towards and are rigidly attached to the spacers 8 a , 8 b , 8 c . The spacer extension 930 prevents rotation of the stationary supports 5 a , 5 b . The stationary support 5 a does not have the stationary support sleeve 42 as in the transmission 100 . The stationary supports 5 a , 5 b hold the hollow shaft 10 in a fixed position. The hollow shaft 10 terminates at one end at the stationary support 5 a and at its other end at the screw 35 . An output drive disc 942 is added and is supported against the case 901 by a case bearing 944 . The output drive disc 942 is attached to an output drive component, such as a drive shaft, gear, sprocket, or pulley (not shown). Similarly, the driving member 69 is attached to the input drive component, such as a motor, gear, sprocket, or pulley.
[0056] Referring to FIG. 16 , shifting of the transmission 900 is accomplished with a single cable 946 that wraps around each of the spindle pulleys 630 , 632 , 634 . At one end, the single cable 946 is attached to a non-moving component of the transmission 900 , such as the hollow shaft 10 or the stationary support 5 a . After traveling around each of the spindle pulleys 630 , 632 , 634 and the spacer pulleys 636 , 644 , the single cable 946 exits the transmission 900 through a hole in the housing 902 . Alternatively a rod (not shown) attached to one or more of the spindles 3 a , 3 b , 3 c , may be used to shift the transmission 900 in place of the single cable 946 .
[0057] The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof.
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A continuously variable transmission is disclosed for use in rotationally or linearly powered machines and vehicles. The single axle transmission provides a simple manual shifting method for the user. An additional embodiment is disclosed which shifts automatically dependent upon the rotational speed of the wheel. Further, the practical commercialization of traction roller transmissions requires improvements in the reliability, ease of shifting, function and simplicity of the transmission. The disclosed transmission may be used in vehicles such as automobiles, motorcycles, and bicycles. The transmission may, for example, be driven by a power transfer mechanism such as a sprocket, gear, pulley or lever, optionally driving a one way clutch attached at one end of the main shaft.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Pat. App. No. 61/585,038 filed Jan. 10, 2012, the entirety of which is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
This invention was not federally sponsored.
BACKGROUND OF THE INVENTION
Field of the invention
This invention relates to the general field of washing machines, and more specifically toward a system for dispensing substances into a washing machine. A plurality of preferably different sized or shaped cartridges are located within removable drawers. Each cartridge contains a particular substance, such as laundry detergent, bleach, or fabric softener, that is released into the washing machine. The system also includes a means to identify the substance contained within the cartridge as well as when and how much of the substance should be released into the washing machine. At the appropriate time, the system dispenses an appropriate amount of substance into the washing machine. A pump pulls the substance out of the container and into the washing basin of a washing machine. Alternatively, a valve is opened and the substance pours into the washing basin due to gravitational forces.
Washing machines enable users to wash their clothes in a shorter period of time and with greater ease than otherwise possible when doing it by hand. Whether it is a top loading or side loading washing machine, the clothes are soaked in water and agitated to get the clothes clean. Often, one or more substances such as laundry detergent, fabric softener, or bleach are added to the water to aid the cleaning process. However, how much of each substance and when it is added depends upon various factors, including the type of substance and the wash cycle set on the washing machine. Many users will place laundry detergent directly into the washing machine as it fills with water, then place fabric softener into a special container that releases the fabric softener at the appropriate time, and may also place bleach into yet another container that releases the bleach at its appropriate time.
Handling laundry detergent, fabric softener, bleach, or other common substances used to clean clothes can be unpleasant and even harmful. For example, bleach, which may include chlorine, is a respiratory irritant that attacks mucous membranes and can burn the skin. When adding these substances to the washing machine, either into the washing basin or into a separate receptacle, the amount of each substance must be measured. Pouring from a container into a measuring device, and then into the appropriate location in the washing machine often results in inadvertent spills as well as requiring that the measuring device be cleaned.
Thus there has existed a long-felt need for a system that dispenses an appropriate amount of a particular substance at the appropriate time into a washing machine without requiring a user to potentially come into contact with that substance. Furthermore, there is a need for a system that automatically dispenses a plurality of substances into a washing machine at the appropriate time during a wash cycle.
SUMMARY OF THE INVENTION
The current invention provides just such a solution by having a system for dispensing substances into a washing machine. A plurality of preferably different sized or shaped cartridges are located within removable drawers. Each cartridge contains a particular substance, such as laundry detergent, bleach, or fabric softener, that is released into the washing machine. The system also includes a means to identify the substance contained within the cartridge as well as when and how much of the substance should be released into the washing machine. At the appropriate time, the system dispenses an appropriate amount of substance into the washing machine. A pump pulls the substance out of the container and into the washing basin of a washing machine. Alternatively, a valve is opened and the substance pours into the washing basin due to gravitational forces.
It is a principal object of the invention to provide a system that enables users to safely, cleanly, and efficiently add substances to a washing machine.
It is another object of the invention to provide a system for dispensing one or more substances into a washing machine at the appropriate time.
It is a further object of this invention to provide a system for dispensing the correct amount of a particular substance into a washing machine.
It is an additional object of the invention to provide a system for reducing human error in dispensing substances into a washing machine.
It is yet another object of the invention to provide a dispensing system that is self-contained so as to eliminate pouring a substance form a separate container into a washing machine.
It is a further object of the invention to provide a system that regulates the amount of a substance dispensed into a washing machine to increase efficiencies and eliminate waste.
In a particular embodiment, the current invention is a system for dispensing a substance into a washing machine comprising a plurality of cartridges, a plurality of level indicators, a plurality of barcode readers, a plurality of dispensing tubes, and a cover, where each cartridge comprises handle, a barcode, a vent, and a delivery tube adapter, where each of the plurality of dispensing tubes mates with a delivery tube of a cartridge, where a substance contained within each cartridge may flow through the delivery tube, where fluid that flows through the delivery tube is inserted into a washing machine, where each level indicator mates with the vent of a cartridge and determines the amount of substance contained within the cartridge, where each barcode reader reads data from a barcode of a cartridge and destroys the barcode of the cartridge, whereby the system for dispensing a substance dispenses a substance from each cartridge at a time and volume determined by the data read from the barcode of each cartridge.
In another embodiment, the current invention is a method of dispensing a substance into a washing machine comprising the steps of: accepting a cartridge, where the cartridge comprises a vent and a barcode; scanning the barcode of the cartridge; destroying the barcode of the cartridge such that it cannot be read again; inserting a level indicator through the vent and into the cartridge; and dispensing a substance contained within the cartridge into a washing machine; whereby data collected from scanning the barcode is used to determine the volume and timing of dispensing the substance contained within the cartridge into the washing machine.
In an additional embodiment, the current invention is a system for dispensing a substance comprising: a barcode reader, a level indicator, and a cartridge, where the cartridge comprises a vent and a barcode, where the barcode reader reads the barcode of the cartridge, where the barcode reader destroys the barcode of the cartridge after the barcode reader has read the barcode, where the level indicator is inserted through the vent and determines the level of a substance remaining within the cartridge.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. The features listed herein and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.
BRIEF DESCRIPTION OF THE FIGURES
The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention.
FIG. 1 is perspective view of a washing machine with a dispensing system according to selected embodiments of the current disclosure.
FIG. 2 is a partial view of the dispensing system and its integration into a drawer of a washing machine according to selected embodiments of the current disclosure.
FIG. 3 is a perspective view of cartridges according to selected embodiments of the current disclosure.
FIG. 4 is a perspective view of a washing machine with a dispensing system and integrated stain remover sprayer according to selected embodiments of the current disclosure.
FIG. 5 is a perspective view of a cartridge according to selected embodiments of the current disclosure.
DETAILED DESCRIPTION OF THE INVENTION
Many aspects of the invention can be better understood with the references made to the drawings below. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating the components of the present invention. Moreover, like reference numerals designate corresponding parts through the several views in the drawings.
FIG. 1 is perspective view of a washing machine with a dispensing system according to selected embodiments of the current disclosure. The dispensing system 10 according to the current invention resides on the top of a washing machine 90 . The dispensing system 10 has a cover 11 that is connected to the back of the dispensing system 10 by a hinge. The dispensing system 10 accepts cartridges, such as a detergent cartridge 20 , fabric softener cartridge 21 , and a bleach cartridge 22 . A level indicator 31 is used to determine the amount of fluid left within each cartridge. Barcode scanners 33 scan the barcode of each cartridge and then puncture (thereby destroying) each barcode after it is scanned. Described in more detail below, the barcode enables the dispensing system to determine what substance is in the cartridge as well as how much of and when to dispense the substance contained therein.
FIG. 2 is a partial view of the dispensing system and its integration into a drawer of a washing machine according to selected embodiments of the current disclosure. After a cartridge is inserted into the dispensing system, barcode readers 33 scan the barcode of each cartridge. After scanning the barcode, the barcode readers 33 move downward toward the cartridge and pierce each barcode thereby destroying it. By destroying the barcode, the dispensing system prevents repeated use (such as refilling) of the cartridges since the barcode reader 33 will not read a destroyed barcode. Level indicators 31 are also lowered though a vent in each cartridge. In a particular embodiment, each cartridge has a cap that covers the vent, which is removed before it is inserted into the dispensing system. At the appropriate time, fluid from each cartridge is dispensed through delivery tubes 35 to dispensing tubes 37 , which deposit the fluid in an appropriate area of a cleaning substance drawer 91 of a washing machine. The cleaning substance drawer 91 may include a detergent area 91 , a fabric softener area 93 , and a bleach area 94 . The dispensing tubes 37 deposit the appropriate fluid into the appropriate area.
FIG. 3 is a perspective view of cartridges according to selected embodiments of the current disclosure. Three cartridges are shown: a detergent cartridge 20 , fabric softener cartridge 21 , and a bleach cartridge 22 . The detergent cartridge 20 contains laundry detergent and is the largest of the three cartridges shown. The fabric softener cartridge 21 contains fabric softener and is the second largest cartridge shown. The bleach cartridge 22 is the smallest cartridge shown and contains bleach. Each cartridge includes a vent 27 that is covered with a cap (not shown) when stored or otherwise not in use and not inserted within the dispensing system. A barcode 25 is also placed on each cartridge, which is used to identify the particular substance contained within the cartridge and the particular use instructions associated therewith.
FIG. 4 is a perspective view of a washing machine with a dispensing system and integrated stain remover sprayer according to selected embodiments of the current disclosure. The dispensing system 10 , in addition to a detergent cartridge, fabric softener cartridge, and bleach cartridge, may include a stain remover cartridge 23 . A tube extends therefrom and thrown an opening in the dispensing system and is connected to a sprayer 39 . The sprayer 39 includes a trigger, which can be pulled to dispense a stain remover substance contained within the stain remover cartridge 23 . Thus, a user may quickly and efficiently treat a stained item of clothing by using the sprayer 39 integrated with the dispensing system 10 .
FIG. 5 is a perspective view of a cartridge according to selected embodiments of the current disclosure. The detergent cartridge 20 includes a handle 26 that is used to grasp the detergent cartridge. A vent 27 is an opening that is used to allow air to enter the detergent cartridge 20 as the substance contained therein is withdrawn. A level indicator (not shown in this figure) may also extend through the vent opening 27 to measure the amount of substance remaining in the detergent cartridge 20 . A barcode 25 identifies that particular substance within the detergent cartridge 20 . The substance within the detergent cartridge 20 is withdrawn through a delivery tube 35 . The delivery tube mates with the detergent cartridge 20 via a dispensing tube adapter 36 . As the detergent cartridge 20 is inserted into the dispensing system, the delivery tube 35 mates the delivery tube adapter 36 , which is integrated into the detergent cartridge.
The level indicators are inserted through the vent and are used to determine the amount of substance remaining in the particular cartridge. A float moves up and down depending on the level of the substance (fluid) in the cartridge. In other words, as the substance is removed from the cartridge, the float travels downward. Sensors determine the location of the float, and through this the relative amount of substance left in the cartridge.
In a particular embodiment, the dispensing system includes fluid pumps. The fluid pumps are in fluid connection with the cartridges via delivery tubes. Each fluid pump 50 is in electrical connection to a circuit board, such as a motherboard of the dispensing system or washing machine. Solenoid valves may also be utilitized to block and unblock the flow of the fluid from the cartridge and to the washing machine cleaning substance drawer. In this manner, the fluid pump and/or solenoid valves are turned on and off as directed by the internal circuitry of the system and/or washing machine.
In another embodiment, the barcode includes data such as the type of substance within the cartridge, volume of the cartridge, manufacturing date, serial number, or codes or encrypted data that verifies the source and authenticity of the laundry detergent cartridge. By checking the data on the barcode of the cartridge, the system ensures that only compatible cartridges manufactured for the system will dispense the substance contained therein. Furthermore, the appropriate volume and timing of the substance to be dispensed is automatically read in by the system and implemented accordingly, thereby reducing user error.
In an alternative embodiment, the barcode includes only encrypted identifying data that is used to query a remote network connected server. By way of example, the barcode reader reads in the data from the barcode. It then uses this data to make a request to a remote server over the internet. The request is made as an http request made over a wifi-network that is connected to the internet. The data from the barcode, either encrypted or decrypted, is transmitted to the remote server, which then responds with various data related to the cartridge. The response data may include confirmation as to whether or not the cartridge is authentic, whether or not the cartridge has been used previously, the substance located within the cartridge, the amount of substance that should be dispensed per load of laundry, at what point in the cycle the substance should be dispensed, and how much substance is located within the cartridge.
The laundry detergent cartridge includes a vent, handle, and a barcode. The length of the laundry detergent cartridge of a particular embodiment is 14.5 inches, where the handle is 2.5 inches and the remaining portion is 12 inches, and the width of the laundry detergent cartridge is 5.875 inches.
In an alternative embodiment, the laundry detergent cartridge has a generally trapezoidal shape, where the width of the top part is 5.875 inches and the width of the bottom part is 5.0625 inches. The height of the laundry detergent cartridge is 5.5 inches. The trapezoidal shape helps ensure that the laundry detergent cartridge has the proper orientation when it is placed into the dispensing system. Notches in the laundry detergent cartridge may be used to align the laundry detergent cartridge in the appropriate position and location in the dispensing system.
A vent cap allows for air to vent into a cartridge as the substance contained within is removed from the cartridge. The vent cap may be a screw-type cap, wherein the vent cap is placed over a vent and screwed into position. When screwed shut, the vent cap closes the vent. When vent cap is unscrewed, the vent is opened and air is allowed to pass therethrough. Without venting the cartridge, fluid would not easily flow out of the cartridge and through the delivery tube.
The fabric softener cartridge is smaller than the laundry detergent cartridge. Often, more laundry detergent is used than fabric softener per load of laundry. Therefore, the fabric softener cartridge needs to hold less fabric softener than the laundry detergent cartridge needs to hold laundry detergent. In this particular embodiment, the main part of the fabric softener cartridge is 7.125 inches long and 3.5 inches wide. The fabric softener cartridge also includes a handle for grasping and maneuvering the fabric softener cartridge and a vent cap for allowing air to vent into the fabric softener cartridge as fabric softener is removed from the fabric softener cartridge.
In an alternative embodiment, the fabric softener cartridge has a generally trapezoidal shape, where the width of the top part is 3.5 inches. The height of the fabric softener cartridge is 5.25 inches. The trapezoidal shape helps ensure that the fabric softener cartridge has the proper orientation when it is placed into the dispensing system. Notches in the fabric softener cartridge align the fabric softener cartridge in the appropriate position and location in the dispensing system.
In a particular embodiment, the laundry detergent cartridge holds 170 oz. of laundry detergent and the bleach cartridge holds 5 oz. of bleach.
In practice, a user opens the lid to the dispensing system, removes the vent cap that covers the vent of a cartridge, and then inserts the cartridge into the dispensing system. The user then closes the lid and the dispensing system reads in the barcode located on the cartridge, verifies its authenticity, and then punctures the barcode making it unreadable in the future. If necessary and enabled, the dispensing system queries a remote server for additional information on the cartridge, such as type of substance, size of the container, and dispensing instructions. At the same time or subsequent to reading the barcode, level indicators are inserted through the vent to read in the level of substance remaining within the cartridge.
The user will then place dirty laundry into the washing machine, and start a washing cycle. The dispensing system dispenses an appropriate amount of the substance contained within the cartridge into the washing machine at the appropriate time. For example, a first substance may be deposited into the cleaning substance drawer of the washing machine when the cleaning cycle begins, while a second substance is deposited fifteen minutes after the cycle beings, and then a third substance is deposited 5 minutes before the cleaning cycle ends.
Multiple loads of laundry may be run for each cartridge. When the level indicators determine that there is little substance left within a particular cartridge, such as substance for five or fewer loads, a user is notified. Notifications include without limitation a blinking light, illuminated light, a beep, a buzz, a text message, an email, or red/yellow/green lights and/or bars.
After a cartridge is empty, the user opens the lid of the dispensing system. As the lid is opened, the level indicators are removed from each cartridge and the user may grasp the handle of the empty cartridge and remove it from the dispensing system. If each cartridge is designed to deliver substance for the same number of loads of laundry, and not necessarily the same amount of substance, then all of the cartridges should need to be replaced at roughly the same time.
The system described herein has been shown with three different sized cartridges. One skilled in the art will appreciate that fewer or more than three cartridges of the same or different substances may be implemented. For example, a four-cartridge system may be used where four different substances are desired to automatically dispense into the washing machine. Furthermore, multiple cartridges of the same type and/or size and shape (such as multiple laundry detergent cartridges) may be implemented into the system. Additionally, gravity or pressure pumps may be used to move the fluid substance contained within the cartridge.
It should be understood that while the preferred embodiments of the invention are described in some detail herein, the present disclosure is made by way of example only and that variations and changes thereto are possible without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims I regard as my invention.
All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved.
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A system for dispensing substances into a washing machine is disclosed. A plurality of preferably different sized or shaped cartridges are located within removable drawers. Each cartridge contains a particular substance, such as laundry detergent, bleach, or fabric softener, that is released into the washing machine. The system also includes a means to identify the substance contained within the cartridge as well as when and how much of the substance should be released into the washing machine. At the appropriate time, the system dispenses an appropriate amount of substance into the washing machine. A pump pulls the substance out of the container and into the washing basin of a washing machine. Alternatively, a valve is opened and the substance pours into the washing basin due to gravitational forces.
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TECHNICAL FIELD
[0001] This invention relates to a connector which is mateable with and removable from a mating structure comprising a pin contact and a lock housing.
BACKGROUND ART
[0002] For example, this type of connector is disclosed in Patent Document 1.
[0003] As shown in FIGS. 20A and 20B , a female connector (connector) disclosed in Patent Document 1 is mateable with and removable from a mating structure, which is formed on a battery body, along a mating direction. The mating structure is formed of a male terminal (pin contact) and a lock rib (lock housing) which are attached to an upper surface of the battery body. The connector comprises a housing and a female terminal (contact) held by the housing. The housing is provided with a bendable arm (resilient piece) having a lock projection. The bendable arm is provided on a periphery of the housing. The lock projection is supported to be movable in a lateral direction perpendicular to the mating direction. When the connector is mated with the mating structure, the lock projection is locked by the lock rib so that the connector is prevented from being unintentionally removed. The connector under a mated state, or the connector mated with the mating structure, can be removed from the mating structure by moving the lock rib toward the center of the housing in the lateral direction.
PRIOR ART DOCUMENTS
Patent Document(s)
[0004] Patent Document 1: JP B 3204918
SUMMARY OF INVENTION
Technical Problem
[0005] The lock projection of Patent Document 1 is formed to be relatively easily moved in the lateral direction in order to enable the connector to be mated with and removed from the mating structure. As a result, if the connector mated with the mating structure receives an upward strong force, or such force that forces the connector to be removed, the lock projection might be moved so that the connector is removed. The connector of Patent Document 1 easily comes off the mating structure, for example, when the connector is swayed.
[0006] It is therefore an object of the present invention to provide a connector which is mateable with and removable from a mating structure comprising a pin contact and a lock housing and which can be more securely prevented from being unintentionally removed from the mating structure.
[0007] Solution to Problem
[0008] An aspect of the present invention provides a connector mateable with and removable from a mating structure along an upper-lower direction. The mating structure has an upper surface and comprises a pin contact and a lock housing which extend upward along the upper-lower direction from the upper surface. The connector comprises a housing, a contact and an operation member. The contact is held by the housing. The contact is brought into contact with the pin contact under a mated state where the connector and the mating structure are mated with each other. The operation member is formed separately from the housing and supported by the housing. The operation member is rotationally movable between a release position and a lock position about a pivot axis which is in parallel to the upper-lower direction. The operation member is provided with a locked portion projecting in a radial direction perpendicular to the pivot axis. The locked portion allows the connector to be moved to the mated state with the mating structure and to be removed from the mating structure when the operation member is located at the release position. The locked portion interferes with the lock housing when the operation member is located at the lock position, so that the locked portion prevents the connector from being moved to the mated state with the mating structure and from being removed from the mating structure.
Advantageous Effects of Invention
[0009] According to the present invention, when the operation member of the connector is rotationally moved from the release position to the lock position, the connector mated with the mating structure is prevented from being removed. Accordingly, the connector can be more securely prevented from being unintentionally removed.
[0010] An appreciation of the objectives of the present invention and a more complete understanding of its structure may be had by studying the following description of the preferred embodiment and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a perspective view showing a connector and a mating structure according to an embodiment of the present invention, wherein the connector and the mating structure are mated with each other, and an operation member of the connector is located at a release position.
[0012] FIG. 2 is a perspective view showing the connector of FIG. 1 .
[0013] FIG. 3 is a perspective view showing the mating structure of FIG. 1 .
[0014] FIG. 4 is an exploded, perspective view showing the mating structure of FIG. 3 .
[0015] FIG. 5 is an exploded, perspective view showing the connector of FIG. 2 .
[0016] FIG. 6 is a top view showing the operation member of the connector of FIG. 5 .
[0017] FIG. 7 is a bottom view showing the operation member of FIG. 6 .
[0018] FIG. 8 is a side view showing the operation member of FIG. 6 .
[0019] FIG. 9 is an enlarged, side view showing the vicinity of a slope of a locked portion of the operation member (the part enclosed by dashed line A) of FIG. 6 .
[0020] FIG. 10 is a cross-sectional view showing the operation member of FIG. 6 , taken along line X-X.
[0021] FIG. 11 is an enlarged, bottom view showing the vicinity of a projection of the operation member (the part enclosed by dashed line B) of FIG. 7 .
[0022] FIG. 12 is a top view showing the connector and the mating structure of FIG. 1 , wherein a cable connected to the connector is not illustrated.
[0023] FIG. 13 is a side view showing the connector and the mating structure of FIG. 12 , wherein the mating structure is indicated by a cross-section of a lock housing taken along line XIII-XIII and a schematic shape of a hidden pin contact.
[0024] FIG. 14 is a top view showing the connector and the mating structure of FIG. 12 under a state where the operation member is rotationally moved to a lock position.
[0025] FIG. 15 is a side view showing the connector and the mating structure of FIG. 14 , wherein the mating structure is indicated by a cross-section of a lock housing taken along line XV-XV.
[0026] FIG. 16 is a perspective view showing the connector and the mating structure of FIG. 1 under the state where the operation member is rotationally moved to the lock position.
[0027] FIG. 17 is a partial, cross-sectional view showing the connector of FIG. 12 taken along line XVII-XVII, wherein the mating structure is not illustrated except a schematic shape of the pin contact.
[0028] FIG. 18 is a cross-sectional view showing the connector of FIG. 17 , taken along line XVIII-XVIII.
[0029] FIG. 19 is a cross-sectional view showing the connector of FIG. 17 under the state where the operation member is rotationally moved to the lock position, taken along line XIX-XIX.
[0030] FIG. 20A is a top view showing an existing connector and a mating connector, wherein a part of the connector, which is hidden under the mating connector, is also illustrated. FIG. 20B is a cross-sectional view showing the connector and the mating connector of FIG. 20A .
DESCRIPTION OF EMBODIMENTS
[0031] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
[0032] As can be seen from FIGS. 1 to 3 , the connector 10 according to an embodiment of the present invention is a cable connector which is mateable with and removable from a mating structure 90 along an upper-lower direction (Z-direction). In detail, the connector 10 can be mated with the mating structure 90 , which is located below, by being moved downward, or along the negative Z-direction. The connector 10 mated with the mating structure 90 is in a mated state. The connector 10 in the mated state can be removed from the mating structure 90 by being moved upward, or along the positive Z-direction. In other words, according to the present embodiment, the mating direction is the negative Z-direction, and the removal direction is the positive Z-direction.
[0033] As shown in FIGS. 1 , 3 and 4 , the mating structure 90 has an upper surface 90 U which is insulated. Moreover, the mating structure 90 comprises a pin contact 910 made of conductor and a lock housing 950 made of insulator. The pin contact 910 and the lock housing 950 extend upward along the Z-direction from the upper surface 90 U. The upper surface 90 U according to the present embodiment is a part of an upper surface, or the positive Z-side surface, of a battery body (not shown). The pin contact 910 according to the present embodiment is connected to the battery body. The pin contact 910 is used to charge electric power supplied via the connector 10 to the battery body, or used to supply the electric power charged in the battery body to a device (not shown) connected to the connector 10 . In other words, according to the present embodiment, the connector 10 is a power connector, and the pin contact 910 is a power contact. However, the present invention is also applicable to a connector other than the power connector.
[0034] As shown in FIG. 4 , the upper surface 90 U is formed with a holding hole 92 . As can be seen from FIGS. 3 and 4 , the pin contact 910 is held in the holding hole 92 so as to extend in the Z-direction. In detail, as shown in FIG. 4 , the pin contact 910 has a contact portion 912 , a held portion 914 and a connection portion 916 . The connection portion 916 is inserted into the holding hole 92 and is electrically connected with the battery (not shown). The held portion 914 is held by the holding hole 92 so that the contact portion 912 extends upward from the upper surface 90 U (see FIG. 3 ). The contact portion 912 according to the present embodiment has a columnar shape. Accordingly, the contact portion 912 has an upper end, or the positive Z-side end, which is formed in a planar shape perpendicular to the Z-direction.
[0035] The lock housing 950 according to the present embodiment is provided so as to be around the pin contact 910 . In detail, the lock housing 950 is provided with a sidewall 952 and a lock wall 954 . The sidewall 952 extends upward from the upper surface 90 U. The sidewall 952 covers opposite sides of the pin contact 910 in a width direction (Y-direction) and a front side, or the negative X-side, of the pin contact 910 in a front-rear direction (X-direction). The lock wall 954 is formed at an upper end of the sidewall 952 . The lock wall 954 is located above the pin contact 910 in the Z-direction. In addition, the lock wall 954 protrudes from the sidewall 952 toward the pin contact 910 in the XY-plane. Since the lock housing 950 is formed as described above, electrical shock due to contact with the pin contact 910 can be prevented.
[0036] The lock wall 954 according to the present embodiment is formed of one arcuate portion 962 and two linear portions 964 . The arcuate portion 962 according to the present embodiment has a semicircular shape in a plane perpendicular to the Z-direction, or in the XY-plane that is a horizontal plane. However, the arcuate portion 962 may have any arc shape different from the semicircular shape, for example, one-third circle shape. The arcuate portion 962 is formed so as to project forward, or in the negative X-direction. The linear portions 964 extend rearward, or in the positive X-direction, from two rear ends, or the positive X-side ends, of the arcuate portions 962 in the X-direction, respectively.
[0037] As can be seen from FIG. 3 , the arcuate portion 962 according to the present embodiment is formed to be apart from the center (CP) of the columnar shape of the contact portion 912 of the pin contact 910 by a predetermined distance (R0). In other words, according to the present embodiment, the center (CA) of the arcuate portion 962 is located at a position same as that of the center (CP) of the pin contact 910 in the XY-plane. However, the center (CA) of the arcuate portion 962 may be apart from the center (CP) of the pin contact 910 .
[0038] As can be seen from FIGS. 3 , 4 and 15 , the lock wall 954 has a lower surface, or the negative Z- side surface. The lower surface of the lock wall 954 is formed with lock portions 956 . The lock portion 956 according to the present embodiment is a plane which is formed mainly on a lower side, or the negative Z-side, of the linear portion 964 and is perpendicular to the Z-direction. However, the lock portion 956 may be oblique to the Z-direction. Moreover, the lock portion 956 may be a curved surface which intersects with the Z-direction.
[0039] As shown in FIG. 5 , the connector 10 comprises a housing 200 made of insulator, a contact 300 made of conductor and an operation member 400 made of insulator. The operation member 400 is formed separately from the housing 200 . The housing 200 according to the present embodiment consists of a first member 210 and a second member 280 . However, the housing 200 may further comprise the other members.
[0040] As shown in FIG. 5 , the first member 210 has an upper plate 220 , a bottom plate 230 and a side plate 240 . In addition, the first member 210 is formed with an accommodation portion 270 to accommodate the contact 300 . In detail, the upper plate 220 and the bottom plate 230 are located at opposite ends of the housing 200 in the Z-direction, respectively. The side plate 240 is formed at one of opposite ends of the housing 200 in the Y-direction. The side plate 240 according to the present embodiment is located at the positive Y-side end of the housing 200 . The side plate 240 couples the upper plate 220 and the bottom plate 230 to each other in the Z-direction. The accommodation portion 270 is a space surrounded by the upper plate 220 , the bottom plate 230 and the side plate 240 . In other words, the upper plate 220 , the bottom plate 230 and the side plate 240 form the accommodation portion 270 .
[0041] The upper plate 220 has an upper surface 220 U in parallel to the XY-plane. The upper surface 220 U is formed with a positioning mark 220 M. The positioning mark 220 M according to the present embodiment has a triangular shape. The upper plate 220 is formed with a support hole 222 and an engagement hole 224 . The support hole 222 is formed so as to partially cut out a front part, or the negative X-side part, of the upper plate 220 from the negative Y-side thereof. More specifically, the support hole 222 is a combination of a semicircular hole (a semicircular portion) and a rectangular cutout. The engagement hole 224 is a hole formed at the negative Y-side end of the upper plate 220 . The engagement hole 224 extends long in the X-direction while piercing the upper plate 220 in the Z-direction.
[0042] The bottom plate 230 is formed with an insertion hole 232 and an engagement hole 234 . The insertion hole 232 is a circular hole piercing the bottom plate 230 in the Z-direction. In the XY-plane, the insertion hole 232 is slightly larger than the contact portion 912 (see FIG. 3 ) of the pin contact 910 . In the XY-plane, the center of the insertion hole 232 is located at a position same as that of the center (CP) (see FIG. 3 ) of the contact portion 912 under the mated state. Moreover, in the XY-plane, the center of the insertion hole 232 is apart from the center of the semicircular portion of the support hole 222 (see FIG. 17 ). The engagement hole 234 is a hole which is formed at the negative Y-side end of the bottom plate 230 so as to correspond to the engagement hole 224 of the upper plate 220 . The engagement hole 234 extends long in the X-direction while piercing the bottom plate 230 in the Z-direction.
[0043] As shown in FIG. 17 , the upper plate 220 and the bottom plate 230 are formed with a step 226 and a step 236 , respectively. The step 226 and the step 236 project into the accommodation portion 270 from the upper plate 220 and the bottom plate 230 , respectively.
[0044] As shown in FIG. 5 , the first member 210 further has a front plate 250 and a rear plate 260 . The front plate 250 and the rear plate 260 are located at opposite ends of the housing 200 in the X-direction, respectively. In detail, the front plate 250 is formed at a front end, or the negative X-side end, of the housing 200 , and the rear plate 260 is formed at a rear end, or the positive X-side end, of the housing 200 . The front plate 250 blocks a front end of the accommodation portion 270 . The rear plate 260 is formed with a connection hole 262 . The connection hole 262 is formed so as to cut out the rear plate 260 from the negative Y-side thereof.
[0045] As shown in FIG. 18 , the housing 200 is provided with a depression 242 and a recess 252 . The depression 242 and the recess 252 together with the support hole 222 form a section for accommodating a part of the operation member 400 . In detail, the side plate 240 has an inner wall which is partially depressed in the positive Y-direction so as to form the depression 242 . The front plate 250 has an inner wall which is partially recessed forward so as to form the recess 252 . The depression 242 and the recess 252 according to the present embodiment have shapes different from each other. However, the depression 242 and the recess 252 may have shapes similar to each other.
[0046] As shown in FIGS. 5 and 13 , the second member 280 has a plate-like shape extending roughly in the XZ-plane. The second member 280 is formed with two engagement projections 282 . The engagement projections 282 have shapes corresponding to those of the engagement hole 224 and the engagement hole 234 , respectively. More specifically, each of the engagement projections 282 projects outward in the Z-direction while extending long in the X-direction.
[0047] As can be seen from FIGS. 5 and 17 , the contact 300 according to the present embodiment has a body portion 310 and a connection portion 330 which are integrally formed.
[0048] The body portion 310 has a shape which is a combination of a half column and a square column. The body portion 310 is formed with a receiving portion 320 . The receiving portion 320 is a columnar hole piercing the body portion 310 in the Z-direction. The receiving portion 320 is formed with an inner wall 322 .
[0049] The connection portion 330 has a columnar shape extending rearward from a rear end of the body portion 310 . The connection portion 330 is connected to a cable 800 . The cable 800 extends in the X-direction, or in a direction perpendicular to the Z-direction. The contact 300 can receive electric power from a power source (not shown) via the cable 800 . The contact 300 is securely connected to the cable 800 by crimping a crimping member 850 at a connection section between the connection portion 330 and the cable 800 .
[0050] As shown in FIG. 17 , a contact member 340 made of metal is attached to the inner wall 322 of the receiving portion 320 . The contact member 340 roughly has an annular shape. The contact member 340 has a middle portion in the Z-direction which has a circular shape smaller than opposite ends of the contact member 340 in the Z-direction. In detail, in the XY-plane, an inner diameter of the middle portion of the contact member 340 is smaller than a diameter the contact portion 912 (see FIG. 3 ) of the pin contact 910 . On the other hand, an inner diameter of each of the opposite ends of the contact member 340 is larger than the diameter of the contact portion 912 . In addition, the middle portion of the contact member 340 is resiliently deformable in the XY-plane.
[0051] As can be seen from FIGS. 5 and 17 , the contact 300 , which is formed as described above and is connected to the cable 800 , is inserted into the accommodation portion 270 of the first member 210 along the positive Y-direction and accommodated therein. The contact 300 , which is accommodated in the accommodation portion 270 , is sandwiched between the upper plate 220 and the bottom plate 230 in the Z-direction so that a movement of the contact 300 in the Z-direction is prevented (see FIG. 17 ). Moreover, the body portion 310 of the contact 300 is sandwiched between the front plate 250 and the steps 226 and 236 in the X-direction so that a movement of the contact 300 in the X-direction is prevented (see FIG. 17 ).
[0052] As can be seen from FIGS. 5 and 13 , the second member 280 is attached to the first member 210 along the positive Y-direction after the contact 300 is accommodated in the first member 210 . In detail, the two engagement projections 282 are engaged with the engagement hole 224 and the engagement hole 234 , respectively, so that the second member 280 is fixed to the first member 210 . When the second member 280 is fixed to the first member 210 , the contact 300 is sandwiched between the side plate 240 and the second member 280 in the Y-direction so that a movement of the contact 300 in the Y-direction is prevented.
[0053] As can be seen from FIGS. 5 and 17 , the contact 300 is held at a predetermined position in the accommodation portion 270 . The receiving portion 320 of the contact 300 held at the predetermined position is located on the insertion hole 232 of the bottom plate 230 . The cable 800 extends to the outside of the housing 200 through the connection hole 262 of the rear plate 260 . As described above, the housing 200 according to the present embodiment is fabricated by combining the first member 210 and the second member 280 in a direction perpendicular to the Z-direction. Accordingly, for example, even if the cable 800 is swayed and applies a force in the Z-direction to the contact 300 , the contact 300 can be securely held within the accommodation portion 270 .
[0054] As can be seen from FIGS. 1 and 2 , the operation member 400 according to the present embodiment is supported by the housing 200 so as to be rotationally movable along a rotation direction about a pivot axis (AX) in parallel to the Z-direction. According to the present embodiment, when the connector 10 is seen along the negative Z-direction, the rotation direction is a clockwise direction. However, the operation member 400 can be formed so as to be rotationally movable in a counterclockwise direction.
[0055] As shown in FIGS. 5 to 7 , the operation member 400 is formed into a disk-like shape as a whole. In detail, the operation member 400 has a pivotable portion 410 , two locked portions 420 , an operation portion 430 and a lower plate 440 .
[0056] As shown in FIGS. 5 and 6 , the pivotable portion 410 has an upper surface 410 U in parallel to the XY-plane. The upper surface 410 U is formed with a positioning mark 410 M. The positioning mark 410 M according to the present embodiment has a triangular shape similar to that of the positioning mark 220 M (see FIG. 2 ). The pivotable portion 410 is formed of a columnar portion 412 of columnar shape and two side portions 414 which project outward in radial directions of the column, or in directions perpendicular to the pivot axis (AX), from the columnar portion 412 . The locked portions 420 further project outward in the radial directions from lower ends, or the negative Z-side ends, of the side portions 414 , respectively.
[0057] As shown in FIGS. 6 , 8 and 9 , each locked portion 420 has an upper side, or an upper surface, which extends to intersect with the Z-direction. In detail, the upper side of the locked portion 420 is formed with a planar portion 422 and a slope 424 . The planar portion 422 extends in the XY-plane along the rotation direction, or along the side portion 414 . The slope 424 extends from the planar portion 422 while sloping downward along the rotation direction. Accordingly, a height (H1), or a size in the Z-direction, of an end of the locked portion 420 in the rotation direction is smaller than another height (H2) of a portion of the locked portion 420 which is formed with the planar portion 422 (see FIG. 9 ). In other words, the end of the slope 424 in the rotation direction is located below the planar portion 422 .
[0058] As shown in FIGS. 7 , 8 and 10 , the lower plate 440 is formed under the pivotable portion 410 with a distance from the pivotable portion 410 . The pivotable portion 410 and the lower plate 440 are coupled to each other in the Z-direction by a columnar portion smaller than the pivotable portion 410 and the lower plate 440 so that the operation member 400 is formed with a recess 480 . The recess 480 is located between the pivotable portion 410 and the lower plate 440 in the Z-direction.
[0059] As shown in FIG. 7 , the lower plate 440 has a first arcuate portion 442 , a second arcuate portion 444 and two tangential portions 446 . According to the present embodiment, the first arcuate portion 442 has a semicircular shape in the XY-plane, and the second arcuate portion 444 has an arc shape in the XY-plane. A size of an imaginary circle having the second arcuate portion 444 as its part is larger than another size of another imaginary circle having the first arcuate portion 442 as its part. The tangential portions 446 couple the first arcuate portion 442 and the second arcuate portion 444 to each other. The second arcuate portion 444 and the tangential portions 446 has connection portions therebetween each of which is formed with a corner 448 . In other words, the lower plate 440 has two of the corners 448 .
[0060] The center of the semicircle of the first arcuate portion 442 is located on the pivot axis (AX) of the operation member 400 . Similarly, the center of the arc of the second arcuate portion 444 is located on the pivot axis (AX) of the operation member 400 . Accordingly, when the operation member 400 pivots, the first arcuate portion 442 and the second arcuate portions 444 pivot about the pivot axis (AX).
[0061] As shown in FIGS. 7 , 10 and 11 , the lower plate 440 is formed with a groove 460 which pierces the lower plate 440 in the Z-direction. The groove 460 extends along the second arcuate portion 444 in the vicinity of the second arcuate portion 444 so that the lower plate 440 is formed with a support portion 450 . The support portion 450 is an arc-shaped, narrow portion which extends long along the groove 460 . The thus-formed support portion 450 is resiliently deformable toward the groove 460 .
[0062] The operation member 400 , namely, the lower plate 440 , is provided with a projection (maintaining member) 470 which projects in the radial direction. The projection 470 is formed at the middle of the support portion 450 . The projection 470 is supported by the support portion 450 so as to be movable in the radial direction, in particular toward the center of the arc of the second arcuate portion 444 .
[0063] As can be seen from FIGS. 5 , 8 and 17 , the operation member 400 is attached to the first member 210 of the housing 200 so that the projection 470 is located at a front end of the lower plate 440 . In detail, the operation member 400 is attached to the support hole 222 so that the upper plate 220 of the first member 210 and the recess 480 of the operation member 400 are engaged with each other. By this engagement, movements of the operation member 400 in the X-direction and in the Z-direction are prevented. Moreover, the second member 280 is fixed to the first member 210 as described above after the contact 300 and the operation member 400 are both attached to the first member 210 . When the second member 280 is fixed to the first member 210 , a movement of the operation member 400 in the Y-direction is prevented. As a result, the operation member 400 is practically only allowed to pivot about the pivot axis (AX).
[0064] As shown in FIGS. 2 , 12 and 13 , when the connector 10 is fabricated as described above, the locked portions 420 of the operation member 400 are located over the housing 200 . Moreover, the locked portions 420 are located in territory of the housing 200 in the XY-plane. The position of the operation member 400 at that time, or the position of the operation member 400 illustrated in FIGS. 2 , 12 and 13 , is referred to as “release position”. The locked portions 420 of the operation member 400 at the release position do not protrude from the housing 200 in the XY-plane.
[0065] The connector 10 explained above is mateable with and removable from the mating structure 90 as described below.
[0066] As can be seen from FIG. 12 , when the operation member 400 is located at the release position, the connector 10 can be mated with and can be removed from the mating structure 90 along the Z-direction with no interference by the lock housing 950 . In detail, the locked portions 420 of the operation member 400 at the release position does not prevent the connector 10 from being mated with the mating structure 90 . Moreover, the locked portions 420 of the operation member 400 at the release position does not prevent the connector 10 from being removed from the mating structure 90 . In other words, the locked portions 420 allow the connector 10 to be moved to the mated state with the mating structure 90 and to be removed from the mating structure 90 when the operation member 400 is located at the release position.
[0067] As can be seen from FIGS. 13 and 17 , when the connector 10 and the mating structure 90 is in the mated state, the contact portion 912 (see FIG. 13 ) of the pin contact 910 is inserted into the receiving portion 320 of the contact 300 through the insertion hole 232 of the housing 200 . In detail, the contact portion 912 is inserted into the contact member 340 of the contact 300 to be in contact with the contact member 340 . In other words, the contact 300 is held by the housing 200 so as to be brought into contact with the pin contact 910 under the mated state. As can be seen from the above explanation, the connector 10 and the mating structure 90 are electrically connected with each other under the mated state.
[0068] As shown in FIG. 13 , the locked portions 420 of the operation member 400 are located above the pin contact 910 under the mated state. In other words, a height of the contact portion 912 of the pin contact 910 according to the present embodiment is lower than another height of the housing 200 . Accordingly, electric shock due to contact with the pin contact 910 can be prevented more effectively.
[0069] As shown in FIG. 18 , when the operation member 400 is located at the release position, the projection 470 of the operation member 400 is located within the recess 252 of the housing 200 and, therefore, projects forward without being pressed by the front plate 250 . According to the present embodiment, the projection 470 of the operation member 400 at the releasing position is apart from the front plate 250 . However, a front end of the projection 470 may be in slight contact with the front plate 250 .
[0070] As can be seen from FIG. 18 , if the operation member 400 of the release position starts the rotational movement in the rotation direction, the projection 470 is brought into abutment with the front plate 250 . Accordingly, the operation member 400 is prevented from unintentionally rotating along the rotation direction, or from pivoting with no pivoting operation. Moreover, in a case where the recess 252 is formed to have a shape similar to that of the depression 242 , the operation member 400 can be also prevented from unintentionally rotating along a reverse rotation direction that is a direction opposite to the rotation direction. As can be seen from the above explanation, the projection 470 according to the present embodiment functions as the maintaining member 470 to maintain the operation member 400 at the release position.
[0071] According to the present embodiment, when the operation member 400 of the release position is rotationally moved in the reverse rotation direction, the corner 448 of the operation member 400 is brought into abutment with the second member 280 of the housing 200 . Accordingly, the rotational movement of the operation member 400 in the reverse rotation direction is regulated. As can be seen from the above explanation, the operation member 400 according to the present embodiment includes a regulation portion, namely, the corner 448 , which regulates the rotational movement in the reverse rotation direction.
[0072] As shown in FIGS. 1 , 12 and 14 , when the operation portion 430 of the operation member 400 of the release position is operated to be rotationally moved in the rotation direction, the pivotable portion 410 of the operation member 400 is also rotationally moved in the rotation direction. When the pivotable portion 410 is rotationally moved in the rotation direction, the locked portions 420 of the operation member 400 are moved while gradually projecting from the housing 200 in the XY-plane (see FIG. 14 ).
[0073] As shown in FIG. 12 , according to the present embodiment, in the XY-plane, the position of the pivot axis (AX) of the operation member 400 is apart from the center (CA) of the arc of the arcuate portion 962 by a distance DO. Accordingly, the locked portions 420 are moved in the rotation direction while passing under the lock portions 956 of the lock housing 950 , respectively. Since the locked portion 420 according to the present embodiment is provided with the slope 424 , the locked portion 420 can be moved under the lock portion 956 without being brought into abutment with the lock wall 954 of the lock housing 950 to be stopped.
[0074] As can be seen from FIG. 14 , as the operation member 400 is rotationally moved in the rotation direction, larger part of the locked portion 420 protrudes under the lock portion 956 . According to the present embodiment, when the operation member 400 is rotationally moved by 90° in the rotation direction, the two locked portions 420 , similar to each other, largely protrude under the lock portions 956 , respectively. The position of the operation member 400 at that time, or the position of the operation member 400 illustrated in FIG. 14 , is referred to as “lock position”.
[0075] The locked portions 420 of the operation member 400 at the lock position protrude from the housing 200 in the XY-plane so that a large area of the locked portion 420 is covered with the lock portion 956 in the Z-direction. Accordingly, when the operation member 400 is located at the lock position, the connector 10 cannot be removed from the mating structure 90 along the Z-direction. Moreover, the connector 10 , which is in a state where the operation member 400 is rotationally moved to the lock position, cannot be brought into mating with the mating structure 90 . In other words, the locked portions 420 interfere with the lock housing 950 to prevent the connector 10 from being moved to the mated state with the mating structure 90 and from being removed from the mating structure 90 when the operation member 400 is located at the lock position.
[0076] In detail, the locked portions 420 of the operation member 400 at the lock position interfere with the lock portions 956 , or are locked by the lock portions 956 , respectively, to prevent the connector 10 from being removed from the mating structure 90 . Thus, when the operation member 400 of the connector 10 is rotationally moved from the release position to the lock position, the removal of the connector 10 , which is mated with the mating structure 90 , can be prevented. As a result, unintentional removal of the connector 10 can be more securely prevented. Moreover, the locked portions 420 of the operation member 400 at the lock position prevent the connector 10 from being mated with the mating structure 90 .
[0077] As shown in FIGS. 12 and 14 , according to the present embodiment, the operation member 400 of the release position is moved to the lock position by rotation of 90° in the rotation direction. In other words, according to the present embodiment, a predetermined pivoting angle, which is necessary to rotationally move the operation member 400 from the release position to the lock position, is 90°. The predetermined pivoting angle can be changed to an angle other than 90°, for example, by modifying the structures of the locked portion 420 and the lock portion 956 . However, the structure according to the present embodiment is preferable in order to more securely lock the locked portions 420 by the lock portions 956 , respectively.
[0078] As can be seen from FIG. 14 , the connector 10 in the mated state can be rotationally moved about the pin contact 910 in a clockwise direction and in a counterclockwise direction. For example, when the cable 800 (see FIG. 1 ) connected to the connector 10 is swayed, the connector 10 might pivot. The connector 10 according to the present embodiment can be rotationally moved to a position where the housing 200 is brought into abutment with the lock housing 950 . Two-dot chain line in FIG. 14 shows a part of the shape of the connector 10 in a state where the side plate 240 of the housing 200 is brought into abutment with the lock housing 950 , wherein the housing 200 is rotationally moved in the counterclockwise direction. According to the present embodiment, even if the connector 10 pivots as described above, the locked portions 420 are locked by the lock portions 956 , respectively. In other words, the locked portions 420 according to the present embodiment are formed to prevent the removal of the connector 10 even when the connector 10 pivots about the pin contact 910 in the XY-plane.
[0079] Moreover, according to the present embodiment, when the operation member 400 is located at the lock position, the two locked portions 420 are locked evenly by the lock portions 956 . Accordingly, the unintentional removal of the connector 10 can be more surely prevented. However, the operation member 400 may be provided three or more of the locked portions 420 . In other words, it is sufficient for the operation member 400 according to the present embodiment to be provided with at least two of the locked portions 420 . Moreover, by modifying the size and the position of each of the locked portion 420 and the lock portion 956 , even only one of the locked portions 420 can prevent the unintentional removal of the connector 10 .
[0080] As can be seen from FIGS. 18 and 19 , when the operation member 400 is operated to pivot and starts to be rotationally moved from the release position (see FIG. 18 ) toward the lock position (see FIG. 19 ), the projection 470 is pressed by the front plate 250 of the housing 200 to be moved inward in the radial direction. When the operation member 400 is moved to the lock position, the projection 470 is located in the depression 242 to be moved outward in the radial direction. At that time, an operator of the operation member 400 can obtain a click feeling which enables the operator to recognize that the operation member 400 just reaches the lock position.
[0081] As can be seen from FIG. 19 , when the operation member 400 of the lock position starts to be rotationally moved in the reverse rotation direction, the projection 470 is brought into abutment with an edge of the depression 242 . Accordingly, the operation member 400 is prevented from unintentionally rotating along the reverse rotation direction, or from pivoting with no pivoting operation. As can be seen from the above description, the projection 470 according to the present embodiment also functions as the maintaining member 470 to maintain the operation member 400 at the lock position. In other words, the connector 10 according to the present embodiment includes the projection 470 which is the maintaining member to maintain the operation member 400 at each of the release position and the lock position. However, the maintaining member can be formed of a component other than the projection 470 .
[0082] When the operation member 400 of the lock position is further moved rotationally in the rotation direction, the corner 448 of the operation member 400 is brought into abutment with the housing 200 . Accordingly, a rotation movement of the operation member 400 in the rotation direction is regulated. As can be seen from the above explanation, the operation member 400 according to the present embodiment includes another regulation portion, namely, the corner 448 , which regulates excessive rotation in the rotation direction. Thus, the operation member 400 according to the present embodiment can be rotationally moved from the release position just to the lock position along the rotation direction.
[0083] As can be seen FIGS. 14 , 16 and 19 , the operation portion 430 of the operation member 400 of the lock position can be operated to be rotationally moved in the reverse rotation direction. When the operation portion 430 is operated to be rotationally moved in the reverse rotation direction, the projection 470 is pressed by the front plate 250 of the housing 200 to be moved inward in the radial direction (see FIG. 19 ). When the operation member 400 is moved to the release position, the projection 470 is located in the recess 252 to be moved outward in the radial direction. At that time, the operator of the operation member 400 can obtain a click feeling which enables the operator to recognize that the operation member 400 just reaches to the release position. As can be seen from the above explanation, the operation member 400 can be rotationally moved just between the release position and the lock position.
[0084] As shown in FIGS. 12 and 14 , when the operation member 400 is located at the release position, the positioning mark 410 M of the operation member 400 is located apart from the positioning mark 220 M of the housing 200 along the rotation direction. According to the present embodiment, the positioning mark 410 M and the positioning mark 220 M are separated by 90° along the rotation direction. Accordingly, when the operation member 400 is located at the lock position, the positioning mark 410 M faces the positioning mark 220 M in the X-direction. According to the present embodiment, the positional relation between the positioning mark 410 M and the positioning mark 220 M enables recognition about the position of the operation member 400 . In particular, according to the present embodiment, facing corners of the positioning mark 410 M and the positioning mark 220 M enable recognition that the operation member 400 is located at the lock position. However, each of the positioning mark 410 M and the positioning mark 220 M may have a shape different from that of the present embodiment.
[0085] Although the specific explanation about the embodiment of the present invention is made above, the connector according to the present invention is not limited to the above described embodiment but can be variously modified.
[0086] For example, the present invention can be applied to also a connector other than the cable connector. Moreover, the lock housing of the mating structure may be formed in a shape different from that of the aforementioned embodiment. For example, the arcuate portion of the lock housing may be provided so as to be a large distance from the front end of the connector in the mated state. Moreover, the arcuate portion may have, for example, one-third circle shape. In this case, the position of the pivot axis of the operating member may be same as that of the center of the arc of the arcuate portion. Moreover, the arcuate portion may be formed of a plurality of unconnected arcuate portions, or may be formed of a plurality of linear portions to have a shape similar to an arc. Moreover, the lock housing can be provided with no arcuate portion.
[0087] The present application is based on a Japanese patent application of JP2012-249661 filed before the Japan Patent Office on Nov. 13, 2012, the content of which is incorporated herein by reference.
[0088] While there has been described what is believed to be the preferred embodiment of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such embodiments that fall within the true scope of the invention.
REFERENCE SIGNS LIST
[0089] 10 connector
[0090] 200 housing
[0091] 210 first member
[0092] 220 upper plate
[0093] 220 U upper surface
[0094] 220 M positioning mark
[0095] 222 support hole
[0096] 224 engagement hole
[0097] 226 step
[0098] 230 bottom plate
[0099] 232 insertion hole
[0100] 234 engagement hole
[0101] 236 step
[0102] 240 side plate
[0103] 242 depression
[0104] 250 front plate
[0105] 252 recess
[0106] 260 rear plate
[0107] 262 connection hole
[0108] 270 accommodation portion
[0109] 280 second member
[0110] 282 engagement projection
[0111] 300 contact
[0112] 310 body portion
[0113] 320 receiving portion
[0114] 322 inner wall
[0115] 330 connection portion
[0116] 340 contact member
[0117] 400 operation member
[0118] 410 pivotable portion
[0119] 410 U upper surface
[0120] 410 M positioning mark
[0121] 412 columnar portion
[0122] 414 side portion
[0123] 420 locked portion
[0124] 422 planar portion
[0125] 424 slope
[0126] 430 operation portion
[0127] 440 lower plate
[0128] 442 first arcuate portion
[0129] 444 second arcuate portion
[0130] 446 tangential portion
[0131] 448 corner
[0132] 450 support portion
[0133] 460 groove
[0134] 470 projection (maintaining member)
[0135] 480 recess
[0136] AX pivot axis
[0137] 800 cable
[0138] 850 crimping member
[0139] 90 mating structure
[0140] 90 U upper surface
[0141] 92 holding hole
[0142] 910 pin contact
[0143] 912 contact portion
[0144] 914 held portion
[0145] 916 connection portion
[0146] 950 lock housing
[0147] 952 sidewall
[0148] 954 lock wall
[0149] 956 lock portion
[0150] 962 arcuate portion
[0151] 964 linear portion
[0152] CA center
[0153] CP center
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A connector is capable of being fitted to, and extracted from, a partner-side structure along the vertical direction. The partner-side structure is provided with a lock housing extending upwards. The connector is provided with a housing, and an operation member formed separately from the housing. The operation member is capable of rotating, about a rotary axis parallel to the vertical direction, between a release position and a lock position. A locked section protruding in the radial direction orthogonal to the rotary axis is provided to the operation member. The locked section allows the connector to be fitted to, and extracted from, the partner-side structure when the operation member is at the release position. The locked section interferes with the lock housing and prevents the connector from being fitted to, and extracted from, the partner-side structure when the operation member is at the lock position.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is entitled to the benefit of British Patent Application No. GB 0707319.0 filed on Apr. 17, 2008.
FIELD OF THE INVENTION
[0002] The present invention relates to a method and apparatus for cooling a starter/generator of a gas turbine engine at start-up.
BACKGROUND OF THE INVENTION
[0003] One conventional means of starting a modern turbofan engine is via a compressed air starter where no dedicated cooling of such an air starter is required, as the heat rejection from such an air starter is low.
[0004] Another conventional method of starting more electric gas turbine engines is via an electric driven starter. Here the starter is a variable frequency starter/generator that has a built-in pump for pumping oil through the starter to a dedicated closed circulating oil cooling circuit to transfer the heat generated from the starter to the oil in the oil circuit. The heated oil is then cooled by a flow of fuel via a heat exchanger. The fuel is pumped to the heat exchanger and returned to a fuel tank housed within the aircraft (conventionally known as a fuel return to tank cooling system). This method relies on the fuel mass in the aircraft's fuel tank acting as an external thermal sink to remove heat from the VFSG oil circuit. Because there is a finite amount of fuel, this system is limited to the amount of heat that it can dissipate. In addition, there are problems in the fuel balance within aircraft fuel tanks and fuel tank contamination.
[0005] In principle, the thermal mass of the fluids and metals in the cooling circuits could be used as a simple static thermal sink, however, this method is of limited use due to the limited thermal capacity in the cooling circuits. Increasing the fuel volume in the loop would increase the thermal sink capacity, which means a large amount of fuel being stored on engine, and hence, adversely increases the weight of the engine and causes an unnecessary fire hazard for the engine.
[0006] Therefore it is an object of the present invention to provide an improved cooling system for the starter/generator that is not hazardous and is acceptable for engine certification requirements.
SUMMARY OF THE INVENTION
[0007] In accordance with the present invention there is provided a as turbine engine comprising a turbine and a compressor connected via a shaft, a main fuel supply line for supplying fuel to a combustor that is positioned to release expanding hot gases to the turbine, the engine further comprises a first fuel and oil heat exchanger associated with an engine starter/generator that is connected to the shaft via a gearbox assembly, the engine is characterised by a re-circulating fuel circuit positioned on the main fuel supply line and comprising a second fuel/oil heat exchanger and a fuel accumulator, the re-circulating fuel circuit cools the oil in the starter/generator via the first fuel and oil heat exchanger.
[0008] Preferably, the second fuel/oil heat exchanger is fluidly connected to an engine oil circuit.
[0009] Preferably, the first fuel/oil heater exchanger is fluidly connected to the starter/generator.
[0010] Preferably, the circuit comprises a fuel filter and which may be positioned between the second fuel/oil heat exchanger and the combustor.
[0011] Preferably, the circuit comprises a shut off valve that is provided to stop fuel return flow during normal engine running.
[0012] In another aspect of the present invention there is provided a method of operating a gas turbine engine comprising a turbine and a compressor connected via a shaft, a main fuel supply line for supplying fuel to a combustor that is positioned to release expanding hot gases to the turbine, the engine further comprises a starter/generator connected to the shaft via a gearbox assembly, the method is characterised the step of during engine start up fuel is circulated in a re-circulating fuel circuit positioned on the main fuel supply line and which comprises a first fuel/oil heat exchanger, for cooling the oil in the starter/generator oil circuit, and a fuel accumulator.
[0013] Preferably, a further step comprises supplying the cooled fuel to the starter/generator for cooling.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic section of part of a ducted fan gas turbine engine incorporating the present invention;
[0015] FIG. 2 is a schematic layout of a re-circulated fuel circuit used for cooling the engine's starter/generator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] FIG. 1 shows a ducted fan gas turbine engine generally indicated at 10 and comprising three main rotational shafts, however, the present invention is equally applicable to an engine having any number of shafts. This engine 10 has a principal and rotational axis 11 . The engine 10 comprises a core engine 9 having, in axial flow series, an air intake 12 , a propulsive fan 13 , an intermediate pressure compressor 14 , a high-pressure compressor 15 , combustion equipment 16 , a high-pressure turbine 17 , and intermediate pressure turbine 18 , a low-pressure turbine 19 and a core exhaust nozzle 20 . A nacelle 21 generally surrounds the engine 10 and defines both the intake 12 and a bypass exhaust nozzle 22 .
[0017] The gas turbine engine 10 works in the conventional manner so that air entering the intake 11 is accelerated by the fan 13 to produce two air flows: a first air flow into the intermediate pressure compressor 14 and a second air flow which passes through a bypass duct 23 to provide propulsive thrust. The intermediate pressure compressor 14 compresses the air flow directed into it before delivering that air to the high pressure compressor 15 where further compression takes place.
[0018] The compressed air exhausted from the high-pressure compressor 15 is directed into the combustion equipment 16 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 17 , 18 , 19 before being exhausted through the nozzle 20 to provide additional propulsive thrust. The high, intermediate and low-pressure turbines 17 , 18 , 19 respectively drive the high and intermediate pressure compressors 15 , 14 and the fan 13 by suitable interconnecting shafts.
[0019] The fan 13 is circumferentially surrounded by a structural member in the form of a fan casing 26 , which is supported by an annular array of outlet guide vanes 27 .
[0020] The engine 10 further comprises a gearbox/generator assembly 28 used for engine start up and for generating electricity once the engine has been started and working in convention fashion. The starter/generator is a variable frequency starter/generator (VFSG) as known in the art. The generated electricity is used for engine and associated aircraft electrical accessories as well known in the art. The gearbox/generator assembly 28 is drivingly connected to the high-pressure shaft 24 , however, in other embodiments may be driven by any one or more of the shafts. In this embodiment, the gearbox/generator assembly 28 comprises an internal gearbox 29 connecting a first drive shaft 30 to the high-pressure shaft 24 , an intermediate gearbox 31 connecting the first drive shaft 30 to a second drive shaft 32 and an external gearbox 33 drivingly connected to the second drive shaft 32 . The external gearbox 33 is drivingly connected to a starter/generator 34 that is capable of the aforesaid engine operation. The starter/generator 34 and external gearbox 33 are housed within the nacelle 21 , but may be positioned on the core engine, as opposed to the fan casing. The first drive shaft 30 , intermediate gearbox 31 and the second drive shaft 32 are housed within a bypass duct splitter fairing 40 .
[0021] Referring now to FIG. 2 the engine 10 further comprises a re-circulated fuel circuit 42 used for cooling the starter/generator 34 . The re-circulated fuel circuit 42 comprises a pump 44 , a first fuel and oil heat exchanger 56 (FOHE), a second fuel and oil heat exchanger 46 and a fuel accumulator 48 . The recirculated fuel circuit 42 is situated on the main fuel line 50 between the main aircraft fuel tank 52 , usually housed within the aircraft's fuselage or wing, and a fuel injector or the combustion equipment 16 . Note that the recirculation fuel circuit 42 is part of the engine 10 and not the aircraft.
[0022] Inclusion of certain engine units in the fuel circuit is to increase the thermal capacity, e.g., the addition of a second FOHE 46 and filter 60 .
[0023] The second FOHE 46 is fluidly connected to an engine oil circuit 54 and the first FOHE 56 is fluidly connected to a starter/generator 34 . The oil in the starter circuit is self-contained; it is not connected to the engine oil system. A small oil sump (not shown) is provided in the starter/generator 34 .
[0024] A filter 60 is positioned between the second FOHE 46 and the combustor 16 . A shut off valve 62 is positioned downstream of the fuel accumulator 48 to stop fuel return flow during normal engine running.
[0025] In use, the circuit 42 re-circulates fuel via the pump 44 , through the variable frequency starter/generator FOHE 56 . The FOHE 56 dissipates heat from the VFSG 34 , which is in contrast to the conventional practice of sending the fuel back to aircraft fuel tank 52 .
[0026] The accumulator 48 , situated on a fuel return line 58 is used to control the volume of fuel in the circuit 42 and increases the fuel's thermal capacity to remove the limitations of the conventional static thermal sink (i.e. the main fuel tank 52 in a conventional engine/aircraft). The accumulator 48 will be filled with fuel before or during the engine start. When the engine has successfully achieved a start, the fuel in the accumulator 48 will be emptied and sent back to the engine fuel line to be consumed by the engine combustor 16 during engine running. The accumulator could be a dedicated unit or a modified existing unit on engine, e.g., the fuel drain tank. A mechanical means or a modified existing unit on engine, such as the ejector pump in fuel drain tank, may be employed to change the effective volume of the accumulator 48 . The mechanical means, such as a piston, may be powered by electrical, pneumatic or hydraulic devices or stored mechanical energy, such as a spring, could be used for this purpose.
[0027] Advantageously, the present invention removes the need of returning fuel back to aircraft fuel tank 52 during engine start up and hence there is no disturbance on fuel balance in aircraft's fuel tanks 52 and there are no fuel contamination issues.
[0028] Addition of the fuel accumulator 48 removes the limitation of the aircraft fuel tank as a static heat sink.
[0029] The accumulator 48 minimises the amount of fuel stored on engine 10 . The accumulator is either evacuated by such means as an ejector pump, where the accumulated fuel is transferred into the main fuel lines and is consumed in the engine combustor or has its effective volume reduced mechanically to expel the contents into the fuel system, also to be consumed in the engine combustor.
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A method of operating a gas turbine engine having a turbine and a compressor connected via a shaft, a main fuel supply line for supplying fuel to a combustor that is positioned to release expanding hot gases to the turbine, the engine further including a starter/generator connected to the shaft via a gearbox assembly, the method is characterised the step of during engine start up fuel is circulated in a re-circulating fuel circuit positioned on the main fuel supply line and which a first fuel/oil heat exchanger, for cooling the oil, and a fuel accumulator.
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