description
stringlengths 2.98k
3.35M
| abstract
stringlengths 94
10.6k
| cpc
int64 0
8
|
|---|---|---|
The invention relates to an apparatus for determining the weight of liquid flowing to or from a test site.
BACKGROUND OF THE INVENTION
An instrument for reproducibly and accurately measuring the liquid absorbency and related properties of a material is useful in the arts relating to absorbent products. Such absorbent products include surgical dressings, disposable diapers, sanitary products, and the like. The present invention is addressed to just such an apparatus which not only provides accurate and reproducible results, but which is also quite versatile in that it can determine liquid absorbency and related properties in a number of different modes simulating different use conditions. The instrument can determine various properties, such as the total quantity of liquid retained by a product under loaded or no-load conditions, the rate at which liquid is taken up, and the rate at which liquid is expressed under load.
THE PRIOR ART
In East German Pat. No. 129,688, there is disclosed an absorbency tester for leather. The tester consists of a tube having an opening in the bottom which is fitted with a felt wick. The tube also has a stopcock at the top. The tube is filled with distilled water, weighed, placed on a movable carriage, and then laid on the surface of the leather to be tested so that the felt tip contacts the leather. A pressure weight is attached and the stopcock is opened. The carriage is moved over a predetermined distance for a selected number of times, the tap is then closed, and the test tube is reweighed. The weight difference indicates the amount of liquid taken up by the test sample. Hunt, in U.S. Pat. No. 2,545,281, describes a fabric moisture absorbency tester. The apparatus includes a vessel filled with water, a screen on the top of the vessel exactly even with the level of the surface of the water, and a capillary tube in contact with the vessel containing water, with the tube being held at the same level as the surface of the water. When a test specimen is pressed down on top of the screen, water is absorbed and is sucked out of the capillary tube.
Anthon, in U.S. Pat. No. 3,155,109, discloses a liquid supply apparatus in which a liquid level in a container is maintained at a constant head by spring means or equivalent resilient means that are constructed to raise the reservoir as the liquid is drawn off by a distance exactly equal to the distance the level drops in the reservoir.
Lichstein, in U.S. Pat. No. 3,952,584, discloses an absorbency tester that measures the volume of liquid absorbed by whatever hydrostatic head is desired.
BRIEF SUMMARY OF THE INVENTION
The invention provides an apparatus for determining the weight of liquid flowing to or from a test site which comprises, in combination:
A vessel for containing liquid, said vessel being supported solely by weighing means;
Indicating means for indicating the weight sensed by said weighing means;
A test surface to receive a specimen to be tested, said test surface including said test site;
Conduit means operatively connecting said vessel to said test site for directing a flow of liquid between said vessel and said test site; and
Means for vertically positioning said test site.
By using this apparatus, the weight of liquid flowing from the vessel to the specimen at the test site or from the specimen back to the vessel, can be accurately determined.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation, partly schematic, of an apparatus embodying the principles of the invention; and
FIGS. 2 through 6 are sectional elevations of different test cells that can be employed with the apparatus of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, in which a partially schematic, front elevation of a preferred form of the apparatus of the invention is shown, the apparatus includes a vessel 12 which acts as a reservoir for the liquid 14 to be employed in testing the performance of a suitable sample 30. The vessel 12 is supported solely by the weight sensing surface of weighing means such as an electronic balance 16 having a tare switch 15 and a display 17. (If desired, the weighing means can be a force transducer or similar device, instead of a balance.) The vessel 12 is preferably a closed vessel having a hole 18 in the top 20 through which a siphon tube 22 may be lowered. The liquid 14 is introduced into the vessel 12 to a predetermined level "L". A siphon tube 22 is inserted through the hole 18 in the top 20 of the vessel 12 so that it extends down into the liquid 14. The siphon tube 22 is connected by tubing 24 to a test cell 26.
The test cell 26 has a surface 28 for receiving the specimen 30 to be tested. As shown in FIG. 1, the test cell 26 is a flat, disk-shaped plate having a hole through its center, although it could have other configurations, such as will be explained in more detail below. The siphon tube 22 is connected by tubing 24 to the bottom of the test cell 26 so that liquid flowing through the siphon tube 22 can flow up through the test cell 26 to the test specimen 30. The test cell 26 is mounted on an "O"-shaped support 32 such that the top surface 28 of the test cell 26 is exactly in the same horizontal plane "L" as the surface 34 of the liquid 14 in the reservoir vessel 12. In order to adjust the vertical position of the test cell 26, the test cell support 32 is attached to an adjustable jack 36 or similar means. By maintaining the top surface 28 of the test cell 26 in the same horizontal plane "L" as the surface 34 of the liquid 14 in the vessel 12, a zero hydrostatic head is then maintained between the reservoir of liquid 14 and the top surface 28 of the test cell 26. The jack 36 permits testing at various hydrostatic heads as may be needed or desired.
In operation, the specimen 30 to be tested is placed on the top surface 28 of the test cell 26, a valve 38 in the tubing 24 is opened so that liquid 14 is free to flow from the vessel 12 to the test cell 26. The specimen 30 then absorbs liquid 14 from the reservoir vessel 12. By noting the weight of the vessel 12 before any liquid 14 has flowed from the vessel 12 to the specimen 30, and the weight after all absorption by the specimen 30 has ceased, the total amount of liquid taken up by the test specimen 30 is then determined. The apparatus can also be employed to evaluate the absorbency rate of a specimen by noting the weight change over a period of time.
A preferred liquid reservoir vessel 12 arrangement is shown in FIG. 1. The vessel 12 is mounted on the balance 16 by means of a leveling spring 39 and a mounting pin 40. The mounting pin 40 on the balance 16 is adapted to fit into a mounting tube 42 in the center of the vessel 12.
The mounting tube 42 contains a spring 39 which, when the vessel 12 is in place on the mounting pin 40, is compressed between the top of the pin 40 and the top of the mounting tube 42. By appropriate selection of the compression strength of the spring 39, the vessel 12 will remain at a constant elevation as liquid 14 flows out of or back into the vessel 12. With a vessel constructed so that the area of the surface of the liquid remains constant with changes in liquid level, the required spring constant can be calculated by multiplying the density of the test liquid by the area of the liquid surface.
FIG. 1 also shows a preferred design of a reserve tank 44 that is constructed to fit over the vessel 12, but without touching the vessel 12 and without impinging on the weight sensing surface of the balance 16. The reserve tank 44 contains a reserve compartment 46 for containing reserve quantities 48 of the liquid. In the bottom of the reserve compartment 46 is an outflow conduit 50 through which liquid 48 can flow into the vessel 12. An outflow valve 52 is included in the conduit 50 to control the flow of liquid.
A variety of different types of test cells can be employed. For instance, FIGS. 1 and 2 show a test cell 26 that can be employed to evaluate the radial wicking characteristics of a test specimen 30. The cell 26 for this purpose consists simply of a flat, disk-shaped plate having a hole 56 in the center through which liquid can flow up to the test specimen. A flange 58 is provided in the lower periphery of the test cell 26 so that the cell 26 will fit into the ring-shaped support 32.
In FIG. 3 there is shown a test cell 60 for evaluating both radial wicking and desorption capability of the test specimen. This test cell 60 contains a hole 62 in the center similar to that in the test cell 26 shown in FIGS. 1 and 2, but is also contains a concentric trough 64 for receiving expressed liquid which may be generated when there is an increase in any compression load that is impressed on the test specimen while its absorbency performance is being tested. The trough 64 is connected to the central hole 62 by a conduit 65. The expressed liquid will flow back to the reservoir vessel 12 causing a change in weight of the vessel 12 plus liquid 14. These changes can be used to analyze the performance of the test specimen 30.
In FIG. 4 there is shown a test cell 66 which can be used to measure transverse wicking, or simply the wicking capability in one direction only. This test cell 66 contains a porous fritted glass plate 68 and is constructed to have a large proportion of the entire bottom of the fritted glass plate 68 in contact with the test liquid. This is accomplished by having the hole 70 through which liquid flows upwardly from the reservoir vessel 12 open up into a hollow chamber 72 just under the porous fritted glass plate 68. After a test specimen has been placed on the porous plate 68, the valve 38 (FIG. 1) is kept open during the test to keep the hollow chamber 72 full of liquid; otherwise, air may be drawn down through the plate 68 as the specimen absorbs liquid.
FIG. 5 shows a test cell 74 that can be used to test vertical wicking of a test specimen. The cell 74 contains a plate 76 similar to the cell 26 of FIGS. 1 and 2, except that the hole 78 in the center communicates with a transverse trough 80. A jig composed of two plates 82, 84 is permanently attached to the plate 76 and holds the test specimen (not shown) vertically over the trough 80 with the bottom edge of the test specimen slightly below the level of the liquid in the trough 80.
The test cell 74 shown in FIG. 5 can be employed in several different ways. First, the two plates 82, 84 can be set a distance apart such that the specimen can simply be suspended freely between them so that it may expand in both directions (i.e., toward each wall 82, 84) when it absorbs liquid. The plates 82, 84 can also be set a preselected distance apart so as to clamp the specimen between two rigid surfaces. Another alternative is to replace the rigid face of one of the walls 84 with a conformable membrane (not shown) with means (not shown) to impart a constant pressure behind the membrane. By so doing, a uniform pressure can be maintained on the specimen during testing.
FIG. 6 shows a test cell 88 that can be employed to test wicking of a specimen at any angle from the horizontal from 0° through 90°. The cell 88 contains a disk-shaped bottom plate 90 that just fits inside the O-shaped support 32 (FIG. 1), and an elongated top plate 92. A hole 94 through both plates 90, 92 delivers liquid to a specimen (not shown) supported by the top surface 96 of the top plate 92. An end of the specimen is in contact with a wall 98 that extends across the width of the top plate 92. Liquid flowing through the hole 94 fills a transverse trough 95 at the base of the wall 98 and then contracts the said end of the specimen. The wicking properties of the specimen can be evaluated at any angle from 0° through 90° by measuring the weight of liquid absorbed and/or the movement of the liquid front. The height of the test cell 88 is preferably adjusted so that the top of the trough 95 is slightly above the horizontal plane "L" of the top surface 34 of the liquid 14 in the reservoir vessel 12, per FIG. 1.
The support 32 (FIG. 1) for the test cells can be attached to the jack 36 in such a way that the support 32 and test cell can be rotated, with the center of rotation being the liquid delivery hole in the test cell surface. In this way, wicking at any angle between 0° and 90° can be evaluated, while maintaining the liquid delivery source on the surface of the test cell at a known vertical level coordinated with the level L of the liquid in the reservoir vessel 12.
A sample loading device may be employed in conjunction with the apparatus of the invention to impress a preselected compression load or weight on the specimen while it is being tested. Such a loading device is described in U.S. patent application Ser. No. 149216 filed on the same day as this application, now U.S. Pat. No. 4,314,482, entitled "Sample Loading Device", by Theodore J. Krainski, Jr., and assigned to the same assignee as this application, the disclosure of which is incorporated herein by reference.
|
An apparatus for determining the weight of liquid flowing to or from a test site is described. The apparatus comprises, in combination:
a vessel for containing liquid, the vessel being supported solely by a balance;
an indicator for indicating the weight sensed by the balance;
a test surface to receive a specimen to be tested, the test surface including the test site;
a conduit operatively connecting the vessel to the test site for directing a flow of liquid between the vessel and test site;
an adjuster for vertically positioning the test site;
Wherein the vessel is supported by the balance through a spring, which serves to maintain the surface of the liquid in the vessel at a constant elevation as liquid flows into and out of the vessel.
| 8
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Chinese Application No. 201610094955.7, filed Feb. 22, 2016, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to methods and systems for design of insurance products and, in particular, to methods and systems for design of insurance products by dynamic modeling. The present invention also relates to methods and systems for data accessing in an insurance product obtained by the present methods, and methods and systems for premium calculation for an insurance product.
BACKGROUND
[0003] Insurance products vary widely in terms of form and content and are subject to frequent adjustments by insurance companies in order to meet local requirements. The adjustments are always carried out by software engineers working in an insurance product or by an insurance software design company through software code tuning and debugging, in order to ensure smooth running of the products. Currently, the code of most software for insurance product design is written according to specific fixed rules. For a specific type of insurance product, therefore, the structure, hierarchy and attribute are normally pre-determined, i.e., statically coded. In some circumstances, the adjustments become very complicated and time consuming, especially when a lot of factors and levels are involved.
[0004] From the view of an insurance software provider, it is also time consuming and hard to repeat for the software adjustment procedures when facing different requirements of insurance companies. In particular, insurance companies in different areas or countries have significant discrepancies in terms of design requirements of insurance products due to diversity of legislation, custom, social habits and so on. In order to meet the needs of international market, extensive adjustments and modifications are performed on the code of software by insurance software provider, which is disadvantageous and undesirable.
[0005] It has become a challenge for an insurance software provider to swiftly adapt their products to different insurance companies according to each of their requirements.
SUMMARY
[0006] One aspect of the invention relates to a computer-implemented method for design of an insurance product. The method comprises steps of (a) creating a basic data template for an insurance product, wherein the basic data template comprises one or more modules, with each of the one or more modules comprising one or more sub-modules, and wherein the species and number of the modules comprised in the basic data template as well as the species and number of the sub-modules comprised in each of the one or more modules are extendable; (b) configuring for a specific insurance product the species and number of the modules, and for each of the modules configured the species and number of the sub-modules; (c) assigning a level to each of the sub-modules; and (d) correlating the sub-modules to obtain the specific insurance product.
[0007] Another aspect of the invention relates to a system for design of an insurance product, comprising at least a processor configured to (a) creating a basic data template for an insurance product, wherein the basic data template comprises one or more modules, with each of the one or more modules comprising one or more sub-modules, and wherein the species and number of the modules comprised in the basic data template as well as the species and number of the sub-modules comprised in each of the one or more modules are extendable; (b) configuring for a specific insurance product the species and number of the modules, and for each of the modules configured the species and number of the sub-modules; (c) assigning a level to each of the sub-modules; and (d) correlating the sub-modules to obtain the specific insurance product; and a storage device configured to store the one or more modules and the one or more sub-modules.
[0008] Another aspect of the invention relates to a system for design of an insurance product, comprising (a) a basic data template creation unit for creating a basic data template for an insurance product, wherein the basic data template comprises one or more modules, with each of the one or more modules comprising one or more sub-modules, and wherein the species and number of the modules comprised in the basic data template as well as the species and number of the sub-modules comprised in each of the one or more modules are extendable; (b) a module and sub-module configuration unit for configuring for a specific insurance product the species and number of the modules, and for each of the modules configured the species and number of the sub-modules; (c) a level assignment unit for assigning a level to each of the sub-modules; and (d) an output unit for correlating the sub-modules to obtain the specific insurance product.
[0009] Another aspect of the invention provides a non-transitory computer-readable medium having instructions stored thereon, the instructions, when executed by at least one processor, performing a method for design of an insurance product, the method comprising: (a) creating a basic data template for an insurance product, wherein the basic data template comprises one or more modules, with each of the one or more modules comprising one or more sub-modules, and wherein the species and number of the modules comprised in the basic data template as well as the species and number of the sub-modules comprised in each of the one or more modules are extendable; (b) configuring for a specific insurance product the species and number of the modules, and for each of the modules configured the species and number of the sub-modules; (c) assigning a level to each of the sub-modules; and (d) correlating the sub-modules to obtain the specific insurance product.
[0010] In some embodiments, in step (a), the basic data template at least comprises a policy module and a clause module. In some embodiments, the basic data template further comprises one or more modules selected from a group consisting of (i) an insured object module, (ii) a coverage module and (iii) one or more intermediate modules.
[0011] In some embodiments, each of the sub-modules has a fixed attribute and an extended attribute. Preferably, the fixed attribute is previously configured. Preferably, the number and content of the extended attribute are configurable.
[0012] In some embodiments, in step (c), the sub-modules are assigned with two to eight levels, for example, four levels.
[0013] In some embodiments, in step (c), a sub-module of the policy module is assigned with level 1, and a sub-module of the policy module is assigned with level 4. In some embodiments, in step (c), a sub-module of the insured object module is assigned with level 2, and a sub-module of the coverage module is assigned with level 3. Alternatively, in step (c), a sub-module of the coverage module is assigned with level 2, and a sub-module of the insured object module is assigned with level 3.
[0014] In some embodiments, in step (d), at least two sub-modules of the insured object module are correlated to a sub-module of the policy module. In some embodiments, in step (d), at least one sub-module of the coverage module is correlated to each of the at least two sub-modules of the insured object module. In some embodiments, in step (d), at least one sub-module of the clause module is correlated to each of the at least one sub-module of the coverage module.
[0015] In some embodiments, in steps (b) and (c), the configuring and the assigning are achieved through an external interface. In some embodiments, the external interface is Excel or XML.
[0016] Another aspect of the invention is related to a computer-implemented method for accessing a specific data element contained in a data structure of an insurance product, wherein the data structure of an insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationship of the specific data element with other data elements of the data structure as well as the level of the specific data element vary from one data structure to another, the method comprising steps of (a) a program initiating a data search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (b) the program interacting with the data structure and finding the specific data element; and (c) returning the specific data element to the program.
[0017] Another aspect of the invention is related to a system for accessing a specific data element contained in a data structure of an insurance product, wherein the data structure of an insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationship of the specific data element with other data elements of the data structure as well as the level of the specific data element vary from one data structure to another, the system comprising at least one processor configured to carry out a method comprising steps of (a) a program initiating a data search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (b) the program interacting with the data structure and finding the specific data element; and (c) returning the specific data element to the program; and a storage device for storing the data structure of the insurance product.
[0018] Another aspect of the invention is related to a system for accessing a specific data element contained in a data structure of an insurance product, wherein the data structure of an insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationship of the specific data element with other data elements of the data structure as well as the level of the specific data element vary from one data structure to another, the system comprising (a) a search initiation unit for a program to initiate a data search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (b) a data interaction unit for the program to interact with the data structure and finding the specific data element; and (c) a data returning unit for returning the specific data element to the program.
[0019] Another aspect of the invention provides a non-transitory computer-readable medium having instructions stored thereon, the instructions, when executed by at least one processor, performing a method for accessing a specific data element contained in a data structure of an insurance product, wherein the data structure of an insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationship of the specific data element with other data elements of the data structure as well as the level of the specific data element vary from one data structure to another, the method comprising steps of (a) a program initiating a data search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (b) the program interacting with the data structure and finding the specific data element; and (c) returning the specific data element to the program.
[0020] In some embodiments, the dynamic programming language is selected from a group consisting of Python, Ruby, Javascript and Groovy.
[0021] In some embodiments, the plurality of levels at least corresponds to the policy and clause levels of the insurance product. In some embodiments, the plurality of levels further corresponds to the insured object and coverage levels as well as one or more intermediate levels.
[0022] In some embodiments, m is an integer from 2 to 8, for example 2 or 3.
[0023] In some embodiments, the specific data element is selected from a group consisting of a premium data, a taxation data, a commission data and a discount data.
[0024] In some embodiments, the level n .level n+m is configurable in the program.
[0025] In some embodiments, the variation is achieved manually through an external interface. In some embodiments, the external interface is Excel or XML.
[0026] Another aspect of the invention is related to a computer-implemented method for calculating a premium of an insurance product, wherein the data structure of the insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationships among data elements as well as the level of a specific data element vary from one data structure to another, the method comprising steps of (a) defining a formula and determining a procedure for calculating the premium; (b) a program initiating a premium data element search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (c) the program interacting with the data structure and finding the premium data element; and (d) returning the premium data element to the program.
[0027] Another aspect of the invention is related to a system for calculating a premium of an insurance product, wherein the data structure of the insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationships among data elements as well as the level of a specific data element vary from one data structure to another, the system comprising at least one processor configured to carry out a method comprising steps of (a) defining a formula and determining a procedure for calculating the premium; (b) a program initiating a premium data element search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (c) the program interacting with the data structure and finding the premium data element; and (d) returning the premium data element to the program; and a storage device for storing the data structure of the insurance product.
[0028] Another aspect of the invention is related to a system for calculating a premium of an insurance product, wherein the data structure of the insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationships among data elements as well as the level of a specific data element vary from one data structure to another, the system comprising (a) a definition and determination unit for defining a formula and determining a procedure for calculating the premium; (b) a search initiation unit for a program to initiate a premium data element with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (c) a data interaction unit for the program to interact with the data structure and finding the premium data element; and (d) a data returning unit for returning the premium data element to the program.
[0029] Another aspect of the invention provides a non-transitory computer-readable medium having instructions stored thereon, the instructions, when executed by at least one processor, performing a method for calculating a premium of an insurance product, wherein the data structure of the insurance product has a plurality of levels, with each level containing one or more data elements, and wherein an relationships among data elements as well as the level of a specific data element vary from one data structure to another, the method comprising steps of (a) defining a formula and determining a procedure for calculating the premium; (b) a program initiating a premium data element search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; (c) the program interacting with the data structure and finding the premium data element; and (d) returning the premium data element to the program.
[0030] In some embodiments, the dynamic programming language is selected from a group consisting of Python, Ruby, Javascript and Groovy.
[0031] In some embodiments, the plurality of levels at least corresponds to the policy and clause levels of the insurance product. In some embodiments, the plurality of levels further corresponds to the insured object and coverage levels as well as one or more intermediate levels.
[0032] In some embodiments, m is an integer from 2 to 8, for example 2 or 3.
[0033] In some embodiments, after step (d), the premium is calculated by the formula and a calculation result is returned to the data structure.
[0034] In some embodiments, in step (a), the determination comprises a step of determining the sequence of premium calculation.
[0035] In some embodiments, the level n .level n+m is configurable in the program.
[0036] In some embodiments, the variation is achieved manually through an external interface. In some embodiments, the external interface is Excel or XML.
[0037] By creating a configurable and extendable basic data template for an insurance product, in which the number and sequence of the modules in the template, the levels of the modules as well as the relationship between modules are configurable, a variety of insurance products can be formulated through diverse configurations and/or extensions of modules, levels and relationships when facing to different requirements. The technicians are able to design an insurance product meeting a specific requirement in a more fast and convenient way by the dynamic (in contrast to static) methods provided by the present invention without the need of modifications or changes of the code of an insurance product.
BRIEF DESCRIPTION OF DRAWINGS
[0038] FIG. 1 is a flow chart showing a method 100 of design of an insurance product according to one embodiment of the invention.
[0039] FIG. 2 illustrates modules and levels contained in a typical insurance product.
[0040] FIG. 3 shows one or more intermediate modules contained in a basic data template according to one embodiment of the invention.
[0041] FIG. 4 shows the modules and sub-modules contained in an example basic data template.
[0042] FIG. 5 is a block diagram showing a design system 200 according to one embodiment of the invention.
[0043] FIG. 6 is a block diagram showing a design system 200 ′ according to one embodiment of the invention.
[0044] FIG. 7 is a flow chart showing a method 300 of accessing a specific data element in a data structure of an insurance product according to one embodiment of the invention.
[0045] FIG. 8 shows the structures of two different insurance products obtained through the invented method.
[0046] FIG. 9 a block diagram showing a data accessing system 400 according to one embodiment of the invention.
[0047] FIG. 10 is a block diagram showing a data accessing system 400 ′ according to one embodiment of the invention.
[0048] FIG. 11 is a flow chart showing a method 600 of calculating a premium of an insurance product according to one embodiment of the invention.
[0049] FIG. 12 is a flow chart showing a method 600 of calculating a premium of an insurance product according to another embodiment of the invention.
[0050] FIG. 13 a block diagram showing a premium calculation system 700 according to one embodiment of the invention.
[0051] FIG. 14 is a block diagram showing a premium calculation system 700 ′ according to one embodiment of the invention.
DETAILED DESCRIPTION
[0052] The inventions will now be described in more detail in reference to the examples given herein. It should be understood that the example provided herein are for illustrative purpose only and should not be explained as limiting to the scope of the invention.
Methods and Systems of Design of an Insurance Product
[0053] A first aspect of the invention relates to a method for design of an insurance product, which is normally implemented by a computer. The flow chart of the method 100 is shown in FIG. 1 , comprising creating a basic data template for an insurance product (step 102 ); configuring a module and a sub-module for a specific insurance product (step 104 ); assigning a level for each of the sub-modules (step 106 ); and correlating each of the sub-modules to obtain the specific insurance product (step 108 ).
[0054] In the present invention, the basic data template comprises one or more modules with each of the one or more modules containing one or more sub-modules. The species and number of the modules comprised in the basic data template, and the species and number of the sub-modules comprised in each of the modules are extendable. By “extendable” it means increasable, changeable or modifiable. That is, the quantity and species of the modules and sub-modules of a basic data template can be increased, changed or modified in order to form more configurable modules and sub-modules, such that more types of insurance products can be provided. The more the number and species of modules and sub-modules that the basic data template has, the more the types of insurance products can be designed. Preferable basic data template should include as many species of modules and/or sub-modules as possible, for example those conventionally used in the art.
[0055] A typical basic data template for an insurance product at least includes a policy module (P) and a clause module (CL). Usually, a basic data template further includes an insured object module (IO) and a coverage module (CT). FIG. 2 shows the modules and levels that a typical insurance product contains. As shown, an insurance product generally contains a policy module P, an insured object module IO, a coverage module CT and a clause module CL.
[0056] A policy module P may contain more than one insured object modules IO (for example IO 1 and IO 2 ). Each of the insured object modules IO may contain one ore more coverage modules CT. For example, the insured object module IO 1 may contain two coverage modules, CT 1 and CT 2 . Each of the coverage modules CT may contain one or more clause modules CL. For example, the coverage module CT 2 contains two clause modules CL 2 and CL 3 . In the insurance product as shown, the policy module P is at the first level L 1 , the insured object module IO is at the second level L 2 , the coverage module CT is at the third level L 3 , and the clause module CL is at the fourth level L 4 .
[0057] For example, a policy may include two policy modules P, a vehicle insurance and a life insurance. The insured object IO can be a car for the vehicle insurance, and a person for the life insurance. With respect to the car, the coverage CT can include collision, robbery and theft, third-party liability and so on. For the person, the coverage CT may comprise accident, critical illness and etc. Each of the coverage including the collision, robbery and theft, third-party liability, accident, and critical illness as mentioned above may include one or more specific insurance clauses CL.
[0058] As shown in FIG. 3 , in some embodiments of the invention, the basic data template further includes one or more intermediate modules IM. As used herein, “intermediate module” means a module that is not specifically named in the present invention as the policy, insured object, coverage and clause modules. The one or more intermediate modules independently constitute a level Lm, for example between L 1 and L 2 as shown in FIG. 2 or between L 2 and L 3 . The quantity and species of the intermediate modules are configurable and also extendable.
[0059] For example, a vehicle insurance can additionally comprises a driver module independent of and in addition to the insured object module, the coverage module and the clause module. The driver module may exist as a level between the policy module and the insured object module, such that a five-level structured insurance product is formed. As a further example, a property policy may additionally include an owner module independent of and in addition to the insured object module, the coverage module and the clause module. The owner module can exist as a level between the insured object module and the coverage module.
[0060] In the method of the present invention, each of the modules comprises one or more sub-modules. The number and type of the sub-modules are extendable. FIG. 4 shows the modules and sub-modules contained in a basic data template. It is noted that the exemplary modules and sub-modules shown in FIG. 4 are exhaustive and more embodiments can be conceived by a skilled artisan. In addition, a same sub-module can exist simultaneously in a plurality of different modules. For example, a vehicle as a sub-module of an insured object can also exist as a sub-module of an intermediate module.
[0061] In the process of design of an insurance product, one or more sub-modules are selected (configured) for each of the module as needed. An insurance product is formed through the level assignment and correlation of each of the sub-modules, which will be described in detail below. In some embodiments, each of the sub-modules has a fixed attribute and an extended attribute. The fixed attribute can be previously configured and the number and type of the extended attribute can be configured later.
[0062] Generally, attributes well-known or common in the art can be previously configured as fixed attributes. For example, for a vehicle as an insured object, the age, model, brand, travel range, number of seats and etc. are provided as fixed attributes. Generally, attributes that are expectable may serve as a fixed attribute. An extended attribute is an attribute that is generally not able to be provided in advance but newly given for a particular purpose such as requirements of local legislation or custom. The provision of extended attributes imparts more applicability of the invented methods provided herein.
[0063] In the present method, in step 106 , each of the sub-modules is assigned with a level, following the sub-module configuration step. Level assignment is performed to assign one level for each sub-module. More than one sub-module can be assigned with a same level such that a single level may comprise one or more sub-modules. For example, in a vehicle insurance product, coverage such as physical damage, third party liability, collision, and flood can be assigned with a same level, such as level 3. As another example, in a house insurance product, house 1 and house 2 can be assigned with a same level, such as level 2.
[0064] Usually, a total of 2 to 8 levels can be assigned to sub-modules with each level comprising a plurality of sub-modules, according to the type of sub-modules and actual needs. However, a 3- to 4-level structure is more common. For example, a sub-module of a policy module is assigned with level 1 and that of a clause module level 4. Alternatively, or in addition, a sub-module of an insured object module is assigned with level 2, and that of a coverage module level 3. There is no limiting regarding the level that a sub-module can be assigned. It is configurable by an appropriate technician. Also, there is no limitation concerning the number of sub-modules that could be included in one level.
[0065] In step 108 , the sub-modules are correlated to assemble a specific insurance product. For instance, at least two sub-modules of insured objects are correlated to a policy sub-module. For example, at least one coverage sub-module is correlated to each of sub-modules of insured objects. For another example, at least one clause sub-module is correlated with each of coverage sub-modules. The correlations among each of the sub-modules enable each level of sub-modules to have corresponding sub-module correlated, such that an insurance product with a completely correlated data structure can be obtained.
[0066] In the present invention, the configuration and assignment can be achieved through an external interface such as Excel or XML. It will be appreciated by a skilled artisan that other suitable man-machine interaction measures are also possible.
[0067] FIG. 5 illustrates a block diagram of a design system 200 according to one embodiment of the invention. The system 200 includes a processor 221 , an input/output (I/O) device 222 , a memory 223 , a storage device 226 , a database 227 , and a display device 228 .
[0068] Processor 221 may be one or more known processing devices, such as a microprocessor from the Pentium™ family manufactured by Intel™ or the Turion™ family manufactured by AMD™. Processor 221 may include a single core or multiple core processor system that provides the ability to perform parallel processing. For example, processor 221 may be a single core processor that is configured with virtual processing technologies. In certain embodiments, processor 221 may use logical processors to simultaneously execute and control multiple processes. Processor 221 may implement virtual machine technologies, or other similar known technologies, to provide the ability to execute, control, run, manipulate, store, etc., multiple software processes, applications, programs, etc. In another embodiment, processor 221 includes a multiple-core processor arrangement (e.g., dual or quad core) that is configured to provide parallel processing functionalities to allow computing system 200 to execute multiple processes simultaneously. One of ordinary skill in the art would understand that other types of processor arrangements could be implemented that provide for the capabilities disclosed herein.
[0069] Memory 223 may include one or more storage devices configured to store instructions used by processor 221 to perform functions related to the disclosed embodiments. For example, memory 223 may be configured with one or more software instructions, such as program 224 that may perform one or more operations when executed by processor 221 . The disclosed embodiments are not limited to separate programs or computers configured to perform dedicated tasks. For example, memory 223 may include a single program 224 that performs the functions of design system 200 , or program 224 could comprise multiple programs. Memory 223 may also store data 225 that may reflect any type of information in any format that may be used to perform functions consistent with the disclosed embodiments. For example, data 225 may include metadata of a plurality of modules and sub-modules of which a detailed description is provided below, and other data enabling processor 221 to perform functions disclosed in consistent with the disclosed embodiments.
[0070] I/O devices 222 may be configured to allow data to be received and/or transmitted. I/O devices 222 may include one or more digital and/or analog communication devices that allow design system 200 to communicate with other machines and devices. Design system 200 may also include or be communicatively connected to one or more of database 227 through a network. In exemplary embodiments, database 227 may store metadata of the basic data template used for the creation of an insurance product.
[0071] FIG. 6 is a diagram illustrating a design system 200 ′ according to some embodiments of the invention. The system 200 ′ include a basic data template creation unit 202 , for creating a basic data template for an insurance product, wherein the basic data template comprises one or more modules, with each of the one or more modules comprising one or more sub-modules, and wherein the species and number of the modules comprised in the basic data template as well as the species and number of the sub-modules comprised in each of the one or more modules are extendable; a module and sub-module configuration unit 204 , for configuring for a specific insurance product the species and number of the modules, and for each of the modules configured the species and number of the sub-modules; a level assignment unit 206 for assigning a level to each of the sub-modules; and an output unit 208 for correlating the sub-modules to obtain the specific insurance product.
Methods and Systems for Accessing a Specific Data Element
[0072] Another aspect of the invention is to provide a method and system for data access, which method is normally carried out by a computer. The method of data access provides a more convenience mode of data access for the insurance products dynamically constructed by the methods disclosed herein, in order for data processing and handling for various purposes.
[0073] The data structures of insurance products obtainable by the present methods significantly vary with respect to each other due to the extensive differences among module and sub-module configurations, level assignments and correlations. The data structure of this kind is usually layered with each level comprising one or more data elements. The relationship of a specific data element with other data elements in the same data structure varies from one data structure to another and/or the level where the specific data element resides in is also variable. This cause the result that conventional data accessing methods, such as traversing method, are not well performed to meeting requirements of fast data access, which will be described in more detail hereinafter.
[0074] In order to satisfy the demands of fast and convenience accessing to a data element of an insurance product obtained through a method described herein, a method for accessing to a specific data element of a data structure for an insurance product is provided. The method is normally implemented by a computer. A exemplary method 300 is illustrated in FIG. 7 , which comprises steps of a program initiating a data search with level n .level n+m by a dynamic programming language (step 302 ), wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; the program interacting with the data structure and finding the specific data element (step 304 ); and returning the specific data element to the program (step 306 ).
[0075] The terms dynamic programming language, dynamic compiling language, or dynamic language can be used exchangeable in the present invention. Non-limiting examples of the dynamic language is Python, Ruby, Javascript or Groovy language. It will be appreciated by a skilled artisan that other dynamic languages are also possible.
[0076] The formula level n .level n+m is not the actual form used during data accessing. In the present invention, level n represents a data element in level n, and level n+m indicates a data element in level n+m. Referring to FIG. 8 , two different insurance products with different structures, obtained through the insurance product design methods of the present invention, are shown. In the insurance product shown on the left side, a policy P may include two insured objects, IO 1 and IO 2 , with IO 1 including two coverage CT 1 and CT 2 , and IO 2 including only one coverage CT 3 . The coverage CT 1 contains only one clause CL 1 , while CT 2 and CT 3 each contain two clauses, CL 2 , CL 3 and CL 4 , CL 5 , respectively. In this situation, P is at level 1, IO 1 and IO 2 are at level 2, CT 1 , CT 2 and CT 3 are at level 3, and CL 1 to CL 5 are at level 4. The insurance product shown on the right differs from that on the left in that a policy P contains an intermediate module IM located at an independent level. Therefore, the insurance product on the right has a 5-level structure with the intermediate module IM located between the level of the policy P and the level of the insured objects IO 1 and IO 2 .
[0077] In this case, data accessing is available for the insurance product shown on the left if a static language, for example C or C++, in the form of e.g. policy.object, is used. However, the data accessing to the insurance product shown on the right will fail if the same language format, i.e., policy.object, is used because of the existence of the IM level. An error will be reported.
[0078] In view of the above, the present invention takes advantage of a dynamic programming language to accessing data with a formula level n .level n+m . For example, a simple format of policy.object could be used to access a data element of an insured object at level 3, and a simple format of policy.clause could be used to access a data element of a clause at level 5. In other embodiments, a format of object.clause can also be used to access the data element of the insurance product shown on the right of FIG. 8 . With respect to formula level n .level n+m , when m>1, an error will be reported when a static language is used. However, data access is available when a dynamic language is used with the data structure of a specific insurance product of the present invention. It is advantageous especially for the data structures of insurance products where the level and location of a data element are variable.
[0079] It should be noted that the data structures shown in FIG. 8 are exemplary only. Data structures in real insurance products may far complex than the examples, for example, as many as 8 levels may be involved and more sub-modules may be provided in each level. The data access methods described herein are easily applicable to more complex data structures.
[0080] In some embodiments, non-limiting examples of the specific data element include premium data, taxation data, commission data or discount data. It can be expected by a skilled artisan that other insurance related data is also possible. The data access methods described herein do not have any limitation regarding the attributes of the data itself and is adaptive to any type of specific data element. For example, when the specific data element is a premium data, the present data access method can be used in conjunction with a premium rating program to achieve premium calculation, which will be described in more detail hereinafter. In some embodiments, when the specific data element is a taxation data, the data access method can be used with a taxation calculation program to achieve tax calculation, and if used further with a net premium calculation program, a tax deduction can be achieved. In some embodiments, when the specific data element is a taxation data, the data access method can be used with a discount calculation program to achieve discount deduction.
[0081] In some embodiments, the formula level n .level n+m is configurable in program, which means that a skilled person in the art is able to access to any specific data element in a given level of a data structure of an insurance product from any level higher than the given level according to requirements or at their will. That is, the access to a specific data element does not necessarily start from the first level, for instance, the policy level.
[0082] Some embodiments of the invention provide a system for specific data access in a data structure of an insurance product. FIG. 9 shows a data access system 400 which includes a processor 421 , an input/output (I/O) device 422 , a memory 423 , a storage device 426 , a database 427 , and a display device 428 . Processor 421 may be one or more known processing devices. Processor 421 may include a single core or multiple core processor system that provides the ability to perform parallel processing. For example, processor 221 may be a single core processor that is configured with virtual processing technologies. In certain embodiments, processor 421 may use logical processors to simultaneously execute and control multiple processes. Processor 421 may implement virtual machine technologies, or other similar known technologies, to provide the ability to execute, control, run, manipulate, store, etc., multiple software processes, applications, programs, etc.
[0083] In another embodiment, processor 421 includes a multiple-core processor arrangement (e.g., dual or quad core) that is configured to provide parallel processing functionalities to allow the data access system 400 to execute multiple processes simultaneously. One of ordinary skill in the art would understand that other types of processor arrangements could be implemented that provide for the capabilities disclosed herein.
[0084] Memory 423 may include one or more storage devices configured to store instructions used by processor 421 to perform functions related to the disclosed embodiments. For example, memory 423 may be configured with one or more software instructions, such as program 224 that may perform one or more operations when executed by processor 421 . The disclosed embodiments are not limited to separate programs or computers configured to perform dedicated tasks. For example, memory 423 may include a single program 424 that performs the functions of data access system 400 , or program 424 could comprise multiple programs. Memory 423 may also store data 425 that may reflect any type of information in any format that may be used to perform functions consistent with the disclosed embodiments. For example, data 425 may include metadata of a plurality of modules and sub-modules, and other data enabling processor 421 to perform functions disclosed in consistent with the disclosed embodiments.
[0085] I/O devices 422 may be configured to allow data to be received and/or transmitted. I/O devices 422 may include one or more digital and/or analog communication devices that allow data access system 400 to communicate with other machines and devices. Data access system 400 may also include or be communicatively connected to one or more of database 427 through a network. In exemplary embodiments, database 427 may store metadata of the basic data template used for the creation of an insurance product.
[0086] Some embodiments of the invention provide a system 400 ′ for specific data access in a data structure of an insurance product. As shown in FIG. 10 , the system 400 ′ includes a search initiation unit 402 for a program to initiate a data search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; a data interaction unit 404 for the program to interact with the data structure and finding the specific data element; and a data returning unit 406 for returning the specific data element to the program.
Premium Calculation Methods and Systems
[0087] The present invention further provides a method for calculating a premium of an insurance product, which is normally implemented by a computer. The data access methods provided in some embodiments of the invention is used with a premium calculation program to achieve premium calculation.
[0088] The term “premium” as used herein includes gross and net premiums as may be determined according to the computational formulas. A computational formula is determined by an insurance company or an insurance software provider empirically, taking into account of other factors. The program of premium calculation is also determined by an insurance company or an insurance software provider and varies upon factors such as legislations and customs. In some embodiments, the determination of a program of premium calculation includes a step of configuring the sequence of premium calculation. The sequence is generally pre-determined, but may vary due to areas, laws and specific campaigns.
[0089] In some embodiments, a method of calculating a premium of an insurance product is provided. The data structure of the insurance product has a plurality of levels, with each level containing one or more data elements, and an relationships among data elements as well as the level of a specific data element vary from one data structure to another. A exemplary method 600 is shown in FIG. 11 . The method 600 comprises defining a formula and determining a procedure for calculating the premium (step 602 ); a program initiating a premium data element search with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m (step 604 ); the program interacting with the data structure and finding the premium data element (step 606 ); and returning the premium data element to the program (step 608 ).
[0090] In certain embodiments, as shown in FIG. 12 , following step 608 , the method proceeds to calculate the premium according to the formula and return the result of calculation to the data structure (step 610 ).
[0091] A premium data element may exist at any level, more than one level, or all of the levels, of a data structure. In some embodiments, the formula level n .level n+m is configurable in program, which means a skilled person in the art is able to access to any specific data element in a given level of a data structure of an insurance product from any level higher than the given level according to requirements or at their will.
[0092] In some embodiments, the present invention provides a system for calculating a premium of an insurance product. FIG. 13 shows a premium calculation system 700 which includes a processor 721 , an input/output (I/O) device 722 , a memory 723 , a storage device 726 , a database 727 , and a display device 728 . Processor 721 may be one or more known processing devices. Processor 721 may include a single core or multiple core processor system that provides the ability to perform parallel processing. For example, processor 721 may be a single core processor that is configured with virtual processing technologies. In certain embodiments, processor 721 may use logical processors to simultaneously execute and control multiple processes. Processor 721 may implement virtual machine technologies, or other similar known technologies, to provide the ability to execute, control, run, manipulate, store, etc., multiple software processes, applications, programs, etc.
[0093] In another embodiment, processor 721 includes a multiple-core processor arrangement (e.g., dual or quad core) that is configured to provide parallel processing functionalities to allow the premium calculation system 700 to execute multiple processes simultaneously. One of ordinary skill in the art would understand that other types of processor arrangements could be implemented that provide for the capabilities disclosed herein.
[0094] Memory 723 may include one or more storage devices configured to store instructions used by processor 721 to perform functions related to the disclosed embodiments. For example, memory 723 may be configured with one or more software instructions, such as program 724 that may perform one or more operations when executed by processor 721 . The disclosed embodiments are not limited to separate programs or computers configured to perform dedicated tasks. For example, memory 723 may include a single program 724 that performs the functions of the premium calculation system 700 , or program 724 could comprise multiple programs. Memory 723 may also store data 725 that may reflect any type of information in any format that may be used to perform functions consistent with the disclosed embodiments. For example, data 725 may include metadata of a plurality of modules and sub-modules, and other data enabling processor 721 to perform functions disclosed in consistent with the disclosed embodiments.
[0095] I/O devices 722 may be configured to allow data to be received and/or transmitted. I/O devices 722 may include one or more digital and/or analog communication devices that allow the premium calculation system 700 to communicate with other machines and devices. Premium calculation system 700 may also include or be communicatively connected to one or more of database 727 through a network. In exemplary embodiments, database 727 may store metadata of the basic data template used for the creation of an insurance product.
[0096] In some embodiments of the invention, a system 700 ′ for calculating a premium of an insurance product. FIG. 14 shows a premium calculation system 700 ′ which includes a definition and determination unit 702 for defining a formula and determining a procedure for calculating the premium; a search initiation unit 704 for a program to initiate a premium data element with level n .level n+m by a dynamic programming language, wherein m>1, m and n are integers, level n indicates a data element of level n, and level n+m indicates a data element of level n+m; a data interaction unit 706 for the program to interact with the data structure and finding the premium data element; and a data returning unit 708 for returning the premium data element to the program.
[0097] In some embodiments, provided is a non-transitory computer-readable medium having instructions stored thereon, the instructions, when executed by at least one processor, performing any one of the methods described herein, for example a method for design of an insurance product, a method of data access or a method for calculating a premium of an insurance product.
[0098] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The scope of the invention is 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. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention indicated by the following claims.
[0099] It will be appreciated that the present invention is not limited to the exact construction that has been described above and illustrated in the accompanying drawings, and that various modifications and changes can be made without departing from the scope thereof. It is intended that the scope of the invention only be limited by the appended claims.
|
Provided are methods and systems for dynamically design of an insurance products, data accessing of insurance-related data elements and premium calculations. By creating a configurable and extendable basic data template for an insurance product, in which the number and sequence of the modules in the template, the levels of the modules as well as the relationship between modules are configurable, a variety of insurance products can be formulated through diverse configurations and/or extensions of modules, levels and relationships when facing to different requirements. The technicians are able to design an insurance product meeting a specific requirement in a more fast and convenient way by the dynamic (in contrast to static) methods provided by the present invention without the need of modifications or changes of the code of an insurance product.
| 6
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a system and method for publishing books. More particularly, the present invention relates to system and method of self-publishing a board book.
[0003] 2. Description of the Related Art
[0004] Known publishing products and systems do not fully meet the creative needs of a user seeking to create (i.e., publish) works having completely personalized and variable content. Some of the known publication systems and methods have significant creative limitations such as, for example, only providing annotations to photographs in an album, and only providing a method of inserting personalized or variable textual content at specific locations of pre-printed text. For example, there is a prior art publishing system that provides a book by the manufacturer having a limited number of blank spaces on certain individual pages thereof where text printed on labels may be affixed. The printed labels may include textual content such as proper names (e.g., Johnny or Mary), nicknames, and relationships (e.g., Nana or Grandma), and team names (e.g., Pirates and Yankees).
[0005] Also, there exist a method for making a children's storybook including a child's personal information entered into a predetermined story, or using transparent stickers with personal data that are then adhered to blank spaces in a preprinted book (U.S. Pat. No. 5,524,932 to Kalisher). The subject matter of the predetermined story is static and the degree of personalization possible is limited. Thus, the resulting book may not be very personal to the child whose name is provided and incorporated into the story.
[0006] In some of the known systems and methods, personal information is forwarded to a third party (e.g., a publishing company) that incorporates the personal information, albeit in a limited fashion, into the book. The book produced by this type of system and method is not published by the user and has the disadvantage of being costly and time consuming to complete, as well as the risk of being destroyed and damaged in transit between the manufacturer and the user. Additionally, creative control of the book, including format, types of content, length of content, and other aspects of the creative inputs to the book may be limited by the third party publisher.
[0007] Therefore, there exists a need to provide a method and system of publishing a book having completely personalized and variable content using the resources of a typical home or small office environment.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a publishing system and method that accepts creative placement of creative content including, for example, drawings, photos, and clip-art.
[0009] It is another object of the present invention to provide such a system and method that provides for the publication of a completely original story by providing a plurality of blank labels, a blank book, and a base software program or module for accepting variable content and controlling the printing of the content to the plurality of blank labels so a story can be fully personalized and published under the complete control of the user, preferably in a local environment, preferably using a general purpose computer, printer, and common software.
[0010] The above and other objects, advantages, and benefits of the present invention will be understood by reference to following detailed description and appended sheets of drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is an exemplary depiction of a board book made in accordance with the present invention;
[0012] [0012]FIG. 2 is an overall schematic diagram of an exemplary system applicable for implementing the system and method in accordance with the present invention;
[0013] [0013]FIG. 3 shows a plan view of an exemplary printed sticker sheet in accordance with the present invention; and
[0014] [0014]FIG. 4 is a flowchart depicting an exemplary method of publishing a creative work in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring to the drawings and in particular FIG. 1, there is depicted an example of a type of book generally represented by reference numeral 100 that may be created, that is, published by the system and method of the present invention. It is contemplated that the present invention will appeal to a wide variety of people interested in publishing books and other creative works, including young children, the parents of young children, schools and educational programs including literacy programs, remedial reading programs, and tutorial servies.
[0016] The present invention will be discussed primarily in the context of a children's board book such as book 100 . Accordingly, exemplary embodiment board book 100 is used as an illustrative example for discussing certain aspects of the present invention in a concise and clear manner, not as a limitation thereof. It should be understood that the particular type of medium used may be varied depending on the application and intended use of the published product. For example, the methods and system of the present invention may include a mixed media presentation application such as, though not limited to, a “book” presenting fixed content (e.g., static text and illustrations) and a combination of animated text (e.g., scrolling text), graphics (e.g., multiple photos/illustrations that are sequentially presented to the reader and/or motion video clips) and sound.
[0017] Board book 100 may have pressed cardboard front cover 105 , pages 110 , and rear cover 115 . The pages of board book 100 may be of about 14 millimeters (mils) thick. Other thicknesses of material may be used. However, the front cover 105 , pages 110 , and rear cover 115 of board book 100 are preferably relatively stiff and resistant to being ripped by a young child, as well as being durable to withstand repeated readings since the instance book 100 is intended for young children.
[0018] In the instance where the book includes the capability of presenting sound, video, and a combination thereof, the book would have suitable storage and display capabilities for storing these types of creative inputs. For example, a memory storage unit (e.g., flash card, memory stick, smart card, etc.) may be connected to and integrated to the book. A voice synthesis module and or speaker may be included in the instance the user's voiced comments and other sounds are to be played back (i.e., presented) by the book. A display mechanism, such as a LCD or plasma screen may be included for the display of video and graphics type creative input.
[0019] Personalized and completely customized graphic and textual creative content may be affixed to front cover 105 , pages 110 , and rear cover 115 by attaching labels 120 thereto. Labels 120 are produced and fully customized by the user. The user preferably has complete creative freedom in determining the content, format, arrangement, color, and size of the creative content placed on label 120 .
[0020] In an aspect of the present invention and in reference to FIG. 2, completely personal and customized book 100 can be created using a PC (personal computer) 210 , a printer 215 , and software (not shown) such as the home and small office environment. FIG. 2 depicts an exemplary process of creating and assembling, i.e., publishing a completed board book 235 in accordance with the teachings of the present invention. It is noted that published board book 235 is similar to board book 100 of FIG. 1.
[0021] It should be appreciated that the particular configuration of the pc, printer, software, and other input, output, and processing devices and controls may vary. In one aspect of the present invention, the particular arrangement and type of input and output controls and devices (hardware and software) used to implement the method and system of the present invention are under the control of the user. In this manner, the user can maintain control of the creative process of creating the book.
[0022] The software may be a word processor, a graphics program, an editor, etc., or a combination thereof. It should be appreciated by those skilled in the art that many word processors, graphics programs, web publication programs, internet browsers, and even operating systems include an interface with programs that can manipulate (i.e., create, edit, store, etc.) text and graphics. Thus, the software program or module used in carrying out the present invention need not be specifically designed or created for use by the present invention.
[0023] A story for inclusion in book 235 is created by providing personal content for inclusion in the published work via an input device interfaced with PC 210 . The input device may include keyboard 212 , mouse 214 , and any of the input sources 205 . Input sources 205 may include a scanner 207 , a World Wide Web {i.e., Web} page, a hypertext link, page or content, a digital camera file, or a memory storage medium having the personal content stored therein. Other input sources, though not shown, are applicable such as, for example, a memory card reader, a hard disk drive, a digitizer, and other file storage and creation devices and means.
[0024] The present invention allows the user (i.e., the bookmaker) to use any combination of text and images including photographs (from a digital camera or scanner), clip art and drawings (created in software or imported from the internet). The software may be used to provide a template of a label 218 . Any combination of text, photographs, pictures, clip art and drawings can be put on the label.
[0025] A monitor connected to PC 210 can be used to aid in composing the creative content for each page of book 100 . Creative content is preferably manipulated by computer 210 according to program instructions of the software program or module to print the creative content onto a label sheet 217 . The program instructions may be implemented as software accessible to PC 210 , whether locally or remotely stored.
[0026] Label sheet 217 is fed to printer 215 . Label sheet 217 is preferably a commercially available product easily and readily handled by printer 215 . Preferably, extensive formatting is not required on the user's behalf in order to format the creative content to correspond to label sheet 217 . Each label 218 including label sheet 217 preferably represents a page in book 100 . Label 218 may comprise only a portion of a page or extend beyond the boundaries of more than one page.
[0027] Once the bookmaker/publisher (i.e., user) is satisfied with the composition of the personal creative content of each page of book 100 , the pages of the book are printed on blank label sheet 217 having a plurality of blank labels 218 , thereby creating a printed label sheet 220 having a plurality of printed labels 222 (similar to printed label 120 of FIG. 1). Multiple labels sheets 217 may be used to create book 225 .
[0028] [0028]FIG. 3 depicts an exemplary printed label sheet 220 .
[0029] In one aspect of the present invention, label sheet 217 includes adhesive-backed labels 218 . The label sheet 217 preferably contains labels 218 that are suitable for a (color) ink jet printer and a laser jet printer. Printed labels 222 are affixed to the pages of the blank board book 225 by the user. Depending on the size of blank board book 225 and printed labels 222 , one printed label covers at least a portion of a page of the blank board book. In a preferred embodiment, one printed label 222 covers substantially one page of blank board book 225 .
[0030] A self-adhesive clear laminate 230 may be applied over the printed labels 222 , that is, the individual pages of the board book 225 to protect and enhance the durability of the pages of the book. Preferably, a clear laminate 230 is applied to printed labels 222 after the printed labels are affixed to the pages of the board book.
[0031] In the event that the printer employs an ink resistant to degradation due to exposure to moisture and light, the step of applying the laminate 230 may be precluded.
[0032] Covering the printed labels 222 with clear laminate 230 allows for easy cleaning of book 235 (and 100 ) with a damp cloth without distortion of the printed labels 222 or damage of book 235 . Each page has a thickness of about 12 mils to about 18 mils. The paper core (about 8 mils thick) is preferably coated with a film laminate of about 3 mils on each side, resulting in an overall page thickness of about 14 mils. Printed labels 222 can be applied to both sides of a page.
[0033] [0033]FIG. 4 is a flowchart depicting an exemplary method of publishing a creative work in accordance with the present invention, various steps of which should be appreciated in view of the discussion above regarding the publication of books 100 and 235 . As shown, creative content for the creative work (e.g., book 100 , 235 ) is prepared and obtained in step 405 . The creative content is then printed to labels 218 at step 410 . The printed labels 222 are affixed to the pages of a blank board book at step 415 and clear laminate 230 is applied over the printed labels 222 at step 420 to complete the publishing process.
[0034] In summary, it is noted that the present invention may be used to publish a children's storybook, a cookbook, a party favor, and to memorialize vacation memories and other events.
[0035] The bookmaker may start with a tabla rosa, i.e., a multiple paged bound board book 225 of approximately 12 pages. Each page being approximately 4 inches×5 inches and a sheet 217 of 6 blank labels 218 . The self-adhesive labels 218 are preferably affixed to an 8½ by 11 inch carrier sheet. Each label 218 corresponds to a page, and 2 carrier sheet of 6 labels 2218 would preferably be used to comprise a book 100 , 235 . Since each page and label is initially completely blank, it allows complete freedom to integrate photographs, line art, clip art and text. Multiple copies of the same book can easily be made from images stored, for example in a hard disk drive, of PC 210 . Thus, second editions, new, and revised editions may also be produced.
[0036] Board books 100 , 235 are a preferred media for children and parents since the pages are specially laminated and therefore very durable and cleanable. Compatible matching label stock provides a durable book. A self-adhesive clear laminate affixed over the printed label 222 further protects the printed label from smudges that may result from a lot of use. A protective covering comprising the laminate may be sprayed and/or brushed onto the pages of the book over printed label 222 .
[0037] Accordingly, the present invention allows children, parents and teachers to publish “readers” (using either the phonics method or the whole word method), alphabet books, etc. for home and school use.
[0038] It should also be appreciated by those skilled in the art that the particular publishing system and method and other aspects of the teachings herein are but examples of the present invention. Thus, they do not limit the scope or variety of applications that the present invention may be suitably implemented. For example, various forms of creative content may be included in the book in addition to textual and graphical content such as audio files for storage and playback by said book, video data files, and web pages.
[0039] Therefore, it should be understood that the foregoing description is only illustrative of a present implementation of the teachings herein. Various alternatives and modification may be devised by those skilled in the art without departing from the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances.
|
A system and method for the publication of a fully personalized and completely customized story is provided. The system and method include providing a blank label, a blank board book, and a base software program or module using a general purpose computer for accepting completely variable creative content and controlling the printing of the content to the blank labels.
| 1
|
This is a contiuation application of prior application Ser. No. 09/661,249, filed on Sep. 13, 2000 which is a continuation of prior application Ser. No. 09/507,450 filed on Feb. 19, 2000, that issued as U.S. Pat. No. 6,144,421 on Nov. 7, 2000, which is a continuation of prior application No. 09,391,087 filed on Sep. 4, 1999, that issued as U.S. Pat. No. 6,075,577 on Jun. 13, 2000, which is a continuation of application Ser. No. 09/025,160, filed on Feb. 18, 1998, that issued as U.S. Pat. No. 6,016,173 on Jan. 18, 2000, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates generally to image generating systems including a reflective type, ferroelectric liquid crystal (FLC) spatial light modulator (SLM). More specifically, the invention relates to an optics arrangement including an FLC compensator cell for allowing the system to generate a substantially continuously viewable image while DC-balancing the FLC material of both the SLM and the compensator cell.
FLC materials may be used to provide a low voltage, low power reflective spatial light modulator due to their switching stability and their high birefringence. However, a problem with FLC materials, and nematic liquid crystal materials, is that the liquid crystal material may degrade over time if the material is subjected to an unbalanced DC electric field for an extended period of time. In order to prevent this degradation, liquid crystal spatial light modulators (SLMs) must be DC field-balanced.
Nematic liquid crystal materials respond to positive or negative voltages in a similar manner regardless of the sign of the voltage. Therefore, nematic liquid crystals are typically switched ON by applying either a positive or negative voltage through the liquid crystal material. Nematic liquid crystal materials are typically switched OFF by not applying any voltage through the material. Because nematic liquid crystal materials respond to voltages of either sign in a similar manner, DC balancing for nematic liquid crystal materials may be accomplished by simply applying an AC signal to create the voltage through the material. The use of an AC signal automatically DC balances the electric field created through the liquid crystal material by regularly reversing the direction of the electric field created through the liquid crystal material at the frequency of the AC signal.
In the case of FLC materials, the materials are switched to one state (i.e. ON) by applying a particular voltage through the material (i.e. +5 VDC) and switched to the other state (i.e. OFF) by applying a different voltage through the material (i.e. −5 VDC). Because FLC materials respond differently to positive and negative voltages, they cannot be DC-balanced in situations where it is desired to vary the ratio of ON time to OFF time arbitrarily. Therefore, DC field-balancing for FLC SLMs is most often accomplished by displaying a frame of image data for a certain period of time, and then displaying a frame of the inverse image data for an equal period of time in order to obtain an average DC field of zero for each pixel making up the SLMs.
In the case of an image generating system or display, the image produced by the SLM during the time in which the frame is inverted for purposes of DC field-balancing may not typically be viewed. If the system is viewed during the inverted time without correcting for the inversion of the image, the image would be distorted. In the case in which the image is inverted at a frequency faster than the critical flicker rate of the human eye, the overall image would be completely washed out and all of the pixels would appear to be half on. In the case in which the image is inverted at a frequency slower than the critical clicker rate of the human eye, the viewer would see the image switching between the positive image and the inverted image. Neither of these situations would provide a usable display.
In one approach to solving this problem, the light source used to illuminated the SLM is switched off or directed away from the SLM during the time when the frame is inverted. This type of system is described in copending U.S. patent application Ser. No. 08-361,775, filed Dec. 22, 1994, entitled DC FIELD-BALANCING TECHNIQUE FOR AN ACTIVE MATRIX LIQUID CRYSTAL IMAGE GENERATOR, which is incorporated herein by reference. However, this approach substantially limits the brightness and efficiency of the system. In the case where the magnitude of the electric field during the DC field-balancing and the time when the frame is inverted is equal to the magnitude of the electric field and the time when the frame is viewed, only a maximum of 50% of the light from a given light source may be utilized. This is illustrated in FIG. 1 a which is a timing diagram showing the relationship between the switching on and off of the light source and the switching of the SLM image data.
As shown in FIG. 1 a , the light source is switched on for a period of time indicated by T 1 . During this time T 1 , the SLM is switched to form a desired image. In order to DC balance the SLM, the SLM is switched to form the inverse of the desired image during a time period T 2 . In order to prevent this inverse image from distorting the desired image, the light source is switched off during the time T 2 as shown in FIG. 1 a.
In order to establish a convention to be used throughout this description, the operation of a given pixel 10 of a reflective type FLC SLM using the above mentioned approach of switching off the light source during the time the frame is inverted will be described with reference to FIGS. 1 b-d . FIG. 1 b shows pixel 10 when it is in its bright state and FIG. 1 c shows pixel 10 when it is in its dark state. As illustrated in both FIGS. 1 b and 1 c , a light source 12 directs light, indicated by arrow 14 , into a polarizer 16 . Polarizer 16 is arranged to allow, for example, horizontally linearly polorized light, indicated by the reference letter H and by arrow 18 , to pass through polarizer 16 . However, polarizer 16 blocks any vertically linearly polarized component of the light and thereby directs only horizontally linearly polarized light into pixel 10 . This arrangement insures that only horizontally linearly polarized light is used to illuminate pixel 10 . For purposes of clarity throughout this description, the various configurations will be described using horizontally linearly polarized light as the initial input light for each of the various configurations.
As also illustrated in FIGS. 1 b and 1 c , pixel 10 includes a reflective backplane 22 and a layer of FLC material 24 which is supported in front of reflective backplane 22 and which acts as the light modulating medium. The various components would typically be positioned adjacent one another, however, for illustrative purposes, the spacing between the various components is provided. In this example, the FLC material has a thickness and a birefringence which cause the material to act as a quarter wave plate for a given wavelength. In this example, the FLC material is typical of those readily available and has a birefringence of 0.142. Therefore a thickness of 900 nm causes the SLM to act as a quarter wave plate for a wavelength of approximately 510 nm.
FLC material 22 has accompanying alignment layers (not shown) at the surfaces which have a buff axis or alignment axis that controls the alignment of the molecules of the FLC material. For this example of a reflective mode SLM, the SLM is oriented such that the alignment axis is rotated 22.5 degrees relative to the polarization of the horizontally linearly polarized light being directed into the SLM. The FLC also has a tilt angle of 22.5 degrees associated with the average optic axis of the molecules making up the FLC material. Therefore, when FLC material 24 of the pixel is switched to its first state, in this case by applying a +5 VDC electric field across the pixel, the optic axis is rotated to a 45 degree angle relative to the horizontally linearly polarized light. This causes the pixel to act as a quarter wave plate for horizontally linearly polarized light at 510 nm. Alternatively, when the pixel is switched to its second state, in this case by applying a −5 VDC electric field across the pixel, the optic axis is rotated to a zero degree angle relative to the horizontally linearly polarized light. This causes the pixel to have no effect on the horizontally linearly polarized light directed into the pixel. In other words, the tilt angle is the angle that the FLC optic axis is rotated one side or the other of the buff axis when the FLC material is switched to its first and second states.
Now that the configuration of the pixel for this example has been described, its effect on the light as it passes through the various elements will be described. Initially, it will be assumed the light is monochrome at the wavelength at which the SLM acts as a quarter wave plate, in this case 510 nm. As illustrated in FIG. 1 b , when the FLC material is switched to its first state, which will be referred to hereinafter as its A state, FLC material 24 converts the 510 nm wavelength horizontally linearly polarized light directed into the pixel and indicated by arrow 18 into circularly polarized light indicated by the reference letters C and arrow 26 . Reflective backplane 22 reflects this circularly polarized light as indicated by arrow 28 and directing it back into FLC material 24 . FLC material 24 again acts on the light converting it from circularly polarized light to vertically linearly polarized light as indicated by reference letter V and arrow 30 . The vertically linearly polarized light 30 is directed into an analyzer 32 which is configured to pass vertically linearly polarized light and block horizontally polarized light. Since analyzer 32 is arranged to pass vertically linearly polarized light, this vertically linearly polarized light indicated by arrow 30 passes through analyzer 32 to a viewing area indicated by viewer 34 causing the pixel to appear bright to the viewer.
Alternatively, as illustrated in FIG. 1 c, FLC material 24 has no effect on the horizontally linearly polarized light directed into the pixel when the pixel is in its second state, which will be referred to hereinafter as its B state. This is the case regardless of the wavelength of the light. Therefore, the horizontally linearly polarized light passes through FLC material 24 and is reflected by reflective backplane 22 back into FLC material 24 . Again, FLC material 24 has no effect on the horizontally linearly polarized light. And finally, since analyzer 32 is arranged to block horizontally linearly polarized light, the horizontally linearly polarized light is prevented from passing through to viewing area 34 causing the pixel to appear dark.
Although the polarization state of the light is relatively straight forward when the light is assumed to be at a wavelength at which the SLM acts as a quarter wave plate, it becomes more complicated when polychromatic light is used. This is because even if the birefringence An of the FLC were constant, the retardance of the SLM in waves would vary with wavelength; furthermore, the birefringence of the FLC material also varies as the wavelength of the light varies. In display applications, this becomes very important due to the desire to provide color displays. FIG. 1 d illustrates the effects the SLM has on visible light ranging in wavelength from 400 nm to 700 nm as a function of the wavelength of the light assuming typical FLC birefringence dispersions. Solid line 36 corresponds to the first case when the pixel is in its A state as illustrated in FIG. 1 b and the dashed line 38 corresponds to the second case when the pixel is in its B state as illustrated in FIG. 1 c. As is illustrated in FIG. 1 d , the resulting output of this configuration varies substantially depending on the wavelength of the light as indicated by line 36 . In fact, only a little more than 50% of the horizontally linearly polarized light at 400 nm that is directed into the SLM is converted to vertically linearly polarized light using this configuration.
The above described configuration makes use of crossed polarizers. That is, polarizer 16 blocks vertically linearly polarized light and analyzer 32 blocks horizontally linearly polarized light. This means that polarizer 16 and analyzer 32 must be different elements. If both polarizer 16 and analyzer 32 were configured to pass the same polarization of light, they would be referred to as parallel polarizers and could be provided by the same element.
In an alternative system configuration, a polarizing beam splitter may be used to replace both the polarizer and the analyzer. FIGS. 1 e and 1 f illustrate such a system when pixel 10 is in its A and B states respectively. In this alternative system, light from light source 12 is directed into a polarizing beam splitter (PBS) 40 as indicated by arrow 42 . PBS 40 is configured to reflect horizontally linearly polarized light as indicated by arrow 44 and pass vertically linearly polarized light as indicated by arrow 46 . The horizontally linearly polarized light indicated by arrow 44 is directed into SLM 24 .
When pixel 10 is in its A state as illustrated in FIG. 1 e , SLM 24 acts as a quarter wave plate as described above converting the horizontally linearly polarized light to circularly polarized light and reflective backplane 22 reflects this light back into SLM 24 . Again, SLM 24 converts this circularly polarized light into vertically linearly polarized light as described above for FIG. 1 b and as indicated by arrow 48 . Since PBS 40 is configured to pass vertically linearly polarized light, this light passes through PBS 40 into viewing area 34 causing pixel 10 to appear bright.
When pixel 10 is in its B state as illustrated in FIG. 1 f , SLM 24 has no effect on the horizontally linearly polorized light. Therefore, the horizontally linearly polarized light that is directed into SLM 24 as indicated by arrow 44 remains horizontally linearly polarized light as it passes through SLM 24 , is reflected by backplane 22 , and again passes through SLM 24 . However, since PBS 40 is configured to reflect horizontally linearly polarized light, this light is reflected back toward light source 12 as indicated by arrow 50 causing pixel 10 to appear dark.
As mentioned above, in the configuration currently being described, the light source is turned off during the time in which the image is inverted for purposes of DC field-balancing the FLC material as illustrated in FIG. 1 a . This substantially reduces the brightness or efficiency of the display. In order to overcome this problem of not being able to view the system during the DC field-balancing frame inversion time, compensator cells have been proposed for transmissive SLMs such as those described in U.S. Pat. No. 5,126,864. These compensator cells are intended to correct for the frame inversion during the time when the FLC pixel is being operated in its inverted state. FIG. 2 a illustrates a transmissive mode system 200 which includes an SLM 202 , a compensator cell 204 , a polarizer 206 , and an analyzer 208 .
As described above for the FLC material of the SLM of the previous configuration, SLM 202 and compensator cell 204 each include an FLC layer which is switchable between an A and a B state. This results in four possible combinations of states for the SLM and compensator cell. For purposes of consistency in comparing various configurations described herein, these four cases will be defined as follows:
Case 1 —compensator cell in B state, SLM pixel in A state
Case 2 —compensator cell in B state, SLM pixel in B state
Case 3 —compensator cell in A state, SLM pixel in B state
Case 4 —compensator cell in A state, SLM pixel in A state
For this configuration, Cases 1 and 2 correspond to the normal operation of the system during which the compensator cell is in its B state and the SLM pixels are switched between their A and B states to respectively produce a bright or dark pixel. This is illustrated in the first half of FIG. 2 b which is a timing diagram showing the states of the light source, the SLM, and the compensator cell. As shown in FIG. 2 b , the light source remains ON throughout the operation of the system. During the first half of the time illustrated in FIG. 2 b , the pixels of the SLM are switched between their A and B states to produce a desired image. Cases 3 and 4 correspond to the time during which the frame is inverted for purposes of DC field balancing (i.e. the SLM pixel states must be reversed) and the compensator cell is switched to its A state to compensate for the inversion. This is illustrated by the second half of the diagram of FIG. 2 b . To properly DC field-balance the display as well as allow the display to be viewed continuously, Case 1 and Case 3 must give the same results and Case 2 and Case 4 must give the same results. That is, for this configuration, Cases 1 and 3 must both produce a bright pixel and Cases 2 and 4 must both produce a dark pixel.
In this example of a transmissive mode system, both the FLC layer of the SLM pixel and the compensator cell are 1800 nm thick which causes them to act as a half wave plate for a wavelength of 510 nm when in the ON state. In this configuration, the polarizer and analyzer perform the functions performed by polarizer 16 and analyzer 32 , or alternatively PBS 40 , of the reflective mode systems described above. Polarizer 206 is positioned optically in front of compensator cell 204 and the SLM pixel 202 such that it allows only horizontally linearly polarized light to pass through it into compensator cell 204 . Also, analyzer 208 which only allows vertically linearly polarized light to pass through is positioned optically behind SLM 202 .
FIGS. 2 c and 2 d illustrate the net result the above described transmissive system configuration has on light directed in to the system. FIG. 2 c shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between its A state for Case 1 and its B state for Case 2 . Case 1 is indicated by solid line 210 and Case 2 is indicated by dashed line 212 . FIG. 2 d shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between its B state for Case 3 and its A state for Case 4 . Case 3 is represented by solid line 214 and Case 4 is represented by dashed line 216 .
As clearly shown by FIGS. 2 c and 2 d , this transmissive configuration produces identical results, that is a bright pixel, for Case 1 and 3 as indicated by lines 210 and 214 , respectively. It also produces identical results for Cases 2 and 4 as indicated by lines 212 and 216 , respectively. It should also be noted that this configuration produces relatively good results over the entire wavelength range from 400 nm to 700 nm. The worst results are at 400 nm where approximately 80% of the horizontally linearly polarized light is converted to vertically polarized light.
Although the compensator cell approach works well for a transmissive SLM as described above, applicant has found that this same general approach does not work as well for a reflective type SLM. To illustrate this difference, and referring to FIG. 3 a , a reflective type display system 300 including a reflective type SLM 302 having a reflective backplane 303 , a compensator cell 304 , a polarizer 306 , and an analyzer 308 will be described. Compensator cell 304 is positioned adjacent to SLM 302 . As described above for FIGS. 1 b and 1 c , polarizer 306 is positioned to direct only horizontally linearly polarized light into compensator cell 304 . Because the light passes through the SLM and the compensator cell twice in a reflective mode system, the FLC material of SLM 302 and compensator cell 304 are configured to act as quarter wave plates for a wavelength of 510 nm rather than half wave plates as described above for the transmissive system of FIG. 2 a.
In this example, the FLC materials of both SLM 302 and compensator cell 304 are 900 nm thick and both have a tilt angle of 22.5 degrees. The buff axis of the SLM is aligned with the horizontally linearly polarized light directed into the system by polarizer 306 . Also, the buff axis of compensator cell 304 is positioned perpendicular to the buff axis of SLM 302 . FIGS. 3 b and 3 c illustrate the net result that system 300 has on light directed in to the system. FIG. 3 b shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between its A state for Case 1 and its B state for Case 2 . Case 1 is indicated by solid line 310 and Case 2 is indicated by dashed line 312 . FIG. 3 c shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between its B state for Case 3 and its A state for Case 4 . Case 3 is represented by solid line 314 and Case 4 is represented by dashed line 316 .
As clearly shown by FIGS. 3 b and 3 c , system 300 produces identical results, that is, a bright pixel for Case 1 and 3 as indicated by lines 310 and 314 , respectively. It also produces identical results for Cases 2 and 4 as indicated by lines 312 and 316 , respectively. However, this configuration does not produces very good results over the entire wavelength range from 400 nm to 700 nm. The worst results are at 400 nm where only approximately 5% of the horizontally linearly polarized light is converted to vertically polarized light. At a wavelength of about 500 nm about 50% of the horizontally linearly polarized light is converted to vertically linearly polarized light. The best results are at 700 nm where about 80% of the horizontally linearly polarized light is converted to vertically linearly polarized light. Since the point to adding the compensator cell is to increase the efficiency or brightness of the system, this arrangement does not improve the efficiency or brightness for the lower wavelength range when compared to the system of FIG. 1 b and 1 c which simply turns OFF the light source during the DC field-balancing time.
As can be clearly seen when comparing FIGS. 3 b-c to FIGS. 2 c-d , the effects on the light caused by the various components of the reflective configuration of FIG. 3 a are very much different from the effects on the light caused by the transmissive configuration of FIG. 2 a . That is, the reflective configuration of FIG. 3 a is not optically equivalent to the transmissive configuration of FIG. 2 a even though it may initially seem as though they should be optically equivalent. These two configurations are optically different from one another because the light must pass through the SLM and compensator cell twice in the reflective configuration with the first pass through the compensator being before the two passes through the SLM and the second pass through the compensator cell being after the two passes through the SLM.
Due to this difference in the transmissive and reflective configurations, it has proved difficult to provide a reflective type system which is DC field-balanced and is substantially continuously viewable while providing improved efficiency or brightness compared to a system which simply turns off the light source during the DC field-balancing portion of the frame. The present invention provides arrangements and methods for overcome this problem.
SUMMARY OF THE INVENTION
As will be described in more detail hereinafter, a reflection mode, spatial light modulating system and methods of operating the system are herein disclosed. The reflection mode, ferroelectric liquid crystal spatial light modulating system, includes a light reflecting type spatial light modulator. The spatial light modulator has a light reflecting surface cooperating with a layer of ferroelectric liquid crystal light modulating medium switchable between first and second states so as to act on light in different first and second ways, respectively. A switching arrangement switches the liquid crystal light modulating medium between the first and second states and an illumination arrangement produces a source of light. An optics arrangement is optically coupled the spatial light modulator and the illumination arrangement such that light is directed from the source of light into the spatial light modulator for reflection back out of the modulator and such that reflected light is directed from the spatial light modulator into a predetermined viewing area. A compensator cell is also positioned in the optical path between the light source and the viewing area. The compensator cell has a layer of ferroelectric liquid crystal light modulating medium switchable between a primary and a secondary state so as to act on light in different primary and secondary ways, respectively.
In one embodiment, the optics arrangement includes a passive quarter wave plate positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area. In this embodiment, the compensator cell is positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings.
FIG. 1 a is a timing diagram illustrating the timing at which a light source for a prior art DC-balanced display system is switched ON and OFF.
FIGS. 1 b and 1 c are diagrammatic cross sectional views of a pixel of a prior art reflective type SLM display system illustrating how the pixel acts on light when the pixel is in the ON and OFF states.
FIG. 1 d is a graph illustrating the effects the system of FIG. 1 b and 1 c has on light after it passes through the system.
FIGS. 1 e and 1 f are diagrammatic cross sectional views of a pixel of a prior art reflective type SLM display system including a polarizing beam splitter.
FIG. 2 a is a diagrammatic cross sectional view of a prior art transmissive SLM display system.
FIG. 2 b is a timing diagram illustrating the timing at which a light source for a prior art DC-balanced display system is switched ON and OFF.
FIGS. 2 c and 2 d are graphs illustrating the effects the system of FIG. 2a has on light after it passes through the system.
FIG. 3 a is a diagrammatic cross sectional view of a prior art reflective SLM display system.
FIGS. 3 b and 3 c are graphs illustrating the effects the system of FIG. 3 a has on light after it passes through the system.
FIG. 4 a is a diagrammatic cross sectional view of a first embodiment of a reflective SLM display system designed in accordance with the present invention.
FIGS. 4 b-c are graphs illustrating the effects the system of FIG. 4 a has on light after it passes through the system.
FIG. 5 a is a diagrammatic cross sectional view of a second embodiment of a reflective SLM display system designed in accordance with the present invention.
FIGS. 5 b-c are graphs illustrating the effects the system of FIG. 5 a has on light after it passes through the system.
FIG. 6 is a diagrammatic cross sectional view of a third embodiment of a reflective SLM display system designed in accordance with the present invention.
FIGS. 7 a-b are diagrammatic cross sectional views of a fourth embodiment of a reflective SLM display system designed in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An invention is described for providing methods and apparatus for producing a substantially continuously viewable reflective type SLM display system which is DC field-balanced and which is more efficient or brighter than would be possible using a reflective type SLM display system which simply turns off the light source during the DC field balancing portion of each image frame. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, based on the following description, it will be obvious to one skilled in the art that the present invention may be embodied in a wide variety of specific configurations. Also, well known processes for producing various components and certain well known optical effects of various optical components will not be described in detail in order not to unnecessarily obscure the present invention.
Referring initially to FIG. 4 a , the present invention will be described with reference to a first embodiment of the invention which takes the form of a reflective type SLM display system generally designated by reference numeral 400 . As illustrated in FIG. 4 a , system 400 includes an SLM 402 having a reflective backplane 403 , a compensator cell 404 , a polarizer 405 , and an analyzer 406 . Alternatively, in the same manner as described above, crossed polarizer 405 and analyzer 406 may be replaced with a polarizing beam splitter.
System 400 is configured in a manner similar to that described above for system 300 of FIG. 3 a . That is, compensator cell 404 is positioned adjacent SLM 402 . Also, polarizer 405 is positioned to direct only horizontally linearly polarized light into compensator cell 404 . Similarly, analyzer 406 allows only vertically linearly polarized light to pass through it and into the viewing area after the light directed in to the system has passed through compensator cell 404 and SLM 402 and been reflected back through SLM 402 and compensator cell 404 . However, in accordance with the invention, system 400 also includes a static quarter wave plate 408 positioned optically between compensator cell 404 and polarizer 405 and analyzer 406 .
As would be understood by those skilled in the art, SLM 402 may be made up of an array of any number of individually controllable pixels which are individually switchable between two states. For purposes of consistency, it will be assumed that each pixel is switched to its A state by applying a +5 VDC electric field through the pixel and each pixel is switched to its B state by applying a −5 VDC electric field through the pixel. It should be understood that the present invention is not limited to these specific voltages and would equally apply regardless of the voltages used to switch the pixels.
System 400 further includes a light source 410 for directing light into the system in a manner similar to that described above for FIGS 1 b and 1 c . With this configuration, light source 410 directs light into polarizer 405 as indicated by arrow 412 . Polarizer 405 blocks any vertically linearly polarized portions of the light from passing through polarizer 405 an allows only horizontally linearly polarized portions of the light to pass through polarizer 405 into static quarter wave plate 408 . This light passes through static quarter wave plate 408 , compensator cell 404 , and SLM 402 and is then reflected by reflective backplane 403 back through SLM 402 , compensator cell 404 , and static wave plate 408 to analyzer 406 as illustrated in FIG. 4 a . Analyzer 406 then blocks any horizontally linearly polarized portions of the light and allows only vertically linearly polarized portions of the light to pass through it to a viewing area indicated by viewer 416 . Since polarizer 405 blocks vertically linearly polarized light and analyzer 406 blocks horizontally linearly polarized light, this type of system is referred to as using crossed polarizers.
For this embodiment and as described above for system 300 , because the light passes through the SLM and the compensator cell twice in a reflective mode system, the FLC material of SLM 402 and compensator cell 404 are configured to act as quarter wave plates for a wavelength of 510 nm. In this configuration, the FLC materials of both SLM 402 and compensator cell 404 are 900 nm thick and both have a tilt angle of 22.5 degrees. In this specific embodiment, the buff axis of the SLM is positioned at a 22.5 degree angle relative to the horizontally linearly polarized light directed into the system. Also, for this embodiment, the buff axis of compensator cell 404 is positioned perpendicular to the buff axis of SLM 402 .
Although the buff axis of the SLM is described as being positioned at 22.5 degrees relative to the horizontally linearly polarized light directed into the system, this is not a requirement. In fact, this configuration works equally as well regardless of the orientation of the SLM buff axis relative to the horizontally linearly polarized light directed into the system so long as the buff axis of the compensator cell is oriented perpendicular to the buff axis of the SLM. This freedom in orienting the buff axis of the SLM relative to the horizontally linearly polarized light directed into the system makes this overall system easier to produce than other conventional systems because only the orientation of the SLM relative to the compensator cell must be precisely controlled.
The orientation of the static quarter wave plate relative to the horizontally linearly polarized light directed into the system is also important. Generally, static quarter wave plate 408 has a primary axis which is oriented at a 45 degree angle to the horizontally linearly polarized light directed into the quarter wave plate.
Although the tilt angles of SLM 402 and compensator cell 404 are described as being 22.5 degrees, this is not a requirement. The configuration described above for this embodiment works regardless of the tilt angle of the FLC material of the SLM and the compensator cell, but works best when the tilt angles of the two components are the same. Therefore, it should be understood that the present invention would equally apply to systems using SLMs and compensator cells having tilt angles other than 22.5 degrees. With this configuration, the bright states obtained by the system remain bright regardless of the tilt angle used provided the tilt angles match. However, the use of tilt angles in the range of 22.5 to 25.5 degrees provides optimum dark state extinction, with the choice of tilt angle at the low end of the range providing best extinction over a narrow range of wavelengths centered on the wavelength for which the SLM and compensator have quarter-wave retardance and with the choice of tilt angle towards the upper end of the range providing good extinction over a more extended range of wavelength. Increasing the tilt angle past 25.5 degrees eventually reduces dark state extinction.
Now that the physical configuration of system 400 has been described, its effect on light directed into system 400 will be described. FIGS. 4 b and 4 c illustrate the net result that system 400 has on light directed in to the system. FIG. 4 b shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between the A state for Case 1 and the B state for Case 2 . Case 1 is indicated by solid line 420 and Case 2 is indicated by dashed line 422 . FIG. 4 c shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between the B state for Case 3 and the A state for Case 4 . Case 3 is represented by solid line 424 and Case 4 is represented by dashed line 426 . Cases 1 - 4 correspond to Cases 1 - 4 for the systems described above in the background.
As illustrated in FIGS. 4 b and 4 c , because of quarter wave plate 408 is included in the configuration of system 400 , Cases 1 and 3 result in a dark pixel rather than a bright pixel and Cases 2 and 4 result in a bright pixel rather than a dark pixel. This is the opposite of the results described in the background. However, this inversion of the bright and the dark states may be compensated for in a variety of ways such as reversing the A and the B states for the SLM (i.e. using a −5 VDC to switch the pixel to the A state and using a 5 VDC to switch the pixel to the B state). The important thing is that the results of Cases 1 and 3 are identical and the results of Cases 2 and 4 are identical.
For system 400 , static quarter wave plate 408 is preferably a readily providable achromatic quarter wave plate. The use of an achromatic static quarter wave plate provides the best results over a broad color spectrum because it flattens out the curves 422 of FIG. 4 b and 426 of FIG. 4 c representing the bright states obtained by Case 1 and Case 2 . This flattening out of the curve improves the optical throughput of system 400 by increasing the amount of light which passes through the system for a given pixel when the combination of that pixel and the other elements are switched to produce a bright state.
In one embodiment of the invention which reverses the bright and dark states described above for FIGS. 4 a-c , parallel polarizers are used instead of crossed polarizers. FIG. 5 a-c illustrate a system 500 which utilizes parallel polarizers. As described above for system 400 , system 500 includes a SLM 502 , a reflective backplane 503 , a compensator cell 504 , a polarizer 505 , a static quarter wave plate 508 , and a light source 510 . Light source 510 directs light into polarizer 505 which blocks any vertically linearly polarized light and allows only horizontally linearly polarized light to pass through. This horizontally linearly polarized light then passes through and is acted upon by static quarter wave plate 508 , compensator cell 504 , SLM 502 , and reflective backplane 503 in the same way as described above for FIG. 4 a . However, in this embodiment, polarizer 505 also acts as the analyzer for the system. This use of polarizer 505 for both the polarizer and the analyzer is what makes this system a parallel polarizer system.
In the configuration of FIG. 5 a , polarizer 505 acts as the analyzer by blocking any vertically linearly polarized light and allowing any horizontally linearly polarized light to pass into the viewing area. This is the opposite of the polarizations of light blocked and passed by analyzer 406 in system 400 . This has the effect of reversing the bright and dark states of the system and results in the net effects illustrated in FIGS. 5 b and 5 c . FIG. 5 b shows the results for Case 1 and 2 during which the compensator cell is in its B state and the SLM is switched between the A state for Case 1 and the B state for Case 2 . Case 1 is indicated by solid line 520 and Case 2 is indicated by dashed line 522 . FIG. 5 c shows the results for Case 3 and 4 during which the compensator cell is in its A state and the SLM is switched between the B state for Case 3 and the A state for Case 4 . Case 3 is represented by solid line 524 and Case 4 is represented by dashed line 526 . Cases 1 - 4 correspond to Cases 1 - 4 for the systems described above in the background and Cases 1 - 4 described above for FIG. 4 .
As clearly shown by FIGS. 5 b and 5 c , system 500 produces identical results, that is, a bright pixel for Case 1 and 3 as indicated by lines 520 and 524 , respectively. It also produces identical results for Cases 2 and 4 as indicated by lines 522 and 526 , respectively. This configuration also produces very good results over the entire wavelength range from 400 nm to 700 nm. In fact, as illustrated by lines 522 and 526 , this configuration provides substantially uniform blockage of the entire range of wavelengths of the light that is directed into the spatial light modulator. Also, in both Cases 1 and 3 , a large portion of the horizontally linearly polarized light passes through the system for the entire range of 400 nm to 700 nm. Since the point to adding the compensator cell is to increase the efficiency or brightness of the system, this arrangement dramatically improves the efficiency or brightness of system 500 over the complete wavelength range when compared to the system of FIG. 1 b and 1 c which simply turns OFF the light source during the DC field-balancing time. This also substantially improves the efficiency of the system compared to system 300 of FIG. 3 described above which does not include the static quarter wave plate. Furthermore, since essentially no light from the light source passes through the system to the viewing area when the elements are switched to produce a dark state as indicated by lines 522 and 526 , this configuration also provides an excellent contrast ratio.
In another embodiment similar to system 400 of FIG. 4 a , a birefringent element may be added to system 400 in order to provide results very similar to the results obtained by system 500 of FIG. 5 a . Using like reference numerals to represent like components, FIG. 6 illustrates a system 600 including SLM 402 , reflective backplane 403 , compensator cell 404 , polarizer 405 , analyzer 406 , static quarter wave plate 408 , and light source 410 . As described above for FIG. 4, polarizer 405 and analyzer 406 are crossed polarizers. However, in accordance with this embodiment of the invention, system 600 further includes an additional birefringent element 612 which can be positioned between SLM 402 and compensator cell 404 , as shown here, or alternately, can be positioned between compensator cell 404 and static quarter wave plate 408 .
In this embodiment, birefringent element 612 is a commercially available polycarbonate film having a retardance of approximately one half of the wavelength of the light for which the system is optimized, for example a wavelength of 510 nm. Alternatively, birefringent element 612 may be any birefringent material capable of providing the desired retardance such as poly vinyl alcohol or any other optically clear birefringent material.
In this embodiment, the buff axes of SLM 402 and compensator cell 404 are parallel to one another and birefringent element 612 has a primary axis which is oriented perpendicular to the buff axis of both SLM 402 and compensator cell 404 . As describe above for system 400 , polarizer 405 directs horizontally linearly polarized light into quarter wave plate 408 and quarter wave plate 408 is oriented at a 45 degree angle to the horizontally linearly polarized light. SLM 402 , compensator cell 404 , and birefringent element 612 may be oriented in any way relative to quarter wave plate 408 so long as the buff axes of SLM 402 and Compensator cell 404 are parallel to one another and the primary axis of birefringent element 612 is perpendicular to the buff axes of SLM 402 and compensator cell 404 .
The addition of the birefringent element causes Case 1 and Case 3 for this embodiment to result in a bright state in which the throughput varies only slightly over the range of the wavelengths similar to curves 520 and 524 of FIGS. 5 b and 5 c . Also, the addition of the birefringent element causes Case 2 and Case 4 for this embodiment to result in a substantially more uniform dark state similar to lines 522 and 526 of FIGS. 5 b and 5 c . This results in a system that is able to provide a high contrast ratio while maintaining a relatively high throughput for the entire wavelength range even though crossed polarizers are utilized.
Although the above described embodiments have been described as having the static quarter wave plate positioned between the polarizer and the compensator cell, this is not a requirement. Instead, the static quarter wave plate may be located between the compensator cell and SLM and still remain within the scope of the invention.
In another embodiment, an off axis system may be utilized in order to provide a continuously viewable DC field-balanced reflective display system. FIGS. 7 a and 7 b illustrate one embodiment of an off axis display system 700 . As illustrated in FIGS. 7 a and 7 b , system 700 includes a SLM 702 , a reflective backplane 703 , a compensator cell 704 , a polarizer 705 , an analyzer 706 , and a light source 710 . In this embodiment, the light is directed into the SLM at an angle and reflected back into a viewing area indicated by viewer 720 such that the light directed into the system only passes through the compensator cell once rather than passing through the compensator cell twice as described above for the previously described embodiments.
Since the light only passes through compensator cell 704 once, the thickness of compensator cell 704 is configured to be twice the thickness of the SLM. Generally, SLM 702 has a thickness which causes SLM 702 to act as a quarter wave plate when switched to its A state and compensator cell 704 has a thickness which causes it to act as a half wave plate when it is switched to its A state. Therefore, in the case in which an FLC material is used for both the SLM and compensator cell that has a birefringence of 0.142, the thickness FLC material for the SLM would be approximately 900 nm and the thickness of the FLC material for the compensator cell would be approximately 1800 nm. Both SLM 702 and compensator cell are configured to have substantially no effect on the polarization of the light passing through them when they are switched to their B states.
For the configuration being described, polarizer 705 is configured to allow only horizontally linearly polarized light to be directed into the system. Analyzer 706 is configured to allow only vertically linearly polarized light to pass into the viewing area. Also, for this embodiment, the buff axis of compensator cell 704 is oriented perpendicular to the buff axis of SLM 702 and the buff axis of SLM 702 is advantageously oriented parallel to horizontally linearly polarized light directed into the system. Other orientations of the buff axes are also effective provided that the SLM and compensator cell buff axes remain perpendicular to one another.
As described above for the previous embodiments, the off axis configuration shown in FIGS. 7 a and 7 b provide identical results for Cases 1 and 3 and Cases 2 and 4 . This configuration also provides good results over a broad spectrum similar to the results illustrated in FIGS. 5 b and 5 c . Therefore, system 700 is also able to provide a continuously viewable system which more effectively utilizes light from the light source when compared to the conventional reflective systems illustrated in FIGS. 1 b-c and FIG. 3 a.
Although only certain specific embodiments of the present invention have been described in detail, it should be understood that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. For example, although the systems have been described above as using horizontally linearly polarized light as the initial input light polarization, this is not a requirement. Instead, it should be understood that the initial input light polarization may alternatively be vertically linearly polarized light. Therefore, the present examples are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope of the appended claims.
|
A reflection mode, ferroelectric liquid crystal spatial light modulating system, includes a light reflecting type spatial light modulator. The spatial light modulator has a light reflecting surface cooperating with a layer of ferroelectric liquid crystal light modulating medium switchable between first and second states so as to act on light in different first and second ways, respectively. A switching arrangement switches the liquid crystal light modulating medium between the first and second states and an illumination arrangement produces a source of light. An optics arrangement is optically coupled the spatial light modulator and the illumination arrangement such that light is directed from the source of light into the spatial light modulator for reflection back out of the modulator and such that reflected light is directed from the spatial light modulator into a predetermined viewing area. The optics arrangement includes a passive quarter wave plate positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area. A compensator cell is also positioned in the optical path between the light source and the spatial light modulator and in the optical path between the spatial light modulator and the viewing area. The compensator cell has a layer of ferroelectric liquid crystal light modulating medium switchable between a primary and a secondary state so as to act on light in different primary and secondary ways, respectively.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to vehicle instrument clusters generally and, more particularly, but not by way of limitation, to novel user controllable color lighting in a vehicle instrument cluster.
2. Background Art
Vehicle instrument clusters of the type under consideration here are found, for example, in automobiles, trucks, watercraft, aircraft, ATVs, and the like. Most, if not all, vehicle instrument clusters include some means of artificial lighting of the elements of the instrument cluster, generally in the form of electrical illumination to provide backlighting of the elements of the instrument cluster. Illumination, of course, is required to permit the operator of a vehicle and others, if necessary, to read in conditions of otherwise low visibility the gages, dials, etc. that are included in the instrument cluster.
Known vehicle instrument clusters provide illumination in only a narrow range of frequencies such that the illumination appears to be of a single, particular color. Usually, some means is provided to permit the operator of the vehicle to adjust the intensity of the illumination. While the preferred level of intensity will vary among operators of a vehicle, having the ability to make adjustments to the intensity to suit various operators is, of course, desirable such that the intensity not be too high or too low to the degree that the level of intensity of illumination interferes with the comfort of a vehicle operator or the safe operation of the vehicle.
No known illuminated vehicle instrument clusters permit the operator of a vehicle to adjust the color of the illumination of the vehicle instrument cluster or to vary the colors of the illumination for various portions of the vehicle instrument cluster. While such ability to adjust color could satisfy personal comfort and esthetic preferences, varying the colors of the illumination for various portions of the vehicle instrument cluster can also increase the level of safe operation of the vehicle by permitting the operator of the vehicle, for example, to set a bright color for the speed indicating portion of the vehicle instrument cluster and to set a less bright color for the tachometer and fuel level indicating portions of the vehicle instrument cluster. Thus, immediately important portions of the vehicle instrument cluster can be highlighted in terms of color and intensity, while less immediately important portions of the vehicle instrument cluster can be more subdued in terms of color and intensity of illumination thereof.
Accordingly, it is a principal object of the present invention to provide user controllable color lighting in a vehicle instrument cluster.
It is a further object of the invention to provide such user controllable color lighting that permits the operator of a vehicle to vary the intensity of the color lighting.
It is another object of the invention to provide such user controllable color lighting that permits the operator of a vehicle to vary the color of illumination of various portions of the vehicle instrument cluster.
It is an additional object of the invention to provide such user controllable color lighting that permits the operator of the vehicle to vary both the color and intensity of illumination of various portions of the vehicle instrument cluster.
It is yet a further object of the invention to provide such user controllable color lighting that can be economically implemented in a vehicle instrument cluster.
Other objects of the present invention, as well as particular features, elements, and advantages thereof, will be elucidated in, or be apparent from, the following description and the accompanying drawing figures.
SUMMARY OF THE INVENTION
The present invention achieves the above objects, among others, by providing, in a preferred embodiment, a user controllable lighting system for a vehicle instrument cluster, comprising: selection means to select a color scheme for individual gage area components of said vehicle instrument cluster; illumination means to illuminate said individual gage area components in accordance with selections made by said selection means; and control means operatively connected to said selection means and to said illumination means to receive said selections made by said selection means and to furnish instructions to said illumination means.
BRIEF DESCRIPTION OF THE DRAWING
Understanding of the present invention and the various aspects thereof will be facilitated by reference to the accompanying drawing figures, provided for purposes of illustration only and not intended to define the scope of the invention, on which:
FIG. 1 is a partially schematic isometric view of an example of a vehicle instrument cluster with which the present invention may be employed.
FIG. 2 is a front plan view of a driver interface for use in the present invention.
FIG. 3 is a software algorithm logic flow diagram for the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference should now-be made to the drawing figures on which similar or identical elements are given consistent identifying numerals throughout the various figures thereof, and on which parenthetical references to figure numbers direct the reader to the view(s) on which the element(s) being described is (are) best seen, although the element(s) may be seen on other figures also.
In general, the present invention provides the ability for operators of a vehicle to tune in the color scheme for the vehicle instrument cluster backlighting and pointer colors that each of the operators prefers and then store them for recall. At any time, a vehicle operator can decide to change the color for that operator. Each vehicle operator can have a color scheme and/or intensity level that is specific to that vehicle operator. More than one color scheme per vehicle operator can be provided. A vehicle operator could, for example, program one color scheme for daytime vehicle operation and another color scheme for nighttime vehicle operation. Because illumination for each gage area and pointer is controlled individually, a vehicle operator can also choose to turn off the backlighting illumination on any gage area or pointer.
Wherever herein “color scheme” is referred to, it will be understood that such encompasses any desired theme and includes any desired light intensity and/or color palette. Lighting elements, LEDs, for example, may be monochromatic, two-color, or multicolor. Lighting may be provided such that it is visible during either daytime or nighttime conditions. Whenever herein “gage area” is referred to, it will be understood that such encompasses groups of gages, or zones, as well a individual gages.
FIG. 1 illustrates an example of a vehicle instrument cluster 20 with which the present invention may be employed. Vehicle instrument cluster 20 is mounted in a vehicle dashboard 22 behind, or forward of, vehicle steering wheel 24 . Vehicle instrument cluster 20 includes a fuel gage area 30 with a pointer 32 , a speedometer gage area 34 with a pointer 36 , and an engine temperature gage area 38 with a pointer 40 . Fuel gage area 30 is illuminated by first backlighting illumination means 42 , speedometer gage area 34 is illuminated by second backlighting illumination means 44 , and engine temperature gage area 34 is illuminated by third backlighting illumination means 44 . First, second, and third backlighting illumination means 42 , 44 , and 46 are operatively connected to and under the control of a programmable microprocessor 50 . First, second, and third backlighting illumination means 42 , 44 , and 46 may represent multicolor LEDs, or edge lighting means, or any other type of backlighting illumination means and also may represent separate lighting means for both the gage areas and the pointers with which they are associated.
It will be understood that the arrangement of vehicle instrument cluster 20 is provided for illustrative purposes and that a vehicle instrument cluster to which the present invention may be applied may include a greater or fewer number of illuminated areas, each of which may have the color and intensity of illumination individually controlled. Also, as noted above, pointers and general background of the areas in which the pointers are disposed can have individual backlighting illumination means. There is an unlimited number of variations of pointer, gage area, colors, etc. that can be provided with the present invention and the ones described are for illustrative purposes and are not to be considered a limitation on the present invention.
FIG. 2 illustrates a driver interface panel, generally indicated by the reference numeral 100 . Driver interface panel 100 is preferably disposed in vehicle instrument cluster 20 (FIG. 1) and is operatively connected to programmable microprocessor 50 (FIG. 1) to change the programming thereof. Driver interface 100 may be analog, as shown on FIG. 2, or it may be digital (and include digital switch devices such as touch pads, for example).
The default factory setup for the color scheme can be, for example, the color white for all programmable backlighting illumination means. At any time, within limits set by the vehicle manufacturer, a vehicle operator, a vehicle dealer, or other authorized person can change the default color scheme to that which the vehicle operator, the vehicle dealer, or other authorized person prefers. To the extent permitted, which component of the instrument cluster that is to have its color changed can be selected. With reference to FIG. 2, for example, this can be done through the Gage Select switches and the Pointer/Backlight Select Switches. By toggling these switches, it is determined which gages and which part of the gage (pointer color or gage area color) is being changed. For instance, with reference to FIG. 2 and the toggle switches in the positions shown thereon, the Color Tuners would control the Backlighting of the Tachometer and the Oil Gage. All the other colors would stay the same. To change the Speedometer backlighting, all Gage Select Switches would be placed in the OFF position except the Speedometer and Backlight switches. When driver interface 100 is digital, the switches can be replaced with touch pads, for example, and the length of time a touch pad is pressed can be used to determined the intensity of illumination of the parameter being adjusted.
Once the vehicle operator, or other authorized person, is satisfied with the color and intensity selections, the vehicle operator, or other authorized person, presses the pushbutton “PROG” and then presses pushbutton “D 1 ”, “D 2 ”, or “D 3 ”. This stores the selections in memory in the memory section associated with the “D” pushbutton pressed. To recall the selection, the vehicle operator simply presses the same memory pushbutton. Alternatively, when the vehicle operator hits the key fob button on a keyless remote entry device, for example, the vehicle operator identification information is transmitted to the receiver in the vehicle. This receiver (already existing in vehicles and not part of the present invention) decodes the identification information and then informs the other modules in the vehicle the identification of the vehicle operator. Programmable microprocessor 50 (FIG. 1) receives the identification information from the receiver and, when the lights on instrument cluster 20 are in power up mode (key in ignition and turned), the programmable microprocessor can initialize the backlighting area and pointer color scheme to that which that vehicle operator had stored for recall.
FIG. 3 illustrates an algorithm logic flow diagram for the present invention. Assuming a vehicle operator has made and stored a color scheme, when a vehicle operator identification is received at 200 , this causes the last color scheme used or placed in memory to be recalled from memory at 202 . The recalled color scheme is then used at 210 to set the backlighting illumination.
If a poll or interrupt signal is received at 220 and no Gage Select or Pointer/Backlight Select switches (FIG. 2) are active, no further action is taken at 220 . If any of those switches is active, analog to digital red, green, and blue tuners are converted at 230 , 232 , and 234 , respectively. Then the vehicle operator selects the desired color scheme and intensities thereof at 240 and the backlighting illumination is set accordingly at 210 .
If a poll or interrupt signal is received at 250 and none of switches “D 1 ”, “D 2 ”, or “D 3 ” (FIG. 2) is active, no further action takes place at 250 . If one of those switches is active and “PROG” is not in active mode at 260 , the color scheme corresponding to the active one of those switches is recalled from memory at 202 and the backlighting illumination color scheme is activated at 210 . If “PROG” is active at 260 , the backlighting illumination color scheme corresponding to the active one of switches “D 1 ”, “D 2 ”, or “D 3 ” is stored in memory at 270 .
If a poll or interrupt signal is received at 280 and the “PROG” switch (FIG. 2) is not active, no further action takes place at 280 . If the “PROG” switch is active, the “PROG” active mode is set at 290 and a timer at 292 gives the vehicle operator an arbitrary predetermined amount of time in which to make color scheme selections, in this case, five seconds, although any length of time may be selected. If no color selection is made within the predetermined amount of time, the “PROG” active mode is turned off at 300 .
It will be understood that the present invention contemplates that colors and intensities of any number of gage areas and pointers may be individually set and stored in any number of memory locations for later recall, the specific ones shown being for illustrative purposes.
In the embodiments of the present invention described above, it will be recognized that individual elements and/or features thereof are not necessarily limited to a particular embodiment but, where applicable, are interchangeable and can be used in any selected embodiment even though such may not be specifically shown.
Terms such as “upper”, “lower”, “inner”, “outer”, “inwardly”, “outwardly”, and the like, when used herein, refer to the positions of the respective elements shown on the accompanying drawing figures and the present invention is not necessarily limited to such positions.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown on the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
|
A user controllable lighting system for a vehicle instrument cluster, including: selection apparatus to select a color scheme for individual gage area components of the vehicle instrument cluster; illumination apparatus to illuminate the individual gage area components in accordance with selections made by the selection apparatus; and control apparatus operatively connected to the selection apparatus and to the illumination apparatus to receive the selections made by the selection apparatus and to furnish instructions to the illumination apparatus.
| 1
|
This application is a Divisional of U.S. application Ser. No. 12/076,356, filed Mar. 17, 2008 pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a flame retardant composition and the like, and particularly to a halogen-free flame retardant composition containing no antimony, phosphorus and phosphorus compounds at all, a halogen-free flame-retardant resin composition of environmental flameproof type made of the flame retardant composition, which is slow in spreading fire during incipient fire and causes little carbon monoxide (CO) during combustion while having high flame retardance, and molded products, electric wires, cables, fiber or fiber post-processed products made of the resin composition.
2. Description of the Related Art
Resin using halogen compounds and antimony compounds together has widely been used for conventional flame-retardant materials. However, in recent years, with regard to halogen flame-retardant materials, the influence on the environment is regarded as a problem and the use thereof tends to be prohibited or restricted due to regulation in Europe; therefore, the development of halogen-free flame-retardant materials is in progress in each company.
Phosphorus-containing compounds are principally considered as halogen-free flame-retardant materials, and phosphorus flame retardants such as red phosphorus and phosphate are used; but yet the occurrence of phosphine gas during the use of red phosphorus is pointed out, and the problem is bleed-out during molding with regard to phosphate.
Thus, a halogen-free flame-retardant resin composition using magnesium hydroxide is proposed for the purpose of preventing secondary disasters such as fuming, toxicity and corrosion during combustion as described in Japanese Unexamined Patent Publication No. 01-141929, for example.
SUMMARY OF THE INVENTION
Generally, flame resisting is surmised as incomplete combustion, and flame resisting mechanism brings a possibility of causing oxygen (O 2 ) concentration to be diluted due to emission of harmful gas in large quantities. Flameproofing of plastics is important for causing no fires, while carbon monoxide poisoning and oxygen deficiency frequently take a precious life in the case of considering a real fire. Thus, the development of flame-retardant materials has been demanded, such as to cause as little carbon monoxide during combustion as possible.
However, due to incomplete combustion of materials as flame resisting mechanism, conventional flame-retardant plastics result in O 2 dilution due to the occurrence of gas in large quantities and the occurrence of harmful CO, and are accompanied by the occurrence of fuming and soot in large quantities. That is to say, while flameproofing is performed, CO as a problem after fire breaking tends to increase, and it is pointed out that the increase of CO is a problem in view of disaster prevention; therefore, materials are expected which have high flame retardance and decrease the occurrence of fuming, CO and soot after combustion is caused. Also, soot is a direct problem such as harmful inhalation and closed our sight during fire breaking, and additionally it is reportedly pointed out that soot is a factor of global warming. Here, high flame retardance signifies UL94 Test V0 ( 1/32″).
The Building Standard Law of Japan prescribes that heating for 5 minutes be the condition, and in fact it is extremely important that the maximum combustion be not caused within 5 minutes; for example, arrival time of the maximum smoke concentration and the maximum heat generation rate is not less than 5 minutes, which leads to the delay of O 2 dilution. Accordingly, the realization of flame-retardant materials in which CO occurrence is little and fuming is restrained is also conceived to be the advent of an epoch-making technique.
The present invention has been made in view of the above-mentioned problems, and an object thereof is to provide a halogen-free flame retardant composition containing no antimony, phosphorus and phosphorus compounds at all, a halogen-free flame-retardant resin composition of environmental type ideal for disaster prevention made of the flame retardant composition, which causes little carbon monoxide (CO) during combustion while having high flame retardance, and molded products, electric wires, cables, fiber or fiber post-processed products made of the resin composition.
In order to achieve the above-mentioned object, the inventors of the present invention have made earnest studies, and as a result, found that a mixture of a specific resin having an average particle diameter of not more than 1000 μm and metal hydrate brings high flame retardance and allows harmful carbon monoxide to be restrained from occurring. The present invention has been completed.
That is, the present invention provides a flame retardant composition comprising a mixture of (A) a resin having an average particle diameter of not more than 1000 μm selected from wholly aromatic polyamide, polyimide, polyamideimide, a copolymer of the wholly aromatic polyamide, the polyimide or the polyamideimide or a mixture of the above mentioned polymers and (B) a metal hydrate.
Also, the present invention provides a flame-retardant resin composition containing the above-mentioned flame retardant composition in an amount of 50 to 200 parts by mass with respect to 100 parts by mass of a thermoplastic resin or a thermosetting resin.
Also, the present invention provides molded products, electric wires, cables, fiber or fiber post-processed products made of the above-mentioned flame-retardant resin composition.
The present invention can provide a flame-retardant resin composition which is flame-retardant, high in an LOI value and slight in the occurrence amount of harmful CO. In addition, molded products to be obtained have no anisotropy and favorable appearance.
The use of a specific resin having an average particle diameter of not more than 1000 μm together with metal hydrate develops high synergistic effect, which has not been capable of being produced in each single system. Therefore, products of environmental type ideal for disaster prevention, which are halogen-free flame-retardant materials, are slow in spreading fire during incipient fire and restrain CO from occurring while having high flame retardance, can particularly be realized in the case of being made into molded products, electric wires, cables and fiber.
A flame retardant composition, a flame-retardant resin composition, molded products, electric wires, cables, fiber or fiber post-processed products of the present invention are conceived to be halogen-free flame-retardant materials of real environmental type, which are free from environmental burden such as phosphoric acid elution during use and abandonment, by reason of containing no phosphorus at all to bring no fear that phosphoric acid is eluted by water under the use environment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Resin having an average particle diameter of not more than 1000 μm as an (A) component used in the present invention forms a char layer on the surface of molded products and has the function of restraining spreading fire and fuming during incipient fire. The resin is at least one kind selected from wholly aromatic polyamide, polyimide, polyamideimide, a copolymer thereof or a mixture thereof; these resins may be used singly or in proper combination of not less than two kinds. When the average particle diameter of the above-mentioned resin exceeds 1000 μm, a resin in a flame retardant composition is not melted at molding temperature of a thermoplastic resin in the case of blending the flame retardant composition with the thermoplastic resin, so that resin pellets can not be produced. The average particle diameter of the resin in a flame retardant composition is preferably not more than 800 μm, more preferably not more than 300 μm.
These resin particles can also be obtained by pulverizing films, sheets and molded products made of the above-mentioned resin. Pulverizing means and pulverizing methods are not particularly limited but known methods can be performed.
Here, a wholly aromatic polyamide is such that at least not less than 85 mol %, preferably 100 mol %, of amide bonds are obtained from an aromatic diamine component and an aromatic dicarboxylic acid component. Specific examples thereof include wholly aromatic polyamides such as polyparaphenylene terephthalamide, polymetaphenylene terephthalamide, polymetaphenylene isophthalamide and polyparaphenylene isophthalamide; aromatic polyamides in which aromatic diamine is bonded by groups such as ether group and contains two phenyl groups, such as 3,3′-oxydiphenylene diamine and 3,4′-oxydiphenylene diamine; or copolymers of the above-mentioned aromatic polyamides, such as a poly-3,3′-oxydiphenylene terephthalamide/polyparaphenylene terephthalamide copolymer and a poly-3,4′-oxydiphenylene terephthalamide/polyparaphenylene terephthalamide copolymer.
A polyimide is a resin produced by condensation polymerization of aromatic tetracarboxylic dianhydride and diamine, or the like, and is excellent in heat resistance, chemical resistance and electrical insulating properties. The polyimide may be either a thermosetting polyimide or a thermoplastic polyimide, and yet a thermoplastic polyimide is preferable in term of formation of a char layer stable in molding.
A polyamideimide is a resin produced by reaction of trimellitic anhydride and diisocyanate, or trimellitic chloride anhydride and diamine, and is so excellent in heat resistance as to be capable of being subjected to thermoforming, and is excellent in chemical resistance and electrical insulating properties.
The metal hydrate as a (B) component has the function of allowing flame retardance and tracking resistance. Examples of metal hydrate include magnesium hydroxide, aluminum hydroxide, calcium hydroxide, and the like. These metal hydrates can be used in the shape of powdery and granular material, flake or fiber. Among them, magnesium hydroxide or aluminum hydroxide is preferable and aluminum hydroxide is particularly preferable. The metal hydrates may be used singly or in proper combination of not less than two kinds.
In the present invention, it is important to blend a mixture of a specific resin having an average particle diameter of not more than 1000 μm as the (A) component and (B) metal hydrate, and in the case of blending either of them singly, flame retardance is insufficiently improved and the maintenance of shrink resistance is not intended. The mass ratio of the (A) component/the (B) component is preferably 1/99 to 80/20, more preferably 2/98 to 50/50. When the ratio of the (A) component is less than 1, flame retardance is deteriorated and the occurrence amount of CO during combustion is increased. On the other hand, when the ratio of the (A) component exceeds 80, moldability during blending a resin is deteriorated.
In a flame retardant composition of the present invention, plasticizer, pigment, filler, foaming agent, crystalline nucleating agent, lubricant, processing aid, antistatic agent, antioxidant, ultraviolet absorbing agent, heat stabilizer and surface-active agent can be blended as required in addition to the above-mentioned (A) and (B) components in a range of not deteriorating the object of the present invention.
Examples of the thermoplastic resin to be used in the present invention include polyolefins such as polyethylene, polypropylene and polybutylene; methacrylates such as polymethyl methacrylate; polystyrenes such as polystyrene, ABS resin and AS resin; polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate, polyethylene naphthalate (PEN) and poly-1,4-cyclohexyldimethylene terephthalate (PCT); polyamides selected from nylons and nylon copolymers such as polycaproamide (nylon 6), polyhexamethylene adipamide (nylon 66), polyhexamethylene sebacamide (nylon 610), polyhexamethylene dodecamide (nylon 612), polydodecaneamide (nylon 12), polyhexamethylene terephthalamide (nylon 6T), polyhexamethylene isophthalamide (nylon 6I), polycaproamide/polyhexamethylene terephthalamide copolymer (nylon 6/6T), polyhexamethylene adipamide/polyhexamethylene terephthalamide copolymer (nylon 66/6T) and polyhexamethylene adipamide/polyhexamethylene isophthalamide copolymer (nylon 66/6I); polyvinyl chlorides; polyoxymethylenes (POM); polycarbonates (PC); polyphenylene sulfides (PPS); modified polyphenylene ethers (PPE); polyetherimides (PEI); polysulfones (PSF); polyethersulfones (PES); polyketones; polyether nitriles (PEN); polyether ketones (PEK); polyether ether ketones (PEEK); polyether ketone ketones (PEKK); polyimides (PI); polyamideimides (PAI); fluororesins; modified resins such that these resins are modified, or mixtures of these resins with each other or other resins.
Examples of the thermosetting resin include phenols, epoxy resins, epoxy acrylates, polyesters (such as unsaturated polyesters), polyurethanes, diallyl phthalates, silicone resins, vinyl esters, melamines, polyimides, polybismaleimide triazine resins (BT resins), cyanates (such as cyanate esters), copolymers thereof, modified resins such that these resins are modified, or mixtures of these resins with each other or other resins.
With regard to the blending ratio of a flame retardant composition to a thermoplastic resin or thermosetting resin, a flame retardant composition is preferably contained in an amount of 50 to 200 parts by mass, more preferably 60 to 150 parts by mass, with respect to 100 parts by mass of a thermoplastic resin or thermosetting resin. The content of the flame retardant composition of not less than 50 parts by mass allows high flame retardance, while the content of not more than 200 parts by mass does not cause flowability necessary for molding to be lost. With regard to the resin composition containing a flame retardant composition of the present invention by the above-mentioned amount, carbon monoxide (CO) concentration in the whole combustion gas by a cone calorimeter in conformity to ISO 5660 becomes not more than 0.01 (g/kg).
In a flame-retardant resin composition of the present invention, plasticizer, pigment, filler, foaming agent, crystalline nucleating agent, lubricant, processing aid, antistatic agent, antioxidant, ultraviolet absorbing agent, heat stabilizer and surface-active agent can be blended as required in addition to the above-mentioned flame retardant composition and thermoplastic or thermosetting resin in a range of not deteriorating the object of the present invention. Also, reinforced fibers such as aramid fiber, glass fiber, carbon fiber, ceramic fiber and fluorine fiber, and fillers such as silica, talc, clay, alumina, mica and vermiculite may be blended unless the object of the present invention is deteriorated.
A flame retardant composition of the present invention can be obtained by dry-blending the above-mentioned resin having an average particle diameter of not more than 1000 μm and metal hydrate.
With regard to a flame-retardant resin composition, shapes of pellet, chopped strand or granule, and a minor axis of 0.1 to 5 mm and a major axis of 0.3 to 10 mm are appropriate for injection molding, extrusion molding, blow molding and film molding. Alternatively, masterbatch in which a flame retardant composition of the present invention is incorporated into a resin at high concentration can also be produced.
A flame-retardant resin composition of the present invention is subject to various kinds of molding such as injection molding, extrusion molding, blow molding, film molding, press molding and pultrusion, to which composition secondary fabrication is further added as required to obtain molded products, electric wires and cables. The above-mentioned addition agents such as plasticizer is blended as required with the molded products, to which desirable properties are also allowed.
Alternatively, a flame-retardant resin composition of the present invention is subject to various kinds of spinning steps such as melt spinning and liquid crystal spinning, to which composition secondary fabrication is further added as required to obtain fiber, and additionally desired post-processing is performed therefor as required to allow fiber post-processed products.
Molded products, electric wires, cables, fiber or fiber post-processed products made of a flame-retardant resin composition of the present invention can be used for all applications in which high flame retardance and electrical characteristics are requested, and are appropriately utilized for insulating materials for electricity.
Molded products, fiber or fiber post-processed products made of a flame-retardant resin composition of the present invention are appropriately utilized also for, beginning with electric wires and cables, electrical and electronic parts such as connector, plug, arm, socket, cap, rotor and motor parts, machine components such as a plate, bearing, gear, cam, pipe and barstock, AV and OA equipment parts such as a speaker cone, bush, washer, guide, pulley, facing, insulator, rod, bearing cage, cabinet, bearing, rod, guide, gear, parts and members for building, stopper for fittings and building materials, guide, sash roller, angle; additionally, helmet, plastic model parts, core materials for tire, reel parts for fishing outfit, seals, packings and gland packing.
EXAMPLES
The present invention is hereinafter described more specifically by using Examples and yet is not limited to only the following Examples. Each physical property value in the following examples and comparative examples is measured as described below.
(LOI Value)
LOI value was measured in accordance with JIS L 1091 method.
(Flame Retardance)
Flame retardance was evaluated with a test piece (bar sample) having a thickness of 1/32 inch in conformity to the vertical flame test prescribed in UL94 of US. UL Standard.
(CO Occurrence Amount)
CO concentration (%) in the whole combustion gas was measured when a test piece of a length of 100 mm×a side of 100 mm×a thickness of 3 mm was heated at a heat intensity of 50 kW/m 2 for 15 minutes in conformity to ISO 5660 by using a cone calorimeter III apparatus manufactured by Toyo Seiki Seisaku-sho, Ltd.
(Average Particle Diameter)
Average particle diameter was measured by a laser analytical scattering method.
Example 1
3% by mass of a polyparaphenylene terephthalamide (PPTA) having an average particle diameter of 200 μm and 97% by mass of aluminum hydroxide (Al(OH) 3 : 99.5% by mass, Na 2 O: 0.25% by mass) having an average particle diameter of 10 μm were dry-blended at 600 rpm for 1 minute by a Henschel mixer. 50% by mass of the blend and 50% by mass of a linear low-density polyethylene (LLDPE) (trade name: NEOZEX2540R prime polymer) were melt-kneaded at a cylinder temperature of 280° C. and a screw speed of 220 rpm by a twin-screw extruder having a screw diameter of 45 mm manufactured by Toshiba Machine Co., Ltd. to form strand-shaped gut. The formed gut was cooled by a cooling bath and thereafter granulated by a cutter to obtain pellets. The obtained pellets were molded at a barrel temperature of 280° C. by using an injection molding machine IS100 manufactured by Toshiba Machine Co., Ltd. to obtain a molded product. The results of evaluating the molded product by the above-mentioned methods are shown in Table 1. Consequently, it is confirmed that flame retardance of the molded product subject to injection molding is remarkably improved.
Example 2
3% by mass of a polyimide having an average particle diameter of 60 μm and 97% by mass of aluminum hydroxide (Al (OH) 3 : 99.5% by mass, Na 2 O: 0.25% by mass) having an average particle diameter of 10 μm were dry-blended at 600 rpm for 1 minute by a Henschel mixer. 50% by mass of the blend and 50% by mass of a linear low-density polyethylene (LLDPE) (trade name: NEOZEX2540R prime polymer) were blended to obtain pellets in the same manner as in Example 1, which obtained pellets were subject to injection molding to obtain a molded product. The results of evaluating the molded product by the above-mentioned methods are shown in Table 1. Consequently, it is confirmed that flame retardance of the molded product subject to injection molding is remarkably improved.
Comparative Example 1
3% by mass of a polyimide having an average particle diameter of 5000 μm and 97% by mass of aluminum hydroxide (Al(OH) 2 : 99.5% by mass, Na 2 O: 0.25% by mass) having an average particle diameter of 10 μm shown in Table 1 were dry-blended at 600 rpm for 1 minute by a Henschel mixer. 50% by mass of the blend and 50% by mass of a linear low-density polyethylene (LLDPE) (trade name: NEOZEX2540R prime polymer) were extruded in the same manner as in Example 1, and then surge and vent-up were caused, so that pellets could not be obtained.
Comparative Example 2
3% by mass of a polyphenylene sulfide (PPS) having an average particle diameter of 100 μm and 97% by mass of aluminum hydroxide (Al(OH) 2 : 99.5% by mass, Na 2 O: 0.25% by mass) having an average particle diameter of 10 μm shown in Table 1 were dry-blended at 600 rpm for 1 minute by a Henschel mixer. 50% by mass of the blend and 50% by mass of a linear low-density polyethylene (LLDPE) (trade name: NEOZEX2540R prime polymer) were blended to obtain pellets in the same manner as in Example 1, which obtained pellets were subject to injection molding to obtain a molded product. The results of evaluating the molded product by the above-mentioned methods are shown in Table 1. Consequently, flame retardance is deteriorated and CO occurrence amount is increased.
Comparative Example 3
50% by mass of aluminum hydroxide (Al(OH) 2 : 99.5% by mass, Na 2 O: 0.25% by mass) having an average particle diameter of 10 μm and 50% by mass of a linear low-density polyethylene (LLDPE) (trade name: NEOZEX2540R prime polymer) shown in Table 1 were blended to obtain pellets in the same manner as in Example 1, which obtained pellets were subject to injection molding to obtain a molded product. The results of evaluating the molded product by the above-mentioned methods are shown in Table 1. Consequently, flame retardance was deteriorated.
Comparative Example 4
50% by mass of a polyimide having an average particle diameter of 60 μm and 50% by mass of a linear low-density polyethylene (LLDPE) (trade name: NEOZEX prime polymer) shown in Table 1 were blended and extruded in the same manner as in Example 1, and attempted to be subject to injection molding but yet a predetermined product could not be obtained due to nozzle clogging.
The results in Table 1 showed that the case of only resin powder and only aluminum hydroxide did not bring a flame retardant satisfying both moldability and flame retardance. The case where the melting point of a resin blended with a flame retardant was low (PPS: 320° C.) brought poor flame retardance, and the case where resin particle diameter was too large brought poor molding. In examples of the present invention, the effects were excellent in flame retardance, LOI value and CO occurrence amount.
TABLE 1
particle
dia-
Ex-
Comparative
meter
amples
Examples
components
(μm)
1
2
1
2
3
4
formulations
aromatic
100
3
polyamide
polyimide
60
3
100
polyimide
3000
3
PPS
50
3
aluminum
10
97
97
97
97
100
hydroxide
LLDPE
100
100
100
100
100
100
evaluations
flame
V0
V0
—
HB
HB
—
retardance
(UL94)
LOI
33
32
—
25
22
—
CO
not
not
—
5.3
0.5
—
occurr-
more
more
ence
than
than
amount
0.01
0.01
(g/kg)
unit: part by mass
A flame retardant composition for a resin of the present invention is a halogen-free flame retardant, so that the blending with various kinds of resins allows flame retardance, and a flame-retardant resin composition to be obtained has excellent flame retardance and low smoking, so that the development into electrical applications around high voltage is greatly expected, such as electric wires, cables, transformers and resistors.
|
To provide a halogen-free flame retardant composition containing no antimony, phosphorus and phosphorus compounds at all, a non-halogen flame-retardant resin composition of environmental type ideal for disaster prevention made of the flame retardant composition, which causes little carbon monoxide (CO) during combustion while having high flame retardance, and molded products, electric wires, cables, fiber or fiber post-processed products made of the resin composition. The flame retardant composition comprises a mixture of (A) a resin having an average particle diameter of not more than 1000 μm selected from wholly aromatic polyamide, polyimide, polyamideimide, a copolymer of the wholly aromatic polyamide, the polyimide or the polyamideimide or a mixture of the above mentioned polymers and (B) a metal hydrate. The flame-retardant resin composition contains 50 to 200 parts by mass of the flame retardant composition to 100 parts by mass of a thermoplastic resin or a thermosetting resin.
| 3
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This patent application claims priority to Japanese Patent Application No. 190862/2008 that was filed on Jul. 24, 2008, Japanese Patent Application No. 270294/2008 that was filed on Oct. 20, 2008 and Japanese Patent Application No. 20591/2009 that was filed on Jan. 30, 2009, and the entire disclosed contents of all are hereby incorporated as part of the disclosure of the present application by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to a pyripyropene A biosynthetic gene.
[0004] 2. Background Art
[0005] As disclosed in Japanese Patent Laid-Open Publication No. 360895/1992 (Patent Document 1) and Journal of Antibiotics (1993), 46 (7), 1168-9 (Non-patent Document 1), pyripyropene A has an inhibitory activity against ACAT (acyl CoA cholesterol acyltransferase). Application thereof to treatment of diseases caused by cholesterol accumulation or the like is expected.
[0006] Additionally, in Journal of Synthetic Organic Chemistry, Japan (1998), Vol. 56, No. 6, 478-488 (Non-patent Document 2), WO94/09147 (Patent Document 2), Japanese Patent Laid-Open Publication No. 184158/1994 (Patent Document 3), Japanese Patent Laid-Open Publication No. 239385/1996 (Patent Document 4), Japanese Patent Laid-Open Publication No. 259569/1996 (Patent Document 5), Japanese Patent Laid-Open Publication No. 269062/1996 (Patent Document 6), Japanese Patent Laid-Open Publication No. 269063/1996 (Patent Document 7), Japanese Patent Laid-Open Publication No. 269064/1996 (Patent Document 8), Japanese Patent Laid-Open Publication No. 269065/1996 (Patent Document 9), Japanese Patent Laid-Open Publication No. 269066/1996 (Patent Document 10), Japanese Patent Laid-Open Publication No. 291164/1996 (Patent Document 11) and Journal of Antibiotics (1997), 50 (3), 229-36 (Non-patent Document 3), pyripyropene analogs and derivatives, as well as ACAT inhibitory activities thereof have been disclosed.
[0007] Further, Applied and Environmental Microbiology (1995), 61 (12), 4429-35 (Non-patent Document 4) has disclosed that pyripyropene A has an insecticidal activity against Helicoverpa armigera larva. Still further, WO2004/060065 (Patent Document 12) has disclosed that pyripyropene A has insecticidal activities against Diamondback moth larva and Tenebrio molitor.
[0008] In addition, WO2006/129714 (Patent Document 13) and WO2008/066153 (Patent Document 14) have disclosed that pyripyropene analogs have insecticidal activities against aphids.
[0009] Furthermore, as a pyripyropene A-producing bacterium, Aspergillus fumigatus FO-1289 strain is disclosed in Japanese Patent Laid-Open Publication No. 360895/1992 (Patent Document 1); Eupenicillium reticulosporum NRRL-3446 strain is in Applied and Environmental Microbiology (1995), 61 (12), 4429-35 (Non-patent Document 4); and Penicillium griseofulvum F1959 strain is in WO2004/060065 (Patent Document 12); and Penicillium coprobium PF1169 strain is in Journal of Technical Disclosure 500997/2008 (Patent Document 15).
[0010] Also, as a biosynthetic route of pyripyropene A, Journal of Organic Chemistry (1996), 61, 882-886 (Non-patent Document 5) and Chemical Review (2005), 105, 4559-4580 (Non-patent Document 6) have disclosed a putative biosynthetic route in Aspergillus fumigatus FO-1289 strain. These documents have disclosed that, in Aspergillus fumigatus FO-1289 strain, partial structures individually synthesized by polyketide synthase and prenyltransferase are linked to synthesize pyripyropene A by a cyclase.
PRIOR ART REFERENCES
Patent Documents
[0000]
[Patent Document 1] Japanese Patent Laid-Open Publication No. 360895/1992
[Patent Document 2] WO94/09147
[Patent Document 3] Japanese Patent Laid-Open Publication No. 184158/1994
[Patent Document 4] Japanese Patent Laid-Open Publication No. 239385/1996
[Patent Document 5] Japanese Patent Laid-Open Publication No. 259569/1996
[Patent Document 6] Japanese Patent Laid-Open Publication No. 269062/1996
[Patent Document 7] Japanese Patent Laid-Open Publication No. 269063/1996
[Patent Document 8] Japanese Patent Laid-Open Publication No. 269064/1996
[Patent Document 9] Japanese Patent Laid-Open Publication No. 269065/1996
[Patent Document 10] Japanese Patent Laid-Open Publication No. 269066/1996
[Patent Document 11] Japanese Patent Laid-Open Publication No. 291164/1996
[Patent Document 12] WO2004/060065
[Patent Document 13] WO2006/129714
[Patent Document 14] WO2008/066153
[Patent Document 15] Journal of Technical Disclosure 500997/2008
Non-Patent Documents
[0000]
[Non-patent Document 1] Journal of Antibiotics (1993), 46 (7), 1168-9
[Non-patent Document 2] Journal of Synthetic Organic Chemistry, Japan (1998), Vol. 56, No. 6, 478-488
[Non-patent Document 3] Journal of Antibiotics (1997), 50 (3), 229-36
[Non-patent Document 4] Applied and Environmental Microbiology (1995), 61 (12), 4429-35
[Non-patent Document 5] Journal of Organic Chemistry (1996), 61, 882-886
[Non-patent Document 6] Chemical Review (2005), 105, 4559-4580
SUMMARY OF THE INVENTION
[0032] The present inventors have now found out a nucleotide sequence encoding at least one polypeptide involved in biosynthesis of pyripyropene A. The present invention has been made based on such finding.
[0033] Accordingly, an object of the present invention is to provide an isolated novel polynucleotide having a nucleotide sequence encoding at least one polypeptide involved in biosynthesis of pyripyropene A, a recombinant vector comprising the polynucleotide, and a transformant comprising the polynucleotide.
[0034] Further, according to one embodiment of the present invention, an isolated polynucleotide which is
[0035] (a) a polynucleotide having a nucleotide sequence of SEQ ID NO:266,
[0036] (b) a polynucleotide having a nucleotide sequence which is capable of hybridizing with the nucleotide sequence of SEQ ID NO:266 under stringent conditions, or
[0037] (c) a polynucleotide having a polynucleotide sequence encoding at least one amino acid sequence selected from SEQ ID NOs:267 to 274 or a substantially equivalent amino acid sequence thereto; is provided.
[0038] Also, according to another embodiment of the present invention, an isolated polynucleotide which has at least one nucleotide sequence selected from the nucleotide sequence in any of (1) or (2) below:
[0000] (1) a nucleotide sequence in any of (a) to (h) below:
[0039] (a) a nucleotide sequence from 3342 to 5158 of a nucleotide sequence shown in SEQ ID NO:266,
[0040] (b) a nucleotide sequence from 5382 to 12777 of a nucleotide sequence shown in SEQ ID NO:266,
[0041] (c) a nucleotide sequence from 13266 to 15144 of a nucleotide sequence shown in SEQ ID NO:266,
[0042] (d) a nucleotide sequence from 16220 to 18018 of a nucleotide sequence shown in SEQ ID NO:266,
[0043] (e) a nucleotide sequence from 18506 to 19296 of a nucleotide sequence shown in SEQ ID NO:266,
[0044] (f) a nucleotide sequence from 19779 to 21389 of a nucleotide sequence shown in SEQ ID NO:266,
[0045] (g) a nucleotide sequence from 21793 to 22877 of a nucleotide sequence shown in SEQ ID NO:266,
[0046] (h) a nucleotide sequence from 23205 to 24773 of a nucleotide sequence shown in SEQ ID NO:266;
[0000] (2) a nucleotide sequence which is capable of hybridizing with a nucleotide sequence in (1) under stringent conditions; is provided.
[0047] Further, according to another embodiment of the present invention, a polynucleotide encoding at least one polypeptide involved in biosynthesis of pyripyropene A is provided.
[0048] In addition, according to another embodiment of the present invention, a polynucleotide encoding a polypeptide having any one or more activities of polyketide synthase activity, prenyltransferase activity, hydroxylase activity, acetyltransferase activity or adenylate synthetase activity is provided.
[0049] Still further, according to another embodiment of the present invention, a polynucleotide which is derived from Penicillium coprobium PF1169 strain is provided.
[0050] Additionally, according to another embodiment of the present invention, a recombinant vector comprising the above-mentioned polynucleotide is provided.
[0051] Still further, according to another embodiment of the present invention, a transformant comprising the above-mentioned polynucleotide is provided.
[0052] In addition, according to one embodiment of the present invention, a method for producing a pyripyropene A precursor, characterized by culturing a transformant in which a polynucleotide having nucleotide sequence of the above-mentioned (c) or (d) is incorporated simultaneously or separately, and isolating the pyripyropene A precursor from pyripyropene E represented by the following formula is provided:
[0000]
[0053] Still further, a production method wherein the above-mentioned pyripyropene A precursor is one represented by the following formula (I) is provided:
[0000]
[0054] Also, a method for producing a pyripyropene A precursor characterized by culturing the above-mentioned transformant and isolating the pyripyropene A precursor from pyripyropene O represented by the following formula is provided:
[0000]
[0055] Still further, a production method wherein the above-mentioned pyripyropene A precursor is a compound represented by the following formula (II) is provided:
[0000]
[0056] According to one embodiment of the present invention, production of a novel pyripyropene analog, improvement of productivity of a pyripyropene A-producing bacterium, production of a novel insecticidal agent for microorganisms, creation of a novel plant resistant to insect pests or the like are provided.
BRIEF DESCRIPTION OF DRAWINGS
[0057] FIG. 1 shows an electrophoresis pattern of PCR products by agarose gel. For the electrophoresis, the PCR products amplified using the following primers were used: M: molecular weight marker (100 bp ladder), lane 1: primers of SEQ ID NOs:1 and 2, lane 2: primers of SEQ ID NOs:239 and 240, lane 3: primers of SEQ ID NOs:237 and 238, lane 4: primers of SEQ ID NOs:241 and 242, lane 5: primers of SEQ ID NOs:247 and 248, lane 6: primers of SEQ ID NOs:251 and 252, lane 7: primers of SEQ ID NOs:245 and 246, lane 8: primers of SEQ ID NOs:243 and 244, lane 9: primers of SEQ ID NOs:249 and 250, lane 10: primers of SEQ ID NOs:235 and 236, lane 11: primers of SEQ ID NOs:233 and 234, lane 12: primers of SEQ ID NOs:227 and 228, lane 13: primers of SEQ ID NOs:229 and 230, lane 14: primers of SEQ ID NOs:231 and 232.
[0058] FIG. 2 Similarly to FIG. 1 , FIG. 2 shows an electrophoresis pattern of PCR products by agarose gel. For the electrophoresis, the PCR products amplified using the following primers were used: M: molecular weight marker (100 bp ladder), lane 1: primers of SEQ ID NOs:253 and 254, lane 2: primers of SEQ ID NOs:257 and 258, lane 3: primers of SEQ ID NOs:259 and 260, lane 4: primers of SEQ ID NOs:255 and 256, lane 5: primers of SEQ ID NOs:261 and 262.
[0059] FIG. 3 Similarly to FIG. 1 , FIG. 3 shows an electrophoresis pattern of PCR products by agarose gel. For the electrophoresis, the PCR products amplified using the following primers were used: lane 1: molecular weight marker (100 bp ladder), lane 2: primers of SEQ ID NOs:264 and 265 (400 bp amplified fragment).
[0060] FIG. 4 shows the plasmid map of pUSA.
[0061] FIG. 5 shows the plasmid map of pPP2.
[0062] FIG. 6 shows a scheme of P450-2 cDNA amplification.
[0063] FIG. 7 shows the plasmid map of pPP3.
[0064] FIG. 8 shows 1 H-NMR spectrum of pyripyropene E in deuterated acetonitrile.
[0065] FIG. 9 shows 1 H-NMR spectrum in deuterated acetonitrile of a product of the culture of Aspergillus oryzae transformed with plasmid pPP2.
[0066] FIG. 10 shows 1 H-NMR spectrum of pyripyropene O in deuterated acetonitrile.
[0067] FIG. 11 shows 1 H-NMR spectrum in deuterated acetonitrile of a product of the culture of Aspergillus oryzae transformed with plasmid pPP3.
DETAILED DESCRIPTION OF THE INVENTION
Deposition of Microorganisms
[0068] Escherichia coli ( Escherichia coli EPI300™-T1®) transformed with plasmid pCC1-PP1 has been deposited with International Patent Organism Depositary, National Institute of Advanced Industrial Science and Technology (Address: AIST Tsukuba Central 6, 1-1-1 Higashi, Tsukuba, Ibaraki, Japan, 305-8566), under accession No. FERM BP-11133 (converted from domestic deposition under accession No. FERM P-21704) (identification reference by the depositors: Escherichia coli EPI300™-T1®/pCC1-PP1) as of Oct. 9, 2008 (original deposition date).
[0069] Aspergillus oryzae transformed with plasmid pPP2 has been deposited with International Patent Organism Depositary, National Institute of Advanced Industrial Science and Technology (Address: AIST Tsukuba Central 6, 1-1-1 Higashi, Tsukuba, Ibaraki, Japan, 305-8566), under accession No. FERM BP-11137 (identification reference by the depositors: Aspergillus oryzae PP2-1) as of Jun. 23, 2009.
[0070] Aspergillus oryzae transformed with plasmid pPP3 has been deposited with International Patent Organism Depositary, National Institute of Advanced Industrial Science and Technology (Address: AIST Tsukuba Central 6, 1-1-1 Higashi, Tsukuba, Ibaraki, Japan, 305-8566), under accession No. FERM BP-11141 (identification reference by the depositors: Aspergillus oryzae PP3-2) as of Jul. 3, 2009.
[0071] Isolated Polynucleotide
[0072] The present invention is an isolated polynucleotide. The isolated polynucleotide according to the present invention is (a) a polynucleotide having the nucleotide sequence of SEQ ID NO:266; (b) a polynucleotide having a nucleotide sequence which is capable of hybridizing with the nucleotide sequence of SEQ ID NO:266 under stringent conditions, or (c) a polynucleotide having a polynucleotide sequence encoding at least one amino acid sequence selected from SEQ ID NOs:267 to 274 or a substantially equivalent amino acid sequence thereto. The above-mentioned isolated polynucleotide preferably has a nucleotide sequence encoding at least one polypeptide which has an enzyme activity involved in biosynthesis of pyripyropene A.
[0073] In the present invention, “a substantially equivalent amino acid sequence” means an amino acid sequence which does not affect an activity of a polypeptide despite the fact that one or more amino acids are altered by substitution, deletion, addition or insertion. The number of the altered amino acid residues is preferably 1 to 40 residues, more preferably 1 to several residues, still more preferably 1 to 8 residues, most preferably 1 to 4 residues.
[0074] Further, an example of the alteration which does not affect the activity includes conservative substitution. The term, “conservative substitution” means substitution of one or more amino acid residues with other chemically similar amino acid residues such that the activity of a polypeptide is not substantially altered. Examples thereof include cases where a certain hydrophobic amino acid residue is substituted with another hydrophobic amino acid residue and cases where a certain polar amino acid residue is substituted with another polar amino acid residue having the same charges. Functionally similar amino acids capable of such a substitution are known in the art for each amino acid. Concretely, examples of non-polar (hydrophobic) amino acids include alanine, valine, isoleucine, leucine, proline, tryptophan, phenylalanine, methionine and the like. Examples of polar (neutral) amino acids include glycine, serine, threonine, tyrosine, glutamine, asparagine, cysteine and the like. Examples of positively charged (basic) amino acids include arginine, histidine, lysine and the like. Examples of negatively charged (acidic) amino acids include aspartic acid, glutamic acid and the like.
[0075] Also, the isolated polynucleotide of the present invention may be a polynucleotide having at least one nucleotide sequence selected from the nucleotide sequence in any of (1) or (2) below:
[0076] (1) a polynucleotide sequence in any of (a) to (h) below:
[0077] (a) a nucleotide sequence from 3342 to 5158 of a nucleotide sequence shown in SEQ ID NO:266,
[0078] (b) a nucleotide sequence from 5382 to 12777 of a nucleotide sequence shown in SEQ ID NO:266,
[0079] (c) a nucleotide sequence from 13266 to 15144 of a nucleotide sequence shown in SEQ ID NO:266,
[0080] (d) a nucleotide sequence from 16220 to 18018 of a nucleotide sequence shown in SEQ ID NO:266,
[0081] (e) a nucleotide sequence from 18506 to 19296 of a nucleotide sequence shown in SEQ ID NO:266,
[0082] (f) a nucleotide sequence from 19779 to 21389 of a nucleotide sequence shown in SEQ ID NO:266,
[0083] (g) a nucleotide sequence from 21793 to 22877 of a nucleotide sequence shown in SEQ ID NO:266,
[0084] (h) a nucleotide sequence from 23205 to 24773 of a nucleotide sequence shown in SEQ ID NO:266;
[0085] (2) a nucleotide sequence which is capable of hybridizing with a nucleotide sequence in (1) under stringent conditions.
[0086] A polynucleotide having at least one nucleotide sequence selected from the nucleotide sequence in any of the above-mentioned (1) or (2) preferably encodes at least one polypeptide having an enzyme activity involved in biosynthesis of pyripyropene A.
[0087] The term, “stringent conditions” in the present invention means conditions where a washing operation of membranes after hybridization is carried out at high temperatures in a solution with low salt concentrations, for example, conditions of washing in a solution with 2×SSC concentration (1×SSC: 15 mM trisodium citrate, 150 mM sodium chloride) and 0.5% SDS at 60° C. for 20 minutes.
[0088] The polynucleotide having at least one nucleotide sequence selected from the nucleotide sequence in any of the above-mentioned (1) or (2) according to the present invention is one encoding a polypeptide having any one or more activities of polyketide synthase activity, prenyltransferase activity, hydroxylase activity, acetyltransferase activity or adenylate synthetase activity; and, in particular, one encoding a polypeptide having the hydroxylase activity.
[0089] Further, according to one embodiment of the present invention, the above-mentioned polynucleotide is one encoding a polypeptide having an activity to hydroxylate the 7-position and/or 13-position of the above-mentioned pyripyropene E or O, or one encoding a polypeptide having an activity to hydroxylate the 11-position of the above-mentioned pyripyropene E.
[0090] Obtainment of Isolated Polynucleotide
[0091] The method for obtaining the isolated polynucleotide of the present invention is not particularly restricted. For instance, the polynucleotide can be isolated from Penicillium coprobium PF1169 strain or filamentous bacterium by the following method.
[0092] Based on a homology sequence obtained by the method of Example 9 below or the like, primers capable of specifically amplifying a polyketide synthase gene are synthesized. PCR is carried out for a fosmid genomic library of Penicillium coprobium PF1169 strain which is separately prepared, followed by colony hybridization. A recombinant vector is thereby obtained and the base sequence of an inserted DNA thereof is determined.
[0093] Also, based on the homology sequence obtained by the method of Example 9 below or the like, primers capable of specifically amplifying a prenyltransferase gene are synthesized. Further, the base sequence of an inserted DNA is determined in the same manner as above.
[0094] Further, based on the homology sequence obtained by the method of Example 9 below or the like, primers capable of specifically amplifying any one or both of a polyketide synthase gene and prenyltransferase gene are synthesized. Further, the base sequence of an inserted DNA is determined in the same manner as above.
[0095] In addition, based on the homology sequence of at least one nucleotide sequence selected from SEQ ID NO:266 and the nucleotide sequence in any of the above-mentioned (1) or (2) according to the present invention, primers capable of specifically amplifying any one or more of a polyketide synthase gene, prenyltransferase gene, hydroxylase gene, acetyltransferase gene or adenylate synthetase gene, preferably the hydroxylase gene are synthesized. Further, the base sequence of an inserted DNA is determined in the same manner as above.
[0096] Still further, based on an amino acid sequence conserved among various filamentous bacterium polyketide synthases, degenerate primers for amplification were synthesized and the base sequence of an inserted DNA is determined.
[0097] Transformant
[0098] In general, examples of a method for improving productivity of a secondary metabolism product by gene recombination include improving expression of a gene encoding a protein catalyzing a biosynthetic reaction which is a rate limiting reaction, improving expression of or disrupting a gene regulating expression of a biosynthetic gene, blocking an unnecessary secondary metabolism system, and the like. Therefore, specifying the biosynthetic gene makes it possible to improve the productivity of the secondary metabolism product by ligating the gene to an appropriate vector and introducing the vector into a production bacterium.
[0099] Meanwhile, in order to create a novel active substance by gene recombination, domain alteration of polyketide synthase [Ikada and Ohmura, “PROTEIN, NUCLEIC ACID AND ENZYME” Vol. 43, p. 1265-1277, 1998], [Carreras, C. W. and Santi, D. V., “Current Opinion in Biotechnology”, (UK), 1998, Vol. 9, p. 403-411], [Hutchinson, C. R., “Current Opinion in Microbiology”, (UK), 1998, Vol. 1, p. 319-329], [Katz, L. and McDaniel, R., “Medicinal Research Reviews”, (USA), 1999, Vol. 19, p. 543-558]; disruption of a biosynthetic gene; introduction of a modification enzyme gene from other organisms [Hutchinson, C. R., “Bio/Technology”, (USA), 1994, Vol. 12, p. 375-380]; and the like are carried out. Thus, specifying the biosynthetic gene makes it possible to create the novel active substance by ligating the gene to an appropriate vector and introducing the vector into a bacterium producing a secondary metabolism product.
[0100] Therefore, pyripyropene A can be produced or productivity thereof can be improved by ligating the isolated polynucleotide according to the present invention to the appropriate vector, introducing the vector into a host, expressing it, enhancing expression thereof, or carrying out gene disruption of part of the isolated polynucleotide using homologous recombination and impairing functions thereof.
[0101] Gene disruption using homologous recombination can be carried out in accordance with a conventional method. Preparation of a vector used for the gene disruption and introduction of the vector into a host are apparent for those skilled in the art.
[0102] The recombinant vector according to the present invention preferably comprises any one or more of polynucleotides having the nucleotide sequence in SEQ ID NO:266 and the above-mentioned (1); a polynucleotide having a nucleotide sequence which is capable of hybridizing with the nucleotide sequence in SEQ ID NO:266 and the above-mentioned (1) under stringent conditions, or a polynucleotide having a polynucleotide sequence encoding at least one amino acid sequence selected from SEQ ID NOs:267 to 274 or a substantially equivalent amino acid sequence thereto. More preferably, the recombinant vector according to the present invention is one wherein the above-mentioned polypeptide comprises a polynucleotide hydroxylating the 7-position and/or 13-position of the pyripyropene E or O, and the above-mentioned polypeptide comprises a polynucleotide hydroxylating the 11-position of the pyripyropene E.
[0103] A recombinant vector for gene introduction can be prepared by modifying the polynucleotide provided by the present invention into an appropriate form depending on an object and ligating it to a vector in accordance with a conventional method, for example, gene recombination techniques described in [Sambrook, J. et al., “Molecular cloning: a laboratory manual”, (USA), 2nd Edition, Cold Spring Harbor Laboratory, 1989].
[0104] The recombinant vector used in the present invention can be appropriately selected from virus, plasmid, fosmid, cosmid vectors or the like. For instance, when a host cell is Escherichia coli , examples thereof include λ phage-based bacteriophage and pBR and pUC-based plasmids. In the case of a Bacillus subtilis , examples include pUB-based plasmids. In the case of yeast, examples include YEp, YRp, YCp and YIp-based plasmids.
[0105] In addition, it is preferred that at least one plasmid among the used plasmids comprise a selection marker for selecting a transformant. As the selection marker, a gene encoding drug resistance and gene complementing auxotrophy can be used. Concrete preferred examples thereof include when a host to be used is bacterium, ampicillin resistant genes, kanamycin resistant genes, tetracycline resistant gene and the like; in the case of yeast, tryptophan biosynthetic gene (TRP1), uracil biosynthetic gene (URA3), leucine biosynthetic gene (LEU2) and the like; in the case of a fungus, hygromycin resistant genes, bialaphos resistant genes, bleomycin resistant genes, aureobasidin resistant genes and the like; and in the case of a plant, kanamycin resistant genes, bialaphos resistant genes and the like.
[0106] Further, DNA molecules serving as an expression vector used in the present invention preferably has DNA sequences necessary to express each gene, transcription regulatory signals and translation regulatory signals such as promoters, transcription initiation signals, ribosome binding sites, translation stop signals, terminators. Preferred examples of the promoters include promoters of lactose operon, tryptophan operon and the like in Escherichia coli ; promoters of alcohol dehydrogenase gene, acid phosphatase gene, galactose metabolizing gene, glyceraldehyde 3-phosphate dehydrogenase gene or the like in yeast; promoters of α-amylase gene, glucoamylase gene, cellobiohydrolase gene, glyceraldehyde 3-phosphate dehydrogenase gene, abp1 gene or the like in fungi; a CaMV 35S RNA promoter, a CaMV 19S RNA promoter or a nopaline synthetase gene promoter in plants.
[0107] A host in which the isolated polynucleotide according to the present invention is introduced may be appropriately selected, depending on the type of the used vector, from actinomycetes, Escherichia coli, Bacillus subtilis , yeast, filamentous bacteria, plant cells or the like.
[0108] A method of introducing a recombinant vector into a host may be selected, depending on a host cell under test, from conjugal transfer, transduction by phage, as well as methods of transformation such as a calcium ion method, a lithium ion method, an electroporation method, a PEG method, an Agrobacterium method or a particle gun method.
[0109] In cases where a plurality of genes is introduced into host cells in the present invention, the genes may be contained in a single DNA molecule or individually in different DNA molecules. Further, when a host cell is a bacterium, each gene can be designed so as to be expressed as polycistronic mRNA and made into one DNA molecule.
[0110] The transformant according to the present invention preferably comprises any one or more of polynucleotides having the nucleotide sequence in SEQ ID NO:266 and the above-mentioned (1); a polynucleotide having a nucleotide sequence which is capable of hybridizing with the nucleotide sequence in SEQ ID NO:266 and the above-mentioned (1) under stringent conditions, or a polynucleotide having a polynucleotide sequence encoding at least one amino acid sequence selected from SEQ ID NOs:267 to 274 or a substantially equivalent amino acid sequence thereto.
[0111] The transformant obtained can be cultured by a conventional method and newly characteristics obtained can be studied. As the medium, commonly used components, for example, as carbon sources, glucose, sucrose, starch syrup, dextrin, starch, glycerol, molasses, animal and vegetable oils or the like can be used. Also, as nitrogen sources, soybean flour, wheat germ, corn steep liquor, cotton seed meal, meat extract, polypeptone, malto extract, yeast extract, ammonium sulfate, sodium nitrate, urea or the like can be used. Besides, as required, addition of sodium, potassium, calcium, magnesium, cobalt, chlorine, phosphoric acid (dipotassium hydrogen phosphate or the like), sulfuric acid (magnesium sulfate or the like) or inorganic salts which can generate other ions is effective. Also, as required, various vitamins such as thiamin (thiamine hydrochloride or the like), amino acids such as glutamic acid (sodium glutamate or the like) or asparagine (DL-asparagine or the like), trace nutrients such as nucleotides, or selection agents such as antibiotics can be added. Further, organic substances or inorganic substances which help the growth of a bacterium and promote the production of pyripyropene A can be appropriately added.
[0112] The pH of the medium is, for example, about pH 5.5 to pH 8. As the method for culturing, solid culturing under aerobic conditions, shake culturing, culturing with bubbling under stirring or deep part aerobic culturing can be employed and, in particular, the deep part aerobic culturing is most appropriate. The appropriate temperature for the culturing is 15° C. to 40° C. and, in many cases, the growth takes place around 22° C. to 30° C. The production of pyripyropene A varies depending on the medium and culturing conditions, or the used host. In any method for culturing, the accumulation usually reaches a peak in 2 days to 10 days. The culturing is terminated at the time when the accumulation of pyripyropene A in the culture reaches the peak and a desired substance is isolated and purified from the culture.
[0113] To isolate pyripyropene A from the culture, it can be extracted and purified by a usual separation means using properties thereof, such as a solvent extraction method, an ion exchange resin method, an adsorption or distribution column chromatography method, a gel filtration method, dialysis, a precipitation method, a crystallization method, which may be individually used or appropriately used in combination.
[0114] Method for Producing Pyripyropene A Precursor
[0115] In order to isolate pyripyropene A, pyripyropene A can be isolated from a pyripyropene A precursor using a known method. An example of the known method includes the method of WO2009/022702. By culturing a microorganism containing a vector containing one or more of the above, the pyripyropene A precursor can be isolated from pyripyropene E. The pyripyropene A precursor may be, for example, the compound represented by the above-mentioned formula (I).
[0116] Also, by culturing a microorganism comprising a vector containing one or more, the pyripyropene A precursor can be isolated from pyripyropene O. An example may be the compound represented by the above-mentioned formula (II).
EXAMPLES
[0117] The present invention will be further illustrated in detail by the following examples, which are not intended to restrict the present invention.
Example 1
Preparation of Genomic DNA of Penicillium coprobium PF1169 Strain
[0118] Sterilized NB medium (500 ml) was placed in an Erlenmeyer flask (1 L). Penicillium coprobium PF1169 strain (Journal of Technical Disclosure No. 500997/2008 (Patent Document 15)) precultured in 1/2 CMMY agar medium at 28° C. for 4 days was added to the above-mentioned medium and subjected to liquid culture at 28° C. for 4 days. Filtration was carried out with Miracloth to obtain 5 g of bacterial cells. From these bacterial cells, 30 μg of genomic DNA was obtained in accordance with the manual attached to genomic DNA purification kit Genomic-tip 100/G (manufactured by Qiagen K.K.).
Example 2
Degenerate Primers for Amplification of Polyketide Synthase (PKS) and Amplified Fragment Thereof
[0119] Based on an amino acid sequence conserved among various filamentous bacterium polyketide synthases, the following primers were designed and synthesized as degenerate primers for amplification:
[0000] LC1: GAYCCIMGITTYTTYAAYATG (SEQ ID NO: 1) LC2c: GTICCIGTICCRTGCATYTC (SEQ ID NO: 2)
(wherein R=A/G, Y=C/T, M=A/C, I=inosine).
[0120] Using these degenerate primers, the genomic DNA prepared in Example 1 and ExTaq polymerase (manufactured by Takara Bio Inc.) were allowed to react in accordance with the attached manual. An amplified fragment of about 700 bp was detected (see FIG. 1 ). Further, the above-mentioned amplified fragment was analyzed to specify the sequence of its internal 500 bp (SEQ ID NO:3).
Example 3
Large-Scale Sequencing of Genomic DNA and Amino Acid Sequence Homology Search
[0121] The genomic DNA of Penicillium coprobium PF1169 strain obtained in Example 1 was subjected to large-scale sequencing and homology search for amino acid sequences. Specifically, part of 50 μg of genomic DNA was pretreated and thereafter subjected to Roche 454FLX DNA sequencer to obtain about 250 bp, 103 thousands of fragment sequences (in total, 49 Mb of sequence).
[0122] For theses sequences, as known sequences among polyketide synthases and prenyltransferases, the following five sequences (sequences derived from polyketide synthases: Aspergillus ( A .) fumigatus PKS 2146 a.a. and Penicillium ( P .) griseofluvum 6-methylsalycilic acid synthase 1744 a.a.; as well as prenyltransferases: Aspergillus ( A .) fumigatus Prenyltransferase, Aspergillus ( A .) fumigatus Prenyltransferase (4-hydroxybezoate octaprenyltransferase) and Penicillium ( P .) marneffei Prenyltransferase) were selected and search by homology sequence search software blastx was carried out, thereby obtaining 89, 86, 2, 1 and 3 of homology sequences, respectively (see Table 1). Further, from the homology sequences of A. fumigatus PKS 2146 a.a. and P. griseofluvum 6-methylsalycilic acid synthase 1744 a.a., 19 and 23 of contig sequences were respectively obtained (the contig sequences of A. fumigatus PKS 2146 a.a.: SEQ ID NOs:179 to 197; the contig sequences of P. griseofluvum 6-methylsalycilic acid synthase 1744 a.a.: SEQ ID NOs:198 to 220) (see Table 1).
[0000]
TABLE 1
Number of
Homology
SEQ ID
Enzyme Name
Origin
Sequences
NO.
Polyketide
A. fumigatus PKS 2146
89
4-92
Synthases
a.a.
P. griseofluvum
86
93-178
6-methylsalycilic acid
synthase 1744 a.a.
A. fumigatus PKS 2146
19 (Contig
179-197
a.a.
sequences)
P. griseofluvum
23 (Contig
198-220
6-methylsalycilic acid
sequences)
synthase 1744 a.a.
Prenyltransferases
A. fumigatus
2
221, 222
Prenyltransferase
A. fumigatus
1
223
Prenyltransferase
(4-hydroxybezoate
octaprenyltransferase)
P. marneffei
3
224-226
Prenyltransferase
Example 4
PCR Amplification from Genomic DNA
[0123] From the search results of blastx obtained in Example 3, for polyketide synthases, 13 types of primer pairs shown in SEQ ID NOs:227 to 252 were synthesized. Similarly, for prenyltransferases, 5 types of primer pairs shown in SEQ ID NOs:253 to 262 were synthesized. When PCR was carried out for the genomic DNA using these primers, amplified fragments with the expected size were seen for all of the primer pairs (see FIG. 1 and FIG. 2 ).
Example 5
Construction of Phage Genomic Library
[0124] A λ phage genomic library of Penicillium coprobium PF1169 strain was constructed using λBlueSTAR Xho I Half-site Arms Kit (manufactured by Takara Bio Inc., Cat. No. 69242-3) in accordance with the attached manual. That is, genomic DNA was partially digested using a restriction enzyme, Sau3A1. The DNA fragment with about 20 kb (0.5 μg) was ligated to 0.5 μg of λBlueSTAR DNA attached to the kit. This ligation solution was subjected to in vitro packaging using Lambda INN Packaging kit (manufactured by Nippon Gene Co., Ltd.) based on the manual attached to the kit to obtain 1 ml of a solution. This solution with packaged phages (10 μl) was infected into 100 μl of E. coli ER1647 strain and cultured on a plaque-forming medium at 37° C. overnight, thereby obtaining about 500 clones of plaques. Thus, the genomic library composed of about 50000 clones of phages in which 10 to 20 kb genomic DNA of Penicillium coprobium PF1169 strain were introduced by infection was constructed.
Example 6
Screening from Phage Library
[0125] For 10000 clones of the phage library prepared in Example 5, the primary screening was carried out by plaque hybridization using, as a probe, the PCR product amplified by LC1-LC2c primer pair prepared above. For labeling and detection of the probe, AlkPhos Direct Labelling and Detection System with CDP-Star (manufactured by GE Healthcare, Cat. No. RPN3690) was used. The above-mentioned hybridization was carried out in accordance with the attached manual.
[0126] By the primary screening, 6 clones remained as candidates. Further, as the result of the secondary screening by plaque hybridization, 4 clones were obtained. These positive clones were infected into E. coli BM25.8 strain and the phages were converted to plasmids in accordance with the attached manual, thereby obtaining 4 types of plasmids containing a desired region.
Example 7
Preparation of Fosmid Genome Library
[0127] A genomic library of Penicillium coprobium PF1169 strain was constructed using CopyControl Fosmid Library Production Kit (manufactured by EPICENTRE, Cat. No. CCFOS110) in accordance with the manual attached thereto. That is, 0.25 μg of DNA fragment of about 40 kb genomic DNA was blunt-ended and then incorporated into fosmid vector pCCFOS (manufactured by Epicentre). This ligation solution was subjected to in vitro packaging using MaxPlax Lambda Packaging Extract attached to the kit based on the manual attached to the kit. This solution with packaged virus (10 μl) was infected into 100 μl of E. coli EPI300™-T1® strain and cultured on a medium containing chloramphenicol at 37° C. overnight and selected, thereby obtaining about 300 clones of plaques. Thus, about 30000 clones of the fosmids in which 40 kb of the genomic DNA of Penicillium coprobium PF1169 strain were introduced by infection were obtained. They were aliquoted in a 96 well plate so as to be about 50 clones per well. Thus, the genomic library composed of 96 pools, about 4800 clones was constructed.
Example 8
Fosmid Library Screening
[0128] In accordance with the manual attached to the fosmid, plasmid DNAs were individually prepared from 96 pools of the library prepared in Example 7. Using the degenerate primers for polyketide synthase amplification synthesized in Example 2, PCR was carried out for 96 pools of these plasmid DNA samples. As a result, DNA fragments of about 700 bp were amplified from 9 pools. Further, a petri dish containing colonies of about 300 clones or more was prepared from the positive pools and re-screening was carried out by colony hybridization. As a result, using by LC1-LC2c primer pair, 9 types of fosmids were obtained from about 4800 clones.
Example 9
Large-Scale Sequencing of Genomic DNA and Amino Acid Sequence Homology Search
[0129] Genomic DNA of Penicillium coprobium PF1169 strain obtained in Example 1 was subjected to large-scale sequencing and homology search for amino acid sequences. Specifically, part of 50 μg of genomic DNA was pretreated and then subjected to Roche 454FLX DNA sequencer to obtain 1405 fragment sequences with an average contig length of 19.621 kb (sequence of a total base length of 27.568160 Mb).
[0130] For these sequences, as known sequences among polyketide synthases and prenyltransferases, the following five sequences (sequences derived from polyketide synthases: Penicillium ( P .) griseofluvum 6-methylsalycilic acid synthase 1744 a.a. (P22367) and Aspergillus ( A .) fumigatus PKS 2146 a.a. (Q4WZA8); as well as prenyltransferases: Penicillium ( P .) marneffei Prenyltransferase (Q0MRO8), Aspergillus ( A .) fumigatus Prenyltransferase (Q4WBI5) and Aspergillus ( A .) fumigatus Prenyltransferase (4-hydroxybezoate octaprenyltransferase) (Q4WLD0)) were selected and search by homology sequence search software blastx was carried out, thereby obtaining 22 (P22367), 21 (Q4WZA8), 2 (Q0MRO8), 3 (Q4WBI5) and 3 (Q4WLD0) of the homologous sequences, respectively.
Example 10
Fosmid Library Screening and Sequence Analysis of Cluster Genes
[0131] In accordance with the manual attached to a fosmid kit (manufactured by EPICENTRE, CopyControl Fosmid Library Production Kit), plasmid DNAs were individually prepared from 96 pools of the library prepared in Example 7. Based on base sequences determined by Roche 454FLX DNA sequencer, homology search for amino acid sequences was carried out to search regions adjacent to polyketide synthase and prenyltransferase. Based on the base sequence of prenyltransferase of the obtained region, a primer pair (No. 27) capable of amplifying 400 bp DNA fragment was synthesized. Using the primers, PCR was carried out for these 48 pools of plasmid DNA samples. As a result, expected DNA fragments of about 400 bp (SEQ ID NO:263) were amplified from 11 pools (see FIG. 3 ). Further, a petri dish containing colonies of about 300 clones or more was prepared from 6 pools of the positive pools and re-screening was carried out by colony hybridization. As a result, by using 27F+27R primer pair (27F primer: SEQ ID NO:264, 27R primer: SEQ ID NO:265), 4 types of fosmids were obtained from about 4800 clones. One of them was named pCC1-PP1 and the entire sequence of the inserted fragment was determined (SEQ ID NO:266).
[0132] The obtained pCC1-PP1 was transformed into Escherichia coli EPI300™-T1® strain (included in the fosmid kit), thereby obtaining Escherichia coli EPI300™-T1® strain/pCC1-PP1.
[0133] When a homology search was carried out between the above-mentioned sequence of SEQ ID NO:266 and each of Adenylate-forming enzyme; LovB-like polyketide synthase; Cytochrome P450 monooxygenase, Integral membrane protein, FAD-dependent monooxygenase, which are hydroxylases; UbiA-like prenyltransferase; Acetyltransferase, Toxin biosynthesis protein Tri7, which are acetyltransferases; and Cation transporting ATPase (the above-mentioned enzymes are all derived from Aspergillus fumigatus Af293 strain), a high homology of 70% or more was seen in any search.
[0134] The nucleotides 3342 to 5158 of SEQ ID NO:266 encode Adenylate-forming enzyme and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:267; the nucleotides 5382 to 12777 of SEQ ID NO:266 encode LovB-like polyketide synthase and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:268; the nucleotides 13266 to 15144 of SEQ ID NO:266 (hereinafter, a protein encoded by this polynucleotide sequence (P450-1) is referred to as Cytochrome P450 monooxygenase (1)) and the nucleotides 16220 to 18018 (hereinafter, a protein encoded by this polynucleotide sequence (P450-2) is referred to as Cytochrome P450 monooxygenase (2)) encode Cytochrome P450 monooxygenases and the corresponding polypeptides are shown with the amino acid sequences depicted in SEQ ID NOs:269 and 270, respectively; the nucleotides 18506 to 19296 of SEQ ID NO:266 encode Integral membrane protein and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:271; the nucleotides 19779 to 21389 of SEQ ID NO:266 encode FAD-dependent monooxygenase and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:272; the nucleotides 21793 to 22877 of SEQ ID NO:266 encode UbiA-like prenyltransferase and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:273; the nucleotides 23205 to 24773 of SEQ ID NO:266 encode Acetyltransferase and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:274; the nucleotides 25824 to 27178 of SEQ ID NO:266 encode Toxin biosynthesis protein Tri7 and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:275; and the nucleotides 27798 to 31855 of SEQ ID NO:266 encode Cation transporting ATPase and the corresponding polypeptide is shown with the amino acid sequence depicted in SEQ ID NO:276.
Example 11
Hydroxylation of Pyripyropene E or Pyripyropene O by Transformation of Aspergillus Oryzae
[0135] Pyripyropene E used below can be produced by, for example, a method for culturing a microorganism based on the method described in Japanese Patent Laid-Open Publication No. 239385/1996 (Patent Document 4), WO94/09147 or U.S. Pat. No. 5,597,835, or the total synthesis method described in Tetrahedron Letters, vol. 37, No. 36, 6461-6464, 1996. Also, pyripyropene O used below can be produced by, for example, a method for culturing a microorganism based on the method described in J. Antibiotics 49, 292-298, 1996 or WO94/09147.
[0136] (1) Preparation of Expression Vector for Introducing into Filamentous Bacterium
[0137] pUSA ( FIG. 4 ) and pHSG399 (Takara Bio Inc.) were individually digested with KpnI and ligated, thereby obtaining pUSA-HSG. This plasmid was digested with SmaI and KpnI in the order mentioned, and subjected to gel purification, thereby obtaining a linear vector DNA having a KpnI cohesive end and SmaI blunt end.
[0138] (2) Preparation of Plasmid pPP2
[0139] With fosmid pCC1-PP1 as a template, the polynucleotide of the above-mentioned P450-1 was amplified using a primer pair P450-1 with Kpn F (SEQ ID NO:277)/P450-1 with Swa R (SEQ ID NO:278). The purified DNA fragment was cloned into pCR-Blunt (Invitorogen, Cat. No. K2700-20). The plasmid obtained was digested with KpnI and SwaI. The above-mentioned P450-1 fragment was ligated to the above-described vector pUSA-HSG. thereby obtaining a plasmid pPP2 shown in FIG. 5 .
[0140] (3) Preparation of Plasmid pPP3
[0141] With fosmid pCC1-PP1 as a template, in accordance with the flow shown in FIG. 6 , exons alone were first amplified using primer pairs F1 (SEQ ID NO:279)/R1 (SEQ ID NO:280), F2 (SEQ ID NO:281)/R2 (SEQ ID NO:282), F3 (SEQ ID NO:283)/R3 (SEQ ID NO:284), F4 (SEQ ID NO:285)/R4 (SEQ ID NO:286), F5 (SEQ ID NO:287)/R5 (SEQ ID NO:288) and F6 (SEQ ID NO:289)/R6 (SEQ ID NO:290), thereby obtaining six fragments. Next, amplification was carried out with these fragments as templates using primer pairs of F1/R2, F3/R4 and F5/R6, thereby obtaining longer fragments. Further, by repeating amplification using primer pairs of F1/R4 and F1/R6, cDNA which did not contain introns of the polynucleotide of the above-mentioned P450-2 was prepared. This cDNA fragment was inserted into pCR-Blunt (Invitorogen, Cat. No. K2700-20) and the obtained plasmid was used as a template for amplification by a primer pair, infusion F of P450-2-cDNA (SEQ ID NO:291)/infusion R of P450-2-cDNA (SEQ ID NO:292). Based on the manual of the kit, a plasmid pPP3 shown in FIG. 7 was obtained using In-Fusion Advantage PCR Cloning Kit (Clontech).
[0142] (4) Transformation of Aspergillus Oryzae ( A. oryzae )
[0143] In a CD-Met (containing L-Methionine 40 μg/ml) agar medium, A. oryzae (HL-1105 strain) was cultured at 30° C. for one week. From this petri dish, conidia (>10 8 ) were collected and seeded in 100 ml of YPD liquid medium in a 500 ml-flask. After 20-hour culturing (30° C., 180 rpm), bacterial cells having a moss ball shape were obtained. The bacterial cells were collected with a 3G-1 glass filter, washed with 0.8 M NaCl, and water was removed well. The resultant was suspended with TF solution I (protoplast formation solution) and then shook at 30° C., at 60 rpm for 2 hours. At a 30-minute interval, observation under the microscope was carried out and the presence of protoplasts was checked. Thereafter, the culture medium was filtered and subjected to centrifugation (2000 rpm, 5 minutes) to collect protoplasts, which were then washed with TF solution II. After washing, 0.8 volume of TF solution II and 0.2 volume of TF solution III were added and mixed, thereby obtaining a protoplast suspension.
[0144] To 200 μl of this suspension, 10 μg of plasmid DNA (pPP2 or pPP3) was added. The mixture was left to stand on ice 30 minutes and added with TF solution III (1 mL). The resulting mixture was gently mixed and then left to stand at room temperature for 15 minutes. Thereafter, the plasmid DNA was introduced into the above-mentioned protoplasts. To this, TF solution II (8 mL) was added and subjected to centrifugation (at 2000 rpm for 5 minutes). Further, protoplasts were then recovered with 1 to 2 ml being left over. The recovered protoplast solution was dropped to a regeneration medium (lower layer) and a regeneration medium (upper layer) was poured. The resultant was mixed by turning a petri dish and then cultured at 30° C. for 4 to 5 days. Generated clones were isolated in the regeneration medium (lower layer), subcultured and purified, thereby obtaining a transformant ( Aspergillus oryzae PP2-1 and Aspergillus oryzae PP3-2).
[0145] The above-mentioned TF solution I (protoplast formation solution) was prepared with the following compositions.
[0000]
Name of Compound
Concentration
Yatalase (manufactured by Takara Bio Inc.)
20 mg/ml
Ammonium sulfate
0.6M
Maleic acid-NaOH
50 mM
[0146] After the above-mentioned compositions (pH5.5) were prepared, filter sterilization was carried out.
[0147] The above-mentioned TF solution II was prepared with the following compositions.
[0000]
Name of Compound
1.2M Sorbitol (MW = 182.17)
43.72
g
50 mM CaCl 2
10
ml
1M CaCl 2 ( 1/20)
35 mM NaCl
1.4
ml
5M NaCl
10 mM Tris-HCl
2
ml
1M Tris-HCl ( 1/100)
Up to total volume
200
ml
[0148] After the above-mentioned compositions were prepared, autoclave sterilization was carried out.
[0149] The above-mentioned TF solution III was prepared with the following compositions.
[0000]
Name of Compound
60% PEG4000
6
g
50 mM CaCl 2
500
μl
1M CaCl 2 ( 1/20)
50 mM Tris-HCl
500
μl
1M Tris-HCl ( 1/100)
Up to total volume
10
ml
[0150] After the above-mentioned compositions were prepared, filter sterilization was carried out.
[0151] The above-mentioned regeneration medium was prepared with the following compositions.
[0000]
Name of Compound
Concentration
Sorbitol (MW = 182.17)
218.6
g
1.2M
NaNO 3
3.0
g
0.3% (w/v)
KCl
2.0
g
0.2% (w/v)
KH 2 PO 4
1.0
g
0.1% (w/v)
MgSO 4 •7H 2 O
2 ml of 1M MgSO 4
0.05% 2 mM
Trace elements solution
1
ml
Glucose
20.0
g
2% (w/v)
Up to the total volume
1
L
[0152] After the above-mentioned compositions (pH5.5) were prepared, autoclave sterilization was carried out.
[0153] In addition, the Trace elements solution used above was prepared with the following composition.
[0000]
Name of Compound
FeSO 4 •7H 2 O
1.0
g
ZnSO 4 •7H 2 O
8.8
g
CuSO 4 •5H 2 O
0.4
g
Na 2 B 4 O 7 •10H 2 O
0.1
g
(NH 4 ) 6 Mo 7 O 24 •4H 2 O
0.05
g
Up to the total volume
1
L
[0154] After the above-mentioned compositions were prepared, autoclave sterilization was carried out.
[0155] (5) Function Analysis and Addition Culture Test of P450-1
[0156] To a YPD medium (1% (w/v) Yeast Extract, 2% (w/v) Peptone, 2% (w/v) Dextrose) containing 1% (w/v) maltose, a 1/100 volume of 2 mg/mL dimethyl sulfoxide solution of pyripyropene E was added to provide medium A. From flora of Aspergillus oryzae PP2-1 cultured in Czapek Dox agar medium, conidia thereof were collected and suspended in sterilized water. This conidia suspension was adjusted to 10 4 spores/mL. Further, 100 μL of this adjusted conidia suspension was added to 10 mL of medium A and cultured with shaking at 25° C. for 96 hours. To this culture solution, 10 mL of acetone was added and the mixture was mixed well. Thereafter, acetone was removed using a centrifugal concentrator. To this, 10 mL of ethyl acetate was added and the resulting mixture was mixed well and then only the ethyl acetate layer was recovered. A dried product obtained by removing ethyl acetate using the centrifugal concentrator was dissolved in 1000 μL of methanol. This was used as a sample and analyzed by LC-MS (Waters, Micromass ZQ, 2996PDA, 2695 Separation module, Column: Waters XTerra C18 (Φ4.5×50 mm, 5 μm)) and LC-NMR (Avance500 manufactured by Burker Daltonik).
[0157] As the results of the above-mentioned LC-MS measurement, it was confirmed that the obtained compound was single compound A which increased by a molecular weight of 16 compared with pyripyropene E. In addition, as the results of the LC-NMR measurement, it was confirmed that this compound A was an 11-position hydroxide of pyripyropene E. It was confirmed that the above-mentioned Cytochrome P450 monooxygenase (1) was an enzyme hydroxylating the 11-position of pyripyropene E with pyripyropene E as a substrate.
[0158] Physicochemical properties of the above-mentioned compound A are shown below:
[0159] 1. Mass spectrum: ES-MS 468M/Z (M+H) +
[0160] 2. Molecular formula: C 27 H 33 NO 6
[0161] 3. HPLC: Column: Waters XTerra Column C18 (5 μm, 4.6 mm×50 mm), 40° C., Mobile phase: From 20% aqueous acetonitrile solution to 100% acetonitrile in 10 minutes (linear gradient), Flow rate: 0.8 ml/min, Detection: Retention time 6.696 minutes at UV 323 nm
[0162] 4. 1 H-NMR spectrum (CD 3 CN, 2H, 3.134, 3.157 H-11)
[0163] The charts of the 1 H-NMR spectrum of pyripyropene E and 1 H-NMR spectrum according to 4 described above are shown in FIG. 8 and FIG. 9 , respectively.
[0164] (6) Function Analysis and Addition Culture Test of P450-2
[0165] To a YPD medium (1% (w/v) Yeast Extract, 2% (w/v) Peptone, 2% (w/v) Dextrose) containing 1% (w/v) maltose, a 1/100 volume of 2 mg/mL dimethyl sulfoxide solution of pyripyropene E was added to provide medium B, and similarly a 1/100 volume of 2 mg/mL dimethyl sulfoxide solution of pyripyropene O was added to provide medium C. From flora of Aspergillus oryzae PP3-2 cultured in Czapek Dox agar medium, conidia thereof were collected and suspended in sterilized water. This conidia suspension was adjusted to 10 4 spores/mL. Further, 500 μL of the adjusted conidia suspension was added to 50 mL of medium B or medium C and cultured with shaking at 25° C. for 96 hours. To this culture solution, 50 mL of acetone was added and the mixture was mixed well. Thereafter, acetone was removed using a centrifugal concentrator. To this, 50 mL of ethyl acetate was added and the resulting mixture was mixed well and then only the ethyl acetate layer was recovered. A dried product obtained by removing ethyl acetate using the centrifugal concentrator was dissolved in 1500 μL of methanol. This was used as a sample and analyzed by LC-MS (manufactured by Waters, Micromass ZQ, 2996PDA, 2695 Separation module, Column: Waters XTerra C18 (Φ4.5×50 mm, 5 μm)) and LC-NMR (manufactured by Burker Daltonik, Avance500). As the results of the LC-MS measurement, from a sample obtained from the medium B, compound B which increased by a molecular weight of 32 compared with pyripyropene E was detected. Also, from a sample obtained from the medium C, compound C which increased by a molecular weight of 32 compared with pyripyropene O was detected. Further, as the results of the LC-NMR measurement, it was confirmed that the compound C was a 7-position and 13-position hydroxide of pyripyropene O. It was confirmed that the above-mentioned Cytochrome P450 monooxygenase (2) was an enzyme hydroxylating the 7-position and 13-position of each of pyripyropene E or pyripyropene O.
[0166] Physicochemical properties of the above-mentioned compound B are shown below:
[0167] 1. Mass spectrum: ES-MS 484M/Z (M+H) +
[0168] 2. Molecular formula: C 27 H 33 NO 7
[0169] 3. HPLC: Column: Waters XTerra Column C18 (5 μm, 4.6 mm×50 mm), 40° C., Mobile phase: From 20% aqueous acetonitrile solution to 100% acetonitrile in 10 minutes (linear gradient), Flow rate: 0.8 ml/min, Detection: Retention time 5.614 minutes at UV 323 nm
[0170] Physicochemical properties of the above-mentioned compound C are shown below:
[0171] 1. Mass spectrum: ES-MS 542M/Z (M+H) +
[0172] 2. Molecular formula: C 29 H 35 NO 9
[0173] 3. HPLC: Column: Waters XTerra Column C18 (5 μm, 4.6 mm×50 mm), 40° C., Mobile phase: From 20% aqueous acetonitrile solution to 100% acetonitrile in 10 minutes (linear gradient), Flow rate: 0.8 ml/min, Detection: Retention time 5.165 minutes at UV 323 nm
[0174] 4. 1 H-NMR spectrum (CD 3 CN, 1H 4.858 H-13), (CD 3 CN, 1H 3.65 H-7)
[0175] The charts of the 1 H-NMR spectrum of pyripyropene O and the above-mentioned compound C are shown in FIG. 10 and FIG. 11 , respectively.
[Accession Numbers]
[0176] FERM BP-11133
[0177] FERM BP-11137
[0178] FERM BP-11141
|
An isolated novel polynucleotide comprising a nucleotide sequence encoding at least one polypeptide involved in biosynthesis of pyripyropene A, a recombinant vector comprising the polynucleotide and a transformant comprising the polynucleotide are disclosed. By the present invention, a pyripyropene A biosynthetic gene useful for production of a novel pyripyropene analog, improvement of productivity of a pyripyropene A-producing bacterium, production of an insecticidal agent for microorganisms, creation of a plant resistant to insect pests or the like are provided.
| 8
|
PRIORITY CLAIM
[0001] The present application claims the benefit of priority under 35 USC 119 of previously regularly filed foreign application UK 1016014.1, filed on Sep. 24, 2010. The present application, filed on Sep. 22, 2011, is filed within twelve months from the date on which this foreign application was filed.
FIELD OF THE INVENTION
[0002] The present invention relates to a thermal cycler apparatus, for use in thermal cycling reactions. Aspects of the invention relate to methods for performing thermal cycling reactions.
BACKGROUND TO THE INVENTION
[0003] Thermal cycling applications are an integral part of contemporary molecular biology. For example, the polymerase chain reaction (PCR), which is used to amplify nucleic acids, uses a series of DNA melting, annealing, and polymerisation steps at different temperatures to greatly ‘amplify’ the amount of DNA in a sample. Other thermal cycling applications are also known.
[0004] A typical thermal cycling apparatus consists of a metal sample block containing an appropriate number of recesses to receive one or more reaction vessels. The sample block may be shaped to conform to a 96-well plate format or individual reaction-tubes that are generally 0.5 μl or 0.20 micro-centrifuge (Eppendorf) tubes. The metal block acts as a thermal mass that transfers its thermal energy to and from the reaction samples. In general thermal cycling energy is provided using a Thermoelectric Cooling (TEC) device, also commonly known as a Peltier Effect element (PE). A thermal cycling apparatus will generally also use a heat sink to assist in heat transfer to and from the Peltier and a large fan or the like, to remove the excess heat generated by the Peltier and transferred to the heat sink during cooling.
[0005] Peltier elements are solid-state devices that convert an electric current into a temperature gradient. They consist of two sides—a hot side and a cold side. The module acts as a heat pump in that it moves heat from the cold side to the hot side. Switching the direction of current flow will swap the hot and cold side states and regulating this current flow is used to cycle temperature of the sample block in order to provide the heating and cooling required for PCR. The hot side of the Peltier requires a method of removing that heat for the unit to function properly and to cool effectively. The more efficient the means of removing this heat from the hot side, the colder the cold side will operate and the more quickly the cold side will reach its optimum temperature for thermal transfer. This is limited by the mass of the heat sink used and the airflow of the fan used to remove the excess heat from the heat sink. In general a thermal cycler design becomes a compromise between the power rating for a specific heat sink, and the size of the heat sink and fans that can be accommodated in the design. In standard Peltier block thermal cyclers, the heat sink and fan units represent the majority of the unit and mass of the device.
[0006] Although convenient, such thermal cyclers suffer from a number of disadvantages. Key among these is that a Peltier element suffers from reduced efficiency when being used for both heating and cooling—for example, the Peltier device has significant thermal mass in the form of a heat sink which must itself be heated or cooled to enable efficient thermal transfer to the sample block. Achieving a reasonable efficiency for both heating and cooling is complex, and most thermal cycler designs must find a compromise between the heating and cooling functions of the Peltier element and the desired rate of thermal transfer to the sample block. As a consequence of this compromise, conventional thermal cyclers typically achieve a maximum heating or cooling rate of no more than 3 degrees Celsius per second and have a high power overhead to achieve these modest rates of performance.
[0007] The present invention provides an alternative thermal cycler arrangement.
SUMMARY OF THE INVENTION
[0008] According to the present invention, there is provided a thermal cycler comprising:
a sample block for receiving a sample; a Peltier-type thermoelectric element adjacent the sample block, configured for cooling the sample block; a non-Peltier-type heating device adjacent the sample block, configured for heating the sample block; a heat sink, separated from the sample block and Peltier-type element; and a heat pipe connecting the heat sink to the Peltier-type element, which permits thermal energy to transfer from the Peltier-type element to the heat sink.
[0014] A thermal cycler according to the present invention separates the heating and cooling functions, allowing each to be optimised for the desired function. Further, the use of separate heater and cooler elements means that the thermal mass of the heat sink need not influence the performance of the Peltier and the efficiency of heating and cooling the sample block. In addition, a conventional heating element, for example an electrical resistance heating element, is in general more efficient than a Peltier-type element used for both heating and cooling; the Peltier-type element is more efficient when used for cooling only or when heating only.
[0015] In the preferred arrangement, the sample block is sandwiched between the Peltier-type element and the non-Peltier-type heating device; for example, the element and the device are located on opposed faces of the sample block. Conventional thermal cycler devices use a stacked arrangement, in which the sample block is positioned above the Peltier element, which is positioned above the heat sink, which is positioned above the cooling fans. Sample tubes are loaded into the sample block from above. This conventional arrangement means that there is no position in which a non-Peltier-type heater may be conveniently located, other than between the sample block and the Peltier element, which would further reduce efficiency due to the need to cool through the heater.
[0016] The cycler may further comprise an optics assembly—for example, including a light source and light detector, optionally with one or more lenses. This allows the cycler to be used in detecting fluorescence or other signal from a reaction as the reaction proceeds in real time. The light source and light sensor may encompass any electromagnetic radiation, not merely visible light. The cycler may also comprise filters to restrict light of particular wavelengths. The cycler may further comprise a second light source; this allows for a relatively low-cost two-label detection system, where the two sources illuminate at different wavelengths. Where the cycler is intended to use a plurality of samples or reaction vessels in each cycling reaction, the cycler may conveniently comprise at least one light source/sensor combination for each sample.
[0017] In preferred embodiments of the invention, the light source is an LED or similar, while the light sensor is a photodiode or the like. The sensor is conveniently a log-response detector, which allows for a wider dynamic range, and a wider copy number of nucleic acids which can be detected. This arrangement allows for simple, robust components to be used without the requirement for lenses or complex optics arrangements. Such a source/sensor combination has been found to be sufficient to obtain qualitative information on the progress of a reaction (for example, that amplification is occurring). For many applications, such data is sufficient, and it is not necessary to quantitate the progress of the reaction.
[0018] The use of an LED/photodiode arrangement also reduces the need for critical positioning or distancing of the source and sensor with respect to the sample, again thereby making the cycler more robust. Conveniently the source and sensor operate at different wavelengths of light; for example, a preferred source is an LED emitting light at 490 nm, while a preferred sensor is most sensitive to light at 530 nm. This is consistent with typical fluorophores used in biochemical reactions. Modulated illumination of the LED or LEDs can be used, in order to help remove noise and background from the signal.
[0019] Where the sample block is sandwiched between the Peltier-type element and the heating device, the sample block will preferably be sized and shaped to receive multiple sample tubes arranged in a linear manner, or a strip of sample tubes. This ensures uniform heating and cooling. The Peltier and heating elements are preferably located above and below the sample block in normal use, and the sample block is orientated to receive the sample holder from the side (rather than from above as with conventional cyclers). This arrangement has an additional advantage over conventional arrangements, in that a side opening means that it is less likely that foreign objects will fall into the opening and either contaminate the sample, or obscure any optical assembly which may be present within the cycler.
[0020] The construction of the sample block sandwiched between heating element and Peltier allows optimum shape and size to receive a sample holder and to provide thermal transfer whilst enabling a design with minimal mass. In combination with high surface to area ratio tubes, thermal transfer rates to the reaction from the sample block is highly efficient.
[0021] The sample holder need not be received generally horizontally; an angle of less than 90 degrees may be sufficient, for example, less than 80, 70, 60, 50, 45, 40 degrees.
[0022] The sample block may be removable from the thermal cycler; this allows use of replaceable or interchangeable blocks, for example to accommodate different sizes or arrangements of sample tubes.
[0023] The non-Peltier-type heating device may be any suitable heater, and is preferably an electrical resistance heater. Other heating devices may be used. The heating device may include one or more openings to allow light to pass through the device; this allows a light source and detector combination to be used which is located outside the sample block/heater.
[0024] Preferably the Peltier-type element is configured so as to be deactivated when the heater is activated; and preferably also vice versa. When the heater is activated and the Peltier element deactivated, the element acts as a thermal insulator that restricts heat loss from the sample block to the heat pipe and heat sink assembly. This significantly reduces the time required to heat the sample block, and so improves utility. Uniquely, the arrangement of the Peltier in this configuration acts as a ‘thermal gate’, providing a block to thermal loss during heating when switched off, whilst also providing an efficient cooling pathway when it is switched on.
[0025] Heat is removed from the hot side of the Peltier during the cooling phase of the thermal cycle via a heat pipe. The heat pipe preferably has a generally flat cross section, and may include micro-channel pipes containing acetone, or other cooling fluid. For example, Flat Cool Pipes from Amec Thermasol are suitable. Conventional heat pipes are typically based on round section copper pipes filled with water as a cooling fluid; these conventional pipes are less efficient than the preferred pipes, which also provide a much more compact footprint. With conventional heat pipes, the fan and heat sink may need to be stacked above the block which leads to considerable height of the unit. Flat Cool Pipes or similar allow the lateral, sequential positioning of components where the conventional method is limited to vertical stacking of components. This provides a compact positioning of parts. Critically it allows the heat sink to be arranged below the heat pipe that provides a highly efficient space footprint compared to conventional assemblies.
[0026] The heat pipe is preferably generally S-shaped, with the upper section contacting the heat sink, and the lower section contacting the Peltier element. The upper section is inclined (preferably around 20°, but in certain embodiments up to 90°) and the lower section is generally horizontal (preferably around 0°), but in certain embodiments up to 90°. The lower section is preferably smaller in area (for example, less than 10%, 20%, 30%, 40, 50% in area) of the upper section. For maximum efficiency at least the last 20% of the heat pipe is preferably inclined to be higher than the lower part where the heat is being generated, though in general greater than 50% of the heat pipe is inclined to provide the upper section. This allows efficient thermal transfer from the heat source, and also allows re-circulation of the cooling fluid within the pipe. Of course, it will be appreciated that the use of an S-shaped heat pipe is not essential to the invention, and that other shapes, including generally horizontal pipes, may be used.
[0027] The upper section of the heat pipe is connected to a heat sink, which may optionally also comprise an axial fan. This is used to remove excessive heat generated and transferred to the upper section of the heat pipe. The heat sink may be of any convenient form or material, but optionally it will be a forged aluminium pad with pin fins. Pins are preferably arranged in a ‘dense’ format of greater than 16 pins per cm 2 .
[0028] Heat is removed from the heat sink using a high airflow fan, typically with airflow greater than 10, 20, 30 or 40 CFM (cubic feet per minute). Airflow via direct impingement is used to remove excess heat from the heat sink and is directed out of the device. Where alternative ‘fin’ heat sinks are used, axial, blower, tangential, or any convenient fan may provide the required airflow.
[0029] The cycler may further comprise a computer processor, which may be used for any or all of monitoring and controlling the light source and detector, temperature regulation, the cycling program, and the like. The processor is conveniently user-programmable, to allow selection of appropriate cycling programs for particular reactions. For example, the cycler may comprise a user interface, such as a keypad or touch-screen, allowing a desired cycling program to be selected, input or edited.
[0030] The computer processor may be mounted on a substrate, such as a circuit board or a PCB. In preferred embodiments of the invention, the remaining components of the cycler—for example, the Peltier-type element, the heater, the sample block, and the heat sink and pipe—are secured to the substrate. For example, the components may be bolted to the substrate. This allows for ease of construction and assembly, and permits a smaller footprint for the cycler. Of course, not all of the components need be secured directly to the substrate; some of the components may be secured to others (for example, the heater may be secured to the substrate, with the sample block secured to the heater and the Peltier element secured to the sample block). A casing may enclose the substrate and the remaining components.
BRIEF DESCRIPTION OF THE FIGURES
[0031] FIG. 1 shows an external view of a thermal cycler in accordance with an embodiment of the invention;
[0032] FIG. 2 shows an external view of the underside of the thermal cycler of FIG. 1 ;
[0033] FIG. 3 shows a side view of the internal chassis components of the thermal cycler of FIG. 1 ;
[0034] FIG. 4 shows an internal view of the thermal cycler of FIG. 1 ; and
[0035] FIG. 5 shows the construction of the optical assembly and sample block of the thermal cycler of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0036] Referring first of all to FIG. 1 , this shows an exterior view of a thermal cycler in accordance with the present invention. The cycler 10 includes an outer casing 12 formed with a carrying handle 14 . The upper surface of the casing 12 is provided with a touchscreen interface 16 allowing the user to operate the cycler. The front of the casing provides an opening 18 into which can be inserted a sample holder 20 , which includes (in this embodiment) three sample tubes 22 of thin-walled plastic.
[0037] The underside of the cycler 10 is shown in FIG. 2 . The outer casing includes an opening 24 within which is mounted a cooling fan 26 which is adjacent a heat sink 28 . The casing is formed with supports 30 which raise the fan 26 off the benchtop, allowing air to circulate.
[0038] The internal architecture of the cycler 10 is shown in FIG. 3 . The outer casing 12 is not shown in this figure. A PCB substrate 32 is provided, on which are mounted the various electronic components needed to control and operate the cycler (for example, operating the user interface via the touchscreen; activating the heating and cooling elements; and operating the optical assembly). Secured to the substrate 32 via bolts 34 are the heat sink 28 and fan 26 assembly. Also secured to the substrate 32 , but separated from the heat sink 28 , is the sample block 34 .
[0039] A Peltier element 36 is mounted beneath the sample block 34 , in thermal contact therewith. Above the sample block 34 is an electrical resistance heater 38 .
[0040] The Peltier element 36 is secured to a heat pipe 40 , of the flat-section type formed with micro channels, using acetone as a coolant. The heat pipe 40 is generally S-shaped, and includes an upper section 42 in contact with the heat sink 28 and fan 26 , and a lower section 44 in contact with the Peltier element 36 . The upper section 42 is inclined at around 20°, while the lower section 44 is generally horizontal (at around 0°). The lower section 44 is around half the area of the upper section 42 .
[0041] A view of the internal chassis is shown in FIG. 4 . The substrate 32 carries the electronic components and processor needed to operate the cycler, while the remaining components are secured to the substrate 32 with bolts 46 or other fasteners. In this figure, a portion of the heat pipe 40 and the sample block 34 can be seen. The whole assembly can be simply mounted within the casing 12 for ease of manufacture.
[0042] The sample block assembly 34 is shown in more detail in FIG. 5 . The block includes various components of the optical assembly (not shown in the other figures). A PCB 46 including three LEDs 48 is located within an optics assembly former 50 , which includes three apertures 52 for receiving sample tubes, and an opening 54 for allowing light from the LEDs to pass. A 490 nm glass excitation filter 56 is placed in the opening above the LEDs 48 , and the electrical heater 38 above the filter. The heater 38 includes three apertures 58 aligning with the LEDs. The sample block 34 is then placed in the former 50 , and a 535 nm glass emission filter 60 placed at the rear of the sample block 34 . The sample block may include apertures aligning with the LEDs and the emission filter, or may be transparent to light of the appropriate wavelength, or may include waveguides in suitable locations. The whole assembly may then be put together with the other components of the cycler.
[0043] In use, the cycler operates as follows. A user may program a desired cycling program using the touchscreen interface 16 . This causes the control electronics to operate the components in the appropriate manner. A sample may then be loaded into the sample tubes 22 of the sample holder 20 , and the holder then inserted into the sample block 34 via opening 18 .
[0044] When the user presses a “START” icon (or similar) on the touchscreen, the heater 38 and Peltier element 36 are operated in an appropriate manner. The heater 38 is first activated to raise the temperature of the sample to a desired first temperature. Simultaneously the Peltier element 36 is deactivated, such that it acts as a thermal insulator between the sample block and the heat pipe 40 , retaining heat within the sample block. When the sample block has reached the desired temperature for the desired time, the heater 38 may be deactivated, and the Peltier element 36 activated. The Peltier element 36 is operated so as to cool the sample block 34 ; heat is transferred from the sample block to the heat pipe 40 . The heat pipe 40 then transfers heat from the lower section 44 to the upper section 42 ; heat is then dissipated via the heat sink 28 and fan 26 . The cycle then repeats as desired.
[0045] In addition to this, the optics assembly may also be used to monitor the progress of the cycling reaction, either while cycling, or afterwards. The LEDs are actuated to illuminate the sample; emitted light is then detected by a light sensor. The intensity or simply the presence or absence of emitted light may be monitored either over time or at a particular time point. This allows for real time PCR to be carried out.
[0046] The cycler as described herein has several advantages over conventional prior art cyclers. Firstly, overall efficiency is improved by separating the heating and cooling functions, and using a non-Peltier heater. The use of a heat pipe to remove waste heat from the Peltier element, in combination with the separation of heating and cooling functions and the use of the Peltier element as a “gate” when the heater is activated, permits physical separation of the sample block/heater/cooler assembly and the heat sink/fan assembly, giving the cycler an improved physical footprint.
[0047] Further, the overall thermal profile of the ‘thermal waste heat’ is low. In a standard thermal cycler which uses a single Peltier element to both heat and cool, the heat sink can rise to in excess of 65 C to 85 C. With the present system the heat sink may only rise to 40 C-45 C, significantly lower. This in part is due to the recycling of energy within the linear flat heat pipe which has not been used in PCR instruments previously. The heat pipe ensures an efficient removal of heat from the hot side of the Peltier during cooling, which re-cycles the thermal energy and rapidly cools the hot side of the Peltier. The heat energy released by the heat sink is much lower, and therefore the power requirement of the Peltier much less.
[0048] The whole assembly can then operate at multiple power inputs which is significant. For example, a portable, field based unit requires a very low power profile such that it may be powered by batteries. Cyclers in accordance with the present invention can run off less than 50 W total power and still provide cycle times for 30× cycles of under 30 minutes. Increasing the power decreases the cycle times and does not over burden the heat exchange mechanism. The present design enables this ‘multi-power’ ability. 100 W input reduces the cycle times down to 20 minutes and 150 W reduces the times down to 15 minutes. In particular, in preferred embodiments of the invention in use, the cycler undergoes 30 or more standard cycles of 5 seconds each at 50°, 72° and 95° C. in under 30 minutes, when operated at a power of 50 W or less; 30 or more standard cycles of 5 seconds each at 50°, 72° and 95° C. cycles in under 20 minutes, when operated at a power of 100 W or less; or 30 or more standard cycles of 5 seconds each at 50°, 72° and 95° C. cycles in under 20 minutes, when operated at a power of 150 W or less.
[0049] By comparison, standard block thermal cyclers require >500 W, rapid block cyclers such as Finnzymes Piko thermal cycler require 180 W, and air cyclers such as the lightCycler 2.0 from Roche require 800 W.
[0050] In fact, in tests when operating a cycler of the invention at 50 W; the heat pipe varied between 47° C. to 57° C., with the heat sink at 40° C. constant. At 100 W; the heat pipe was at 50° C. to 60° C., and the heat sink at 48° C. constant. At 150 W; the heat pipe was at 53° C. to 63° C., and the heat sink 49° C. constant.
[0051] So with variable power delivery the cooling efficiency remains high and in all circumstances the heat sink does not exceed 50° C. meaning that vented air will sit significantly below 40° C. The benefit of this is that as the ambient temperature increases, the performance of the unit will remain unperturbed.
[0052] Another benefit of the system is that it is less sensitive to changing outside ambient temperatures, again because of the efficiency of the arrangement and because there are multiple routes to remove heat from the system. This is again important for portable units. So even in ambient temperatures in excess of 50 C the unit still returns similar thermal cycling times as conventional units. This is because the fan and heat sink have significant overhead so that if the ambient temperature goes up, more of the heat is removed from the system by the fan and heat sink, rather than the evaporative properties of the heat sink. In fact, we believe that certain embodiments of the invention may operate in ambient temperatures of up to 55 C or more, whereas standard Peltier cyclers can only operate to 30-40 C.
[0053] The configuration allows use of a low mass sample block made from aluminium or thermoelastomer polymers that have high thermal transfer properties; these allow flexibility in the block which means consumables do not get stuck and allows a good resistance fit which is not generally possible with solid blocks and long, thin walled tubes.
[0054] Other advantages of the present invention will be apparent.
|
We describe a thermal cycler comprising a Peltier-type thermoelectric element used for cooling a sample block, and a non-Peltier-type heating device for heating the sample block. The cycler also includes a heat sink connected to the Peltier-type element by a heat pipe, which permits thermal energy to transfer from the Peltier-type element to the heat sink. This configuration operates more efficiently than conventional thermal cyclers which use Peltier-type elements for heating and cooling, and allows a more rapid cycling time as well as operation in a wider range of ambient temperatures. Certain embodiments utilise the Peltier-type element as a thermal gate to reduce thermal loss during heating when the Peltier-type element is switched off.
| 1
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. No. 61/848,248 filed on Dec. 29, 2012 and U.S. Provisional Application Ser. No. 61/848,252 filed on Dec. 29, 2012 and U.S. Provisional Application Ser. No. 61/848,253 filed on Dec. 29, 2012 and U.S. Provisional Application Ser. No. 61/855,583 filed on May 28, 2013 all of which are incorporated by reference herein in their entirety.
TECHNICAL FIELD
[0002] The present invention relates to the field of stakes used to hold a water fowl decoy in position to attract ducks or geese or to hold a trail camera in position for use on an outdoor trail.
BACKGROUND OF THE INVENTION
[0003] Duck hunters often use decoys for attracting ducks during a duck hunt. The decoys are typically displayed near or in the water and many are animated, that is, many decoys are provided with movable wings and heads which may or may not be motorized. Often times, decoys are attached to a pole or stake which holds the decoy in a preferred position which is likely to attract ducks. The decoy may be held above the water so that the motion of the wings gives the appearance of a duck landing on the water. Therefore, it is a requirement that the stake which holds the duck be firmly connected to the ground. Some decoy stakes have only one spiked end. Other decoy stakes have two or more parallel spikes which are shoved into the ground: a stout primary spike and lighter secondary parallel spikes which are simultaneously shoved into the ground. The stout spike gives the stake strength and rigidity and the lighter spikes provide further stability and prevent the stake from spinning in the ground.
[0004] Turkey hunters often use decoys for attracting turkeys. Often times, decoys are attached to a pole or stake which holds the decoy in a preferred position which is likely to attract turkeys. Moreover, the turkey decoy is moved via a jerk line to establish movement. Therefore, it is a requirement that the stake which holds the turkey decoy be firmly connected to the ground. Some decoy stakes have only one spiked end. Other decoy stakes have two spikes which are shoved into the ground: a stout primary spike and a lighter secondary parallel spike, the two spikes being simultaneously shoved into the ground. The double spikes gives the stake strength and rigidity and the lighter spike prevents the stake from spinning in the ground; however, depending upon whether the ground is hard and rocky it can be difficult to set the single or double prong stakes.
DESCRIPTION OF THE RELATED ART
[0005] Stakes or poles for holding decoys, cameras and the like are available from numerous sporting goods outlets which are similar in form to the stakes described above. However, the applicant is unaware of any decoy stakes or trail camera holders which are available or any patents which include all of the elements and limitations of the herein described invention.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention, there is provided a decoy/camera stake comprising, consisting of, or consisting essentially of an elongated rod having a helical coil formed at a bottom end thereof and an integral S-shaped crank handle formed therein above the helical coil. The rod is adjustable in length and male threads at a top end thereof. The threads have a diameter of one quarter inch and a pitch of 20 threads per inch. When compared to a stake with one or more spikes to be driven into the ground for support, a helical coil is a superior form of attachment to the ground for a decoy stake. A stake screwed into soil provides a more stable anchor than a straight shaft of the same length engaging the ground. Moreover, the area around a duck blind used by hunters is likely to be swampy or in a shallow lake or pond where the ground is muddy and soft. Sticking a spike into mud does not provide as secure support as a connection made by screwing in a helical coil, even in the mud. It is an object of this invention to provide a duck decoy stake which includes a helical coil at one end which can be screwed into the ground. It is an object of this invention to provide a duck decoy stake which includes a integral crank handle for the purpose of screwing the stake into the ground. It is an object of this invention to provide a duck decoy stake with helical coiled threads at one end and an opposite end which is square for receiving a duck decoy. It is an object of this invention to provide a duck decoy stake with a helical coil at one end and a crank handle which can be used to thread the coil into the ground, thus forming a rigid connection with the ground and providing secure support for a decoy. It is an object of this invention to provide a duck decoy stake which also includes a loop for attaching a jerk line to the upper end of the decoy stake. It is an object of this invention to provide a duck decoy stake or pole with ¼ inch by 20 threads at the top end for holding a standard camera. It is an object of this invention to provide a duck decoy stake or pole with a receiver at the top end for holding a standard camera wherein the receiver includes rod portion with ¼ inch by 20 threads and the rod portion is adjustably attached to the top end of the stake so that the camera may be held at any desired angle.
[0007] In accordance with the present invention, there is provided a device comprising, consisting of, or consisting essentially of an elongated rod having a helical coil formed at a first end thereof and a lug at the second end thereof. The lug is capable of cooperatively engaging a lug receiver in a turkey decoy. The rod has a U-shaped handle formed therein within about five inches of the lug. The U-shaped handle is formed by bending the rod at a right angle and then, at a location about three inches from the right angle bend, bending the rod one hundred eighty degrees back onto itself, thus forming a U-shape, and then bending the rod at a right angle so that the axis of the rod above the U-shape and the axis of the rod below the U-shape are coaxial.
[0000] Moreover, there is provided a device comprising, consisting of, or consisting essentially of an elongated rod having a helical coil formed at a bottom end thereof and an end cap at a top distal end thereof The rod includes a crank handle formed therein by formation of a “U-shaped handle” near the top end of the decoy stake providing for a holding means to rotate the rod. The top end of the rod includes at least one transverse aperture formed therein about one inch below the top end of the stake and a second transverse aperture formed therein about two inches below the top end, a second transverse aperture contains a ring which is capable of holding a jerk line. It is contemplated that a plurality of transverse apertures can be drilled or formed within the stake to provide adjustable attachment of the decoy which are generally mounted onto a base comprising a round aperture member which fits in cooperative relationship with the top end cap of the rod. When compared to a stake with one or two spikes, a helical coil is a superior form of attachment to the ground for a decoy stake. A stake screwed into soil is more secure than a straight rod, particularly when a user is trying to fix a decoy stake to soil which may be muddy and soft. Sticking a spike into mud is not as secure as a connection made by screwing in a helical coil, even in the mud.
[0008] It is an object of this invention to provide a turkey decoy stake which includes a helical coil at one end which can be screwed into the ground. It is an object of this invention to provide a turkey decoy stake which includes a U-shaped integral handle for the purpose of screwing the stake into the ground. It is an object of this invention to provide a turkey decoy stake with helical coiled threads at one end and a lug at the opposite end for receiving a turkey decoy. It is an object of this invention to provide a turkey decoy stake with a helical coil at one end and an integral handle which can be used to thread the coil into the ground, thus forming a rigid connection with the ground and providing secure support for a decoy.
[0009] Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings showing a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the views wherein:
[0011] FIG. 1 is a front view of a one piece integral decoy stake including a crank handle;
[0012] FIG. 2 is a front view of a disassembled three piece decoy stake kit;
[0013] FIG. 3 is a front view of an assembled three piece decoy stake kit;
[0014] FIG. 4 is a front view of decoy fitted with a square receiver for mounting the decoy on a square ended decoy stake of the present invention;
[0015] FIG. 5 is front view of a decoy stake spinning wing adjustable pole including a square decoy receiver on the top end with an integrated horizontally disposed w-shaped handle disposed near the top end of the stake immediately beneath the decoy receiver supported by a steel rod having a coiled spiral auger on the distal end, wherein the longitudinal shaft comprises at least one outer section of tubing including holes corresponding with a corresponding sized an shaped inner section of the rod having holes and being slidably adjustable within the outer section;
[0016] FIG. 6 is a front view of a one piece decoy/camera stake “low profile turkey stake” including a threaded or smooth portion at the top end and a horizontal disposed S-shaped crank handle at the bottom of the stake above the helical coiled bottom end spiral auger;
[0017] FIG. 7 is a front view of a one piece decoy/camera stake having a trail camera attached to a threaded top end and an S-shaped crank handle located about half way up the length of the stake;
[0018] FIG. 8 is a front view of a two piece decoy/camera stake with a the crank handle located about half way up the stake;
[0019] FIG. 9 is a perspective view of a decoy/camera stake apparatus;
[0020] FIG. 10 is a front view of a top portion of a decoy/camera stake including an camera holding fixture;
[0021] FIG. 11 is a perspective view of an adjustable decoy/camera stake;
[0022] FIG. 12 is a front view of a decoy/camera stake including a decoy rest in the form of a sleeve with a disc stop means and a square conduit on the top distal end including a t-shaped member, an integrated horizontally disposed S-shaped handle, a steel support rod and a spiral auger on the distal end;
[0023] FIG. 13 is a perspective view of a decoy anchor stake;
[0024] FIG. 14 is a perspective view of a turkey decoy anchor stake;
[0025] FIG. 15 is a perspective view of a turkey decoy mounted on the decoy anchor stake of FIG. 14 ;
[0026] FIG. 16 is a front view of the one piece integral decoy stake;
[0027] FIG. 17 is a front view of a disassembled three piece decoy stake kit;
[0028] FIG. 18 is a front view of an assembled three piece decoy stake kit;
[0029] FIG. 19 is a front view of decoy fitted with a square receiver for mounting the decoy on a square ended decoy stake of the present invention;
[0030] FIG. 20 is a side view of a fowl decoy stake;
[0031] FIG. 21 is a front plan view of the fowl decoy stake of FIG. 20 including a handle and a mounting cap;
[0032] FIG. 22 is an enlarged perspective view of the cap of FIG. 21 ;
[0033] FIG. 23 is a perspective view o the fowl decoy stake and cap;
[0034] FIG. 24 is a side view of the camera adapter mounting on a stake;
[0035] FIG. 25 is an enlarged view of the camera adapter of FIG. 24 ;
[0036] FIG. 26 is a front view of the camera adapter and stake of FIG. 24 ;
[0037] FIG. 27 is a perspective view of the camera adapter and stake of FIG. 24 ;
[0038] FIG. 28 is a side view of the locking cam mechanism and stake;
[0039] FIG. 29 is a front view of the locking cam mechanism and stake of FIG. 28 ;
[0040] FIG. 30 is an enlarged view of the locking cam mechanism of FIG. 28 ;
[0041] FIG. 31 is perspective view of the locking cam mechanism and stake of FIG. 28 ;
[0042] FIG. 32 is a side view of the locking cam mechanism;
[0043] FIG. 33 is top view of the locking cam mechanism of FIG. 32 ;
[0044] FIG. 34 is front view of the locking cam mechanism of FIG. 32 ;
[0045] FIG. 35 is sectional rear view of the locking cam mechanism of FIG. 32 ;
[0046] FIG. 36 is a perspective view of the locking tube of the cam mechanism of FIG. 32 ; and
[0047] FIG. 37 is a perspective view of the cam mechanism of FIG. 32 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] In accordance with the present invention, there is provided a decoy stake which holds a duck decoy in position for attracting ducks during a duck hunt.
[0049] FIG. 1 shows a decoy stake 10 which includes an elongated shaft 11 which terminates at one end with a length of helical coil 12 and includes an elongated squared off shape 16 at the opposite distal end. The helical coil can be welded onto the end of a rod or fabricated by twisting the rod. The distal end of the rod typically includes a sharpened point 51 for piecing the ground. The medial portion of the stake 11 can be of any desired length; however, the stake is typically 1-3 feet long. An integral crank portion 14 is positioned above a selected length of the lower straight shank section 53 . The crank 55 is formed by bending the rod at generally 90 degree angles (right angles), wherein a selected length of the rod or first crank section 55 is bent at outwardly horizontal to the ground at an angle from about 80 to 90 degrees, a second crank section 56 is bent upwardly vertical at an angle of between 80-90 degrees forming the handle portion. The rod is then bent inwardly at from 80-90 degrees horizontal with and parallel to the first crank section 55 forming a third crank section 58 with the outwardly bent portion in alignment therewith. The rod is then bent upwardly vertical to the ground at an angle of from 80-90 degrees in axial alignment with the lower portion of the rod 53 forming a top section 60 . The top distal end of the top section 60 of the rod includes a squared off cross-section end 16 having a first transverse aperture 18 formed therein about one inch below the top end of the stake and a second transverse aperture formed therein about two inches below the top end, the second transverse aperture contains a ring which is capable of holding a jerk line. It is contemplated that a plurality of transverse apertures can be drilled or formed within the stake to provide adjustable attachment of the decoy which is generally mounted onto a base with a tubular square shaped member which fits in cooperative relationship with the top end 16 of the rod. As shown in FIGS. 28-37 , a cam lock is shown which secures the rod or male fitting of a decoy, camera, or other mounted item within the female coupling at the distal end of the stake. The cam lock is shown having a square cross sectional area; however, it is contemplated that the cam lock is adaptable to cylindrical coupling units.
[0050] The transverse hole 18 near the tip 15 of the squared off end 16 is provided for insertion of a pin or keeper when the square hollow receiver 54 of the decoy 50 is installed on the squared end 16 . Another transverse hole 19 contains a ring 20 for connection of a jerk line which a user may pull or jerk to cause the decoy stake to move.
[0051] After the stake 10 is screwed into the ground, the square hollow receiver 54 of a decoy 50 , as shown in FIG. 4 , is slipped over the square end 16 of the stake 10 . The hole 52 in receiver 54 is aligned with the hole 18 in the square end 16 of the stake 10 , and a lynch pin , such as shown in lynch pin 40 in FIG. 2 , is slipped through to lock the decoy 50 into place on the stake 10 . Thus a jerk line may be attached to a ring, such as a D-ring extending through the aperture or the line may be threaded through an aperture.
[0052] Another preferred embodiment of the present invention is shown in FIG. 2 and FIG. 3 . The decoy stake 30 is contains a three part shaft including two round rods 33 and 34 and a tube 36 into which the rods 33 and 34 are slipped. The transverse hole 31 in rod 33 is aligned with the transverse hole 37 in the tube 36 and a lynch pin 40 is inserted therein. Likewise, the transverse hole 35 in rod 34 is brought into alignment with the transverse hole 38 of tube 36 and a lynch pin 40 is inserted therein. Thus assembled as shown in FIG. 3 , the stake 30 can be used in the same way as the stake 10 is used. The disassembled three part shaft enables more compact storage of the stake 30 and also the capability of having an even longer assembled stake 30 depending on the size and number of rods and tubes and a plurality of transverse holes 38 located incrementally from a bottom end of tube 36 . The three part nature of the stake 30 also facilitates transport in a back pack, or small case which is space saving.
[0053] The decoy stake can be formed in one integral piece by bending a single length of rod or can be formed by welding, brazing or using other means of securing the individual members together.
[0054] It is also contemplated that portions of the kit comprising the decoy stake may be fabricated from carbon fiber, fiberglass, or even molded from high density plastic in an integral form or individual sections.
[0055] It is further contemplated that a sleeve may be utilized in combination with the handle section 56 .
[0056] Further embodiments of the decoy/camera stake are shown in FIGS. 5-11 and include a variety of decoy/camera receiving fixtures at the top of the stake and an S-shaped crank handle located at various vertical positions between the tope end and the helical coiled bottom end.
[0057] A one piece decoy stake 13 shown in FIG. 5 includes a helical coil 12 at the bottom end, an upward extending longitudinal shaft 22 , an integral S-shaped crank handle near the top end, and a square decoy receiver.
[0058] A one piece decoy/camera stake 21 shown in FIG. 6 includes a helical coil 12 at the bottom end, an integral S-shaped crank handle just above the helical coil, and an upward extending longitudinal shaft ending with a one quarter inch diameter end with threads spaced at 20 per inch or in other words, ‘quarter 20 ’ threads. This thread arrangement is capable of removably holding cameras with female quarter 20 threads integrated on the bottom of the camera. Decoys supplied with such threads can also be mounted on this threaded rod.
[0059] Another one piece decoy/camera stake 23 shown in FIG. 7 is the same as stake 21 in FIG. 6 except that the S-shaped crank handle is located in a central position along the length of the stake. Stake 23 is shown with a trail camera installed thereon.
[0060] An adjustable two piece decoy/camera stake 57 , shown in FIG. 8 includes an upper portion having a threaded top end 25 and a hollow pipe section 36 fixedly attached at the lower end with a plurality of transverse holes, one above another, for attaching a lower portion 48 of the stake, and a lower portion 48 which includes a helical coil, an S-shaped crank handle and a longitudinal top portion which is inserted into the hollow pipe section. The longitudinal top portion includes a transverse hole which is brought into alignment with a selected one of the plurality of transverse holes in the hollow pipe section. A lynch pin 40 is inserted into the aligned holes to hold the top portion to the lower portion. The selection of a particular one of the plurality of transverse holes in the hollow pipe section determines the length of the adjustable decoy/camera stake.
[0061] As best illustrated in FIG. 9 , one preferred three piece adjustable decoy/camera stake apparatus 59 includes an upper longitudinal hollow pipe or sleeve portion 82 which is rotatably and supported by the distal end of upper rod section 83 and secured in a selected position by a wing nut set screw arrangement 62 . The decoy/camera mounting fixture includes a pair of opposing horizontal T-shaped plates 68 for holding a camera thereon, mounted to the sleeve portion 82 by welding or other fastening means such as a second wing nut set screw arrangement 63 . A horizontal disposed s-shaped crank handle 26 is integrally formed in the a lower portion of the upper rod section 83 which is removably and rotatably connected with a lower rod section 65 by an adjustable trail cam mount coupling device 64 . It is contemplated that a receiver 66 for a decoy could be placed on the top of the sleeve 82 . The lower rod portion 65 includes a integral spiral auger 69 extending from its distal end for anchoring the stake into the ground. A tripod assembly 74 includes a tripod adjustment means comprising a sliding and rotating sleeve or collar 67 slipped over the lower rod and secured with holding means such as a set screw arrangement at a selected position. A plurality of legs 75 extend downward at a selected acute angle from the collar to rest upon a supporting surface.
[0062] Another three piece adjustable decoy/camera stake 60 is shown in FIGS. 10 and 11 . The stake 60 includes upper portion 84 with a longitudinal hollow pipe member 85 including an S-shaped crank handle 26 , a clamp with thumbscrew 62 at the lower end and a spherical ball 78 at the upper end on which a decoy/camera mounting fixture 80 is adjustably held tight by thumbscrew 62 . A lower portion 86 includes a longitudinal rod 69 held within an adjustable tripod 74 with a locking thumbscrew 73 and three legs 75 . The longitudinal rod 69 has a helical coil (not shown in FIG. 11 ) at the lower end thereof. The decoy/camera mounting fixture includes a horizontal T-shaped plate 68 with an aperture 70 into which can be placed a quarter 20 screw which will then hold a camera or a decoy. A spherical ball and socket arrangement or clamp 78 camera mounting fixture 80 and thumbscrew 62 form a fixable or lockable ball joint which allows the camera mount 80 and therefore, the camera to be tilted at a wide range of vertical and horizontal angles with respect to the ground.
[0063] As shown in FIG. 13 , a decoy stake 110 which includes an elongated shaft 111 which terminates at one end in the shape of a helical coil 112 and includes an elongated squared off shape 116 at the opposite distal end. The helical coil can be welded onto the end of a rod or fabricated by twisting the rod. The distal end of the rod typically includes a point 150 for piecing the ground. The medial portion 152 of the stake 111 can be of any desired length; however, it is typically 1 - 3 feet long. Decoy stake 110 also includes a T-handle 114 located near the square end 116 whereby a user can use the T-handle 114 while pressing the end of the helical coil 112 into the soil and can turn the T-handle 114 to cause the helical coil 112 to be threaded into the ground. Another transverse hole 119 contains a ring 120 for connection of a jerk line which a user may pull or jerk to cause the decoy stake to move, thus imparting motion to the decoy 150 . After the stake 110 is screwed into the ground, the square hollow receiver 154 of a decoy 150 is slipped over the square end 116 of the stake 110 . The hole 152 in receiver 154 is aligned with the hole 118 in the square end 116 of the stake 110 , and a lynch pin is slipped through to lock the decoy 150 into place on the stake 110 . The decoy stake can be formed in one integral piece by bending a single length of rod or it can be formed by welding, brazing or using other means of securing the individual members together. Another preferred embodiment of the present invention provides a decoy stake including a three part shaft including two rods and a tube into which the rods are cooperatively engaged. The transverse holes formed in the in rods are aligned with the transverse hole in the tube and a lynch pin is inserted therein. The transverse hole in the rod can be brought into alignment with the transverse hole of tube and a lynch pin inserted therein. The disassembled three part shaft enables more compact storage of the stake and also the capability of having and even longer assembled stake depending on the size and number of rods and tubes. It also facilitates transport in a back pack, or case which will fit into a luggage compartment. It is also contemplated that portions of the kit comprising the decoy stake may be fabricated from carbon fiber, fiberglass, or even molded from high density plastic in an integral form or individual sections. It is contemplated that the T-handle may be formed by hinged members which may be folded up and/or folded down against the longitudinal rod for storage or transportation.
[0064] FIGS. 14-15 show a decoy stake 210 which includes an elongated shaft 211 which terminates at a point at the lower distal end and forms a spiral in the shape of a helical coil 212 which supports a turkey decoy holding lug at the other end cap. One preferred embodiment of the turkey decoy anchor 210 includes an integral U-shaped handle 214 at a selected location near the top of the end cap whereby a user can hold the rod with one hand and rotate the U-shaped handle 214 causing the end of the helical coil 212 to penetrate the soil rotating the helical coil 212 into the ground. After the stake 210 is screwed into the ground, the mounting lug receiver of a decoy 250 cooperatively engages the end cap 216 of the stake 210 . In an alternate embodiment, the turkey decoy anchor includes an elongated shaft which terminates at one end in the shape of a helical coil and includes an annular end cap at the opposite distal end. The helical coil can be welded onto the end of a rod or fabricated by twisting the rod. The distal end of the rod typically includes a point for piecing the ground. The medial portion of the stake can be of any desired length; however, it is typically 1-3 feet long. An integral crank portion is positioned above a selected length of the lower straight shank section. The crank is formed by bending the rod at generally 90 degree angles (right angles), wherein a selected length of the rod or first crank section is bent at outwardly horizontal to the ground at an angle from about 80 to 90 degrees, a second crank section is bent upwardly vertical at an angle of between 80-90 degrees forming the handle portion. The rod is then bent inwardly at from 80-90 degrees horizontal with and parallel to the first crank section forming a third crank section with the outwardly bent portion in alignment therewith. The rod is then bent upwardly vertical to the ground at an angle of from 80-90 degrees in axial alignment with the lower portion of the rod forming a top section. The top distal end of the top section of the rod includes an annular end cap having a first transverse aperture formed therein about one inch below the top end of the stake and a second transverse aperture formed therein about two inches below the top end, the second transverse aperture contains a ring which is capable of holding a jerk line. It is contemplated that a plurality of transverse apertures can be drilled or formed within the stake to provide adjustable attachment of the decoy which are generally mounted onto a base with a tubular square shaped member which fits in cooperative relationship with the top end 16 of the rod. The transverse hole near the end cap is provided for insertion of a pin or keeper when the square hollow receiver of the decoy is installed on the end cap. Another transverse hole contains a ring for connection of a jerk line which a user may pull or jerk to cause the decoy stake to move. Another alternate embodiment of the present invention contains a three part shaft including a bottom spiral section, an intermediate section with the handle and a top section with the mounting end cap. The disassembled three part shaft enables more compact storage of the stake and also the capability of having and even longer assembled stake depending on the size and number of rods and tubes. It also facilitates transport in a back pack, or case which will fit into a luggage compartment. The decoy stake can be formed in one integral piece by bending a single length of rod or it can be formed by welding, brazing or using other means of securing the individual members together. It is contemplated that a sleeve may be utilized in combination with the handle section 56 .
[0065] FIGS. 16-19 show a decoy stake 10 which includes an elongated shaft 311 which terminates at one end in the shape of a helical coil 312 and includes an elongated squared off shape 316 at the opposite distal end. The helical coil can be welded onto the end of a rod or fabricated by twisting the rod. The distal end of the rod typically includes a point 350 for piecing the ground. The medial portion 352 of the stake 311 can be of any desired length; however, it is typically 1-3 feet long. An integral crank portion 314 is positioned above a selected length of the lower straight shank section 352 . The crank 354 is formed by bending the rod at generally 90 degree angles (right angles), wherein a selected length of the rod or first crank section 354 is bent at outwardly horizontal to the ground at an angle from about 80 to 90 degrees, a second crank section 356 is bent upwardly vertical at an angle of between 80-90 degrees forming the handle portion. The rod is then bent inwardly at from 80-90 degrees horizontal with and parallel to the first crank section 354 forming a third crank section 358 with the outwardly bent portion in alignment therewith. The rod is then bent upwardly vertical to the ground at an angle of from 80-90 degrees in axial alignment with the lower portion of the rod 333 forming a top section 360 . The top distal end of the top section 360 of the rod includes a squared off cross-section end 316 having a first transverse aperture 318 formed therein about one inch below the top end of the stake and a second transverse aperture formed therein about two inches below the top end, the second transverse aperture contains a ring which is capable of holding a jerk line. It is contemplated that a plurality of transverse apertures can be drilled or formed within the stake to provide adjustable attachment of the decoy which are generally mounted onto a base with a tubular square shaped member which fits in cooperative relationship with the top end 316 of the rod. The transverse hole 318 near the tip 315 of the squared off end 316 is provided for insertion of a pin or keeper when the square hollow receiver 354 of the decoy 350 is installed on the squared end 316 . Another transverse hole 319 contains a ring 320 for connection of a jerk line which a user may pull or jerk to cause the decoy stake to move. The crank handle 314 is located near the square end 316 whereby a user can loosely hold the squared end 316 in one hand and the crank handle 314 in the other hand while pressing the end of the helical coil 312 into the soil and can turn the crank handle 314 with respect to the square end 316 to cause the helical coil 312 to be threaded into the ground. The crank handle is formed by bending rod 311 ninety degrees about 5 inches below the top end to form a horizontal portion. About four inches past the first ninety degree bend, make a second ninety degree bend vertically downward. About four inches from the second ninety degree bend, make a third ninety degree bend so that the rod now forms a U shape. Finally, about four inches from the third ninety degree bend, bend rod 311 vertically downward so that the top portion of rod 311 above the U shape, is coaxial with the bottom portion of rod 311 below the U shape. After the stake 310 is screwed into the ground, the square hollow receiver 354 of a decoy 350 is slipped over the square end 316 of the stake 310 . The hole 352 in receiver 354 is aligned with the hole 318 in the square end 316 of the stake 310 , and a lynch pin , such as shown in lynch pin 340 is slipped through to lock the decoy 350 into place on the stake 310 . Thus a jerk line may be attached to a ring, such as a D-ring extending through the aperture or the line may be threaded through an aperture. In an alternate embodiment, the decoy stake 330 is contains a three part shaft including two round rods 333 and 334 and a tube 336 into which the rods 333 and 334 are slipped. The transverse hole 331 in rod 333 is aligned with the transverse hole 337 in the tube 336 and a lynch pin 340 is inserted therein. Likewise, the transverse hole 335 in rod 334 is brought into alignment with the transverse hole 338 of tube 336 and a lynch pin 340 is inserted therein. Thus, the stake 330 can be used in the same way as the stake 310 is used. The disassembled three part shaft enables more compact storage of the stake 330 and also the capability of having and even longer assembled stake 330 depending on the size and number of rods and tubes. It also facilitates transport in a back pack, or case which will fit into a luggage compartment.
[0066] The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made upon departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplification presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims.
|
A stake which can be screwed into the ground to hold a device such as a water fowl decoy or a trail camera in position primarily for use out doors. The stake includes a helical coil at one end for fixedly and removably attaching that end of the stake into the ground by screwing the helical coil into the ground. The other end of the stake includes a receiver for removably and fixedly attaching a water fowl decoy such as a duck decoy or other elements such as a camera in cooperative engagement with the receiver on the top end of the stake. The stake includes an integral handle configured to manually turn the stake in order to screw the coiled end into the ground. One embodiment includes three outrigger legs for further stability.
| 5
|
BACKGROUND OF THE INVENTION
The present invention relates to improved silver-glass paste compositions for use in attaching semiconductive elements, e.g., silicon dies, to appropriate substrates.
Prior patents directed to this type of paste include U.S. Pat. Nos. 3,497,774; 4,401,767; 4,436,785; 4,459,166; 4,636,254 and 4,761,224. Typically, these pastes are used for attaching silicon dies to ceramic substrates.
The aforementioned pastes generally comprise the following essential components in the ranges indicated:
______________________________________Component % by Weight______________________________________silver flake 55-75lead borate glass frit 10-25resin 0.5-2%organic vehicle 5-20%______________________________________
Other additives, e.g., silver oxide, thixotropic agents, or the like may also be included.
In a representative die-attachment process, the paste comprising silver flake, glass frit, resin and vehicle is placed in a cavity in a ceramic substrate, the die is placed on the paste and the resulting die/substrate package is fed on a belt onto and through a furnace where the package is heated to remove the organic vehicle and sinter the residual silver and glass to bond the die firmly to the substrate. The final bond layer must be completely free of voids and, as a consequence, the process usually requires a preliminary drying step where vehicle is evaporated followed by firing in the furnace to remove residual vehicle and melt the glass.
The preliminary drying step of necessity is quite lengthy, requiring between about 2-10 hours at 60-80° C., depending on, for example, the die size. Additionally, the ramp rate, i.e., the rate at which the package is fed from the drying step into the furnace, is carefully controlled so as to ensure that organic burnout is at least essentially completed before the sintering of the silver-glass mix takes place. Relatively low temperature (e.g., up to 50° C./minute) ramp rates are very commonly used to insure vehicle removal and optimum results. Belt-type furnaces are normally employed for the firing stage and, depending on the number of temperature zones involved, the dwell time in the furnace can vary from 30-90 minutes or more. Overall, therefore, from preliminary drying through firing, the processing time for effectively attaching a silicon die to a ceramic substrate is a relatively lengthy one.
BRIEF DESCRIPTION OF THE INVENTION
The pastes of the invention permit the elimination of the preliminary drying step and faster overall processing to provide a void - and crack-free bond layer for die attachment. These pastes can be effectively used in a single pass through the furnace at a high temperature ramp rate without sacrificing performance requirements. Other advantages of the present pastes will be hereinafter apparent.
Broadly speaking, the pastes of the invention are characterized by including a small amount of one or more ionic or nonionic surfactants which include both a lyophobic group and a lyophilic group with the basic paste components (silver flake, glass frit and vehicle). This additive has been found to enhance stability of the paste so as to avoid or minimize aggregation or settling of the silver and glass particles with consequent overall improvement in the performance of the paste. Additionally, the surfactant additive functions to permit use of the paste without a preliminary drying step and at a faster ramp rate (e.g., 90° C./min) to give a bond layer which is essentially free from voids and/or cracks.
The silver and glass components in conventional pastes have a tendency to flocculate because of Van der Waals attractive forces and the resulting increase in free energy of the system when the silver and glass particles are separated from each other. It appears that by using the surfactant additive of the invention, i.e., a surfactant containing a lyophobic group which has very little, if any, attraction for the solvent or organic vehicle together with a lyophilic group which has a strong attraction for the vehicle, the tendency for flocculation to occur is reduced and paste stability consequently enhanced. Without intending to be limited to any particular theory of operation, it appears that the lyophobic group of the surfactant is adsorbed onto the surface of silver or glass particles to form a steric barrier to the vehicle while the lyophilic portion or "tail" of the surfactant extends into the vehicle or steric layer. Flocculation of particles is inhibited by thickening the steric barrier and physically keeping dispersed particles apart and by reducing the efficiency of interparticle collision. This results in enhanced paste stability with consequent advantages as noted above, e.g., the possibility of eliminating the drying step, faster heating rates with reduced time to obtain a void- and crack-free bond between silicon die and substrate.
DETAILED DESCRIPTION OF THE INVENTION
A wide variety of surfactants may be used for present purposes provided they include both a lyophobic group and a lyophilic group and are stable at temperatures above about 300° C., i.e., close to or above the temperature where sintering of the silver-glass mix begins. Advantageously the lyophobic group is a long chain hydrocarbon radical while the lyophilic group is an ionic or highly polar group. As examples of lyophobic groups, there may be mentioned:
C 8 -C 20 straight or branched chain alkyl;
phenyl groups substituted with C 8 -C 20 alkyl;
naphthyl groups substituted with alkyl containing 3 or more carbons;
rosin derivatives;
high molecular weight propylene oxide polymers (polyoxypropylene glycol derivatives); or the like.
As the lyophilic component, there may be mentioned such nonionic materials as the monoglyceride of long chain fatty acids of the formula RCOOCH 2 CHOHCH 2 OH where R is a long chain alkyl (e.g., C 12 or more) and/or polyoxyethylenated alkyl phenols of the formula R-C 6 H 4 (OC 2 H 4 ) x OH where R is alkyl of 8 to 20 carbons and x is an integer, e.g., from 1 to 70, sulfated derivatives thereof and the alkali metal salts of such derivatives.
As specific examples of surfactants containing both lyophobic and lyophilic groups suitable for use herein, there may be mentioned: Triton X (the sodium salt of an octylphenol which is ethoxylated and sulfated), Pluronic (ethylene oxide propylene oxide block copolymer), Tetronic (fatty amine ethoxylate), Post-4 (hydrogenated castor oil), Tinagel (fatty amine ethoxylate), Lecithin (B-N-alkylamino propionic acid).
The amount of surfactant used can be relatively widely varied and will depend, at least to some extent, on the surfactant employed. Usually, however, the surfactant will comprise from 0.05-2% by weight of the paste, i.e., based on the total weight of silver, glass, resin, solvent and surfactant.
The surfactant may be added at any convenient stage in the formulation of the paste. In one preferred embodiment, the silver flake, resin and solvent are mixed together with the surfactant and the glass added thereafter. Alternatively, however, all of the components may be mixed together at one time until a homogeneous formulation is obtained. Usually low shear mixing for 2-6 hours is adequate to provide a homogeneous composition.
Apart from the addition of the ionic or nonionic surfactant as described, the paste includes conventional components. Preferably, the silver flake has a surface area of 0.5-1.0 m 2 /g and a tap density of 2.5-4.0 gram/cc. For present purposes, it is desirable that the silver flake is essentially uniform in size although variations may result in the flake as milled. The amount of flake used can be varied but usually will fall in the range of 55-75%, based on the total weight of the paste.
The glass component is lead borate glass frit which is silica- and sodium-free. Normally this glass will comprise a lead borate frit having a softening point in the range of 325° C. to 425° C., a coefficient of thermal expansion no higher than about 15 ppm/° C., a surface area of at least about 0.3 m 2 /gm and a tap density of up to about 4 gm/cc. Usually the glass will comprise 10-25% of the weight of the paste.
A variety of different resin components can be used for present purposes. This includes lower alkyl methacrylates such as methyl, ethyl or isobutyl methacrylate, the latter being preferred. This component usually comprises from about 0.5-2.0% by weight of the paste.
The composition of the solvent can be widely varied. However, the solvent should be one which has a boiling range of 120-200° C. This allows for a one pass paste that requires no drying. A particularly useful solvent comprises an alcohol, notably 2-octanol, preferably in mixture with minor amounts (e.g., 1-20% by weight of the solvent total) of additives such as benzyl alcohol and 4-hydroxy-3-methoxy benzaldehyde. Normally the paste will include 10-20% solvent, on a weight basis.
Other additives may also be included in the pastes of the invention, e.g., silver oxide, a thixotrope, without departing from the invention.
The invention is illustrated, but not limited, by the following examples showing preparation and use of representative compositions of the invention:
EXAMPLE A
The following composition was prepared by blending together the indicated components in the amounts stated:
______________________________________silver flake about 69%lead borate glass about 17%isobutyl methacrylate about 1%ethyleneglycol diacetate about 6%2,2,4 trimethylpentanediol-1,3 about 7%monoisobutyrate 100%______________________________________
This composition, designated A, does not include any surfactant according to the invention, and was used for comparison purposes as described below.
EXAMPLE B
Example A was repeated except that 0.3% of the surfactant "Post-4" was included in the composition to give a composition B.
EXAMPLE C
Example B was repeated except that the "Post-4" was replaced by 0.5 parts of Triton-X.
Triton-X is an octylphenoxypolyethoxyethanol wherein the lyophobic group is a phenyl alkyl group and the lyophilic group is polyethoxyethanol.
EXAMPLE D
Example B was repeated except that 0.5 parts of lecithin was used as the surfactant additive in place of "Post-4".
EXAMPLE E
Example B was repeated except that in this case the surfactant was 0.5 parts "Tinegal", a nonionic alkoxylate.
The compositions of Examples A-E were used to bond a conventional silicon die to a bare ceramic substrate. The process used involved applying the paste to a die cavity on the ceramic substrate, placing the die on the paste and passing the resulting package through a conventional belt furnace to bond the die to the substrate. The ramp rate was 90° C./minute. No preliminary drying step was used. The furnace was operated at a peak temperature of 430° C. The firing process was completed in 20 minutes. After cooling, the bond between the die and substrate was examined for percentage voids, percentage cracks and adhesion (lbs. per inch). The results are tabulated below:
TABLE 1______________________________________ AdhesionComposition % Additive % Void % Crack (lb)______________________________________A 0 20 25 29B 0.3 6 0 26 (Post-4)C 0.5 6 7 36 (Triton-X)D 0.5 4 6 25 (Lecithin)E 0.5 6 0 28 (Tinegal)______________________________________
The foregoing results show that in each instance the use of surfactant (Examples B-E) gave a bond with significantly less voids and cracks while maintaining essentially the same adhesion. It is believed the formation of a steric barrier by the use of the surfactant produced a more stable and homogeneous system and hence reduced the voids. This barrier also seems to slow down the sintering rate of silver-glass mixture and thereby eliminates cracks in a single pass, fast ramp temperature process.
The invention and it advantages are further illustrated by the drawings wherein:
FIG. 1A shows the stable system obtained using the additive according to the invention;
FIG. 1B shows the flocculated system which results without the additive;
FIG. 2 is a representative thermal analysis graph for surfactants suitable for use according to the invention; and
FIG. 3 is a typical thermal mechanical analysis graph for a silver-glass mixture.
Referring more specifically to the drawings, FIG. 1A shows how the particles (1) of silver-glass are stabilized with the surfactant additive providing a steric barrier (2) with respect to the organic solvent or vehicle which preferably is a mixture of organic liquids.
FIG. 1B shows how the particles tend to flocculate without the additive thus leading to voids and cracking when the vehicle is removed.
FIG. 2 illustrates that typically suitable surfactants, e.g., Triton-X or lecithin, are thermally stable up to 300° C. or so at or near the temperature where sintering of the silver-glass mixture starts to occur. It appears that it is this stability of the steric surfactant barrier to temperatures up to 300° C. that helps to control the rate of sintering with elimination of, or reduction in, cracks and voids.
FIG. 3 shows that the conventional silver-glass mix begins to sinter at around 350° C. where the ΔL/L significants drops off. In this connection, it is noted that L represents initial thickness while ΔL is the change in thickness.
It will be appreciated that various modifications are contemplated. Hence, the invention is defined in the following claims wherein:
|
An improved silver-glass paste for bonding a silicon die to a ceramic substrate consisting essentially of silver flake, lead borate glass, resin, surfactant containing lyophilic and lyophobic groups and solvent. The surfactant provides a steric barrier around the silver and glass to stabilize the paste and reduce voiding and cracking when the paste is used to bond the die to the substrate.
| 7
|
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
--
CROSS REFERENCE TO RELATED APPLICATION
--
BACKGROUND OF THE INVENTION
The present invention relates to architectures for integrated circuits and in particular to an improved method and apparatus providing reliable and power conserving, low-voltage operation of the cache structures.
Current computer architectures employ a set of intermediate memories (cache memories) between the processor and a main solid-state memory. A cache memory provides high-speed local storage for the processor that may help overcome the relatively slower access speeds available between the processor and the main solid-state memory. Successful operation of the cache memory takes advantage of the ability to predict likely future use of data by the processor so that data required by the processor may be pre-stored or retained in the cache memory to be quickly available when that data is needed.
Often multiple hierarchical cache memories are be used with the smallest and fastest cache (L1) operating in coordination with successively larger and slower caches (L2, L3) the largest of which is designated the “last-level cache” (LLC). Multiple levels of cache memories allow a flexible trade-off between speed of data access and the likelihood that the requested data will be in the cache memory (a cache hit). Caches are normally managed by a cache controller, which determines which portions of the cache “lines” should be ejected when new data is required in response to a cache miss, for example, and which keeps track of “dirty” cache lines in which the processor has written data to the cache, which must be reflected back into the main computer memory.
With increased circuit density in integrated circuits, power efficiency has become a design priority for high-performance and low-power processors. The maximum speed of high-performance processors is often limited by problems of power dissipation which may be addressed by improving energy efficiency. For low-power processors, energy efficiency increases the operating time of the processor when operating on battery power source.
An effective technique to increase processor efficiency is dynamic voltage and frequency scaling (DVFS) in which the processor voltage and processor clock speed are reduced at times of low processing demand. Reducing the processor voltage and frequency significantly lowers dynamic and static power consumption of transistors.
The minimum voltage (V DDMIN ) that may be used with DVFS for cache memories is determined by the lowest voltage at which the transistor circuitry of the memory cells of the cache may maintain their logical state. V DDMIN may be reduced by increasing the size of the transistors in the SRAM cells of the cache memories. This makes the transistors less sensitive to mismatches induced by process variations such as random dopant fluctuations (RDF) and line edge roughness (LER) limits. Increasing the size of these transistors, however, is undesirable because cache memories currently occupy more than 50 percent of the total area for many processor systems.
SUMMARY OF THE INVENTION
The present invention provides a heterogeneous cache structure in which the cache is divided into predefined portions that may be ranked according to their ability to operate reliably at low voltages. As a voltage on the cache is reduced, different portions of the cache are deactivated according to this ranking, effectively reducing the capacity of the cache while allowing the remaining portions of the cache to remain operable. The decrease in processor performance caused by this reduction in cache capacity at low voltage is strongly mitigated by the reduced performance penalty of accessing main computer memory in a cache miss at concomitant low clock speeds.
Specifically, the invention provides a cache system comprising a series of addressable transistor memory cells holding digital data when powered by an operating voltage. The addressable transistor memory cells are grouped into at least two portions that may be independently deactivated wherein the portions provide different architectures having different predetermined susceptibility to errors as a function of operating voltage. Individual portions of the cache system may be deactivated or activated with changes in operating voltage according to the predetermined susceptibility to errors as a function of operating voltage.
It is thus a feature of at least one embodiment of the invention to vary the architecture of the cache to allow lower voltage operation of at least a portion of the cache and thereby rendering a flexible trade-off between cache area and the ability to conserve power.
The addressable transistor memory cells may be grouped into at least three portions that may be independently deactivated
It is thus a feature of at least one embodiment of the invention to permit a flexible trade-off between performance and power conservation through multiple levels of voltage reduction and cache capacity reduction.
The transistor memory cells of the different portions may differ according to area of the integrated circuit associated with transistors of each memory cell, with the portions having a greater area being less susceptible to errors as operating voltage decreases than memory portions having lesser area.
It is thus a feature of at least one embodiment of the invention to provide the variation in cache architecture by varying the amount of circuit area devoted to each memory cell. Generally, the extra area required for some memory cells may be may be more than offset by the ability to make area devoted to other memory cells smaller, which is possible because those latter memory cells need not operate at homogeneously low voltages.
Corresponding individual transistors of the memory cells of different portions may have different sizes of transistor area.
It is thus a feature of at least one embodiment of the invention to provide a simple method of varying the architecture by scaling the size of the memory cells among the different portions.
Alternatively, the memory cells of different portions may be associated with different numbers of transistors implementing error correcting codes of different lengths.
It is thus a feature of at least one embodiment of the invention to permit variation in the architecture by changing the association of memory cells in different portions with different amounts of error correction circuitry.
Alternatively, the memory cells of different portions may be associated with different numbers of spare memory cells that may be substituted for the memory cells of the portion.
It is thus a feature of at least one embodiment of the invention to control the susceptibility of the memory cells to low-voltage failure through the ability to select among different memory cells for low-voltage properties.
The memory cells may be static random access memory cells.
It is thus a feature of at least one embodiment of the invention to provide a system that works with the most common cache memory architecture.
The cache may work with a cache controller that operates to identify dirty cache lines in groups of memory cells to be deactivated and to move data of these cache lines into main memory.
It is thus a feature of at least one embodiment of the invention to preserve processor operating state after changes in cache capacity.
The cache controller may further operate to identify dirty cache lines in groups of memory cells to be deactivated and to move the data of these cache lines into clean cache lines of groups of memory cells.
It is thus a feature of at least one embodiment of the invention to significantly reduce the overhead of preserving data from cache portions that will be shut down by performing an intra-cache transfer instead of a write back to main memory.
The cache controller may move the data of the cache lines into the clean cache lines of a group of memory cells that have been least recently accessed.
It is thus a feature of at least one embodiment of the invention to decrease the likelihood of displacing useful cache data during the intra-cache transfer. Generally, the least recently accessed cache portions have the least value for future cache access.
These particular features and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a simplified block diagram of a circuit element having a processor, cache controller and multilevel cache structure implementing the present invention;
FIG. 2 is a detailed diagram of a last level cache of FIG. 1 divided into portions or ways associated with different minimum operating voltages further showing the hierarchical data structures forming the cache and variations in the area of the transistors forming memory cells four different ways;
FIG. 3 is a graph of changes in operating voltage showing corresponding changes in cache capacity according to the present invention;
FIG. 4 is a fragmentary diagram of multilevel cache similar to that of FIG. 2 showing intra-cache transfer of dirty cache data;
FIG. 5 is a diagram similar to that of FIGS. 2 and 4 showing an alternative cache architecture in which different numbers of error correcting bits are associated with each memory cell of the different ways;
FIG. 6 is a figure similar to that of FIG. 5 showing alternative cache architecture in which different numbers of backup memory cells provided for each memory cell of the different ways; and
FIG. 7 is a flowchart of a method according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , an integrated circuit element 10 , for example, a core of a microprocessor or a freestanding microprocessor, may include a processor element 12 communicating via cache controller 14 with an L1 cache 16 a , an L2 cache 16 b , and L3 cache 16 c.
Each cache 16 may include a data portion 18 and tag portion 20 , as is generally understood in the art, and, operating under the control of the cache controller 14 , may load data from a main memory 22 together with a tag address identifying the source address of that loaded data in the main memory 22 , and may provide that loaded data to the processor element 12 in response to instructions reading the main memory 22 at the particular source address. The caches 16 may further receive modifications of the loaded data from the processor element 12 and may store that data back to the main memory 22 under control of the cache controller 14 . In these respects, the cache controller 14 may operate in a conventional manner as is understood in the art.
The integrated circuit element 10 may include input lines for operating voltage 24 and ground 26 , these lines together providing power to the circuitry of the integrated circuit element 10 . The integrated circuit element 10 may also receive a clock signal 28 permitting synchronous operation of various elements of the integrated circuit element 10 as is understood in the art.
The operating voltage 24 and the clock signal 28 may be provided by a dynamic voltage frequency scaling (DVFS) circuit 30 monitoring operation of the integrated circuit element 10 and possibly other similar elements of a larger integrated circuit, to change the level of the operating voltage 24 and the frequency of the clock signal 28 according to the operating conditions of the integrated circuit 10 and the other similar elements. In particular the DVFS circuit 30 may monitor use of the integrated circuit element 10 , for example, with respect to queued instructions or its operating temperature, to raise or lower the operating voltage 24 and the frequency of the clock signal 28 at times when the integrated circuit element 10 is busy or idle or is below or has reached an operating temperature limit. The DVFS circuit 30 may provide for a communication line 32 communicating with the cache controller 14 for indicating changes in the operating voltage 24 or clock signal 28 , or the cache controller 14 may receive the operating voltage 24 and clock signal 28 directly and monitor them to deduce changes accordingly.
In the present invention, at least one of the caches 16 , and preferably at least the largest cache 16 c (typically the last-level cache LLC), may be constructed with a heterogeneous architecture in which memory cells 34 (for example, each storing a single bit in the cache memory) are grouped into multiple ways 36 . Because the LLC cache 16 normally has the greatest number of memory cells, the invention provides the greatest impact with this cache, however the invention may also be implemented all caches or different caches.
Each way 36 will thus hold multiple memory cells 34 that may be activated and deactivated as a group by the cache controller 14 . The deactivation of a way 36 substantially removes all operating power from the memory cells 34 of that way 36 so that they lose state information (lose stored information) and cease consuming substantial power. When a given way 36 is deactivated, addressing for reading and writing of the remaining memory cells 34 of the ways 36 that have not been deactivated continues to operate as normal Importantly, the grouping of memory cells 34 into ways 36 (defined by the ability to activate or deactivate all memory cells 34 in a way 36 at once) is consistent among different integrated circuit elements 10 to provide deterministic performance behavior for all such integrated circuit elements 10 .
Each of the memory cells 34 may be composed of multiple transistors receiving the operating voltage 24 to provide power and biasing to the transistors together with control lines, such as word lines, or bit lines, which are used for transferring data. During normal operation of the memory cells 34 the operating voltage 24 will typically be constant and the word lines and bit lines controlled and read in order to read and write data.
Referring now to FIG. 2 , an example LLC cache 16 c may provide for four different ways 36 a - 36 d shown as columns spanning multiple rows 40 of memory cells 34 . Generally each row 40 within each way 36 will provide storage space for multiple cache lines 42 . The cache lines may each be composed of multiple computer words 44 which are in turn composed of multiple bits 48 . Each bit will comprise one memory cell 34 .
The memory cells 34 in each of the different ways 36 will be associated with different circuits using different amounts of integrated circuit area in the integrated circuit element 10 . In the example of FIG. 2 , the sum 50 a of the areas of the transistors associated with each memory cell 34 for way 36 a will be larger than a sum 50 b of the areas of the transistors associated with each memory cells 34 for way 36 b , which in turn will be larger than the sum 50 c of the areas of the transistors associated with each memory cell 34 for way 36 c , which in turn will be larger than the sum 50 d of the areas of the transistors associated with each memory cell 34 for way 36 d.
By changing the areas 50 among the ways 36 , the minimum operating voltage 52 (V DDMIN ) of the memory cells 34 of each of the ways 36 a - 36 d may be varied in a predetermined manner to be lowest for memory cells 34 associated with way 36 a and successively higher for memory cells 34 associated with successive ways of 36 b - 36 d . This increase in minimum operating voltage V DDMIN results from differences in the areas of the transistors of memory cells 34 where larger areas make them less sensitive to mismatches induced by process variations. As noted above, the minimum operating voltage V DDMIN defines how low the operating voltage 24 can be for the memory cells 34 without loss of state information.
Generally the area of the transistor may be any consistent measurement of transistor geometry and will typically be the overlap between the gate and other transistor components for field effect type transistors.
Referring now to FIG. 3 , the cache controller 14 may monitor the operating voltage 24 over time to selectively activate and deactivate the different ways 36 a - d as a function of the operating voltage 24 . Thus, in a first time period 54 a where the operating voltage 24 is above the minimum operating voltages 52 for all ways 36 a - 36 d (shown in FIG. 2 ), all of the ways 36 a - 36 d will be activated for loading and storing of data. As the operating voltage 24 drops progressively below minimum operating voltages 52 for additional individual ways 36 in time periods 54 h - 54 d , those ways 36 whose minimum operative voltage is greater than the current operating voltage 24 will be deactivated starting with way 36 d and progressing through way 36 b until all but way 36 a is deactivated. This process of the activation may be reversed, for example in time periods 54 e and 54 f as the voltage 24 rises to reactivate individual ways 36 .
The present inventors have determined that the performance loss from deactivating ways 36 and thus effectively decreasing the size of the associated cache 16 is substantially offset at lower voltages (where such deactivation will occur) because of lowered frequency of the clock signal 28 of the processor (necessary to match the decreased switching speed of transistors at lower voltages) placing less of a premium on fast access to the main memory 22 and thus permitting a greater number of cache misses with reduced effective penalty for the cache misses.
The use of a heterogeneous cache 16 permits a flexible trade-off between the degree to which the operating voltage 24 may be decreased and loss of performance. The heterogeneous cache 16 even though it employs larger transistors for some ways 36 (e.g. way 36 a ), may nevertheless reduce total cache area by allowing a reduction in the area of the memory cells 34 for some of the other ways 36 (e.g. way 36 d ) whose areas would have to be larger if a uniform value V DDMIN were enforced for each way 36 . As a result, the cache 16 according to the present invention may be comparable in total area on the integrated circuit element 10 to caches in similar machines having higher minimum voltage.
Referring now to FIG. 4 , when the cache controller 14 deactivates a given way 36 , for example, indicated by the cross 56 on way 36 d , it must evaluate the state of the given cache lines 42 a and 42 b associated with that way 36 d . Cache lines 42 b that are “clean” meaning that they have not been modified by the processor element 12 after being loaded from the main memory 22 , may be simply deactivated and any state data lost.
Cache lines 42 a that are “dirty”, meaning that they hold modified data that has been changed by the processor element 12 after having been received from the main memory 22 , cannot be deactivated without loss of data that would affect the execution state of the integrated circuit element 10 . Accordingly the cache controller 14 must preserve this data.
In a simplest embodiment, the cache controller 14 may write data of dirty cache lines 42 a back to main memory 22 using normal cache control techniques.
Alternatively, the dirty cache lines 42 a may be transferred via intra-cache transfer 60 to a clean cache line 42 c in a different way 36 a that is not being deactivated. In one embodiment, the cache controller 14 may select a cache line 42 c to receive the data of the dirty cache line 42 a according to how recently data was loaded into the cache line 42 c from the main memory 22 indicated schematically by numbers 62 associated with each cache line 42 . In this example, the cache controller 14 moves the dirty data from cache line 42 b (in a way 36 d to be deactivated) into the clean cache line 42 c associated with a way 36 a that is not being deactivated and that currently has the oldest stored data. This approach greatly reduces the power and resources necessary for transfer of data from the deactivated cache lines 42 a.
After deactivation or reactivation of a way 36 , the cache controller 14 may compensate for the change in the capacity of the cache 16 by changing stored value indicating cache capacity and available cache lines using techniques well understood in the art in current cache controller technology.
Referring now to FIG. 5 , a division of the cache 16 into multiple ways 36 having rankable differences in minimum operating voltages V DDMIN and thus their response to lowering of the operating voltage 24 , need not change the physical sizes of the transistors of the memory cells 34 but may instead increase the area of the integrated circuit element 10 devoted to each memory cell 34 by associating additional transistors with a given memory cell 34 , wherein the number of additional associated transistors changes according to the particular way 36 . Thus, for example, a cache line 42 in way 36 a may include memory cells 34 associated with multiple error correcting bits 66 (four shown, in this simplified example) which may serve to correct for errors those memory cells 34 as voltage is reduced providing the corresponding cache line with a lower value of V DDMIN . The memory of the error correcting bits 66 and associated circuitry contribute to the effective area of the memory cells 34 according to the area of the error correcting circuitry divided by the number of memory cells 34 for which it provides error correction. The error correcting bits 66 thus effectively increase the area of the integrated circuit element 10 supporting each memory cell to provide greater robustness against low voltage memory loss.
Continuing with this example, cache line 42 for way 36 b may be associated with fewer (e.g. three) parity bits and cache line 42 associated with way 36 c may be associated with two error correcting bits 66 and cache line 42 associated with way 36 d may be associated with one error correcting bit 66 . It will be understood that these numbers of bits are shown for explanation only and that the invention is not bound to a particular number of error correcting or detecting bits provided that a difference in the memory cells 34 for different ways 36 in response to lowering voltage 24 may be effected.
Referring now to FIG. 6 , in an alternative embodiment, different numbers of redundant memory components 67 may be associated with the cache lines 42 of each way 36 . The redundant memory components 67 may be single bits 48 of the cache line 42 or individual computer words 44 of the cache line 42 or even individual memory cells 34 or transistors of a multi transistor memory cell 34 representing a single bit 48 . Importantly, the redundant memory components 67 can be substituted or rewired for corresponding components 67 ′ of the cache line 42 (by setting fuses or the like).
During manufacture, the cache lines 42 of each way 36 are tested to the desired voltage (e.g., lower voltages for way 36 a than for way 36 d ) and components 67 ′ of the tested cache lines 42 that cannot perform at the desired voltage are identified. These underperforming components 67 ′ are then replaced by particular redundant components 67 that have been identified as performing at the desired voltage. Generally, components 67 that will perform at lower relative voltages under normal manufacturing variations will be less common than components 67 that will perform at higher relative voltages. Further, underperforming components 67 ′ will be more common at lower voltages. Accordingly access to more components 67 is provided to the ways 36 that must operate at lower voltages.
Thus, in way 36 a , for example, one component 67 ′ may be replaced by any of four other redundant components 67 , whereas the components 67 ′ in the ways 36 b , 36 c , and 36 d , may be replaced by only three two and one redundant components 67 respectively. In this case, heterogeneous structure is a result of the associations of different numbers of redundant components 67 with the cache lines 42 of each way 36 .
In one embodiment, the redundant components 67 individually may be of equal size in each of the ways 36 a - 36 d and of equal size to the replaced components 67 ′. In different embodiments, however, the redundant components 67 may be slightly larger or smaller than the components they replace to increase or decrease the chance that they may serve as replacement components for a given voltage. In addition, the area of the individual redundant components 67 may be varied according to the ways 36 in some embodiments. In one embodiment, the redundant components 67 may be selected by any of the ways 36 from a common pool shared by all of the ways 36 . The redundant components 67 may then be characterized with respect to voltage and those operating at the lowest voltage levels allocated as needed to the ways 36 operating at the lowest voltage.
The present invention, in each of these embodiments, follows a methodology that begins with the preparation of area differentiated cache structures with error susceptibility ranking of the different portions of the area differentiated cache structure as indicated by process block 70 . This cache structure may be produced by any of the techniques described with respect to FIGS. 2 , and 6 in which each way 36 is associated with a minimum operating voltage threshold V DDMIN of the operating voltage 24 . Different portions of the cache structure having different rankings may be individually activated or deactivated, for example, using a common control line for the portion.
At process block 72 , an error parameter is sensed, for example the value of the operating voltage 24 , the frequency of the clock signal 28 , temperature, detected errors or other proxies for reduced voltage which will be used to control the activation and deactivation of the portions of the cache structure.
At process block 74 , based on the sensed error parameter, different ways 36 may be switched in or out of the cache 16 according to the ranking and based on the sensed error parameter.
While the above described embodiments contemplates that multiple memory cells 34 may be activated and deactivated by the cache controller 14 as a group defined by ways 36 which are represented by columns, it will be understood that the cache controller 14 may alternatively activate and deactivate memory cells 34 according to rows. As before, deactivation of a row substantially removes all operating power from the memory cells 34 of that way 36 so that they lose state information (lose stored information) and cease consuming substantial power.
Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
References to “a processor” should be understood to include not only a stand-alone processor, but a processing core that may be one portion of a multicore processor. The term “processor” should be flexibly interpreted to include a central processing unit and a cache structure or the central processing unit alone as context will require. Furthermore, references to memory, unless otherwise specified, can include one or more processor-readable and accessible memory elements and/or components that can be internal to the processor-controlled device, external to the processor-controlled device, and can be accessed via a wired or wireless network.
The depiction of the circuit elements, for example, the caches, should be understood to be a schematic and representing the logical construction of the elements rather than their physical layout.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. All of the publications described herein, including patents and non-patent publications are hereby incorporated herein by reference in their entireties.
|
A heterogeneous cache structure provides several memory cells into different ways each associated with different minimum voltages below which the memory cells produce substantial state errors. Reduced voltage operation of the cache may be accompanied by deactivating different ways according to the voltage reduction. The differentiation between the memory cells in the ways may be implemented by devoting different amounts of integrated circuit area to each memory cell either by changing the size of the transistors comprising the memory cell or devoting additional transistors to each memory cell in the form of shared error correcting codes or backup memory cells.
| 8
|
BACKGROUND
[0001] This invention relates to a compressed gas utilization system and method and, more particularly, to such a system and method in which the compressed gas is stored in a sub-sea environment and later utilized as energy.
[0002] Compressed air energy storage (CAES) systems are generally known, and are for the purpose of storing energy, in the form of compressed gas, and later utilizing this stored potential energy for such purposes as the generation of electrical power. Typically, the CAES systems use electrical power purchased at low cost during off-peak periods to compress gas for storage. During periods of peak power demand, the potential energy in the stored gas is used to produce electrical power, which may be sole at a premium rate.
[0003] These systems can be used in a stand-alone mode for generating electrical power connected in a power grid, or they can be used with a conventional electrical power generating plant connected in a power grid, or the like. In the latter case, the power generated by the CAES system can be utilized as an adjunct to the power normally generated by the conventional power generating plant, usually during relatively high load conditions. CAES systems can also be used for balancing, optimizing, and enhancing the reliability of power grids and associated base-loaded power generating plants. Also, CAES systems can create spinning reserves or standby generating capacity, and can come on line in a relatively short time to take up a power load in the event a power generating plant on the grid malfunctions. Further, CAES systems can balance the power grid by taking and saving excess power, and can make up extra demand without a ramp up required by conventional power generating plants. Still further, CAES systems can improve the availability of renewable resource power by storing excess power and generating power when the renewable resource power is unavailable or inadequate.
[0004] A typical CAES system, or plant, includes a compression train in which a motor-driven compressor compresses a gas, such as air. The compressed gas is then transferred to, and stored at, a storage site, usually at a remote location, for later use at which time it is transferred back to an expansion side of the CAES plant. During the expansion cycle, the compressed gas is expanded through a conventional expansion train that may include high pressure and/or low pressure turbines that drive an electrical power generator to generate electrical power. In these arrangements, a fuel gas is often burned with the expanding gas to raise the temperature of the gas and improve the efficiency of the system
[0005] However, known CAES plants utilize underground storage facilities for the compressed gas, along with piping systems to connect the storage facility to the compression and expansion sides of the CAES plant. This severely limits the site location due to the dependence on an acceptable geology for underground storage location. Also, the underground storage facility is usually located a considerable distance from the power generation or power consumption areas, resulting in transmission costs, losses and related expenses. Furthermore, underground storage facilities are susceptible to earthquake damage.
[0006] Therefore what is needed is a system of the above type for storing the gas that avoids the above problems. To this end, an embodiment of the present invention is directed to a sub-sea energy storage system which provides a significant improvement over the previous systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a diagrammatic view depicting the system of the present invention.
[0008] [0008]FIG. 2 is a diagrammatic view of the control/monitoring system for the system of FIG. 1.
DETAILED DESCRIPTION
[0009] [0009]FIG. 1 depicts a system according to an embodiment of the invention which includes a plant 10 having a compression side 10 a that includes a conventional motor-driven compression train and associated equipment (not shown) for compressing a gas, such as ambient air. The plant 10 also has an expansion side 10 b in which the compressed gas is expanded through a conventional expansion train that includes high pressure and low pressure turbines that drive an electrical power generator to generate electrical power. It is understood that during operation of the expansion side 10 b of the plant 10 , the gas can be burned with fuel to improve the efficiency of the plant. Since the turbines, the compression and expansion trains, and the power generator are conventional they are not shown nor will they be described in further detail.
[0010] The plant 10 is located on the ground surface in the vicinity of a coastline near an adjacent water source such as a lake, sea, or ocean (hereinafter referred to as “sea”) having a sea floor SF that drops off in height as it extends from the coastline. A piping system 12 is connected between the plant 10 and a manifold 14 resting underwater below the sea level SL on the sea floor SF, and at a distance from the coastline. It is understood that the piping system 12 includes at least one pipe that connects an outlet on the compression side 10 a of the plant 10 to an inlet on the manifold 14 , and at least one pipe that connects an outlet on the manifold to an inlet on the expansion side 10 b of the plant. It can be appreciated that the piping system can include branch pipes, valves, etc. (not shown) to enable these connections to be made. The piping system 12 and the manifold 14 are commercially available devices commonly used in offshore piping systems for oil or gas applications.
[0011] A storage vessel 16 is mounted to the sea floor SF in the vicinity of the manifold 14 . The vessel 16 is fabricated from a flexible material, such as a plastic, fabric, or similar material, that can collapse but does not stretch, and defines a fixed maximum closed volume. Although not shown in the drawings, it is understood that a suitable inlet and outlet are provided on the manifold 14 and the vessel 16 which can be controlled by valves in a conventional manner.
[0012] A conduit 20 connects the outlet of the manifold 14 to the inlet of the vessel as well as the outlet of the vessel to the inlet of the manifold so that the gas flow between the manifold and the vessel can be controlled. To this end it is understood that the conduit 20 can be provided with branch end portions and valving (not shown) to make the above connections. Although the vessel 16 is shown substantially cylindrical in shape with rounded ends, it is understood that this shape can vary, as will be discussed.
[0013] A mooring system 22 is provided that supports the vessel 16 slightly above the sea floor SF with the axis of the vessel extending substantially horizontally. The mooring system 22 is conventional and, as such, can, for example, be in the form of a piling system, an anchor system, a dead weight system, a combination of same, or the like.
[0014] When the flexible vessel 16 is inflated with the stored gas, and it is desired to release the gas from the vessel, the above-mentioned outlet valve associated with the vessel is opened and the hydrostatic pressure acting on the vessel causes a compression of the vessel to force the stored gas out from the vessel and into the conduit 20 . The volume of the vessel 16 and the depth of the vessel below the sea level SL are determined so that this hydrostatic pressure acting on the vessel enables the gas to be discharged from the vessel at a substantially constant discharge pressure as the volume of the gas in the storage vessel decreases. In particular, the volume of the vessel 16 is determined by the combination of the depth of the vessel, the amount of electrical power to be generated by the plant 10 , and the run time of the power generation cycle; while the depth of the vessel 16 is determined by the operating pressure of the plant and the volume of the vessel. The discharged gas passes through the conduit 20 and into the manifold 14 for return to the plant 10 via the piping system 12 .
[0015] Although only one storage vessel 16 is shown in FIG. 1, it is understood that a plurality of vessels can be provided, in which case the manifold 14 would be connected to each vessel.
[0016] A monitoring and control unit 24 is located on the ground surface and is adapted to monitor the conditions of the plant 10 , the piping system 12 , the conduit 20 , the manifold 14 , and/or the storage vessel 16 , and control the operation of same. In particular, and referring to FIG. 2, the unit 24 is electrically connected to five sensors 26 which are associated with the plant 10 , the piping system 12 , the conduit 20 , the manifold 14 , and the vessel 16 , respectively. The sensors 26 sense and monitor the volume, pressure and other parameters of the gas in the plant 10 , the piping system 12 , the conduit 20 , the manifold 14 , and/or the storage vessel 16 and send corresponding output signals to the unit 24 . Also, it is understood that the above-mentioned valves can be operated in any conventional manner, and that the control unit 24 controls the operation of the valves to selectively control the flow of the gas through the piping system 12 from the compression side 10 a of the plant 10 to the manifold 14 , from the manifold to the vessel 16 , from the vessel back to the manifold, and from the manifold to the expansion side 10 b of the plant.
[0017] The unit 24 receives the signals from the sensors 26 and includes a microprocessor, or other computing device, to control the flow of the gas through the piping system 12 and the conduit 20 in the above manner. The unit 24 also can be adapted to monitor other parameters, such as the volume of gas stored in the vessel 16 , the electrical power used to compress the gas in the plant, etc. Since this type of monitoring and control system is conventional, it will not be described in further detail.
[0018] In operation, the compression side 10 a of the plant 10 receives a gas, such as air, and compresses it in the manner discussed above, before the gas flows to the manifold 14 via the piping system 12 , under the control of the control unit 24 . The manifold 14 directs the compressed gas into the storage vessel 16 at a flow rate that produces a pressure greater than the hydrostatic pressure exerted on the vessel. The vessel 16 is initially in a collapsed condition but inflates due to the presence of the compressed gas. This gas flow continues until tension is placed on the wall of the vessel, as measured by a strain gauge, or the like, which indicates that the vessel 16 is fully inflated at which time the gas flow is terminated so that there is minimum or no tensile stress on the vessel insuring that it will not be stretched.
[0019] When it is desired to release the gas from the vessel 16 , the above-mentioned outlet valve associated with the vessel is opened and the hydrostatic pressure acting on the vessel causes a compression of the vessel to force the stored gas out from the vessel and into the conduit 20 . The volume of the vessel 16 and the depth of the vessel below the sea level SL are determined in the manner discussed above so that the hydrostatic pressure acting on the vessel enables the gas to be discharged from the vessel at a substantially constant discharge pressure as the volume of the gas in the storage vessel decreases. The gas discharged from the vessel 16 passes via the conduit 20 , the manifold 14 , and the piping system to the expansion side 10 b of the plant 10 for generating electrical power in the manner discussed above.
[0020] This system thus lends itself to the uses set forth above, including compressing and storing the gas during relatively low load conditions when the cost of electricity to compress the gas is relatively low, while permitting the stored compressed gas from the storage vessel 16 to be used in generating electricity during relatively high load conditions when the cost of the energy is relatively high. Also, due to the fact that the gas is discharged from the vessel 16 at a substantially constant discharge pressure as the volume of the gas in the vessel decreases, as described above, the efficiency is increased while the required overall storage volume is reduced. Further, the system enjoys a reduced susceptibility to earthquake damage and post-compression cooling of the gas due to the low temperature of the sea. This is all achieved while overcoming the drawbacks of the other underground storage facilities discussed above.
[0021] It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the shape and orientation of the storage vessel 16 may be varied from that shown in the drawings as long as the pressure differential (or pressure swing) along the height (or diameter) of the vessel is limited so that a substantially constant discharge pressure is obtained during system operation, as discussed above. Also, a plurality of vessels 16 can be used, in which case the manifold 14 would be adapted to distribute the compressed gas to the vessels simultaneously or sequentially, and the operation would be the same as described above. Further, the manifold 14 can be eliminated and the gas transferred directly to the vessel 16 , especially if only one vessel is used. Moreover, the gas stored in the vessel 16 can be utilized in manners other than the generation of electrical power.
[0022] It is also understood that when the expression “gas” is used in this application, it is intended to cover all types of gas, including air, natural gas, and the like. For example, natural gas can be stored in the above manner and utilized to provide fuel for burners on the expansion side 10 b of the plant 10 , as discussed above. Still further, it is understood that the piping system 12 and the conduit 20 can be used to transfer the compressed gas from the compression side 10 a of the plant 10 to the manifold 14 and to the vessel 16 , respectively, and another conduit and piping system can be used to transfer the stored gas from the vessel and the manifold, respectively, to the expansion side 10 b of the plant.
[0023] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many other modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.
|
A system and method utilizing compressed gas according to which the gas is compressed at a location above ground and transported to an underwater location. The gas is stored at the underwater location and later returned from the underwater location to the above-ground location for utilization as energy.
| 5
|
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present invention relates to a machine for mounting parts, more particularly to a machine which can mount various kinds of parts onto desired positions of a work piece.
An operation cycle of the above mentioned kind of machine includes the steps of:
removing a part from a container of parts,
gripping the taken-out part in a mounting head,
adjusting a direction and position of the part in the mounting head,
mounting the adjusted part onto a desired position of a work piece,
ascertaining whether the part is correctly mounted (this step may be deleted),
fixing the mounted part to the work piece, and
ascertaining whether the part is fixed correctly and securely on the work piece (this step may be deleted).
If the machine as above described is required to mount various kinds of parts in one operation cycle, it is necessary for the machine to have multiple removal devices, gripping devices, adjusting devices, mounting devices and fixing devices whose designs are changed in accordance with the shapes of the parts, and one main controller to control these devices.
In conventional parts mounting machines, it is difficult to exchange any one of the containers of parts, the removal devices, the gripping devices, the adjusting devices, the mounting devices, the fixing devices and a work-piece positioning device for the other one while still maintaining correct positional and operational-timing relations among them. Therefore, conventional parts mounting machines include problems as follows:
(1) When any one of the kinds of parts is exchanged for the other kind thereof, or a total number of the kinds of parts is increased, it is necessary to stop the operation of the parts mounting machine for a long time to remodel the machine.
(2) In order to prevent a number of the parts mounting machines from being remodeled to vary the kinds of parts mounted thereby, or in order to continue operating the parts mounting machines for a long term without remodeling thereof, it is necessary to make a long-term and detailed plan for managing the parts mounting machines. When the managing plan is disturbed once, it is difficult to reconstruct the managing plan to obtain the predetermined production.
OBJECT AND SUMMARY OF THE INVENTION
An object of the present invention is to provide a parts mounting machine which can be easily remodeled to vary the kinds of parts mounted thereby.
According to the present invention, a parts mounting machine comprises,
work piece positioning device having a movable table for positioning a work piece at various desired places,
a plurality of parts handling units detachably fixed to the work piece positioning device, each unit further comprising:
mounting head means fixedly attached to the unit, for holding a part and for mounting the part onto the work piece;
transfer means fixedly attached to the unit, for transferring the part from a container of parts to the mounting head means; and
branch control means, for controlling the mounting head means and the transfer means; and
a main controller, for selectively controlling the plurality of branch control means so that the parts handling units cooperate with the work piece positioning device.
Since each of the parts-handling-units includes the mounting head means and the transfer means cooperating with each other and fixed on one of the units detachably fixed on the work piece positioning device so that each of the parts-handling-units is fixed in relation to the work piece positioning device, it is not necessary that the parts-handling-unit fixed on the body be disassembled when one parts-handling-unit is removed from the parts mounting machine and another one is substituted for the removed parts-handling-unit, so that it is not necessary that the positional and operational-timing relations between the mounting head means and the transfer means in the removed parts-handling-unit be readjusted when the removed parts-handling-unit is fixed again in relation to the work piece positioning device. Moreover since the mounting head means and the transfer means in each of the parts-handling-units are controlled by one of the branch controllers to cooperate with each other and the branch controllers are selectively controlled by the main controller so that in accordance with a desired kind of parts the main controller selects a suitable parts-handling-unit to cooperate with the work piece positioning device, the main controller does not control the cooperation between the mounting head means and the transfer means in each of the parts-handling-units, instead it but controls the cooperation between the selected parts-handling-unit and the work piece positioning device. Thus it is not necessary for the main controller to consider the difference between the cooperation in the removed parts-handling-unit and the cooperation in the substitute parts-handling-unit. Therefore, the types of the parts-handling-units may be exchanged easily for the other ones to vary the kinds of parts mounted onto the work piece.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an embodiment of the present invention.
FIGS. 2a, 2b and 2c are perspective views showing parts-handling-units, a work piece positioning device, and containers of parts, respectively.
FIG. 3 is a flow-chart diagram showing operational steps of the embodiment of FIG. 1.
FIGS. 4a and 4b are a front view and a side view, showing the parts-handling-unit.
FIG. 4c is an enlarged view showing a part indicated by a broken line of FIG 4a.
FIG. 5 is a flow-chart diagram showing operational steps for mounting a wire in the embodiment of FIG. 4.
FIGS. 6a, 6b, 6c and 6d are schematic views showing data used in a positional compensating operation.
FIG. 7a is a schematic view for explaining a method for measuring a distance between a datum point of a work piece positioning table and a work piece setting point.
FIG. 7b is a schematic view for explaining a method for measuring a distance between the datum point of the work piece positioning table positioned at its initialized position and a datum point of a parts-handling-unit.
FIGS. 8a, 8b and 8c are schematic views for explaining a method for calculating a distance between the initialized position of the work piece positioning table and a mounting position thereof at which a work piece correctly set o work piece positioning table by the work piece point is positioned adequately in relation to the parts-handling-unit.
FIG. 9 is a schematic partially cross-sectional view showing an inner structure of the parts-handling-unit.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As shown in FIGS. 1, 2a, 2b and 2c, in one of the parts-handling-units 10, one of the parts-transfer devices 12, one of the mounting hand devices 13, one of the parts-code readers 14, one of the branch controllers 15 and one of the parts fixing devices 16 are securely fixed on one of the bodies 11. Each of the bodies 11 has a signal-interface opening 17 and a power-supply opening 18. One of the parts containers 40 is attached detachably to the body 11. Each of the parts containers 40 has thereon a code-mark 41 corresponding to the kind of parts contained in the parts container 40.
Each of the parts-transfer devices 12 transfers a part from a parts-container 40 to a mounting head 19 included by the mounting head devices 13. Each of the mounting head devices 13 moves the mounting head 19 between a part receiving place, at which the mounting head 19 receives the part transferred from the parts container 40, and a part mounting position, at which the mounting head 19 releases the part to mount it onto a work piece 71 positioned by a work piece positioning device 20. An air-cylinder or a linear servo electric actuator is used for the driving operation of the mounting head 19. Each of the parts-code readers 14 reads the code-mark, for example, the bar-code-mark 41 shown on the parts container 40, and informs the branch controller 15 of the kind of parts contained by the parts container 40. The parts containers 40 contain respective kinds of parts, and the parts are transferred through parts outlet 42.
When the branch controller 15 receives a mounting-operation-starting-signal from a main controller 30 through the signal-interface opening 17, the branch controller 15 outputs a work-piece-positioning-request-signal to the main controller 30. After the work piece positioning device 20 completes the work piece positioning operation according to the work-piece-positioning-request-signal and the part is transferred from the parts container 40 to the mounting head 19, the branch controller 15 operates the parts-handling-unit 10 to mount the transferred part onto the work piece 71. The parts fixing device 16 fixes the mounted part to the work piece. When the mounted part is a discrete IC with lead wires and the work piece is a printed circuit board with holes receiving the lead wires, the parts fixing device 16 cuts and clinches the lead wires received by the holes. When the mounted part is another kind of part, the parts fixing device 16 may have a screw tightening mechanism. In each of the parts-handling-unit 10, the designs of the mounting head 19 and of the parts fixing device 16 are changed in accordance with the kind of parts handled. The signal-interface opening 17 and the power-supply opening 18 of the parts-handling-unit 10 are connected to a signal-interface opening 21 and a power-supply opening 22 of the work piece positioning device 20, respectively, when the parts-handling-unit 10 is attached on the work piece positioning device 20. The branch controllers 15 communicate with the main controller 30 through the signal-interface openings 17 and 21, and the electricity and fluid power for the parts-handling-unit 10 is supplied through the power-supply openings 18 and 22.
Each of the parts-handling-units 10 is detachably fixed on the work piece positioning device 20. In order that the datum points of the parts-handling-units 10 can be set as correctly as possible at respective desired positions in relation to the work piece positioning device 20, each of the parts-handling-units 10 has two positioning holes (not shown) on an attaching surface thereof, and the work piece positioning device 20 has sets of positioning pins (not shown) each set of which has two positioning pins fitted respectively in the two positioning holes of the parts-handling-units 10. After the parts-handling-unit 10 is set on the work piece positioning device 20, the attaching surface of the parts-handling-unit 10 is pressed against an attaching surface of the work piece positioning device 20. The work piece positioning device 20 has a bed 23 and a table driving device 24 fixed on the bed 23. A X-Y table 242 is movable on shafts 241 and is positioned by a combination of a screw-nut unit and a servo motor (not shown) in a longitudinal direction of the shafts 241 which are positioned by another combination of a screw-nut unit and a servo motor (arranged in the table driving device 24) in a direction perpendicular to the longitudinal axes of the shafts 241, so that the X-Y table 242 is movable and positioned on a plane. A X-direction length measuring device 244 and a Y-direction length measuring device 245 are arranged at respective corners of the table 242, and an indexing table 243 is arranged at the center of the X-Y table 242. The work piece is set on the indexing table 243.
After the parts-handling-units 10 are fixed at respective positions on the work piece positioning device 20, the main controller 30 investigates magnitudes of deviations of the actual positions of the datum points of the fixed parts-handling-units 10 from the respective intended positions thereof. Thereafter, when the main controller 30 receives mounting operation instructing signals inputted through a control panel 50, the main controller 10 selects one of the parts-handling-units 10 in accordance with data included by the mounting operation instructing signal, outputs a mounting operation starting signal to the selected parts-handling-unit 10, and instructs the work piece positioning device 20 to position the tables 242 and 243 on the basis of the work-piece-positioning-request-signal outputted by the selected parts-handling-unit 10. When the selected parts-handling-unit 10 completes one mounting operation cycle as above described after the work piece positioning device 20 has positioned the work piece, the main controller repeats the above described operation cycle. Each of the mounting operation instructing signals includes data showing the type of parts-handling-unit 10 needed, the kind of parts needed, a position at which the part is mounted on the work piece, an attitude of the mounted part, and limitations of the operation of the parts-handling-unit 10.
The operation of the parts mounting machine according to the present invention includes three stages as described below. In order to explain the operation intelligibly, it is supposed that the indexing table 243 is held at its reference rotational position. When the parts mounting machine has a plurality of the parts handling units, a compensating operation as described below is repeated according to the number of parts handling units being used. In stage 1, a master piece 72 is set correctly on the indexing table 243 by at least three positioning pins 251 which extend from the indexing table 243 and against which at least two datum sides of the work piece 71 or of the master piece 72 are pressed by an elastic member (not shown). Subsequently, the main controller 30 is requested via a control panel 50 to measure an actual distances between the datum point of the X-Y table 242 and the datum sides of the master piece correctly set by the positioning pins 251, that is, the actual distances between the datum point of the X-Y table 242 and the datum line of the positioning pins 251, in X and Y directions perpendicular to each other, as described below in detail. The measured distance is memorized in the main controller 30. Thereafter, the master piece 72 is replaced by the work piece 71. In stage 2 as shown in steps 1 to 4 of FIG. 3, after the parts-handling-units 10 are fixed on the work piece positioning device 20 and the electricity is supplied from the parts mounting machine, the branch controllers 15 request the main controller 30 to compensate the deviations of the actual positions of the datum points of the fixed parts-handling-units 10 from the respective intended positions thereof (step 1). In step 2, when the main controller 30 receives this request, the parts mounting machine is controlled by the main controller 30 to measure the actual distances between the datum points of the fixed parts-handling-units and the X-Y table reference point, and the measured distance is memorized in the main controller 30, as described below in detail. In Step 3, subsequently, the branch controller 15 of each of the parts-handling-units 10 outputs data showing the type of function performed by the parts-handling-unit 10 and a part kind read by a parts code reader 14 to the main controller 30. In step 4, the main controller 30 memorizes data therein. In stage 3 as shown in steps 5 to 10 of FIG. 3, the main controller 30 selects one of the parts-handling-units 10 suitable for mounting the first kind of parts and outputs a mounting operation starting signal to the selected parts-handling-unit 10 (step 5) after the memorized functional data of the parts-handling-units 10 has been compared with the first in a series of mounting operation instructing signals inputted to the main controller 30 through the control panel 50. In step 6, the selected parts-handling-unit 10 outputs a compensated-positioning data which is calculated by the branch controller 15 in accordance with distances in the X and Y directions between the datum point of the selected parts-handling-unit 10 and the datum point of the handled part on the basis of the mounting operation starting signal including data showing a position where the part is mounted on the work piece 71. The distances in the X and Y directions between the datum point of the selected parts-handling-unit 10 and the datum point of the handled part were previously measured. In step 7, after the main controller 30 receives the compensated-positioning data, the main controller 30 calculates distances in the X and Y directions between the X-Y table reference point and the datum points of the X-Y table 242 as below described, which distances are required for positioning suitably the X-Y table 242. In step 8, when the selected parts-handling-unit 10 receives a positioning completion signal outputted by the main controller 30 after the X-Y table 242 has been correctly positioned, the selected parts-handling-unit 10 starts its mounting operation controlled by the branch controller 15, in which the mounting head having the part transferred from the parts container 40 to the mounting head 19 of the mounting head devices 13 by the parts-transfer device 12 descends to the work piece and releases the part to mount it thereon. After the part has been mounted on the work piece, if the part has the lead wires received by the holes of the work piece, the parts fixing device 16 cuts the lead wires at suitable length and clinches the remaining wires. If it is confirmed that the part is securely and correctly fixed on the work piece, one mounting operation cycle is completed. If the mounted part, for example, a wire, has two portions fixed to the work piece, the steps 6 to 8 are repeated and the compensated-positioning data is changed in accordance with a positional difference between the hands 191 and 192. When a problem occurs in the parts-handling-unit 10, for example, when all of the parts in the parts container 40 have been transferred, the operation of the parts mounting machine proceeds to step 9, in which the branch controller outputs an operator request signal. In step 10, when one mounting operation cycle is completed, the branch controller 15 outputs a mounting operation completion signal to the main controller 30. When the main controller 30 receives the mounting operation completion signal, the main controller 30 selects the next one of the parts-handling-units 10 suitable for mounting the next kind of parts in accordance with the next mounting operation instructing signals, so that the mounting operation cycle is repeated according to the total number of mounting operation instructing signals in the series.
The operation cycle for mounting the wire is described more in detail as follows. FIG. 4 shows the parts-handling-unit 10 suitable for mounting wire 60, FIG. 5 shows operational steps for mounting the wire 60, whose first step starts after the above mentioned step 5 of FIG. 3.
As shown in FIG. 5, in step 100, the parts-handling-unit 10 receives the mounting operation starting signal from the main controller 30, and in step 101, the parts-handling-unit 10 outputs the compensated positioning data for appropriately positioning the work piece in relation to the mounting head 191 gripping an end 61 of the wire 60. In step 102, after the main controller 30 receives the compensated positioning data, the main controller 30 calculates a rotational degree of the indexing table 243 and distances in the X and Y directions between the X-Y table reference point and the datum points of the X-Y table 242, which rotational degree and distances are required for positioning a desired hole of the work piece 71 correctly in relation to the end 61. The work piece positioning device 20 positions the X-Y table 242 and the indexing table 243 in accordance with the calculated rotational degree and distances. This calculation will be described below in detail. In step 103, when the parts-handling-unit 10 receives the positioning completion signal outputted by the main controller 30 after the X-Y table 242 and the indexing table 243 have been correctly positioned, the mounting head 191 having the end 61 descends to the work piece and inserts the end 61 into the desired hole. Subsequently, in step 104, the parts-handling-unit 10 outputs the compensated positioning data for appropriately positioning another hole of the work piece 71 in relation to a mounting head 192 gripping an end 62 of the wire 60. In step 105, after the main controller 30 receives the compensated positioning data, the main controller 30 calculates the rotational degree of the indexing table 243 and the distances in the X and Y directions between the X-Y table reference point and the datum points of the X-Y table 242, which rotational degree and distances are required for positioning the other desired hole of the work piece 71 correctly in relation to the end 62. The work piece positioning device 20 positions the X-Y table 242 and the indexing table 243 in accordance with the calculated rotational degree and distances. In step 106, when the parts-handling-unit 10 receives the positioning completion signal outputted by the main controller 30 after the X-Y table 242 and the indexing table 243 have been correctly positioned, the mounting head 192 gripping the end 62 descends to the work piece 71 and inserts the end 62 into the desired hole. In step 107, when one mounting operation cycle is completed, the branch controller 15 outputs the mounting operation completion signal to the main controller 30.
In order to intelligibly explain the measuring and calculating operation of the parts mounting machine according to the present invention, it is supposed that the indexing table 243 is held at its reference rotational position, and only the measuring and calculating operation in the X direction is explained. The measuring and calculating operation of the Y direction is performed in the same way as that of the X direction.
When the parts mounting machine measures the distance X MP between the X-direction datum point of the X-Y table 242 and the X-direction datum line of the positioning pins 251 contacting and setting the X-direction datum side of the work piece 71, the master piece 72 is set correctly by the positioning pins 251 on the indexing table 241. As shown in FIG. 6a, the master piece 72 has a square column 721 whose one datum master surface is perpendicular to the mounting surface of the indexing table 243 and is parallel to the X-direction datum side of the master piece 72. The distance X PM between the X-direction datum side of the master piece 72 and the datum master surface was previously measured by a measuring machine and is memorized in the main controller 30. When the distances on the X-Y table 242 are measured by an optical length measuring device 244 attached on the X-Y table 242 as shown in FIG. 7A, the reference point of the optical length measuring device 244 is the X-direction datum point of the X-Y table 242. The optical length measuring device 244 measures a distance X LM between the X-direction datum point of the X-Y table 242 and the datum master surface. The main controller 30 calculates the distances X MP from the measured distance X LM and the predetermined distance X PM , that is, the difference between the distance X LM and the distance X PM is the distance X MP between the X-direction datum point of the X-Y table 242 and the X-direction datum line of the positioning pins 251, as shown in FIG. 7a. The distance X MP is memorized in the main controller 30.
The approximate distance X MH between the X-Y table reference point and the mounting central point of each of the parts-handling-units 10 is memorized in the main controller 30. The mounting central point of each of the parts-handling-units 10 may be the center point of the positioning hole of the parts-handling-unit 10 or may be any point of the parts-handling-units 10, as in FIG. 6c. The approximate distance X UT between the mounting central point and the datum point of the parts-handling-unit 10 and the distance X up between the datum point of the parts-handling-unit 10 and the datum point of the handled part were previously measured and memorized in the branch controller 15. The datum point of the parts-handling-unit 10 may be an end surface of the mounting head 19, as shown in FIG. 6d. The distance X UT is output to the main controller in the stage 2.
When the parts mounting machine is requested by the branch controller 15 to compensate the deviation of the actual position of the datum point of each of the parts-handling-units 10 from the intended position thereof, that is, to measure the actual distance between the datum point of each of the parts-handling-units 10 and the X-Y table reference point, the X-Y table 242 is at first positioned at its initialized position so that the reference point of the optical length measuring device 244 is positioned at the X-Y table reference point as shown by the broken line in FIG. 7b. Subsequently the X-Y table 242 is moved by a distance X DT , which is less than the sum amount of the distance X UT and the distance XMH, that is, XDT=X MH +X U -X LT , (X LT , is a certain distance measurable by the optical length measuring device 244), and the optical length measuring device 244 measures a distance X LT between the reference point of the optical length measuring device 244 and the end surface of the mounting head 19, that is, the datum point of the parts-handling-unit 10. A sum total of the distance X DT and the distance X LT is the actual distance X MHR between the datum point of each of the parts-handling-units 10 and the X-Y table reference point. The actual distance X MHR is memorized in the main controller 30.
As shown in FIGS. 8a, 8b and 8c, when the parts-handling-unit 10 receives the mounting operation starting signal from the main controller 30, including the distance data Xpp between the X-direction datum side of the work piece 71 and the position where the datum point of the mounted part should be positioned on the work piece 72, the branch controller 15 calculates the compensated-positioning data X pos between the datum point of the parts-handling-unit 10 and the X direction datum line of the positioning pins 251 contacting with the X-direction datum side of the work piece 71, in accordance with the distance X UP between the datum point of the parts-handling-unit 10 and the datum point of the handled part on the basis of the data X pp , that is,
X.sub.pos =X.sub.pp -X.sub.UP.
The branch controller 15 outputs the compensated-positioning data X pos to the main controller 30. When the main controller 30 receives the compensated-positioning data X pos , the main controller 30 calculates the distance X D between the X-Y table reference point and the datum point of the X-Y table 242 in accordance with the distance X MP between the X-direction datum point of the X-Y table 242 and the X-direction datum line of the positioning pins 251 and the distance X MHR between the datum point of the parts-handling-unit 10 and the X-Y table reference point, that is,
X.sub.D =X.sub.MHR -X.sub.MP -X.sub.pos.
The X-Y table 242 is positioned in accordance with the distance data X D .
The parts container 40 as above described is attached detachably on the parts-handling-unit 10, however, the parts container may be integrally formed with the parts-handling-unit 10, as shown in FIG. 9. Therein, the part slides downwardly in a magazine 111 of an inclined cartridge 110, and a forward end of the parts-transfer device 12 catching the part moves to the left to transfer the part to the mounting head 19 of the mounting head devices 13. Subsequently, the mounting head 19 gripping the part descends to mount the part on the work piece 71. Thereafter, the parts fixing device 16 ascends to fix the part to the work piece 71.
In this embodiment, since the cartridge 110 was previously fixed on the parts-handling-unit 10, it is not necessary to adjust a positional relation between the parts-handling-unit 10 and the cartridge 110, and a device for taking out the part from the parts container is not needed.
|
A parts mounting machine for easily changing the type or number of parts being used within includes a work piece positioning device for positioning a work piece on a movable table thereon, and a plurality of part handling units which can be fixed to and detached from the work piece positioning device. Each of the parts handling units comprises mounting head means for holding a part and transferring it to the work piece, and transfer means for removing the part from a container and transferring the part to the mounting head means. Also contained in each handling unit is a controller for regulating the operation of the mounting head and transfer means. A main controller selectively controls the branch control means so that the parts handling units cooperate with the work piece positioning device as required by a user.
| 1
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to secondary and tertiary methods of oil recovery and, more particularly, to improved methods for determining the progress and shape of a flood front when oil is recovered by flooding a formation.
2. The Prior Art
In oil production, primary drilling and pumping operations are frequently ineffective to recover a substantial proportion of the available oil, often leaving as much as 30 to 70% of the oil as residual. It is common, therefore, to employ so-called secondary or tertiary methods to obtain the additional oil. One such secondary or tertiary method involves flooding the producing formation with an oil-displacement fluid, such as water, steam, gases, etc., through one or more injection wells spaced from the producing well. As the leading edge, or front, of the flood fluid progresses through the formation, the oil in the formation is pushed towards the producing well. Where plural injection wells are used, the fluids from neighboring wells may merge to form a combined front, and such combined front may indeed completely surround a producing well.
It is important in maximizing the amount of oil recovered to be able to determine the direction and speed of movement of the flood front through the producing formation. Typically, however, a flood front does not progress uniformly from the injection well or wells to the producing well because the formations are usually not uniform. This non-uniformity is generally referred to as "fingering." For example, a flood front may follow a crevice in the formation and a "finger" of the flood front may "breakthrough" into the producing well, thus interrupting the production of oil. If it is known that only "fingering" has occurred and that the front has not reached the producing well, appropriate steps may be taken to prevent premature breakthrough. It is important, therefore, to know not only the location and time of arrival of the foremost edge of the flood front but also to have information of the movement and shape of the front as a whole. That is to say, for maximum oil production a complete description of the spatial shape, or "profile", of the front in the vicinity of the producing well is required.
Since oil-bearing formations differ significantly in matrix and fluid composition, it is desirable that the flood front detection process be carried out in a way which allows of the use of a wide variety of tracer elements and detection techniques, thereby permitting detection of the front or of different parts of the front in all formations likely to be encountered. Additionally, the detection process should not cause any significant interference in the movement of the front itself and should be capable of being made at a distance from the producing well sufficient to allow for modification of the flooding operation in order to maximize production.
One prior art approach to flood front detection is disclosed in U.S. Pat. No. 3,874,451 to Jones et al., according to which observation boreholes spaced from the injection wells are used to detect the arrival of the flood front by measuring a pressure change in the boreholes. By measuring the time it takes for the front to arrive at an observation borehole and knowing the distance from it to the injection hole, the progress of the front, which is related to the oil saturation, can be determined. A disadvantage of this method is that the observation boreholes must be uncased in order to measure the pressure; hence, they disturb the flood front and affect its progress. Also, the Jones et al. method does not determine the depth at which the front reached the observation well, and thus does not permit its profile to be ascertained.
U.S. Pat Nos. 2,888,569 to S. B. Jones and 3,002,091 to F. E. Armstrong disclose two other prior art techniques for detecting the arrival of a flood front. In the Jones technique, a beta-emitting tracer (e.g. krypton 85) is injected into a formation along with a flooding gas. The arrival of the flood (gas) front at the producing well is detected in the borehole with a beta detector. In the Armstrong technique, the flood fluid includes a normally stable element which is rendered unstable by neutron irradiation. At the producing well, the flood fluid is brought to the surface, separated from the oil, and bombarded with neutrons. A gamma ray detector is used to sense the presence of the unstable tracer element in the bombarded fluid. If present, it indicates that the flood fluid has reached the producing well. In both the Jones and Armstron methods, the detection of the tracer at the producing well represents a serious disadvantage because it interferes with production. These methods, moreover, afford no information about the front until it reaches the producing well. As a result, it is too late to take effective action to maximize the production of oil by controlling the flooding operation. In addition, with the Armstrong method the depth at which the front reaches the production well is not known since the detecting step is done uphole.
The foregoing and other disadvantages of the prior art are overcome by the present invention.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method of determining the progress of a flood front through an oil-bearing formation.
Another object of the invention is to provide such a method which affords a complete profile of the flood in the vicinity of a producing well.
A further object of the invention is to provide an improved method of flood front detection which permits in situ determination of the flood profile without interference with or disruption of the flood front.
Still another object of the invention is to provide a method of detecting the progress and shape of the flood front as it approaches a producing well in a manner permitting maximum oil recovery through control of the flood operation.
It is a further object of the invention to provide a flood front detection method which allows the use, for detection purposes, of a wide variety of tracer elements and detection techniques.
These and other objects are attained, in accordance with the invention, by detecting gamma rays emanating from the oil-bearing formation undergoing flooding at a number of elevations over its depth and obtaining, by spectral analysis of said detected gamma rays, an indication of the arrival of the flood front at each of the elevations examined. A complete vertical profile of the flood front may therefore be generated as the front reaches the observation borehole. By the use of plural observation boreholes spaced about the periphery of the producing well, information about the horizontal profile of the flood front may also be obtained. Such knowledge of the shape and progress of the flood front permits appropriate control of the flooding operation in order to maximize oil recovery. p According to the invention, the arrival of a flood fluid at an observation borehole is detected by gamma ray spectroscopy techniques, including, for example, spectral line analysis with or without half-life analysis. To that end, a tracer element having a characteristic gamma ray emission energy may be added to the flood fluid. The tracer element may be unlike any element normally found in abundance in the formation, in which case the presence of gamma rays of such characteristic energy at an observation borehole will indicate the arrival of the front, or it may be an element normally found in the formation, in which case the arrival of the front will be indicated by an increase in the magnitude of the spectrum at the characteristic energy. Also, the tracer employed may be a radioactive element or it may be a normally stable element which is rendered radioactive by neutron or gamma bombardment at the observation borehole. Alternatively, no particular tracer element need be used, and the arrival of the front may be detected by observing changes in the gamma ray spectrum for constituents of the formation.
According to another feature of the invention, more complete information concerning the shape and movement of the flood front may be obtained when a plurality of injection wells spaced around the producing well are used, by selecting a different tracer element for each injection well. Information is thereby obtained both as to the progress of the overall flood front and as to the movement and location of the flood fluids from each injection well. For example, the detection of more than one tracer at an observation borehole, or of a tracer different from that expected at such borehole, might indicate that the flood fluid from a particular injection well is moving more rapidly than the other fluids or that it has been diverted, e.g., due to a crevice in the formation, from its expected path. Corrective action, such as adjustment of the pumping rate at the injection well in question, may therefore be taken. In this way it is possible to monitor the progress of the individual injected flood fluids and, in response thereto, to adjust pumping operations among the injection wells to provide an overall flood front profile of optimum shape and effectiveness.
The gamma rays emanating from the formation are preferably detected at the observation borehole or boreholes over a comparatively broad energy range, e.g., 100 keV to 4 MeV, so that tracers having significantly different gamma ray energies may be utilized. This not only facilitates the identification of the several tracers but also allows for the simultaneous detection of flood fluid from a number of different injection wells at each individual observation borehole.
Although naturally occurring gamma rays may be detected in accordance with the invention, neutron bombardment is preferably employed to induce gamma ray emission since it affords greater flexibility in the identity and amounts of tracer elements used and in the spectroscopic techniques which can be employed. Thus, not only may stable elements be used as tracers, thereby allowing selection among a larger range of elements which may be employed and at the same time reducing radiation hazards, but selection may be made of specific types of gamma rays to be detected, e.g., inelastic scattering, capture or activation gamma rays. Also, neutron sources of different energy distributions may be used to distinguish between tracer elements and other elements having interfering spectral lines. Half-life analysis is likewise facilitated by neutron inducement of gamma ray emission.
A further important advantage of the invention, particularly where neutron bombardment is employed, is that gamma ray detection of the flood fluid front may be made through cased observation wells. This permits in situ determination of the flood front profile as a function of depth without disruption of modification of the profile.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the invention will be more readily apparent from the following detailed description and drawings of illustrative embodiments of the invention, in which:
FIG. 1 is a section through an earth formation illustrating the detection of a flood front profile according to the invention;
FIGS. 2A and 2B are schematic plan views of an oil field showing the possible placement of injection wells, observation boreholes and producing wells and further showing representations of a horizontal flood front profile;
FIG. 3 is a schematic diagram of a well logging tool useful in practicing the invention;
FIG. 4 is a graph of gamma ray activity resulting from irradiation of a formation with a pulse of neutrons;
FIG. 5 shows typical gamma ray energy spectra taken at two different times following neutron irradiation of a formation; and
FIG. 6 is a graphical representation of a vertical flood front profile.
DETAILED DESCRIPTION
In an illustrative embodiment of the invention, FIG. 1 depicts in section an oil-bearing formation 10 in which primary production methods have become unprofitable and secondary or tertiary flooding operations have been initiated. The formation 10 is shown as undergoing flooding through two injection wells 12A and 12B spaced on opposite sides of a producing well 14, through which oil is withdrawn by a pump 16. Observation boreholes 18A and 18B are located between the injection wells 12A and 12B and the producing well 14. It will be understood that the number and location of the injection wells and the observation boreholes may differ from that shown in FIG. 1, which is intended to be exemplary only. Both the producing well 14 and the injection wells 12A and 12B would normally be cased, with suitable perforations at the level of formation 10. In accordance with the invention, the observation wells are also preferably cased over the depth of the formation, but not perforated, to avoid disruption of the flood front. Advantageously, the wells already in existance in an oil field are used for these purposes, but where necessary new wells can be drilled.
A suitable flooding fluid, e.g. fresh water mixed with a surfactant, is pumped by pumps 20A and 20B into the injection wells 12A and 12B and expands radially therefrom through the formation 10 (indicated by the arrows in FIG. 1) driving the oil in the formation (indicated in zones 10A and 10B) towards the producing well 14. In addition to the residual oil, there would normally be some indigenous water in the formation, and the movement of the flood fronts 22A and 22B of the injected fluids causes a buildup of the formation water in oil-water zones 10C and 10D between the flood fronts 22A and 22B and the driven oil in zones 10A and 10B.
The progress of the flood fronts 22A and 22B is detected in observation boreholes 18A and 18B, respectively, by means of a well logging sonde or tool 24. Movement of the tool 24 through the boreholes 18A and 18B, which as noted are preferably cased, is accomplished by means of cables 25 connected in the usual manner to motor driven winches (not shown). As is conventional in well logging, the cables 25 also carry power to the downhole tool 24 and convey the data-bearing logging signals to the surface for processing and recording in a data van 26. In practice the flood fronts 22A and 22B move only on the order of a few inches to a foot per day. Therefore, one logging tool and data van would normally be sufficient effectively to cover all of the observation boreholes surrounding a producing well. Additional tools and data vans may of course be provided if desired or needed.
As is described in more detail hereinafter in connection with FIG. 3, the tool 24 includes a gamma ray detector of the type which generates an output signal whose amplitude is representative of the energy of the incident gamma ray. Although for purposes of the present invention any detector having an energy resolution suitable for detection of the elements of interest in the flood fluid may be used, the detector preferably comprises a high-resolution device such as a solid state Ge detector. Pulse height analysis circuitry is also provided, either in the tool 24 or in the data van 26, to sort the detector signals according to amplitude into a number of channels so as to generate energy spectra of the detected gamma rays. Representative spectra are illustrated in FIG. 5. Such spectra are used, in accordance with the invention, to detect the presence at an observation borehole of gamma rays known to originate from elements of the flood fluid as an indication of the arrival thereat of the flood front or fronts.
It is a feature of the invention that the detection of flood fluid fronts in accordance therewith permits the use both of a broad range of elements or isotopes and of a wide variety of spectroscopy detection techniques. Thus, the flood fluid elements detected may be either primary constituents of the fluid or tracer elements added to the fluid, and they likewise may be either radioactive (including both natural and man-made radioisotopes) or they may be normally stable elements which are rendered radioactive by neutron or gamma bombardment. Suitable radioactive elements might include, for example, uranium, thorium and potassium, while suitable stable elements might include aluminum, sodium, magnesium, as well as isotopically enriched stable elements. The elements selected for detection need not be different from elements naturally present in the borehole or formation, as provision is made for determining the concentration of any formation elements of interest, such as by generating individual or composite spectra of such elements, prior to the arrival of the flood front at the observation point. For instance, since formation water (zones 10C and 10D in FIG. 1) normally contains NaCl, the arrival of the flood front 22A or 22B, assuming a fresh water flood, could be signalled by a reduction in the NaCl spectrum or the Cl spectrum. Alternatively, thermal decay time measurements, such as those described in U.S. Pat. No. Re 28,477 to W. B. Nelligan, may also be used to detect the arrival of the front under these circumstances.
Where a tracer is added to the flood fluid, the particular concentration required for detection purposes will depend upon a number of factors, including the half-life of the tracer, the radiation source strength, the porosity of the formation, the neutron capture cross section of the tracer, the energy of the gamma rays emitted by the tracer, the relative branching of the tracer as it decays and the fraction of the decay events which emit gamma rays, other constituents in the formation or borehole with spectral lines near the line for the tracer, and the like. Generally, information on the required concentration will not be known precisely beforehand. Based on the foregoing factors, however, reasonable estimates of such concentrations can be made or can be determined by routine experimentation.
A number of spectroscopy techniques may be employed to optimize detection, depending upon the emission characteristics of the elements to be detected and the presence of interfering emissions by other elements in the formation surrounding the borehole. In the absence of interfering spectra, detection may be made in a straightforward manner from the amplitude of the detected spectrum at the characteristic gamma ray energy of the element of interest. If interfering gamma rays from another element (referred to as a "contaminant" because it contaminates the spectrum of the tracer) are present, detection may be aided by half-life determinations or, where neutron bombardment is used, by selectively detecting the formation gamma rays on a time basis to sense only those originating from a particular type of neutron reaction, such as inelastic scattering, capture, or activation processes. Again, a desired element may be distinguished in the presence of interfering gamma rays from a contaminant by irradiating the formation separately with neutrons of two different mean energies. For example, if the element of interest has a higher threshold than the contaminant for the particular gamma ray reaction to be detected, one neutron source will have an energy above the threshold of the element and the other source will have an energy below said threshold but above the threshold of the contaminant. Comparison of the two resulting spectra then permits determination of whether the element of interest is in fact present and contributing to the gamma radiation detected at the higher neutron energy.
During the detection process the tool 24 is lowered in the observation borehole to a point adjacent to or below the oil bearing formation 10. The tool is then raised in increments over the depth of the formation and a gamma ray energy spectrum, such as those shown in FIG. 5, is generated from the gamma rays detected at each elevation. As will be appreciated, the particular depth increment between detection points used in a given case will vary with the formation and with the degree of vertical definition required. The tool 24 includes a suitable neutron source, as discussed more fully hereinafter, for use where radioactive elements are not employed.
From the gamma ray spectra generated, the presence of the element or elements of interest, e.g. a tracer element added to the flood fluid, at a particular depth is detected as an indication of the arrival at such elevation of the flood front. This process is repeated as necessary until the arrival of the flood front is detected for each elevation investigated. Since a log of the formation is run over a period of time a vertical profile such as that shown at 28 in FIG. 6 can be constructed, in which time of arrival (as indicated by detection of the tracer element) is plotted against depth. Such a profile depicts the shape and progress of the flood front over the depth of the formation. Taking the profile 28 of FIG. 6 as representative of the front 22B of FIG. 1, it may be seen from the bulge 30 in profile 28 that fingering, as indicated at 32 in FIG. 1, has occurred and that the front 22B as a whole is progressing more slowly. This knowledge helps in arriving at an accurate figure for the "time to flood", which is used to measure the production capability of a formation. The "time to flood" is a measure of how long it will take the flood front to reach the producing well and thus is a measure of the quantity of oil that may still be extracted and the profitability of continuing the flooding procedure. By providing additional observation boreholes over the distances between the observation borehole 18B and the producing well 14 the further progress and shape of the front 22B as it approaches the producing well 14 may be monitored. The same is of course true for flood front 22A.
Still other features of the invention will be apparent from FIGS. 2A and 2B, which illustrate how flood front detection in accordance with the invention is useful in controlling the flooding operation so as to maximize oil recovery. In FIG. 2A, four injection wells 34A, 34B, 34C and 34D are spaced in generally surrounding relation to a producing well 36. A first line of observation boreholes 38A, 38B, 38C and 38D is located between the injection wells 34A-34D and the producing well 36, and a second line of observation boreholes 40A, 40B, 40C and 40D is located between the first line boreholes 38A-38D and the producing well 36. The zones flooded by the injection wells 34A-34D are indicated by the letters A, B, C and D, respectively. According to the invention, the fluid injected into the respective zones A, B, C and D contains a different tracer element, i.e. the tracer in any one zone will have a characteristic gamma ray emission energy which differs from that of the tracer injected into any other zone. It is possible, therefore, to detect not only the movement of the combined flood front of zones A-D but also to determine the progress and shape of the individual flood zone fronts.
In the illustration of FIG. 2A, the flood front of zone B is shown as having passed its first-line observation borehole 38B and, due to an irregularity in the formation, to have also reached the first-line observation borehole 38A for flood zone A. This is an indication that the injection procedure should be slowed or stopped in zone B until the other flood zone fronts catch up. The flooding in zones C and D have reached their first-line observation boreholes, 38C and 38D, respectively, together and can be used as the norm. However, the front in zone A has not reached its first-line borehole 38A, indicating that the pressure or quantity of displacing fluid injected through well 34A should be increased.
The arrangement of FIG. 2B shows a single injection well 42 located between a number of producing wells 44A, 44B 44C and 44D. A group of three observation boreholes 46A, 46B and 46C surround the injection well 42, but are not on a direct line with the producing wells 44A-44D. Although there is less control over the advance of the flood front, indicated at 48 in FIG. 2B, with such an arrangement than with the arrangement of FIG. 2A, useful information concerning the shape and progress of the front may nevertheless be obtained. For example, it is possible to determine the "time to flood" to each of the producing wells 44A-44D. In proper circumstances, it may still be possible to exercise directional control over the progress of the front 48, e.g., by closing off the perforations in injection well 42 in the sector or sectors in which the front is moving too rapidly.
In any event, it will be appreciated that by providing observation boreholes about the periphery of a producing well, as in FIG. 2A, or about the periphery of an injection well, as in FIG. 2B, information is obtained in accordance with the invention concerning both the vertical profile and the horizontal profile of the flood front. It will be understood, of course, that the required degree of horizontal definition can be attained by selection of the horizontal spacing between adjacent observation boreholes. Generally, fewer boreholes (larger spacings) are possible with more uniform formations. The number and location of the injection wells may also be varied as needed to provide further control over flood front movement and configuration.
In the embodiment of FIG. 3, the tool 24 includes a neutron source 54 located at the upper end of the sonde. The source may be either of the chemical type, e.g. californium 252, or of the accelerator type, such as the 14 MeV generators disclosed in U.S. Pat. Nos. 3,461,291 to C. Goodman and 3,546,512 to A. H. Frentrop. If only radioactive elements are to be detected, the source 54 may be omitted or left dormant. Preferably, however, it will be included in the tool to afford the greatest flexibility in practicing the invention. Assuming a non-radioactive (stable) element has been selected as the tracer, the neutron source 54 is positioned opposite the formation at the depth to be investigated and the formation irradiated for a time sufficient to generate enough gamma rays to provide a statistically accurate spectrum. Depending on the tracer element employed and the type of gamma rays to be detected, the irradiation period may extend anywhere from a few seconds to an hour or more. For example, if aluminum is used as the tracer and activation gamma rays are detected, the required irradiation period is short enough to permit continuous movement of the tool 24 along the formation at the rate of 600 ft/hour.
The source 54 is preferably isolated by a neutron shield 56 to protect the downhole electronics from direct neutron irradiation and also to minimize activation of the detector 58 and the sonde portions adjacent the detector. To the same end, and particularly where a chemical neutron source is used, the detector 58 is preferably spaced a substantial distance from the source 54, e.g. on the order of 10 to 20 feet. Such spacing also functions to prevent early gamma rays, such as those resulting from inelastic scattering reactions within the borehole for example, from reaching the detector 58. Appropriate gamma ray shielding (not shown) may of course be provided within and around the sonde to further reduce unwanted gamma radiation at the detector.
The source-to-detector spacing may also serve to discriminate against unwanted gamma rays on a time basis. For instance, if activation gamma rays are to be detected, the portions of the time distribution of gamma rays following a neutron pulse in which inelastic scattering gamma rays, on the one hand, and thermal neutron capture gamma rays, on the other hand, predominate, which portions may be roughly identified as indicated in FIG. 4, can be substantially eliminated from the detected spectrum simply by the length of time taken to move the detector 58 upward along the formation to a position opposite the elevation previously irradiated by the source 54. Where it is desired to detect inelastic scattering gamma rays or thermal neutron capture gamma rays or short half-life activation gamma rays, a shorter source-to-detector spacing is preferred.
As may also be seen from FIG. 4, inelastic scattering gamma rays or thermal neutron capture gamma rays may also be selectively detected by appropriate gating of the detector 58 relative to the time of occurrence of the neutron pulse. In the usual case, the type of gamma rays of interest, e.g., capture gamma rays, would be detected following each of a number of neutron pulses and the counts per channel accumulated over a period long enough to achieve a statistically accurate spectrum. Activation gamma rays may of course also be selected by time-gating of the detector rather than by movement of the tool 24.
As mentioned, the detector 58 preferably comprises a high-resolution gamma ray detector, and may, for example, be of the solid-state Ge type disclosed in U.S. Pat. No. 3,633,030 to S. Antkiw, the pertinent portions of which are incorporated herein by reference. The resolution of such a detector is so good that it can distinguish between aluminum with an activation spectral line at 1.779 MeV and manganese with a line at 1.811 MeV. Upon detection of the gamma rays emanating from the formation, the detector 58 generates a corresponding distribution of signals, whose amplitudes are proportional to the energies of the incident gamma rays. The time distribution of different types of gamma rays and their relative intensities is illustrated in FIG. 4. These signals are amplified in amplifier 60 and applied to a multichannel pulse height analyzer (PHA) 62. The PHA 62 may be of any conventional type, such as a single-ramp (Wilkinson run-down) type, which is operable to sort incoming pulses according to amplitude into a number of energy segments or channels over the gamma ray energy range of interest.
The PHA 62 will be understood to include the usual low-level and high-level discriminators for selection of the energy range to be analyzed and linear gating circuits for control of the time portion of the detector pulses to be analyzed. Appropriate signals may be generated in a downhole programmer 64 in conventional fashion and applied to the PHA 62 to adjust discriminator levels, if desired, and to enable the linear gating circuits. Where a pulsed neutron generator is used as the source 54, signals of predetermined duration and repetition rate may be transmitted to the source from the programmer 64, as indicated by the broken-line conductor 65 in FIG. 3, in order to cause the generator to produce a neutron pulse. Although shown downhole in FIG. 3, it will be understood that the PHA 62 and the programmer 64 could be located at the surface if desired.
The output signals from the PHA are applied to data link circuits 66 for transmission to the surface. Circuits 66 may be of any conventional construction for encoding, time-division multiplexing or otherwise preparing the data-bearing signals applied to them in a desired manner and for impressing them on the cable 25, and the specific forms of the circuits employed for these purposes do not characterize the invention. Where the PHA 62 is located downhole, the data link circuits disclosed in the copending, commonly-owned U.S. application Ser. No. 563,507, filed Mar. 31, 1975 by W. B. Nelligan for "System for Telemetering Well-Logging Data", now U.S. Pat. No. 4,012,712, are particularly useful.
At the surface the transmitted data-bearing signals are received in data link circuits 68, where they are amplified, decoded and otherwise processed as needed for application to a computer 70 and to a tape recorder 72. The computer sums the counts in each channel over the energy range of interest and transmits signals indicative thereof to a visual plotter 74 to generate plots of the gamma ray spectra. Two such plots 76 and 78 are illustrated in FIG. 5. The tape recorder 72 and plotter 74 are conventional and are suitable to provide the desired record of logging signals as a function of depth. The usual cable-following linkage, indicated schematically at 80, and depth indicator 82 are provided for this purpose.
As will be appreciated, the peaks of the spectra 76 and 78 of FIG. 5 are characteristic of particular elements of the formation and borehole constituents, one of which will correspond to each of the tracer elements of interest. Where there is sufficient resolution between the peaks, the peak characteristic of a particular tracer may be identified by peak form analysis and the number of counts under the peak determined. This count may then be used to detect whether or not the tracer has in fact arrived at the observation borehole in question. This might be done, for example, by comparing the count thus determined against a predetermined reference count. Such comparison could readily be carried out in computer 70, with an output signal indicative of the arrival being sent to the plotter 74 for recording. The computer could then also compute the corresponding time of arrival of the tracer at the observation borehole and instruct the plotter 74 to plot such time-of-arrival information as a function of depth as indicated in FIG. 6. In certain cases, the log analyst might be able to detect the arrival of the tracer based on visual inspection of the spectra plots generated, as in FIG. 5. In cases where only one tracer with a sharp peak is used it is possible to forego the creation of a spectrum by eliminating the PHA and relying on threshold detectors to create a small gamma ray energy window or range. A sufficient number of counts in this range would indicate the arrival of the front.
Additionally, spectra may be taken at two different times and the counts measured for the same peak in each spectrum so as to perform a half-life measurement. Such a half-life determination could then be used as a basis for extrapolating backwards to arrive at an estimate of the concentration of the element in the formation, with the concentration measurement then used for comparison with a reference value for detection purposes. By measuring concentration it can be determined when the flood front has arrived, as well as the uniformity of the propagation of the front.
The foregoing half-life measurements and concentration extrapolations are well known straight-forward computations once the peak counts at two different times are known and may be readily implemented in the computer 70.
Half-life measurements are also useful where long half-life contaminants having spectral lines which interfere with the tracer line are present in the formation or flood fluid. Such a situation is depicted in FIG. 5, where for illustrative purposes it is assumed that the tracer element is magnesium and that the formation contains manganese, both of which have an activation gamma ray peak near 0.840 MeV when excited into the isotopes magnesium 27 and manganese 56, respectively. This peak is indicated at 84 in plot 76 of FIG. 5, which represents a spectrum taken one minute after the termination of neutron irradiation, and at 86 in plot 78, which represents a spectrum taken ten minutes after termination of neutron irradiation. Since the activation gamma ray half-lives of manganese 56 and magnesium 27 are 2.58 hours and 9.45 minutes, respectively, the later spectrum 78 should show a marked decrease in the 0.840 MeV peak when magnesium 27 is present and contributing to the first spectrum 76. As a result, a determination can be made whether the tracer has been received, as is the case in the example of FIG. 5, or whether the original peak was due merely to an element (manganese in this instance) normally found in the formation. If desired, spectra may be taken at a number of different times for purposes of identifying elements on the basis of half-life. The number and timing of such spectra will be dependent on the characteristics of the particular tracer element or elements used and the other elements expected to be found in the formations under investigation. For instance, the detection period might be delayed until contaminants with short half-lives have died out. Control of the time of occurrence and the duration of the detection period or periods, as the case may be, may be effected by the downhole programmer 64, through gating signals transmitted to the PHA 62, or by means of gating or other control signals sent downhole by the computer 70. Such signals prefereably are related to the time of neutron irradiation, and may, for example, be timed from the start or the end of the irradiation interval. Preferably, a measurement of elapsed time between the end of neutron irradiation and the beginning of detection will be made in order to permit extrapolation backward to determine element concentrations.
In those cases in which the tracer is an element normally found in the formation, it is desirable to run a complete spectrum log of the formation before the flood front arrives. The arrival of the flood front may then be detected by noting an increase in the amplitude of the peak for the tracer, thereby indicating an increase in its concentration. Another way of distinguishing a tracer from the formation elements is by taking a spectrum of gamma rays produced by a low energy neutron source, e.g. a californium 252 source having a mean energy of 2.3 MeV, and thereafter taking a second spectrum of gamma rays produced by a high energy source, e.g. the 14 MeV pulsed neutron source of the aforementioned Goodman and Frentrop patents. Since activation is a threshold function, i.e. activation will occur only above a certain incident neutron energy, elements whose thresholds are above the level of the low energy source will only be activated by the high-energy source. Hence, they will emit gamma rays only when irradiated by the high-energy source. Representative elements for the neutron source energies given, i.e. 2.3 MeV and 14.0 MeV, are iron and manganese. To this end, either two sources may be included in the tool 24 or a source capable of producing neutrons of two different energies may be provided. An appropriate source of the latter type is disclosed in the aforementioned U.S. Pat. No. 3,461,291 to C. Goodman, the pertinent portions of which are hereby incorporated herein by reference.
If desired, profiles such as that illustrated in FIG. 6 may be plotted on a common chart for a number of different observation boreholes. This permits ready determination of the movement and shape of the flood front among the several boreholes. Where such boreholes are spaced about the periphery of a producing well, as shown in FIG. 2A, or an injection well, as shown in FIG. 2B, such a combined plot affords information both of the horizontal profile and of the vertical profile of the flood front over the depth of the formation investigated. Alternatively, the computer 70 could be used to drive a CRT graphical display so as to combine the data of FIGS. 2 and 6 to produce a three-dimensional plot of the surface of the flood front relative to the producing well. Such a plot could be rotated by the operator through commands to the computer in order to better view the front.
A plot such as that shown in FIG. 2A or FIG. 2B may be made after the flood front has passed all of the first line of observation boreholes if the computer 70 is given the relative positions of the boreholes. An assumption is made that the flood front is progressing uniformly in a cylindrical fashion from each injection well. The time at which each front passed its first observation borehole is then used to calculate its diameter at the time the plot is drawn. While such a plot is not exact it does give a rough approximation of the shape of a complete front, the amount of oil remaining and the time required to complete the flooding operation, i.e. the "time to flood." If such a plot is repeated for a second line or third line of observation wells, it can be seen whether the steps taken to equalize the progress of the front have been successful.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. All such changes, therefore, are intended to be included within the spirit and scope of the appended claims.
|
A method of determining the flood front profile created during the production flooding of an oil-bearing formation utilizes cased observation boreholes located between the injection wells and the producing wells. The time and depth of arrival of the flood front at an observation borehole are detected by gamma ray spectroscopy examination of the formation. Tracer elements having characteristic gamma ray emission energies are employed to facilitate detection of the flood front and its direction of travel. The tracer elements may be naturally radioactive substances or they may be normally stable elements which are rendered radioactive by neutronbombardment. Elements having interfering spectral lines may be separated on the basis of half-life measurements, selective detection periods or the response of the elements to different energy neutrons. By repeating the detection process at different depths and times, the profile of the flood front as it approaches the producing wells may be developed. This information may be used to control the flooding operating to prevent or localize premature breakthrough to the producing wells.
| 4
|
REFERENCE TO PENDING PRIOR PATENT APPLICATIONS
[0001] This patent application:
(i) is a continuation-in-part of pending prior U.S. patent application Ser. No. 10/289,944, filed Nov. 6, 2002 by Daniel Mahgerefteh et al. for POWER SOURCE FOR A DISPERSION COMPENSATION FIBER OPTIC SYSTEM (Attorney's Docket No. TAYE-59474-00006); (ii) is a continuation-in-part of pending prior U.S. patent application Ser. No. 10/308,522, filed Dec. 3, 2002 by Daniel Mahgerefteh et al. for HIGH-SPEED TRANSMISSION SYSTEM COMPRISING A COUPLED MULTI-CAVITY OPTICAL DISCRIMINATOR (Attorney's Docket No. TAYE-59474-00007); (iii) is a continuation-in-part of pending prior U.S. patent application Ser. No. 10/680,607, filed Oct. 6, 2003 by Daniel Mahgerefteh et al. for FLAT DISPERSION FREQUENCY DISCRIMINATOR (FDFD) (Attorney's Docket No. TAYE-59474-00009); (iv) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/548,230, filed Feb. 27, 2004 by Yasuhiro Matsui et al. for OPTICAL SYSTEM COMPRISING AN FM SOURCE AND A SPECTRAL RESHAPING ELEMENT (Attorney Docket No. TAYE-31 PROV); (v) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/554,243, filed Mar. 18, 2004 by Daniel Mahgerefteh et al. for FLAT CHIRP INDUCED BY FILTER EDGE (Attorney Docket No. TAYE-34 PROV); (vi) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/566,060, filed Apr. 28, 2004 by Daniel Mahgerefteh et al. for A METHOD OF TRANSMISSION USING PARTIAL FM AND AM MODULATION (Attorney Docket No. TAYE-37 PROV); (vii) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/567,737, filed May 3, 2004 by Daniel Mahgerefteh et al. for ADIABATIC FREQUENCY MODULATION (AFM) (Attorney Docket No. TAYE-39 PROV); (viii) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/569,769, filed May 10, 2004 by Daniel Mahgerefteh et al. for FLAT CHIRP INDUCED BY AN OPTICAL FILTER EDGE (Attorney Docket No. TAYE-40 PROV); (ix) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/569,768, filed May 10, 2004 by Daniel Mahgerefteh et al. for METHOD OF TRANSMISSION USING PARTIAL FM AND AM MODULATION (Attorney's Docket No. TAYE-41 PROV); (x) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/621,755, filed Oct. 25, 2004 by Kevin McCallion et al. for SPECTRAL RESPONSE MODIFICATION VIA SPATIAL FILTERING WITH OPTICAL FIBER (Attorney's Docket No. TAYE-47 PROV); and (xi) claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/629,741, filed Nov. 19, 2004 by Yasuhiro Matsui et al. for OPTICAL SYSTEM COMPRISING AN FM SOURCE AND A SPECTRAL RESHAPING ELEMENT (Attorney's Docket No. TAYE-48 PROV).
[0013] The eleven above-identified patent applications are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0014] This invention relates to signal transmissions in general, and more particularly to the transmission of optical signals and electrical signals.
BACKGROUND OF THE INVENTION
[0015] The quality and performance of a digital fiber optic transmitter is determined by the distance over which the transmitted digital signal can propagate without severe distortions. The bit error rate (BER) of the signal is measured at a receiver after propagation through dispersive fiber and the optical power required to obtain a certain BER, typically 10 −12 , called the sensitivity, is determined. The difference in sensitivity at the output of the transmitter with the sensitivity after propagation is called dispersion penalty. This is typically characterized the distance over which a dispersion penalty reaches a level of ˜1 dB. A standard 10 Gb/s optical digital transmitter, such as an externally modulated source can transmit up to a distance of ˜50 km in standard single mode fiber at 1550 nm before the dispersion penalty reaches the level of ˜1 dB, called the dispersion limit. The dispersion limit is determined by the fundamental assumption that the digital signal is transform limited, i.e. the signal has no time varying phase across its bits and has a bit period of 100 ps, or 1/(bit rate). Another measure of the quality of a transmitter is the absolute sensitivity after fiber propagation.
[0016] Three types of optical transmitters are presently in use in prior art fiber optic systems: (i) directly modulated laser (DML), (ii) Electroabsorption Modulated Laser (EML), and (iii) Externally Modulated Mach Zhender (MZ). For transmission in standard single mode fiber at 10 Gb/s, and 1550 nm, it has generally been assumed that MZ modulators and EMLs can have the longest reach, typically reaching 80 km. Using a special coding scheme, referred to as phase shaped duobinary, MZ transmitters can reach 200 km. On the other hand, directly modulated lasers (DML) reach <5 km because their inherent time dependent chirp causes severe distortion of the signal after this distance.
[0017] By way of example, various systems for long-reach lightwave data transmission (>80 km at 10 Gb/s) through optical fibers which increase the reach of DMLs to >80 km at 10 Gb/s in single mode fiber are disclosed in (i) U.S. patent application Ser. No. 10/289,944, filed Nov. 6, 2002 by Daniel Mahgerefteh et al. for POWER SOURCE FOR A DISPERSION COMPENSATION FIBER OPTIC SYSTEM (Attorney's Docket No. TAYE-59474-00006); (ii) U.S. patent application Ser. No. 10/680,607, filed Oct. 6, 2003 by Daniel Mahgerefteh et al. for FLAT DISPERSION FREQUENCY DISCRIMINATOR (FDFD) (Attorney's Docket No. TAYE-59474-00009); and (iii) U.S. patent application Ser. No. 10/308,522, filed Dec. 3, 2002 by Daniel Mahgerefteh et al. for HIGH-SPEED TRANSMISSION SYSTEM COMPRISING A COUPLED MULTI-CAVITY OPTICAL DISCRIMINATOR (Attorney's Docket No. TAYE-59474-00007); which patent applications are hereby incorporated herein by reference. The transmitter associated with these novel systems is sometimes referred to as a Chirp Managed Laser (CML)™ by Azna LLC of Wilmington, Mass. In these new systems, a Frequency Modulated (AFM) source is followed by an Optical Spectrum Reshaper (OSR) which uses the frequency modulation to increase the amplitude modulated signal and partially compensate for dispersion in the transmission fiber. In one embodiment, the frequency modulated source may comprise a Directly Modulated Laser (DML). The Optical Spectrum Reshaper (OSR), sometimes referred to as a frequency discriminator, can be formed by an appropriate optical element that has a wavelength-dependent transmission function. The OSR can be adapted to convert frequency modulation to amplitude modulation.
[0018] In the novel system of the present invention, the chirp properties of the frequency modulated source are separately adapted and then further reshaped by configuring the OSR to further extend the reach of a CML™ transmitter to over 250 km on standard single mode fiber at 10 Gb/s and 1550 nm. The novel system of the present invention combines, among other things, selected features of systems described in (i) U.S. Provisional Patent Application Serial No. 60/548,230, filed Feb. 27, 2004 by Yasuhiro Matsui et al. for entitled OPTICAL SYSTEM COMPRISING AN FM SOURCE AND A SPECTRAL RESHAPING ELEMENT (Attorney Docket No. TAYE-31 PROV); (ii) U.S. Provisional Patent Application Ser. No. 60/554,243, filed Mar. 18, 2004 by Daniel Mahgerefteh et al. for FLAT CHIRP INDUCED BY FILTER EDGE (Attorney Docket No. TAYE-34 PROV); (iv) U.S. Provisional Patent Application Ser. No. 60/566,060, filed Apr. 28, 2004 by Daniel Mahgerefteh et al. for, A METHOD OF TRANSMISSION USING PARTIAL FM AND AM MODULATION (Attorney Docket No. TAYE-37 PROV); (iv) U.S. Provisional Patent Application Ser. No. 60/567,737, filed May 3, 2004 by Daniel Mahgerefteh et al. for ADIABATIC FREQUENCY MODULATION (AFM) (Attorney Docket No. TAYE-39 PROV); (v) U.S. Provisional Patent Application Ser. No. 60/569,769, filed May 10, 2004 by Daniel Mahgerefteh et al. for FLAT CHIRP INDUCED BY AN OPTICAL FILTER EDGE (Attorney Docket No. TAYE-40 PROV), which patent applications are hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
[0019] This invention provides an optical spectrum reshaper (OSR) which works in tandem with a modulated optical source which, by modifying the spectral properties of the modulated signal, results in extending the optical transmission length well beyond the dispersion limit. The OSR can be defined as a passive optical element that imparts an optical frequency dependent loss and frequency dependent phase on an input optical signal. This invention also provides a modulated laser source and an optical spectrum reshaper system that increases tolerance to fiber dispersion as well as converting a partially frequency modulated signal into a substantially amplitude modulated signal.
[0020] The optical spectrum reshaper (OSR) may be a variety of filters such as a Coupled Multicavity (CMC) filter to enhance the fidelity of converting a partially frequency modulated signal into a substantially amplitude modulated signal. The OSR may also partially compensate for the dispersion of the fiber. In one embodiment of the present invention, a modulated laser source may be provided that is communicatably coupled to an optical filter where the filter is adapted to lock the wavelength of a laser source as well as converting the partially frequency modulated laser signal into a substantially amplitude modulated signal.
[0021] In one form of the present invention, there is provided a fiber optic communication system comprising:
an optical signal source adapted to receive a base binary signal and produce a first signal, said first signal being frequency modulated; and an optical spectrum reshaper adapted to reshape the first signal into a second signal, said second signal being amplitude modulated and frequency modulated; characterized in that: the frequency characteristics of said first signal, and the optical characteristics of said optical spectrum reshaper, being such that the frequency characteristics of said second signal are configured so as to increase the tolerance of the second signal to dispersion in a transmission fiber.
[0026] In another form of the present invention, there is provided an optical transmitter comprising:
a frequency modulated source for generating a first frequency modulated signal, and an amplitude modulator for receiving the first frequency modulated signal and for generating a second amplitude and frequency modulated signal.
[0029] In another form of the present invention, there is provided a method for transmitting an optical signal through a transmission fiber comprising: receiving a base binary signal;
operating an optical signal source using the base binary signal to produce a first signal, said first signal being frequency modulated; passing the frequency modulated signal through an optical spectrum reshaper so as to reshape the first signal into a second signal, said second signal being amplitude modulated and frequency modulated; the frequency characteristics of said first signal, and the optical characteristics of said optical spectrum reshaper, being such that the frequency characteristics of said second signal are configured so as to increase the tolerance of the second signal to dispersion in a transmission fiber; and passing the second signal through a transmission fiber.
[0034] In another form of the present invention, there is provided a method for transmitting a base signal, comprising:
using the base signal to produce a frequency modulated signal; and providing an amplitude modulator for receiving the frequency modulated signal and for generating an amplitude and frequency modulated signal.
[0037] In another form of the present invention, there is provided a fiber optic communication system comprising:
an optical signal source adapted to produce a frequency modulated signal; and an optical spectrum reshaper adapted to convert the frequency modulated signal into a substantially amplitude modulated signal;
characterized in that:
the operating characteristics of the optical signal source and the optical characteristics of the optical spectrum reshaper combine to compensate for at least a portion of a dispersion in an optical fiber.
[0041] In another form of the present invention, there is provided a method for transmitting an amplitude modulated signal through a fiber comprising:
providing a laser and providing a filter having selected optical characteristics; inputting the amplitude modulated signal into the laser, and operating the laser, so as to generate a corresponding frequency modulated signal; passing the frequency modulated signal through the filter so as to generate a resulting signal and passing the resulting signal into the fiber; the laser being operated, and the filter being chosen, such that the resulting signal is configured to compensate for at least a portion of the dispersion in the fiber.
[0046] In another form of the present invention, there is provided a fiber optic communication system comprising:
an optical signal source adapted to produce a first signal, said first signal being frequency modulated; and an optical spectrum reshaper adapted to convert said first signal into a second signal, said second signal being amplitude modulated and frequency modulated; characterized in that: the frequency characteristics of said first signal, and the optical characteristics of said optical spectrum reshaper, being such that the frequency characteristics of said second signal are configured so as to extend the distance said second signal can travel along a fiber before the amplitude characteristics of said second signal degrade beyond a given amount.
[0051] In another form of the present invention, there is provided a fiber optic communication system comprising:
a module adapted to receive a first signal and convert said first signal into a second signal, said second signal being amplitude modulated and frequency modulated; characterized in that: the frequency characteristics of said second signal are configured so as to extend the distance said second signal can travel along a fiber before the amplitude characteristics of said second signal degrade beyond a given amount.
[0055] In another form of the present invention, there is provided a system adapted to convert a first signal into a second signal, said second signal being amplitude modulated and frequency modulated;
the improvement comprising: tailoring the frequency characteristics of said second signal so as to extend the distance said second signal can travel along a fiber before the amplitude characteristics of said second signal degrade beyond a given amount.
[0058] In another form of the present invention, there is provided a fiber optic communication system comprising:
an optical signal source adapted to receive a base signal and produce a first signal, said first signal being frequency modulated; and an optical spectrum reshaper adapted to convert said first signal into a second signal, said second signal being amplitude modulated and frequency modulated; characterized in that: the frequency characteristics of said first signal, and the optical characteristics of said optical spectrum reshaper, being such that the frequency characteristics of said second signal are configured so as to extend the distance said second signal can travel along a fiber before the amplitude characteristics of said second signal degrade beyond a given amount.
[0063] In another form of the present invention, there is provided a fiber optic communication system comprising:
an optical signal source adapted to produce a first signal, said first signal being frequency modulated; and an optical spectrum reshaper adapted to convert said first signal into a second signal, said second signal being amplitude modulated and frequency modulated; characterized in that: the frequency dependent loss of the optical spectrum reshaper is adjusted to increase the dispersion tolerance of the second signal.
[0068] In another form of the present invention, there is provided a fiber optic system comprising:
an optical source adapted to produce a frequency modulated digital signal; characterized in that: said digital signal has a time varying frequency modulation which is substantially constant across each 1 bit and equal to a first frequency and substantially constant over each 0 bit and equal to a second frequency, wherein the difference between said first frequency and said second frequency is between 0.2 times and 1.0 times the bit rate frequency.
[0072] In another form of the present invention, there is provided a method for generating a dispersion tolerant digital signal, comprising:
modulating a DFB laser with a first digital base signal to generate a first optical FM signal, wherein said first FM signal has a π phase shift between 1 bits that are separated by an odd number of 0 bits, and modulating amplitude of said first optical FM signal with a second digital base signal to produce a second optical signal with high contrast ratio.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0076] Many modifications, variations and combinations of the methods and systems and apparatus of a dispersion compensated optical filter are possible in light of the embodiments described herein. The description above and many other features and attendant advantages of the present invention will become apparent from a consideration of the following detailed description when considered in conjunction with the accompanying drawings wherein like numbers refer to like parts and further wherein:
[0077] FIG. 1 illustrates an optical digital signal with concomitant amplitude modulation and frequency modulation (i.e., flat-topped chirp);
[0078] FIG. 2 illustrates the instantaneous frequency and phase of a 101 bit sequence for flat-topped chirp values of 5 GHz and 10 GHz for a 10 Gb/s digital signal;
[0079] FIG. 3 illustrates a 101 bit sequence with (CML output) and without (Standard NRZ) flat-topped chirp before and after propagation;
[0080] FIG. 4 illustrates a Gaussian pulse with adiabatic chirp profile before an OSR and the resulting pulse shape and flat-topped chirp after an OSR;
[0081] FIG. 5 illustrates the instantaneous frequency profile of the pulse and definitions of the pulse;
[0082] FIG. 6 illustrates the receiver sensitivity after 200 km as a function of the rise times and fall times of the instantaneous frequency profile;
[0083] FIG. 7 illustrates the instantaneous frequency profile and intensity profile after an OSR with two different slopes;
[0084] FIG. 8 illustrates the optical spectrum of an adiabatically chirped signal, the spectrum of the OSR, and the resulting reshaped spectrum;
[0085] FIG. 9 illustrates receiver sensitivity after 200 km of 17 ps/nm/km fiber for various values of adiabatic chirp, and the spectral shift of signal relative to the OSR, which in this example is a 3 cavity etalon filter;
[0086] FIG. 10 illustrates an example of a non-Gaussian OSR and the spectral position of the signal relative to the OSR spectrum;
[0087] FIG. 11 illustrates the definition of slope of slope on an OSR;
[0088] FIG. 12 illustrates Bessel filters used as OSR provide the desired slope of slope;
[0089] FIG. 13 illustrates optical and electrical eye diagrams before and after transmission through 200 km (3400 ps/nm) of fiber;
[0090] FIG. 14 illustrates eye diagrams for back-back and after 200 km of fiber for a chirp managed laser (CML™) transmitter with transient chirp at the output of the laser;
[0091] FIG. 15 illustrates measured slope and slope of slope for a 2 cavity etalon;
[0092] FIG. 16 illustrates transmission and slope of an edge filter used as an OSR;
[0093] FIG. 17 illustrates an example of an OSR with its dispersion profile;
[0094] FIG. 18 illustrates sensitivity versus fiber length of dispersion in 17 ps/nm/km fiber with and without dispersion of the OSR taken into account;
[0095] FIG. 19 illustrates FM optical source with a DFB FM modulator and separate amplitude modulator;
[0096] FIG. 20 illustrates FM optical source with a modulated DFB and integrated Electro-absorption modulator;
[0097] FIG. 21 illustrates the temporal profiles of the AM and FM signals; and
[0098] FIG. 22 illustrates an optical FM/AM source with a bandwidth limiting OSR or filter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0099] In one embodiment of the present invention, the CML™ generates a digital optical signal having concomitant amplitude and frequency modulation, such that there is a special correlation between the optical phases of the bits. This phase correlation provides a high tolerance of the resulting optical signal to dispersion in the optical fiber; further extending the reach of the CML™.
[0100] In one preferred embodiment of the present invention, the CML™ consists of a directly modulated DFB laser and an optical spectrum reshaper (OSR). The distributed feedback (DFB) laser is modulated with an electrical digital signal, wherein a digital signal is represented by 1 bits and 0 bits. The DFB laser is biased high above its threshold, for example, at 80 mA, and is modulated by a relatively small current modulation; the resulting optical signal has amplitude modulation (AM), the 1 bits having larger amplitude than the 0 bits. The ratio of the amplitude of the 1 bits to the 0 bits is typically referred to as the extinction ratio (ER). Importantly, the modulated optical signal has a frequency modulation component, called adiabatic chirp, which is concomitant with the amplitude modulation and nearly has the same profile in time, an example of which is shown in FIG. 1 . The extinction ratio (ER) of the optical output can be varied over a range depending on the FM efficiency of the laser, defined as the ratio of the adiabatic chirp to the modulation current (GHz/mA). A higher modulation current increases ER, as well as the adiabatic chirp.
[0101] The chirp property of directly modulated lasers has been known for some time. When the laser is modulated with an electrical digital signal, its instantaneous optical frequency changes between two extremes, corresponding to the 1s and 0s, and the difference in the frequency changes is referred to as adiabatic chirp. In addition to adiabatic chirp, which approximately follows the intensity profile, there are transient frequency components at the 1 to 0 and 0 to 1 transitions of the bits, called transient chirp. The magnitude of transient chirp can be controlled by adjusting the bias of the laser relative to the modulation current. In one embodiment of the present invention, the transient chirp component is minimized by using a high bias and small modulation. The signal is then passed through an optical spectrum reshaper (OSR), such as the edge of an optical band pass filter with a sharp slope. The OSR modifies the frequency profile of the input optical signal, generating a flat-topped and square shaped frequency profile such as that shown in FIG. 1 . In the preferred embodiment of the present invention, the magnitude of the resulting flat-topped chirp is chosen to be such that it provides a special phase correlation between the bits, as described below. Given an FM efficiency value, η FM , the desired adiabatic chirp, Δν specifies the modulation current, Δi=Δν/η FM , which in turn determines the extinction ratio,
ER = 101 log ( I b - I th + Δ i I b - I th - Δ i ) ,
where I b is the bias current, and I th is the threshold current of the laser. The magnitude of the flat-topped chirp after the OSR is determined by the magnitude of the adiabatic chirp at the output of the laser and the slope of the OSR. For a 10 Gb/s NRZ signal, for example, the desired adiabatic chirp is ˜4.5 GHz, and the ER ˜1 dB for a DFB laser with FM efficiency ˜0.2 GHz/mA. Passing this optical signal through an OSR with average slope of approximately 2.3 dB/GHz increases this chirp magnitude to about 5 GHz. The significance of this value is the desired phase correlation between the bits as described below.
[0102] One important aspect of the present invention is the realization that as the frequency of an optical signal is changing with time, due to the chirp, the optical phase of the bits changes as well, depending on the bit period, rise fall times and the amount of chirp. It should be noted that when monitoring the optical carrier wave, which is a sine wave, it can be observed that at some point in time, phase is a particular position on the carrier wave. The phase difference between the crest of the wave and its trough, for example, is π. Frequency describes the spacing between the peaks; higher frequency means the waves are getting bunched up and more crests are passing by per unit time. Mathematically, phase is the time integral of optical frequency. When the laser is modulated by a digital signal with bit period T, the optical phase difference between two bits depends on the flat-topped chirp, as well as on the total time difference between the bits. This phase difference can be used to increase the propagation of the signal in the fiber as is shown in the following example.
[0103] An optical electric filed is characterized by an amplitude envelope and a time varying phase and a carrier frequency as follows:
E ( t )= A ( t )exp(− iω 0 t+iφ ( t )) (1)
where A (t) is the amplitude envelope, ω 0 is the optical carrier frequency, and φ(t) is the time varying phase. For example, for a chirp-free, or so-called transform limited, pulse, the time varying phase is zero. The instantaneous frequency is defined by the following equation:
f ( t ) = - 1 2 π d ϕ ( t ) dt ( 2 )
Note that the negative sign in Equation 2 is based on the complex notation convention that takes the carrier frequency to be negative frequency. Hence the optical phase difference between two time points on the optical filed is given by:
Δϕ = ϕ ( t 2 ) - ϕ ( t 1 ) = 2 π ∫ t 1 t 2 f ( t ) ⅆ t ( 3 )
[0104] Let's consider a 101 bit sequence at the output of a CML™ having a certain magnitude flat-topped chirp. Taking the frequency of the 1 bits as a reference frequency, we obtain the plot shown below in two cases for a 10 Gb/s digital signal (100 ps pulse duration) for flat-topped chirp values of 5 GHz and 10 GHz. The pulses are assumed to have ideal square shape amplitudes and flat-topped chirp with 100 ps duration. Significantly, for 5 GHz of flat-topped chirp there is a π phase shift between the two 1 bits separated by a single zero.
Δφ=2π×5 GHz×100 ps=π (4)
Following Equations 3 and 4, the phase shift is 2π between two 1 bits separated by two 0 bits, and 3π for two 1 bits separated by three 0 bits and so on. In general, two 1 bits separated by an odd number of 0 bits are π out of phase for 5 GHz of chirp, and a 10 Gb/s signal. For 10 GHz of chirp and 10 Gb/s square pulses the 1 bits separated by odd number of bits are in phase; i.e. phase difference is 2π.
[0105] The significance of this phase shift is realized when the 101 bit sequence with 5 GHz of flat-topped chirp is propagated through dispersive fiber, where each pulse broadens due to its finite bandwidth. FIG. 3 shows that the π phase shift causes the two bits to interfere destructively at the center of the 0 bit, therefore keeping the 1 and 0 bits distinguishable by the decision circuit at the receiver. The decision threshold chooses a threshold voltage above which all signals are counted as 1 and below which they are counted as 0 bits. Hence, the phase shift helps differentiate between the 1 and 0 bits and the pulse broadening does not reduce the BER for this bit sequence. Therefore, the π phase shift constructed, based on the preferred embodiment of the present invention, increases tolerance to dispersion. For intermediate chirp values, there is partial interference, which is enough to extend transmission distance, but not to distances in the case described above.
Optical Spectrum Reshaping
[0106] In one embodiment of the present invention, the FM modulated signal generated is passed though an optical spectrum reshaper so as to change the instantaneous frequency profile of the signal across the 1 and 0 bits in such a way so as to increase the tolerance of the signal to dispersion. In the prior art, such as UK Patent No. GB 2107147A by R. E. Epworth, the signal from the FM source is filtered to produce an intensity modulation, which is higher modulation depth after passing through the filter than that before passing through the filter. In the present invention, optical spectrum reshaping, rather than increase in amplitude modulation alone, can be achieved using an optical spectrum reshaper (OSR). In one embodiment of the present invention, the instantaneous frequency profile of the output signal is modified across its bits after the OSR, so as to increase the distortion free propagation distance.
[0107] In a preferred embodiment of the present invention, a semiconductor laser is directly modulated by a digital base signal to produce an FM modulated signal with adiabatic chirp. The output of the laser is then passed through an OSR, which, in this example, may be a 3 cavity etalon filter used at the edge of its transmission. The chirp output of a frequency modulated source, such as a directly modulated laser, is adiabatic. This means that the temporal frequency profile of the pulse has substantially the same shape as the intensity profile of the pulse.
[0108] In a preferred embodiment, the OSR converts the adiabatic chirp to flat-topped chirp, as described in U.S. Provisional Patent Application Ser. No. 60/554,243, filed Mar. 18, 2004 by Daniel Mahgerefteh et al. for FLAT CHIRP INDUCED BY FILTER EDGE (Attorney Docket No. TAYE-34 PROV), which patent application is hereby incorporated herein by reference.
[0109] FIG. 4 shows the optical intensity and the instantaneous frequency profile of a Gaussian pulse before and after an OSR. The Gaussian pulse has adiabatic chirp before the OSR, i.e., its instantaneous frequency profile has the same Gaussian shape as its intensity profile. After the OSR, both the amplitude and instantaneous frequency profiles are altered. The ratio of peak power-to-power in the background (extinction ratio) is increased, and the pulse narrows slightly in this example. An important aspect of the present invention is the flat-topped instantaneous frequency profile resulting from passage through the OSR, indicated by the dotted horizontal green line in FIG. 4 . The flat-topped chirp is produced when the spectral position of the optical spectrum of the signal is aligned with the edge of the OSR transmission. The optimum position depends on the adiabatic chirp and the slope of the OSR transmission edge.
[0110] The instantaneous frequency profile of a flat-topped chirp pulse is characterized by a rise time, a fall time, duration and a slope of the flat-top, and a flat-topped chirp value as shown in FIG. 5 . The slope, in turn, can be defined by the two frequency values f 2 and f 1 . In an embodiment of the present invention the rise time, fall time, duration, and slope of the top-hat portion of the frequency profile are adjusted relative to the rise time, fall time, duration of the amplitude profile, in order to increase the transmission distance of the signal beyond the dispersion limit.
[0111] The importance of reshaping the instantaneous frequency profile of the pulses can be realized by simulation which shows the bit error rate of such a spectrally reshaped 10 Gb/s pulse after propagation though 200 km of dispersive fiber having 17 ps/nm/km dispersion. FIG. 6 shows that for a given flat-topped chirp value as measured in the instantaneous frequency profile of the signal after the OSR. In such a case, the BER sensitivity can be optimized by varying the rise time and fall time. Also, for a given rise time and fall time of the instantaneous frequency profile, the chirp value can be varied over a range from 3 GHz to 10 GHz in order to achieve a desired BER sensitivity after propagation through fiber.
[0112] The following conclusions can be drawn from this example calculation:
(i) the optimum adiabatic chirp after the OSR is 5 GHz, with short rise time and fall time for the instantaneous frequency profile; this achieves the lowest sensitivity after fiber propagation; (ii) any chirp in the range of 3-10 GHz can be used to extend transmission relative to the case of no chirp. The rise time and fall times have to be adjusted based on the adiabatic chirp value. In the above example, a rise time and fall time of <30 ps is always optimum; and (iii) the rise time and fall time of the instantaneous frequency can be reduced by increasing the slope in dB/GHz of the transmission profile of the OSR. Slope of top-hat portion of the frequency profile is determined by the dispersion of the OSR and provides further dispersion tolerance.
[0116] FIG. 7 shows another example, where the rise time and fall time of the instantaneous frequency profile are reduced after the OSR by increasing the slope in dB/GHz of the OSR, here by a factor of 2. In one embodiment of the present invention, the output of a frequency modulated signal is passed through an OSR and the rise time and fall time of the frequency profile are reduced by increasing the slope (in dB/GHz) of the OSR.
Spectral Narrowing
[0117] Simultaneous frequency modulation and amplitude modulation with the same digital information reduces the optical bandwidth of the signal and suppresses the carrier frequency. This effect is most marked for a chirp value that is ½ the bit rate frequency; i.e., 5 GHz chirp for 10 Gb/s. This corresponds to the phase change of 0 to π between 1 bits separated by an odd number of 0 bits, i.e., optimum correlation between the phases of the otherwise random bit sequence. For an approximate range of chirp values between 20% to 80% of the bit rate frequency (2-8 GHz for 10 Gb/s bit rate) the carrier is significantly suppressed and the spectrum is narrowed. For 0 value of chirp or for chirp equal to the frequency of the bit rate frequency, the carrier is present and the spectrum broadens again. This is because the phase of all the pulses becomes equal for these two cases and the phase correlation is lost. As shown in FIG. 8 , the narrowing of the spectrum by application of amplitude modulation and frequency modulation narrows the spectrum on the high frequency side. Note that in this example the chirp is ˜7.5 GHz for 10 Gb/s. The spectral position of the signal relative to the peak transmission of the OSR is adjusted such that the spectrum in on the low frequency edge of the OSR. This further reduces the spectral width on the low frequency side. Reducing the spectral bandwidth extends the transmission distance.
[0118] In one embodiment of the present invention the Bandwidth (BW) of the OSR is less than the bit rate. The spectrum of a digital signal is determined by the product of the spectrum of the digital information and the Fourier transform of the pulse shape. Using the correct amount of FM modulation (5 GHz of chirp for 10 Gb/s data rate) which gives a π phase shift between 1 bits separated by odd number of 0 bits as prescribed above, reduces the information BW. In order to increase tolerance to dispersion it is still necessary to reduce the spectrum of the pulse shape. This is done by a bandwidth limiting OSR in the preferred embodiment of the present invention.
[0119] FIG. 8 shows that for a given value of adiabatic chirp, the spectral position of the signal relative to the peak transmission of the OSR can be adjusted to increase the transmission distance. FIG. 8 shows the sensitivity for a 10 Gb/s signal at the transmitter (Back-back) and after propagation through 200 km of fiber having 17 ps/nm/km of dispersion as a function of the spectral shift relative to the OSR. Sensitivity is defined as the average optical power (in dBm) required to achieve a bit error rate of 10 −12 . The OSR in this example is a 3 cavity etalon. It is therefore an embodiment of the present invention to adjust the adiabatic chirp of the frequency modulated source as well as the spectral position of the resulting spectrum relative to the OSR in order to achieve a desired bit error rate after propagation through dispersive fiber.
[0120] FIG. 9 shows an example of an OSR, formed by a non-Gaussian shaped band pass filter. FIG. 9 shows the transmission profile in dB scale as well as the derivative, or frequency dependent slope, of the OSR. FIG. 9 also shows the spectral position of the input FM signal to be reshaped. It is a preferred embodiment of the present invention that the optimal spectral position of the FM signal on the OSR be such that the Is peak frequency be near the peak logarithmic derivative of the transmission profile of the OSR. In this example, the derivative is not linear on the dB scale, indicating that the OSR has a non-Gaussian spectral profile. A Gaussian OSR would have a linear slope as a function of frequency. FIG. 9 also shows the position of the clock frequency components of the input FM signal, which are reduced substantially after the OSR. This in-turn reduces the clock frequency components in the RF spectrum of the resulting second signal after the OSR. In this example, the peak slope is 2.7 dB/GHz, and the 3 dB bandwidth of the OSR in this case is approximately 8 GHz.
[0121] It is an embodiment of the present invention for the OSR to also reduce the clock frequency components, 10 GHz for a 10 Gb/s NRZ signal, in the RF spectrum of the signal resulting after the OSR.
[0122] The optimum OSR shape is one for which the transmitter has good performance both at its output (Back-to-back) as well as after transmission. The back-to-back performance is determined by having minimum distortion of the bits in the eye diagram, while after transmission performance is determined by a low dispersion penalty. As described in U.S. Provisional Patent Application Ser. No. 60/554,243 (Attorney Docket No. TAYE-34 PROV) and 60/629,741 (Attorney's Docket No. TAYE-48 PROV), which patent applications are hereby incorporated herein by reference, a certain value of filter slope is required to convert an adiabatically chirped input signal to one having flat-topped chirp. It was shown that the OSR converts the first derivative of the amplitude of the input pulse to blue shifted transient chirp at the edges. For an optimum value of slope the added transient chirp increases the chirp at the edges to produce a nearly flat top chirp.
[0123] U.S. Provisional Patent Application Ser. No. 60/554,243 (Attorney Docket No. TAYE-34 PROV) and 60/629,741 (Attorney's Docket No. TAYE-48 PROV) disclose that a significant parameter of the OSR is the slope of its slope. As defined in the present invention, slope of slope (SoS) is the ratio of the peak logarithmic derivative of the transmission (in dB/GHz) to the frequency offset of this peak form the transmission peak (in GHz), as illustrated in FIG. 11 . In one embodiment of the present invention, the slope of slope of an OSR is adjusted to optimize both the back-to-back transmitter BER and to reduce the BER after fiber transmission. For example, for a 10 Gb/s transmitter good back-to-back eye diagram, as well as low BER after transmission is obtained if the slope of slope is approximately in the range of 0.38 dB/GHz 2 to 0.6 dB/GHz 2 . In addition the slope of the OSR near the center of the transmission needs to be approximately linear. Deviations from linearity introduce distortions in the resulting output eye diagram and thus cause increased bit error rate. A linear slope corresponds to a round-top shape filter. So, for example, a flat-topped filter, which has a near zero slope near the center is not desirable. The 3 dB band width of the band-pass OSR has to be in the range of 65% to 90% of the bit rate.
[0124] Two examples of such OSRs, as shown in FIG. 12 , are 2 nd order Bessel filters having a 6 GHz or 5.5 GHz band widths. The 2 nd order Bessel filter shape is well known to the skilled in the art and is described mathematically by
T ( p ) = 1 3 + 3 p + p 2 ( 6 )
where p=2if/Δf 3 dB . Here T is the field transmission, f is the optical frequency offset from the center of filter, and Δf 3 dB is the 3 dB band width of the filter. The measured quantity is the optical transmission of the filter, which is the absolute square of the field transmission in Eq. 6, |T(p)| 2 and is plotted in FIG. 12 . The Bessel filter is usually used as an electrical low pass filter because it minimizes distortion in its pass band. In one embodiment of the present invention, the Bessel filter is an optical filter, and it is chosen because it provides the desired slope of slope and linear slope near its peak transmission. The slope of slope for the 2 nd order Bessel filter with a 6 GHz bandwidth is 0.46 dB/GHz 2 , and the slope of slope for the 5.5 GHz bandwidth 2 nd order Bessel filter is 0.57 dB/GHz 2 . These examples show that the bandwidth of the filter can be adjusted to change SoS to be the desired value.
[0125] Another example of a filter that can be used in accordance with the present invention is a 4 th order Bessel filter with a band width of 7.5 GHz, also shown in FIG. 12 . This OSR has a slope of slope of 0.41 dB/GHz 2 . The field transmission of the 4 th order Bessel filter is given as a function of the normalized frequency by
T ( p ) = 1 15 + 15 p + 6 p 2 + p 3 ( 7 )
[0126] FIG. 13 shows examples of calculated eye diagrams for back-back and after 200 km of fiber having 3400 ps/nm dispersion. In this example, the 2 nd order Bessel filter with 5.5 GHz bandwidth was used. The eye diagrams on the left column are the back-back optical eye (so-called O-eye) of transmitter (top) and the eye transmitted after 200 km (3400 ps/nm). The eye diagrams on the right column are the eye diagrams measured after an optical to electrical converter with a typical ˜8 GHz band width, which is called electrical eye (E-eye). The electrical eye is that at the output of the receiver, which converts the optical to electrical signal and provides it to the decision circuit for distinguishing the 1 and 0 bits.
[0127] A directly modulated laser produces transient chirp, which occurs at the 1 to 0 and 0 to 1 bit transitions, in addition to adiabatic chirp. In a conventional directly modulated laser, transient chirp is detrimental as it hastens pulse distortion and increases BER after transmission. However, in the present invention, it has been found that when used as the FM source, where the directly modulated laser is followed by an OSR, some transient chirp at the output of the laser is desirable. FIG. 14 shows the results of simulation of a transmitter in accordance with the present invention. In this example, the adiabatic chirp of the laser is 4.5 GHz and the OSR is a 2 cavity etalon filter operated near its transmission edge.
[0128] FIG. 14 shows the eye diagrams of a 10 Gb/s transmitter at its output (back-back), as well as the eye after propagation through 200 km of fiber with 3400 ps/nm dispersion. The transient chirp at the output of the laser, before the OSR, is either nearly zero (˜0.2 GHz) (left column) or 2 GHz (right column). Looking at FIG. 14 , it is clear that the case having 2 GHz transient chirp produces a less distorted eye back to back. The eye after 200 km of fiber is also more open and has less inter-symbol interference (ISI) in the case having 2 GHz transient chirp. It is, therefore, one embodiment of the present invention to adjust the transient chirp of the frequency modulated source as well as the slope of slope of the optical spectrum reshaper to obtain the desired transmitter output having minimum distortion and to increase the error free propagation length of the transmitter beyond the dispersion limit.
[0129] In practice, an optical filter such as a multicavity etalon may not have the desired transmission shape and slope of slope. Therefore, in another embodiment of the present invention, the angle of incidence and the beam divergence of the optical signal impinging upon the filter are adjusted to obtain the desired SoS. FIG. 15 shows an example of the measured slope as well as slope of the slope as a function of angle of incidence for a 2 cavity etalon. The peak slope initially decreases for increasing angles, reaches a minimum, and then increases again. The increase in slope at large angles is caused by spatial filtering, as described in U.S. Provisional Application Ser. No. 60/621,755, filed Oct. 25, 2004 by Oct. 25, 2004 et al. for SPECTRAL RESPONSE MODIFICATION VIA SPATIAL FILTERING WITH OPTICAL FIBER (Attorney's Docket No. TAYE-47 PROV), which patent application is hereby incorporated herein by reference. For the same range of angles the slope of slope monotonically decreases from 0.75 dB/GHz 2 to 0.35 dB/GHz 2 because the peak position is increasing with increasing angle. In this example, the optimum value of 0.45 dB/GHz 2 is obtained by adjusting the angle of incidence to 1.5 to 2 degrees.
[0130] In the above described examples, the optical spectrum reshaper (OSR) was a multicavity etalon filter. In another preferred embodiment of the present invention the OSR may be an edge filter, as shown in FIG. 16 . The edge filter has a substantially flat transmission with frequency over a frequency range and a sharp edge on one side of the peak transmission. The position of the first optical signal in this case will be substantially on the slope of transmission.
OSR Dispersion
[0131] The OSR can also provide some dispersion compensation as well as the spectral reshaping. FIG. 17 shows the transmission characteristics of a filter and its corresponding dispersion profile.
[0132] The filter dispersion can compensate for a portion of the fiber dispersion. For example, if the laser frequency spectrum substantially overlaps with the normal dispersion peak, having a negative dispersion, the transmission for a standard single fiber having positive dispersion is extended. If the laser frequency spectrum substantially overlaps with the anomalous dispersion peak, where dispersion is positive, it reduces the transmission distance for a standard fiber with positive dispersion, but extends the reach over negative dispersion fiber such as Dispersion Compensating Fiber (DCF). FIG. 18 shows the sensitivity as a function of fiber distance for a case of an OSR with and without dispersion. The laser spectrum substantially overlaps with the negative dispersion peak of the OSR. As shown in FIG. 18 , the negative distance indicates a fiber having negative dispersion of that length. So, for example, −100 km indicates a 100 km dispersion compensating fiber having −17 ps/nm/km dispersion.
FM Sources
[0133] The present invention teaches a variety of methods for generation of a dispersion tolerant FM signal with high extinction ratio (ER). In one preferred embodiment of the present invention the FM signal is generated in two steps.
[0134] First, a base digital signal is chosen to modulate a directly modulated DFB laser so as to generate an FM signal with adiabatic chirp such that the phase difference between two 1 bits separated by an odd number of 0 bits is an odd integer multiple of π. As an example, for a 10 Gb/s NRZ signal with 100 ps pulses and near square shaped instantaneous frequency profile, this is 5 GHz.
[0135] Next, the resulting optical signal is sent through a second amplitude modulator, such as a LiNbO 3 modulator or an electro-absorption modulator, as shown in FIG. 19 . The amplitude modulator is modulated by a second digital base signal, which is a replica of the first digital base signal. The base signal supplied to the modulator may be inverted relative to that modulating the laser, depending on the transfer function of the modulator. This is the case, for example, if a higher signal increases the loss of the modulator. Hence, a high signal produces a higher amplitude optical signal from the laser and a corresponding low signal is supplied to the modulator. The AM modulator may be a variety of optical amplitude modulators such as a LiNbO 3 modulator, or an electro-absorption modulator. The DFB and EA may be integrated on the same chip, as shown in FIG. 20 .
[0136] In one preferred embodiment of the present invention, the first and second base signals supplied to the laser and modulator may be adapted to generate FM and AM signals, respectively. These FM and AM signals are different in temporal profiles, as demonstrated in FIG. 21 , in that there may be a phase difference between the two digital base signals. Also, the rise time and fall time of the instantaneous frequency of the first signal and the rise time and fall time of the resulting second signal after the AM modulator may be different. In addition, the durations of the FM and AM pulse profiles may be different. In a preferred embodiment of the present invention the duration, rise time and fall time, adiabatic chirp, amplitude modulation depth, and the phase delay between the two digital base signals are varied, as described by the prescriptions and examples above, so as to increase the dispersion tolerance of the transmitted signal to fiber dispersion. These parameters for the frequency and amplitude profiles are defined in FIG. 21 .
[0137] In another embodiment of the present invention, and as shown in FIG. 22 , there may be a bandwidth limiting filter or an OSR placed after the FM/AM source described above. The OSR or filter is chosen so as to reduce the optical frequency components that are at, or higher than, the bit rate frequency, 10 GHz for a 10 Gb/s NRZ signal, for example.
Parameter Ranges
[0138] In various embodiments of the present invention, for longer distance transmission of signal, performance after the optical spectrum reshaper needs to be optimized, leading to the following preferred characteristics:
(i) AM ER<3 dB (i.e., the extinction ratio of the laser's intensity output is preferably less than 3 dB in order to minimize transient chirp); (ii) adiabatic chirp in the range 2.5-7.5 GHz (i.e., the adiabatic chirp of the laser's output Δf=f 1 −f 0 ≈2.5-7.5 GHz for optimum transmission); and (iii) Optical spectrum reshaper bandwidth is in the range of 5-10 GHz (i.e., the OSR has a filter bandwidth of 5-10 GHz to maximize spectral narrowing effect).
Modifications
[0142] It will be appreciated that still further embodiments of the present invention will be apparent to those skilled in the art in view of the present disclosure. It is to be understood that the present invention is by no means limited to the particular constructions herein disclosed and/or shown in the drawings, but also comprises any modifications or equivalents within the scope of the invention.
|
In one form of the present invention, there is provided a fiber optic communication system comprising: an optical signal source adapted to receive a base binary signal and produce a first signal, said first signal being frequency modulated; and an optical spectrum reshaper adapted to reshape the first signal into a second signal, said second signal being amplitude modulated and frequency modulated; characterized in that: the frequency characteristics of said first signal, and the optical characteristics of said optical spectrum reshaper, being such that the frequency characteristics of said second signal are configured so as to increase the tolerance of the second signal to dispersion in a transmission fiber. In another form of the present invention, there is provided an optical transmitter comprising: a frequency modulated source for generating a first frequency modulated signal, and an amplitude modulator for receiving the first frequency modulated signal and for generating a second amplitude and frequency modulated signal. In another form of the present invention, there is provided a method for transmitting an optical signal through a transmission fiber comprising: receiving a base binary signal; operating an optical signal source using the base binary signal to produce a first signal, said first signal being frequency modulated; passing the frequency modulated signal through an optical spectrum reshaper so as to reshape the first signal into a second signal, said second signal being amplitude modulated and frequency modulated; the frequency characteristics of said first signal, and the optical characteristics of said optical spectrum reshaper, being such that the frequency characteristics of said second signal are configured so as to increase the tolerance of the second signal to dispersion in a transmission fiber; and passing the second signal through a transmission fiber. In another form of the present invention, there is provided a method for transmitting a base signal, comprising: using the base signal to produce a frequency modulated signal; and providing an amplitude modulator for receiving the frequency modulated signal and for generating an amplitude and frequency modulated signal.
| 7
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/050,908, filed Sep. 16, 2014, entitled “Distributed Steam Generation Process for Use in Hydrocarbon Recovery Operations,” the contents of which are incorporated herein in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The invention relates to thermal recovery methods and systems for heavy hydrocarbon deposits, and specifically to such methods and systems requiring steam injection to mobilize the deposits.
BACKGROUND
[0003] In the field of subsurface hydrocarbon production, it is known to employ various stimulation procedures and techniques to enhance production. For example, in the case of heavy oil and bitumen housed in subsurface reservoirs, conventional drive mechanisms may be inadequate to enable production to surface, and it is well known to therefore inject steam or steam-solvent mixtures to make the heavy hydrocarbon more amenable to movement within the reservoir permeability pathways, by heating the hydrocarbon and/or mixing it with lighter hydrocarbons or hot water.
[0004] In steam-assisted gravity drainage (“SAGD”) and cyclic steam stimulation (“CSS”) hydrocarbon recovery operations, steam is generated at surface by steam generation units and injected downhole into a well, where it is subsequently introduced into an underground hydrocarbon formation in which the well lies, after which the steam warms bitumen and oil within the formation. Thus-warmed hydrocarbon within the formation is mobilized and moves or is drawn toward the well, where it is then collected and produced to surface. The steam, when contacting cooler subterranean bitumen and oil, typically condenses to water, releasing latent heat of condensation and thereby effectively transferring heat to the oil/bitumen.
[0005] Due to the foregoing condensation of injected steam to water, and also by reason that underground formations typically contain amounts of water in the form of brine or the like, water is typically produced to surface with the recovered hydrocarbon. Because proximate sources of water for producing steam for injection downhole are often in very short supply, or their use prevented due to governmental restrictions, it is very desirable to use produced water to generate steam. Not only is such water (although contaminated) available at site, but by generating steam from produced water the disposal costs (which are also impacted by regulatory limitations) of such contaminated produced water is reduced.
[0006] Typically, water that is produced to surface with the collected hydrocarbon arrives in the form of free water and/or water-in-oil emulsions and/or oil-in-water reverse emulsions. The produced water must go through a series of processing steps to be useful as boiler feedwater, such as de-oiling, softening and ion exchange. Typical de-oiler systems include a free water knock out (“FWKO”) vessel, followed by a skim tank, induced gas floatation and finally an oil removal filter. The de-oiler system is conventionally used at surface to separate the recovered hydrocarbons from the produced water, and the produced water is thereafter recycled to the steam generation unit for re-use in converting same to steam for injection downhole; typically, however, the produced water contains significant impurities in the form of inorganic compounds, such as silica, calcium and magnesium ions, which must be addressed and controlled before the de-oiled produced water can be introduced to steam generation units as feedstock.
[0007] Conventional drum boilers operating at circa 2% blowdown cannot typically be used to generate steam from the produced water without the use of evaporators to generate high purity feedwater due to the concentration of impurities such as calcium, silica, organics and the like that cause precipitation and thereby scaling and fouling within boiler tubes during the boiling of the water, which thereby very quickly renders the boiler ineffective in transferring heat to the water to generate steam and can also rupture boiler tubes due to the generation of hot spots.
[0008] Alternatively, special types of steam generators are commonly used, namely so-called “once-through steam generators” (“OTSG” or “OTSGs”), which can better handle higher amounts of impurities in the produced water feed stream and generate steam ranging from 65% to 90% steam quality (10-35 parts water containing the impurities, 65-90 parts steam vapor). Operating at this steam quality greatly reduces the dissolved salts which foul and scale the tubes. Nevertheless, produced water pre-conditioning steps are still necessary, such as the warm lime softening (“WLS”) or hot lime softening (“HLS”) process, which injects lime to reduce water hardness and alkalinity and precipitates silica and carbonate ions out of the water, and in conjunction with a weak acid cation or strong acid cation ion exchange (“WACS” or “SACS”) process, removes the calcium and magnesium scale generating ions to acceptable concentrations, thereby reducing build-up of scale in the OTSG. The major bulk chemicals used in these processes are lime (Ca(OH)2), magnesium oxide (MgO), soda ash (Na2CO3), caustic (NaOH), and hydrochloric acid (HCl). Minor amounts of coagulant and polymer are used to aid in solid separation.
[0009] The above-mentioned equipment and systems are conventionally situated in a large, centrally-located facility that can produce steam for use at various nearby injection wells in the target reservoir. Some current conventional thermal recovery operations are accordingly designed based on the concept of a central processing facility (“CPF”) and a plurality of dispersed well pads. As can be seen in FIG. 1 , the CPF-pad arrangement 1 comprises a CPF 2 and well pads 3 a , 3 b , 3 c that are distributed at some appropriate and functional distance from the CPF 2 , and are in communication with the CPF 2 by means of various pipelines 4 that transport materials between each well pad 3 and the CPF 2 . By distributing the well pads around and at a distance from the CPF, the idea is that the reservoir can be exploited with a complex central facility (the CPF) but relatively simple and easy-to-construct well pads at various points above the reservoir that can be serviced from the central facility.
[0010] Each well pad in such a conventional arrangement essentially functions to inject steam downhole, and to recover produced materials and pipe them to the CPF for processing. Turning to FIG. 2 , the CPF 2 and pad 3 are again seen connected by pipes 4 . Such pipes 4 conventionally include a produced materials pipe 5 for sending produced materials (generally bitumen, gas, water and solids) from the pad 3 to the CPF 2 for processing as described above. Also, the CPF 2 feeds various inputs to the pad 3 , such as a steam supply through a high pressure steam pipe 6 . Other inputs may also need to be supplied from the CPF to the well pad, as is known to those skilled in the art.
[0011] However, the requirement for the supply of steam from the CPF to each of the well pads introduces a high-pressure pipeline environment. That being the case, certain civil structural works are required, such as above-ground racks and expansion loops for the pipes. In addition, constructing a very large central facility in a mega project fashion introduces enhanced costs and execution risks, both in terms of construction and operation. Smaller and more modular equipment would facilitate more rapid installation and execution. Focusing most of the processing equipment in one relatively large CPF can negatively impact the ability to effectively exploit the reservoir.
[0012] It would therefore be desirable to have an arrangement that addresses the issues arising from constructing a large CPF to process the materials coming from the wells and generating steam while retaining the benefits of the distributed well pad system.
BRIEF SUMMARY
[0013] The present invention therefore seeks to provide a novel CPF-pad arrangement that locates certain equipment and produced materials treatment at the pads themselves, including the generation of steam at each pad for injection and thus avoiding the need for steam piping from the CPF. As the high-pressure steam pipeline environment is avoided, pipes between the CPF and well pads will be reduced in number and can be buried.
[0014] According to a first aspect of the present invention there is provided a method for generating steam for use in a subsurface hydrocarbon recovery operation, the operation comprising a central processing facility in fluid communication with at least one well pad, the well pad for servicing a related hydrocarbon recovery well, the method comprising the steps of:
[0000] locating produced materials treatment means and steam generation means at the well pad;
producing produced materials from the related hydrocarbon recovery well at the well pad; treating the produced materials at the well pad to separate water and hydrocarbon from the produced materials;
transporting the hydrocarbon from the well pad to the central processing facility;
feeding the water to the steam generation means to generate steam; and
injecting the steam into the related hydrocarbon recovery well.
[0015] In some exemplary embodiments of the first aspect of the present invention, gas is separated from the produced materials and treated using gas treatment means located on the well pad, for example for sulphur removal, before piping the gas for re-use as fuel.
[0016] In some exemplary embodiments of the first aspect of the present invention, the hydrocarbon separated from the produced materials can be subjected to partial upgrading on the well pad before being transported to the central processing facility, thus avoiding or reducing the need for diluent to enable pipelining of the hydrocarbon. Alternatively, the hydrocarbon can be subjected to partial upgrading at the CPF.
[0017] According to a second aspect of the present invention there is provided a system for generating steam for use in subsurface hydrocarbon recovery, the system comprising:
[0000] a central processing facility;
at least one well pad in fluid communication with the central processing facility;
each well pad adjacent a related hydrocarbon recovery well(s), the related hydrocarbon recovery well(s) for producing produced materials;
produced materials treatment means at the well pad for separating gas, solids, water and hydrocarbon from the produced materials;
pipeline means for transporting the hydrocarbon from the well pad to the central processing facility;
steam generation means at the well pad for generating steam from the water; and
steam injection means for injecting the steam into the related hydrocarbon recovery well.
[0018] In some exemplary embodiments of the second aspect of the present invention, the produced materials treatment means at the well pad is used for separating water, gas, solids, and hydrocarbon from the produced materials. The system may further comprise gas treatment means at the well pad for treating gas separated from the produced materials, for example for sulphur removal, before piping the gas for re-use as fuel.
[0019] In some exemplary embodiments of the second aspect of the present invention, the system further comprises a partial upgrading plant at the well pad for partially upgrading the hydrocarbon separated from the produced materials before being transported to the central processing facility, thus avoiding or reducing the need for diluent to enable pipelining of the hydrocarbon. Alternatively, the hydrocarbon can be subjected to partial upgrading at the CPF.
[0020] A detailed description of exemplary embodiments of the present invention is given in the following. It is to be understood, however, that the invention is not to be construed as being limited to these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the accompanying drawings, which illustrate exemplary embodiments of the present invention:
[0022] FIG. 1 is a simplified view of a conventional prior art arrangement of a central processing facility and a plurality of well pads;
[0023] FIG. 2 is a simplified view of conventional piping of materials between a well pad and a central processing facility;
[0024] FIG. 3 is a simplified schematic view of a first exemplary system in accordance with the present invention; and
[0025] FIG. 4 is a simplified schematic view of a second exemplary system in accordance with the present invention.
[0026] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0027] Turning now to FIGS. 3 and 4 , exemplary embodiments of the present invention are illustrated. The exemplary embodiments are presented for the purpose of illustrating the principles of the present invention, and are not intended to be limiting in any way.
[0028] FIG. 3 illustrates a first exemplary embodiment of the present invention. A single well pad 10 is illustrated as being in fluid communication with a CPF (not shown), but it is to be understood that in most cases a plurality of well pads 10 would be in communication with a single CPF. The well pad 10 comprises a separator 12 and a steam generator 14 .
[0029] While FIG. 3 shows the separator 12 as a single unit, it will be clear to those skilled in the art that this would normally represent a number of discrete cooperating pieces of equipment, establishing oil removal and water treatment systems. For example, separator 12 can represent a conventional combination of a FWKO, skim tanks, induced gas flotation, WLS and WACS units. A flash-treater could also be employed. Although many different types of separation technologies could be used with the present invention as would be clear to those skilled in the art, it is preferred that the separator 12 comprise compact and modular units such as hydrocyclones, centrifuges and membrane systems, although the separator 12 need not be limited to either of these technologies.
[0030] The function of separator 12 is to take produced material and separate it into various desired components. The produced material is normally a mixture of water and hydrocarbon (in an emulsion), gas and solids, drawn from the well through line 16 to the separator 12 intake. The separator 12 —through whatever process is inherent in the particular type of separator selected—separates the produced material into four streams: gas, solids, hydrocarbon and de-oiled water—the latter intended for use in steam production. The solids stream passes through line 18 to a landfill or other storage means familiar to those of skill in the art. The gas stream can be treated on the well pad 10 , for example if it contains H 2 S, and combusted in the steam generator 14 .
[0031] The separator 12 also produces a hydrocarbon output 22 , which may be a heavy hydrocarbon such as bitumen. Bitumen is normally too heavy to transport by pipeline and it is therefore common to dilute it with a diluent, conventionally a lighter hydrocarbon, to make it amenable to transport to the CPF for further processing. As can be seen in the embodiment of FIG. 3 , a diluent 32 is piped in from the CPF or from a diluent line and injected into the hydrocarbon output line 22 to enable piping to the CPF; however, the use of diluent can be avoided if hot bitumen is pipelined, and diluent should therefore be viewed as optional. Other additives such as drag reduction additives are also known to those skilled in the art, and may be considered for use with this exemplary embodiment, and would be added using a line such as the chemical line 34 .
[0032] In addition, chemicals such as a demulsifier may need to be sourced (from the CPF via pipeline or by tanker) to enable the desired separation of the produced material. The introduction of such chemicals is illustrated as line 34 entering the separator 12 .
[0033] The final component of the produced material separated by the separator 12 is the water output 24 . As discussed above, there are existing technologies that can be used to generate water of sufficient purity to be used as boiler feedstock, and the particular separation technology must be selected to match the specification needs of the steam generation technology, which is within the knowledge of the skilled person. The water output 24 from the separator 12 is then fed into the steam generator 14 , producing steam 26 ; solids 28 and waste water (or boiler blowdown) 30 would commonly also be produced depending on the steam generation technology employed. Any solids 28 and waste water 30 would be disposed of in accordance with common knowledge in the field and applicable laws. The steam 26 is injected back into the well (not shown) to enable continued production of hydrocarbons as part of the thermal recovery operation.
[0034] Turning now to FIG. 4 , an alternative embodiment of the present invention is illustrated. While similar in most respects to the method illustrated in FIG. 3 and as described above, the alternative embodiment instead seeks to partially upgrade the separated hydrocarbon stream output from the separator 12 . In this embodiment, the hydrocarbon stream is directed to a partial upgrading plant (“PUP”) 36 , in which the hydrocarbon is made lighter and more amenable to pipeline transport to the CPF. The partially upgraded hydrocarbon stream 38 is output from the PUP 36 and pipelined to the CPF for further processing. In this embodiment, then, there is potentially less need for a diluent stream from the CPF, although some diluent addition as illustrated in FIG. 3 may still be required. The operation of a PUP is within the knowledge of the skilled person and will therefore not be described further herein.
[0035] As can be readily seen, then, there are numerous advantages provided by the present invention. With the elimination of high-pressure steam pipes, pipelines can be buried between the CPF and the well pads, reducing the need for above-ground civil works, and on-pad steam generation can reduce the risk of steam loss and the need for pipe insulation. The total area of the CPF itself can be reduced, possibly by as much as 50% to 75%. Also, as equipment is sized for a single well pad, project execution costs and risks can be minimized in many situations.
[0036] The foregoing is considered as illustrative only of the principles of the invention. Thus, while certain aspects and embodiments of the invention have been described, these have been presented by way of example only and are not intended to limit the scope of the invention. The scope of the claims should not be limited by the exemplary embodiments set forth in the foregoing, but should be given the broadest interpretation consistent with the specification as a whole.
|
A method and system for producing steam for use in heavy hydrocarbon recovery operations. In an arrangement with or without a central processing facility and/or a plurality of well pads in communication with the central processing facility, each well pad is provided with equipment for separation of materials produced from its respective wells, and steam generation equipment for that well pad, thus allowing for simplified piping transport.
| 4
|
TECHNICAL FIELD
[0001] Embodiments of the present invention relate to the field of browser-based HTML document editing. In particular, embodiments of this invention relate to an approach of browser-based HTML contents editing in a “What You See Is What You Get” manner. In particular, the processes of the embodiments of the present invention edit HTML contents on selected elements via virtual properties and automatic CSS creations, which differ from commonly adopted approaches of mimicking word-processing in browser-based visual HTML editing, which edit and format HTML contents on selected text.
BACKGROUND ART
[0002] There are two types of visual HTML editors: standalone programs and in-browser editors. A standalone HTML editor may use all functionality provided by the Operating System it runs under. But an in-browser HTML editor is hosted in a web browser and thus it can only use functionality available from a web browser; it also subjects to security restrictions imposed by a web browser.
[0003] This invention is in the field of in-browser visual HTML editing. It is also referred to as “browser-based HTML editing”, “in-place HTML editing”, “in-browser HTML editing”, “online HTML editing”, “online rich-text editor” (see http://en.wikipedia.org/wiki/Online_rich-text_editor), “Through the Web (TTW) editor” (see http://www.geniisoft.com/showcase.nsf/WebEditors), etc.
[0004] An “in-browser” visual HTML editor uses the contents editing capabilities provided by a web browser. Usually such an editor is created in JavaScript.
[0005] In-browser visual HTML editing is now supported by most browsers for “What You See Is What You Get (WYSIWYG)” HTML editing. Industry standardization is progressing on this field.
[0006] WYSIWYG document editing allows the user to edit a document while the document is displayed in its formatted viewing form. Standalone programs such as Microsoft Word, Adobe Acrobat, etc., all provide WYSIWYG document editing.
[0007] A traditional WYSIWYG document editor works by providing a set of buttons and a set of menus for executing editing commands on the selected document text or the text under caret.
[0008] Traditional ways of WYSIWYG document editing is adopted by all state-of-art browser-based HTML editors. Actually it is considered a major design goal of a browser-based visual HTML editor to mimic traditional WYSIWYG document editing (see http://en.wikipedia.org/wiki/Online_rich-text_editor).
[0009] Microsoft added an “execCommand” function to the web page's DOM object, “document”, and added a set of HTML editing commands to its Internet Explorer web browser (see http://msdn.microsoft.com/en-us/librarv/ms536419.aspx). Most of other web browsers followed what Microsoft did and added supports of “execCommand” function and the editing commands the Internet Explorer uses (see http://www.ouirksmode.orv/dom/execCommand.html. http://tifftiff.de/contenteditable/compliance test.html, and http://ehsanakhgari.org/blog/2010-03-08/thoughts-future-web-based-html-editors). With such support from a web browser, a browser-based HTML editor can be made like a word-processor: a toolbar can be created to execute editing commands provided by the browser.
[0010] The HTML editing commands are being standardized by W3C (see http://www.whatwg.org/specs/web-apps/current-work/#editing-apis. https://dvcs.w3.org/hg/editing/raw-file/tip/editing.html, and http://www.w3.org/community/editing/).
[0011] There is a large number of in-browser HTML editors available from the internet (see http://en.wikipedia.ort/wiki/Online_rich-text editor and http://www.geniisoft.com/showcase.nsf/WebEditors). All of them provide a word processor user interface.
[0012] EditUve claims that it is a “Word processing for the web” (see http://editlive.com/features).
[0013] CKEditor is adopted by many products, and it promotes itself by saying that “It brings to the web common editing features found on desktop editing applications like Microsoft Word and OpenOffice.” (see http://ckeditor.com/what-is-ckeditor)
[0014] Asbru is for web developers/programmers. It uses a toolbar to provide a set of commands for editing HTML contents (see http://editor.asbrusoft.com/).
[0015] Tinymce is for embedding visual HTML editing into web page. When it starts it shows a word-processing user interface (see http://www.tinymce.com/).
[0016] Yahoo! is also putting large efforts in creating YUI Rich Text Editor (see http://developer.yahoo.com/yui/editor/), which converts a text area into a word processor.
SUMMARY OF INVENTION
Technical Problem
[0017] State-of-art browser-based visual HTML editors are mimicking word-processing and W3C is making standardization to help making browser-based word-processors for HTML editing. But doing such a word-processing in WYSIWYG document editing for HTML contents editing has serious problems because HTML document has its own characteristics which are significantly different than other rich formatted documents such as Microsoft Word, Adobe PDF file, etc.
[0018] One problem is related to the using of CSS. CSS is a major way of HTML authoring. But it requires writing text code and it targets elements, not text. A word-processor is for editing text, it is very difficult to include CSS. Some survey says that “WYSIWYG editor designers have been struggling ever since with how best to present these concepts to their users without confusing them by exposing the underlying reality. Modern WYSIWYG editors all succeed in this to some extent, but none of them has succeeded entirely.” (see http://htmleditor.in/index.html). Even for a very popular editor like CKEditor (see http://ckeditor.com/what-is-ckeditor), it cannot allow end users to use CSS; it only allows a developer to write CSS code to provide new formatting for end users; that is one kind of “succeed in this to some extent”.
[0019] Another problem relates to the hierarchical nature of HTML contents. Suppose an HTML element has two levels of parents. For accurate HTML editing, an editor should allow the user to apply styles, for example, font, to the element or to each level of parent element. State-of-art word-processor editors apply text attribute modifications to selected text, not to elements.
[0020] Another problem is related to the command parameters. For example, the commands for setting font family and font size need command parameters for specifying font family name and font size. For a state-of-art WYSIWYG document editor, dropdown lists are displayed in a toolbar for selecting font family and font size. FIG. 1 shows a typical state-of-art word-processing style editor 101 . There is a dropdown list 102 for selecting font family. There is a dropdown list 103 for selecting font size. There are a set of command buttons 104 for doing various editing not requiring command parameters. But for editing HTML contents, there are lots of other editing operations which also need parameters. For example, setting “href” of an anchor needs a parameter for specifying hyper link URL; setting “alt” attribute of an image needs a parameter for specifying the image description; etc. It will be unpractical for every command parameter to add one dropdown list box or a text box on an editor toolbar. State-of-art editors use dialogue boxes to solve the problem. Using too many dialogue boxes is disrupting and inconvenient for a user.
[0021] Another problem is the reviewing/editing of hidden attributes. For documents other than HTML, almost all attributes are for document display. For a HTML document, lots of attributes are not for controlling display. For hidden elements like HEAD element, META elements, STYLE elements, SCRITP elements, and LINK elements, it is difficult to use a word-processor editor to edit those elements because these hierarchical elements are not visible document contents.
[0022] The problems with a word-processing WYSIWYG HTML editor make it limited in getting required HTML features comparing to code—based text editors.
[0023] Since W3C is making standardization to help making word-processors for HTML editing, and all state-of-art browser-based visual HTML editors are word-processors, it is not obvious that a totally different approach can be advantageous.
Solution to Problem
[0024] The embodiments of the present invention provide processes for creating an element-targeting in-browser WYSIWYG HTML editor. The processes provide a bi-directional element navigation allowing navigation of elements from lowest level to the top-most level and from a higher level to a lower level, and thus provide an element-targeting editor. The processes combine visual attribute setting with automatic CSS class generation using virtual properties, and thus allow the user to virtually and visually use CSS without actually writing CSS code.
[0025] The embodiments of the present invention provide processes for obtaining lowest level HTML element covering caret; for showing the said lowest level element and all levels of parent element all the way to <HTML> element; for navigating downwards to all levels of child elements from an element. Some elements cannot be accessed by obtaining an element covering caret and all levels of parent elements. For example, <HEAD> element under <HTML>, <META> under <HEAD>, <INPUT type=“hidden”> under <BODY>, etc. <HEAD> can be accessed by downwards navigating from <HTML>, <META> can be accessed by downwards navigating from <HEAD>, <INPUT type=“hidden”> can be accessed by downwards navigating from <BODY>, etc. Thus, all elements on a web page can be visually accessed and edited, forming an element-targeting editing, suitable for hierarchical nature of HTML elements.
[0026] The embodiments of the present invention provide processes for mapping CSS styles into virtual properties. A traditional object property value only belongs to one object; a virtual property value belongs to a group of HTML elements. The processes form a CSS based visual element editing. The invention of virtual properties also solves command parameters problem in a word-process approach. All command parameters can be virtual property values.
[0027] The embodiments of the present invention provide a foundation for future innovations in the field of browser-based visual HTML editors. For example, a virtual property may relate to more than one CSS style and graphic user interfaces may be used for creating CSS styles in different innovative visual approaches. One CSS style may also be represented by more than one virtual property. For example, each of the parameters for a linear-gradient style can be represented by one virtual property.
[0028] The embodiments of the present invention provide processes for putting a selected element into design mode by showing all the attributes and virtual properties of the said selected element for editing, by presenting all editing commands for the said selected element, including element hierarch navigation commands. Thus, all attributes and styles can be easily edited, including hidden attributes, attributes of hidden elements, and commands with parameters showing as attributes and virtual properties.
[0029] As shown in FIG. 2 , the user interface of the Editor 201 is formed by an HTML element list 204 (hereafter referred to as the Parent List) for listing an HTML element and all levels of parents of the element, a property grid 206 (hereafter referred to as the Property Grid) for showing and editing all attributes and virtual properties of an element, and an element-specific command list 205 (hereafter referred to as the Command List) for editing an element.
[0030] A caret is the point of the text insertion. All major web browsers support detection of caret. When a caret location is moved, the lowest level of the HTML element at the caret location is detected. The detected element and all levels of its parent elements are displayed in the Parent List. The user may select an element from the Parent List. When the item selection of the Parent List changes, all attributes and virtual properties of the selected element are displayed in the Property Grid, and element-specific editing commands are displayed in the Command List.
[0031] The items listed in the Property Grid are not just HTML attributes defined by W3C. All commands requiring parameters can be made into attributes. Setting an attribute value triggers an execution of the corresponding command. Thus there is not a need to put dropdowns on an editor toolbar for a command, and there is not a need to use dialogue boxes. Thus it solves the problem of too many parameter-requiring commands for a word-processor.
[0032] If an element supports CSS styles then the Property Grid includes a virtual property named styleName. It is a string property only available during editing. If styleName is given a value then it is included in the class names for the element. Each CSS style of the element becomes a virtual property in the Property Grid; the virtual property value is the computed style value of the element; when the virtual property value is modified by the user, the modified value becomes a CSS style value in a CSS style sheet for the page, the selector of the CSS style value depends on the styleName value; if styleName is empty then the selector is the tag name of the element, if styleName is not empty then the selector is the tag name of the element plus a dot and followed by styleName.
[0033] The above virtual property processes allow all elements with the same styleName value share the same CSS styles. Unlike a traditional property, the value for a virtual property representing a CSS style does not belong to a specific element, the value belongs to a CSS class. Such processes can be extended to use multiple styleName for generating virtual properties; each styleName corresponds to a group of CSS styles; for example, text formatting styles, box styles, background styles, etc.
[0034] The above virtual property processes can be extended beyond standard HTML elements defined by W3C standards. One or more elements may form an element providing particular functionality, for example, a menu bar, tree view, etc. The styling of such non-standard elements can also be mapped to virtual properties in the same way as standard elements.
[0035] The parent list makes it easy to navigate through hierarchical elements. Combined with visual property-setting, it is easy to apply editing to each level of element hierarch. Thus it provides more accurate style editing than mimicking word-processor.
[0036] The user of the Editor modifies HTML contents by typing in the browser, modifying element attributes and virtual properties in the Property Grid, and executing commands from the Command List, inserting new elements in caret location, and deleting unwanted elements.
[0037] Since all web browsers provide HTML editing capability in the way of word-processing, creating an element-targeting editor may face some difficulty.
[0038] One problem is that for most web browsers the cursor cannot be positioned between two elements, hence it is difficult to insert a new element between two existing elements. This invention uses following processes to solve the problem.
[0039] The invention uses an “add space” operation to allow the user to insert a space between two existing elements. After inserting a space between two existing elements, the cursor can be placed in the space between the two existing elements and therefore new elements can be inserted between the two existing elements.
[0040] The invention uses a “level-up” operation to make an element become a sibling of its parent element. This operation provides another way for the user to insert a new element into a desired location. For example, suppose the user wants to insert a SPAN between two DIV elements. The user may first make the first DIV the selected-element and insert a new SPAN into the first DIV; the user then uses the “level-up” operation to make the SPAN a sibling of the first DIV and thus the SPAN is located between the two DIV elements.
Advantageous Effects of Invention
[0041] By implementing the present invention, an element-targeting in-browser WYSIWYG HTML editor can be created which provides much more accurate and powerful editing than a state-of-art editor which mimics word-processors. Element-targeting editing makes it possible to use CSS. A virtual CSS applying process makes it possible for end users to use CSS in an in-browser WYSIWYG HTML editor without writing CSS code. Element-targeting editing makes it easy to edit attributes and elements not to be displayed visually on a HTML page.
[0042] By creating virtual properties and using scrollbars, in a limited screen space a Property Grid may list a large number of element CSS styles for editing and sharing. For implementing an editing command, which requires a parameter, the Editor may simply add a virtual property in the Property Grid; the required command parameter will be the virtual property value. Large number of parameter-requiring commands can thus be easily implemented by the Editor without a single dialogue box. Any kinds of attributes can be included in the Property Grid, including hidden attributes.
[0043] The user of the Editor may navigate to any HTML element by locating the caret to a desired location and selecting desired element from the Parent List. The user of the Editor may view and modify any attribute by selecting the desired element and modifying the desired attribute from the Property Grid. The elements and attributes to be modified can be invisible from the browser. For example, the user may edit HEAD contents by selecting the <HTML> element from the Parent Ust; when caret is in a TD element the user may edit attributes of the TD, the user may also easily edit its parent elements such as TR, THEAD, TFOOT, TBODY, TABLE, etc., the user may also easily edit column CSS styles related to the TD.
[0044] The Editor uses the Command Ust to provide editing operations based on specific element. For example, when a TD element is selected, a set of commands for splitting column, splitting cell, splitting row, merging columns, merging cells, merging rows, etc., may appear in the Command List. Although available commands for all kinds of elements can be huge, but because at any time only the commands specific to the selected element are displayed, the Command List does not need large screen space.
[0045] Thus the Editor, occupying a small part of screen space, provides much more editing power than a word-processor toolbar.
[0046] This invention also solves a cross-browser compatibility problem because it does not rely on the editing commands provided by web browsers (see http://www.quirksmode.org/dom/execCommand.html and http://ehsanakhgari.org/blog/2010-03-08/thoughts-future-web-based-html-editors).
BRIEF DESCRIPTION OF DRAWINGS
[0047] FIG. 1 shows a typical word-processor
[0048] FIG. 2 shows a typical implementation of this invention. It can be a floating window or a docked window. It may be minimized to show more editing space.
DESCRIPTION OF EMBODIMENTS
[0049] One embodiment of this invention is by using JavaScript to create an absolutely positioned DIV element, hereafter referred to as the Editor-DIV, to hold all components forming an in-browser HTML editor, and moving and resizing the Editor-DIV change the location and size of the Editor.
[0050] With reference to FIG. 2 , the outer box 201 represents the Editor-DIV element.
[0051] Title bar 202 can be implemented by another DIV element. Title bar 202 may serve as a mouse event capturing area for allowing the user to move the Editor around the web page.
[0052] Minimize-button 203 can be implemented by an IMG element. Clicking Minimize-button 203 , the Editor-DIV's height is reduced to only holding Title bar 202 . Clicking Minimize-button 203 again, the Editor-DIV's height restores to its original height.
[0053] Parent Ust 204 is a SELECT element. An array of HTML elements is associated with Parent Ust 204 . The first array item is the Base-Element. The Base-Element is the deepest level of HTML element covering the caret or text selection on the web page. Each of other array items is the parent element of the previous array item. Parent List 204 has the same number of items as the element array. Each item of Parent Ust 204 is a text representation of the corresponding element in the element array. The text representation of an element is formed by element id, element name and element tag name. The HTML element corresponding to the selected item of Parent List 204 is called the Selected Element.
[0054] Command List 205 is a DIV element. Each command can be an IMG element. Depending on the Selected-Element, different set of commands are created and displayed in Command Ust 205 . For example, if the Selected-Element is a TD then among the other standard commands, there are following commands: add new row below; add new row above; add new column on left; add new column on right; merge with left cell; merge with right cell; merge with above cell; merge with cell below; split cell horizontally; split cell vertically, and show column styles. When a TR becomes the Selected-Element, there are commands for adding new row below and adding new row above. When a TABLE becomes the Selected-Element, there are commands for adding THEAD, adding TFOOT, selecting THEAD and selecting TFOOT. If the Selected-Element may contain child elements then there is a command for adding new child elements. Clicking “add new child” command, a list of all addable element types are displayed. Clicking an element type, a new child of the selected element type is created and placed inside the Selected-Element. If the Selected-Element can be removed then there is a command for removing the Selected-Element. If the Selected-Element can be a sibling of its parent element then there is a “level-up” command; clicking the “level-up” command, the Selected-Element will be removed from its parent element and re-added back as the next sibling of its original parent element. If the Selected-Element can be removed and its innerHTML attribute can be valid contents of the Selected-Element's parent element then there is a “un-tag” command; clicking the command will remove the Selected-Element and add the innerHTML of the Selected-Element to the original location of the Selected-Element.
[0055] Command List 205 may contain an IMG element acting as a “Finish” button. Clicking the “Finish” button, an HTML text of the element being edited is generated according to the type of the element being edited; a CSS file will also be generated according to the virtual property settings.
[0056] Property Grid 206 contains all attributes and virtual properties of the selected element for viewing and editing.
Example 1
[0057] Source code—file name: htmlEditor_js.txt, line numbers: 7113-7136, the line 7113 contains following words: ‘Setting styleName to a non-empty string will add it as a class name to the element; all your modifications of the element styles will be added to the class and thus applied to all elements using the class. Note that setting styleName to an empty string will not remove the existing class which may be used by other elements. To remove classes you may do it via the HTML element. If styleName is empty then all your style modifications will be applied to the same type of elements which do not use classes.’
[0058] The processes of Claim 1 create a virtual property “style name”. Lines from 7310 to 7333 define said virtual property. “byAttribute” is true indicating that the value will be stored in an element as an attribute. “editor” is EDIT_ENUM indicating that when setting the property a list of values will be displayed for the user to select, the list of values come from a function named “values”. “allowEdit” is true indicating that the user may enter new value besides selecting a value from a list. “values” is a function which gives a list of previously entered values, the returned list of this function will be used by the Editor to show a dropdown list box. “setter” is a function which is executed when the user sets the value for this virtual property. The function retrieves existing attribute of “styleName”; sets the “styleName” attribute to the new value; if the existing “styleName” attribute is not empty then remove it from the class names of the element. “onsetprop” is a function to be executed after setting the property value, it adds the value to the class names of the element.
Example 2
[0059] Source code—file name: htmlEditor_js.txt, line numbers: 501-681, function name: captureSelection
[0060] The processes of Claim 1 create an in-browser HTML editor targeting HTML elements. In this example, function captureSelection is executed when caret location is moved. This function locates the HTML element covering the current caret, as the base-element of Claim 1 . If there is a selection range on the web page then it tries to find the element covering the range, as the base-element of Claim 1 .
Example 3
[0061] Source code—file name: htmlEditor_js.txt, line numbers: 5272-5344, function name: selectEditElement
[0062] The processes of Claim 1 create an in-browser HTML editor targeting HTML elements. In this example, function selectEditElement takes a given element and sets it as the base-element of Claim 1 by calling function showSelectionMark (see Example 4) and showProperties (see Example 5).
Example 4
[0063] Source code—file name: htmlEditor_js.txt, line numbers: 2106-2163, function name: showSelectionMark
[0064] The processes of Claim 1 create an in-browser HTML editor targeting HTML elements. In this example, function showSelectionMark takes a given element and sets it as the base-element of Claim 1 by showing a red dot on the base-element and showing the base-element and all levels of its parent elements in a list.
Example 5
[0065] Source code—file name: htmlEditor_js.txt, line numbers: 4461-5179, function name: showProperties
[0066] The processes of Claim 1 create an in-browser HTML editor targeting HTML elements. In this example, function showProperties takes a given element as the selected HTML element of Claim 1 . The function retrieves property description objects for the selected element, and saves it in a variable named “properties”. From “properties” it finds all the commands and put them in the element-command-area of Claim 1 . The function shows other properties in the Property Grid of Claim 1 .
Example 6
[0067] Source code—file name: htmlEditorClient_js.txt, line numbers: 1288-1305, function name: _getElementSelector
[0068] The processes of Claim 1 and Claim 2 create virtual properties for CSS styles. The selector for CSS styles is formed by tag name and value of “style name” virtual property of Claim 1 . Function getElementSelector returns the selector for an element using the tag name and “styleName” attribute of the element (see Example 1). The function also handles tag names COL and TD specially. The function looks for the parent table element of COL and TD; checks the table element's “styleName” attribute. If the table's “styleName” is not empty then combine the selector for COL or TD with the table's selector. This coding is for such logic: COL or TD belong to a table, their style-sharing scope should be consistent with the style-sharing scope of their parent table.
Example 7
[0069] Source code—file name: htmlEditorClient_js.txt, line numbers: 1222-1246, function name: _getElementStyleValue
[0070] The processes of Claim 2 create virtual properties for CSS styles. The value for a virtual property is the computed CSS styles value. Function _getElementStyleValue returns the computed CSS style value.
Example 8
[0071] Source code—file name: htmlEditorClient_js.txt, line numbers: 1306-1318, function name: _setElementStyleValue
[0072] The processes of Claim 2 create virtual properties for CSS styles. When the user sets a value to a virtual property, the value is used as the style value of the corresponding CSS style. Function _setElementStyleValue applies the value to a CSS style using a selector defined by the processes of Claim 2 ; removes the CSS style from the element because according to the cascading rule the CSS style on the element will override CSS styles in Cascade Style Sheets; adds “styleName” to the classes of the element so that the element will use the CSS style in Cascade Style Sheets.
Example 9
[0073] Source code—file name: htmlEditor_js.txt, line numbers: 3714-3967, function name: _getElementProperties
[0074] The processes of Claim 3 and Claim 4 create a set of editing commands targeting selected element. In this example, each editing command is represented by one object; “editor” of the object indicates the type of command: EDIT_DEL indicates a delete-command, EDIT_DEL2 indicates a “un-tag” command, EDIT_DEL3 indicates a “level-up” command.
Example 10
[0075] Source code—file name: htmlEditor_js.txt, line numbers: 1970-1990, function name: stripTag
[0076] The processes of Claim 3 create a set of editing commands targeting selected element. One editing command is a “un-tag” command. Function stripTag handles the Click event of the “un-tag” command. The function executes the “un-tag” operation by adding the element's children to the element's parent and then deletes the element. The “un-tag” operation cannot be applied to a table or list, so, the function simply deletes the element in such a situation.
Example 11
[0077] Source code—file name: htmlEditor_js.txt, line numbers: 2026-2041, function name: moveOutTag
[0078] The processes of Claim 3 and Claim 4 create a set of editing commands targeting selected element. One editing command is a “level-up” command. Function moveOutTag handles the Click event of the “level-up” command. The function gets the grandparent of the element; removes the element and then adds the element to its original grandparent right after its original parent.
Example 12
[0079] Source code—file name: htmlEditor_js.txt, line numbers: 1591-1600, function name: stopTagClick
[0080] The processes of Claim 3 , Claim 4 and Claim 5 create a set of editing commands targeting selected element. One editing command is an “add space” command. It adds a space outside the end of current element so that the user may enter new contents outside of the current element. Function stopTagClick handles the Click event of the “add space” command. The function adds a SPAN element, containing one space, to the current element; call moveOutTag function (see Example 11) on the SPAN element so that the SPAN element becomes the next sibling of the current element; call stripTag function (see Example 10) on the SPAN element to remove the SPAN element but keep the space it contains. Thus a space is appended immediately outside of the current element.
Example 13
[0081] Source code—file name: htmlEditorClient_js.txt, line numbers: 1787-1795, function name: getDocType
[0082] The processes of Claim 6 create a virtual property for viewing and setting DOCTYPE of the web page being edited. Function getDocType returns the value for said virtual property. If the variable for DOCTYPE has value then the function returns it; if the variable for DOCTYPE does not have value then the function calls function getDocTypeString (see Example 14) to get DOCTYPE value.
Example 14
[0083] Source code—file name: htmlEditorClient_js.txt, line numbers: 170-187, function name: getDocTypeString
[0084] The processes of Claim 6 create a virtual property for viewing and setting DOCTYPE of the web page being edited. Function getDocTypeString returns the web page DOCTYPE setting; the returned setting is the value in the web page file, not the setting currently made by the user. The DOCTYPE setting takes effect only by reloading the web page. Function getDocType (see example 13) returns the current user setting.
Example 15
[0085] Source code—file name: htmlEditor_js.txt, line numbers: 7523-7527, the line 7523 contains following words: tagname: ‘table’
[0086] The processes of Claim 7 access child elements of a selected element. In this example, for a <table> element 4 commands are added to the element-command-area of Claim 1 for the processes of Claim 7 . Command “thead” is for selecting <THEAD> element of the <table>; command ‘tfoot” is for selecting <TFOOT> element of the <table>; command “addHeader” is for creating a <THEAD> eleent in the <table>; command “addFooter” is for creating a <TFOOT> element in the <table>.
Example 16
[0087] Source code—file name: htmlEditor_js.txt, line Number: 7416, the line contains following words: {name: ‘head’, editor: EDIT_GO, cmdText: ‘show page head’, action: gotoPageHead}
[0088] The processes of Claim 7 access child elements of a selected element. In this example, when the <HTML> element is selected a “head” command is added to the element-command-area of Claim 1 for the processes of Claim 7 . The “head” command is for selecting <HEAD> element.
Example 17
[0089] Source code—file name: htmlEditor_js.txt, line numbers: 7438-7446, the line 7438 contains following words: tagname: ‘head’
[0090] The processes of Claim 7 access child elements of a selected element. In this example, when the <HEAD> element is selected via the “head” command (see Example 16), 4 commands are added to element-command-area of Claim 1 : “addmeta” for adding a new <META> child element to the <HEAD> element; “addscript” for adding a new <SCRIPT> child element to the <HEAD> element; “addcss” for adding a new <LINK> child element to the <HEAD> element for a CSS file; “addlink” for adding a new <LINK> child element to the <HEAD> element. 4 groups of virtual properties are added to the <HEAD> element: “meta” group includes <META> elements; “script” group includes <SCRIPT> elements; “css” group includes <LINK> elements for CSS files; “link” group includes <LINK> elements for non-CSS files.
Example 18
[0091] Source code—file name: htmlEditor_js.txt, line numbers: 2005-2025, function name: gotoChildByTag
[0092] The processes of Claim 7 access child elements of a selected element. In this example, when the “head” command (see Example 16), the “thead” command (see Example 15), or the “tfoot” command (see Example 15) are executed, function gotoChildByTag is executed. The function assumes there is only one child element for specified child type; it calls getElementsByTagName to locate the child element.
Example 19
[0093] Source code—file name: htmlEditorClient_js.txt, line numbers: 10, 1843-1868, function name: resetDynamicStyles
[0094] The processes of Claim 8 create virtual properties for CSS styles. In this example, a constant string, ‘dyStyle8831932’, is defined for identifying “virtual property holder” of Claim 8 by the title of <STYLE> element. Function resetDynamicStyles is executed when a web page is loaded into the HTML editor. The function removes all <STYLE> elements if title of the elements is ‘dyStyle8831932’; creates a new <STYLE> element and sets its title to ‘dyStyle8831932’. Thus an empty “virtual property holder” is prepared for holding virtual property values.
Example 20
[0095] Source code—file name: htmlEditorClient_js.txt, line numbers: 573-605, function name: getDynamicStyleNode
[0096] The processes of Claim 8 create virtual properties for CSS styles. In this example, function getDynamicStyleNode returns “virtual property holder” of Claim 8 .
Example 21
[0097] Source code—file name: htmlEditorClient_js.txt, line numbers: 1054-1212, function name: _updateDynamicStyle
[0098] The processes of Claim 8 create virtual properties for CSS styles. In this example, function _updateDynamicStyle saves a virtual property value into “virtual property holder” of Claim 8 . It calls function _getDynamicStyleNode (see Example 20) to get the said “virtual property holder”. If the CSS style already exists in the said “virtual property holder” then the value is updated for the existing style; if the CSS style does not exist then the style is added into the said “virtual property holder”. If the value for the virtual property is empty then the CSS style is added to variable _removedCss, indicating that the style is to be removed; the default value of the CSS style is applied to the said “virtual property holder” so that the effects of removing the style are visible immediately to the user.
Example 22
[0099] Source code—file name: htmlEditorClient_js.txt, line numbers: 669-732, function name: _getDynamicCssText
[0100] The processes of Claim 8 create virtual properties for CSS styles. In this example, function _getDynamicCssText returns a string representation of editing of CSS styles. The function returns the CSS text by processing and concatenating cssText property of each style in the “virtual property holder” of Claim 8 . The major purpose of processing each cssText property is to solve web browser compatibility problem: some CSS styles are not defined in the same by different web browsers. This example only tries to solve the web browser compatibility problem between IE, Chrome, Opera, Firefox and Safari. Function _getDynamicCssText also returns removed CSS styles as a JSON string, as a beginning part of the return value, delimited by a string $$$, followed by processed CSS text of “virtual property holder” of Claim 8 .
Example 23
[0101] Source code—file name: htmlEditor_js.txt, line numbers: 1219-1264, function name: finishEdit
[0102] The processes of Claim 8 create virtual properties for CSS styles. In this example, function finishEdit is executed when saving the editing results. It gets HTML text of the page being edited; it removes the “virtual property holder” of Claim 8 , from the HTML text. The results of editing are represented by two strings; one string is for HTML contents; another string is for CSS contents. The two strings are sent to web server for processing.
Example 24
[0103] Source code—file name: htmlEditor_js.txt, line numbers: 6259-6461, function name: _getresultHTML
[0104] The processes of Claim 9 generate HTML contents as part of editing results. In this example, function _getresultHTML returns HTML contents as a string. In this example, a small red box, which is an IMG element, is used in the web page being edited. The red box is for indicating the base-element of Claim 1 on the web page. The function removes the red box from the page; forms HTML string as described in Claim 9 ; adds the red box back to the web page.
INDUSTRIAL APPLICABILITY
[0105] In-browser HTML editors have been used for web contents creation and editing, for example in web mail, blogs, forum message submissions, etc. Because this invention makes in-browser HTML editors much more powerful in visual editing capability than state-of-art editors, it will be possible to do complete remote web page creations in a cloud-computing environment.
DRAWINGS
[0106]
FIG. 1
|
This invention is related to a cross-browser “What You See Is What You Get” HTML editor using caret-sensitive element selection, parent-element list, child-element accessing, virtual properties, automated CSS creations, and element-specific command list.
| 6
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a dandy roll useful in producing paper having a twill weave wiremark pattern.
2. Description of Prior Art
In papermaking, watermarks are conventionally formed by contacting the paper stock while it is still damp with a dandy roll having raised and/or recessed areas on the surface. An opaque mark known as a "shaded mark" is formed on the paper in areas contacting the recesses on the surface of the dandy roll and is the result of pulp fibers accumulating in the recesses as the paper stock travels under the dandy roll on the papermaking machine. Translucent marks, known as "wire marks," are formed in the paper in areas contacting the raised areas on the surface of the dandy roll. These marks are the result of the raised surface of the roll displacing the fibers in the stock resulting in areas in which the fibers are less concentrated and the paper is more translucent.
It is conventional in the art to form shaded marks by depressing the surface of the wire screen forming the dandy roll and to form wire marks by soldering wire segments, known as electro wires, to the surface of the dandy roll screen. See, for example, U.S. Pat. No. 353,666 to Z. Crane, Jr. (1886) and U.S. Pat. No. 1,571,715 to Fearing (1926). It has also been known to watermark paper by altering the drainage rate of the Fourdrinier screen by modifying the weave in the screen such as by using larger gauge wire to form the screen or by omitting a wire from the screen altogether. See, for example, U.S. Pat. No. 1,616,222 to Harrigan (1927).
In a previous patent to Waters, U.S. Pat. No. 4,526,652, a papermaking process is disclosed wherein paper bearing the look of an oxford cloth weave is produced. The oxford cloth simulation is achieved by positioning narrow pockets and electrowires along the circumferential and longitudinal axis of a plain weave dandy roll screen. While the oxford cloth weave is a desirable effect, other aesthetic effects are also desirable.
By departing from the plain weave dandy roll screen in favor of a twill weave screen, a different aesthetic effect can be achieved. More specifically, the twill weave screen of the present invention imparts more of a "box-like" effect than that of the plain weave dandy roll screen.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a dandy roll which is useful in manufacturing paper bearing a twill weave wiremark pattern.
A further object of the present invention is to provide a process for producing paper which carries a twill weave wiremark pattern.
Still a further object of the invention is to provide a paper having a twill weave wiremark.
These and other objects of the present invention will become apparent from the following description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overhead view of a dandy roll screen in accordance with the present invention.
FIG. 2 is a horizontal view of a shute wire along the widthwise axis of the dandy roll screen.
FIG. 3 is a horizontal view of a warp wire along the lengthwise axis of the dandy roll screen.
FIG. 4 is a perspective view of a dandy roll in accordance with the present invention on a conventional papermaking machine.
DETAILED DESCRIPTION OF THE INVENTION
A paper bearing a twill weave wire mark produced in accordance with the present invention exhibits a background of woven translucent lines. In addition to the simulated weave, the paper may bear one or more conventional watermarks such as the name of a paper manufacturer, a company logo, or the like.
The dandy roll of the present invention is used in conjunction with standard papermaking techniques. The dandy roll is usually positioned near the end of the papermaking machine where the paper stock leaves the wire, as is conventional in the art. At this point, the paper stock is sufficiently damp that the fibers forming the paper can be displaced by the surface of the dandy roll. A typical arrangement is shown in FIG. 4. The paper web 10 is supported on a table of rollers 12 as it passes into contact with the dandy roll 14.
The dandy roll is constructed of a cylindrical frame which is wrapped with two wire mesh covers (one shown). The frame is constructed in a conventional manner. To provide rigidity, a large diameter spiral truss wire (not shown) is wound in either clockwise or counter-clockwise direction between two bronze spidered heads 16 (one shown) on each end of the Dandy roll. Longitudinal braces (not shown) are typically welded across the length of the roll between the spidered heads. Each spidered head 16 has a journal 18 protruding from its center which holds the dandy roll in place on the papermaking machine. These journals are not necessary if the dandy roll is mounted with a trunnion drive. In this case, the dandy heads are not spidered but have concave groove around each open head which matches the trunnion drive wheel. An inner wire cover (not shown) is then spirally wound around the circumference of the roll in the direction opposite the windings of the truss wire. The inner wire cover may have a conventional plain weave with the shute wires being one over and one under the warp wires. The mesh size may vary from as open as 10 mesh per inch to as closed as 24 mesh per inch. The outer wire mesh cover 20, that which will come in contact with the paper, is affixed to the cylindrical frame by soldering to the spidered heads and seaming the edges of the screen across the length of the roll.
The outer wire mesh cover 20 of FIG. 1 comprises length wise warp wires 22 and width wise shute wires 24 woven in a twill weave pattern. This is a deviation from standard practice whereby the outer wire mesh cover is woven in a conventional plain weave design. To produce the twill weave pattern of the present invention, the outer wire mesh cover is woven with the shute wires 24 being one over then two under the warp wires 22. A screen woven in this fashion exhibits long warped knuckles 26 on one face and short warped knuckles 28 on the opposing face. In FIG. 3, long warp knuckles 26 are defined as lengthwise warp wires 22 passing over two consecutive width-wise shute wires 24. Short warp knuckles 28 are defined as lengthwise warp wires passing over individual width-wise shute wires.
It has previously been known to construct the paper machine wire (not the dandy roll) with a twill weave. This was done to increase the life of the paper machine wire. The short warp knuckles were placed adjacent the paper in order to minimize screen wear.
In accordance with the preferred embodiments of the present invention, the outer wire mesh cover is affixed to the dandy roll with the long warped knuckles facing the paper. The long warp knuckles make an impression on the paper surface in this manner.
In accordance with preferred embodiments of the present invention, the outer screen mesh size ranges from between 4 to 9 mesh per inch and the outer screen wire diameter is about 0.016 to 0.018 inches and preferably about 0.017 inches. Standard wire diameters for a conventional dandy roll screen with a mesh range of 4 to 9 ranges between 0.045 to 0.027 inches.
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
|
Paper having an unique twill weave wiremark produced using a dandy roll in which the outer screen bears has a twill weave; the dandy roll and the papermaking process are also disclosed.
| 3
|
TECHNICAL FIELD
[0001] Described herein is a new family of crystalline molecular sieves designated as SSZ-91, methods for preparing SSZ-91 and uses for SSZ-91.
BACKGROUND
[0002] Because of their unique sieving characteristics, as well as their catalytic properties, crystalline molecular sieves and molecular sieves are especially useful in applications such as hydrocarbon conversion, gas drying and separation. Although many different crystalline molecular sieves have been disclosed, there is a continuing need for new molecular sieves with desirable properties for gas separation and drying, hydrocarbon and chemical conversions, and other applications. New molecular sieves may contain novel internal pore architectures, providing enhanced selectivities in these processes.
[0003] Molecular sieves have distinct crystal structures which are demonstrated by distinct X-ray diffraction patterns. The crystal structure defines cavities and pores which are characteristic of the different species.
[0004] Molecular sieves are classified by the Structure Commission of the International Zeolite Association according to the rules of the IUPAC Commission on Zeolite Nomenclature. According to this classification, framework type zeolites and other crystalline microporous molecular sieves, for which a structure has been established, are assigned a three letter code and are described in the “Atlas of Zeolite Framework Types” Sixth Revised Edition, Elsevier (2007) and the Database of Molecular sieve Structures on the International Zeolite Association's website (http://www.iza-online.org).
[0005] The structure of a molecular sieve can be either ordered or disordered. Molecular sieves having an ordered structure have periodic building units (PerBUs) that are periodically ordered in all three dimensions. Structurally disordered structures show periodic ordering in dimensions less than three (i.e., in two, one or zero dimensions). Disorder occurs when the PerBUs connect in different ways, or when two or more PerBUs intergrow within the same crystal. Crystal structures built from PerBUs are called end-member structures if periodic ordering is achieved in all three dimensions.
[0006] In disordered materials, planar stacking faults occur where the material contains ordering in two dimensions. Planar faults disrupt the channels formed by the material's pore system. Planar faults located near the surface limit diffusion pathways otherwise required in order to allow feedstock components to access the catalytically active portions of the pore system. Therefore, as the degree of faulting increases, the catalytic activity of the material typically decreases.
[0007] In the case of crystals with planar faults, interpretation of X-ray diffraction patterns requires an ability to simulate the effects of stacking disorder. DIFFaX is a computer program based on a mathematical model for calculating intensities from crystals containing planar faults. (See, M. M. J. Treacy et al., Proceedings of the Royal Chemical Society, London, A (1991), Vol. 433, pp. 499-520). DIFFaX is the simulation program selected by and available from the International Zeolite Association to simulate the XRD powder patterns for intergrown phases of molecular sieves. (See, “Collection of Simulated XRD Powder Patterns for Zeolites” by M. M. J. Treacy and J. B. Higgins, 2001, Fourth Edition, published on behalf of the Structure Commission of the International Zeolite Association). It has also been used to theoretically study intergrown phases of AEI, CHAand KFI molecular sieves, as reported by K. P. Lillerud et al. in “Studies in Surface Science and Catalysis”, 1994, Vol. 84, pp. 543-550. DIFFaX is a well-known and established method to characterize disordered crystalline materials with planar faults such as intergrown molecular sieves.
[0008] The designation ZSM-48 refers to a family of disordered materials, each characterized as having a one-dimensional 10-ring tubular pore system. The pores are formed of rolled up honeycomb-like sheets of fused tetrahedral 6-ring structures, and the pore aperture contains 10 tetrahedral-atoms. Zeolites EU-2, ZSM-30 and EU-11 fall into the ZSM-48 family of zeolites.
[0009] According to Lobo and Koningsveld, the ZSM-48 family of molecular sieves consists of nine polytypes. (See, J. Am. Chem. Soc. 2002, 124, 13222-13230). These materials have very similar, but not identical, X-ray diffraction patterns. The Lobo and Koningsveld paper describes their analysis of three ZSM-48 samples provided by Dr. Alexander Kuperman of Chevron Corporation. Each of the three samples, labeled Samples A, B and C, respectively, were prepared using three different structure directing agents. Comparative Examples 2 and 3 herein below correspond to Samples A and B described in the Lobo and Koningsveld paper.
[0010] The Lobo and Koningsveld paper describes Sample A as being polytype 6, and Sample B as being a faulted polytype 6. The paper further describes the morphology of Sample A as consisting of needle-like crystals having a diameter of ˜20 nm and a length of ˜0.5 μm. The morphology of Sample B consisted of long, narrow crystals having a width of ˜0.5 μm and a length of 4-8 μm. As indicated in Comparative Examples 2 and 3 below, the scanning electron microscopy images for Samples A and B are presented herein in FIGS. 3 and 4 .
[0011] Kirschhock and co-workers describe the successful synthesis of phase-pure polytype 6. (See, Chem. Mater. 2009, 21, 371-380). In their paper, Kirschhock and co-workers describe their phase-pure polytype 6 material (which they refer to as COK-8) as having a morphology consisting of long needle-like crystals (width, 15-80 nm; length, 0.5-4 μm) with a very large length/width ratio, growing along the interconnecting pore direction.
[0012] As indicated in the Kirschhock paper, molecular sieves from the ZSM-48 family of molecular sieves consist of 10-ring, 1-dimensional pore structures, wherein the channels formed by the interconnected pores extend perpendicular to the long axis of the needles. Therefore, the channel openings are located at the short ends of the needles. As the length-to-diameter ratio (also known as aspect ratio) of these needles increases, so does the diffusion pathway for the hydrocarbon feed. As the diffusion pathway increases, so does the residence time of the feed in the channels. A longer residence time results in increased undesirable hydrocracking of the feed with a concomitant reduction in selectivity.
[0013] Accordingly, there is a current need for ZSM-48 molecular sieves which exhibit lower degree of hydrocracking over known ZSM-48 molecular sieves. There is also a continuing need for ZSM-48 molecular sieves which are phase pure or substantially phase-pure, and have a low degree of disorder within the structure (a low degree of faulting).
SUMMARY
[0014] Described herein below is a family of crystalline molecular sieves with unique properties, referred to herein as “molecular sieve SSZ-91” or simply “SSZ-91.” Molecular sieve SSZ-91 is structurally similar to sieves falling within the ZSM-48 family of zeolites, and is characterized as: (1) having a low degree of faulting, (2) a low aspect ratio that inhibits hydrocracking as compared to conventional ZSM-48 materials having an aspect ratio of greater than 8, and (3) is substantially phase pure.
[0015] As will be shown in the Examples below, a ZSM-48 material lacking any one of the three uniquely combined characteristics of SSZ-91 (low aspect ratio, low EU-1 content, high polytype 6 composition) will exhibit poor catalytic performance.
[0016] In one aspect, there is provided a molecular sieve having a mole ratio of 40 to 200 of silicon oxide to aluminum oxide. In its as-made form, the X-ray diffraction lines of Table 2 herein are indicative of SSZ-91.
[0017] SSZ-91 materials are composed of at least 70% polytype 6 of the total ZSM-48-type material present in the product, as determined by DIFFaX simulation and as described by Lobo and Koningsveld in J. Am. Chem. Soc. 2012, 124, 13222-13230, where the disorder was tuned by three distinct fault probabilities. It should be noted the phrase “at least 70%” includes the case where there are no other ZSM-48 polytypes present in the structure, i.e., the material is 100% phase-pure polytype 6.
[0018] In another aspect, SSZ-91 is substantially phase pure. SSZ-91 contains an additional EUO-type molecular sieve phase in an amount of between 0 and 3.5 percent by weight (inclusive) of the total product.
[0019] Molecular sieve SSZ-91 has a morphology characterized as polycrystalline aggregates, each of the aggregates being characterized as being composed of crystallites collectively having an average aspect ratio of between 1 and 8 (inclusive). SSZ-91 exhibits a lower degree of hydrocracking than those ZSM-48 materials having a higher aspect ratio. An aspect ratio of 1 is the ideal lowest value, where the length and width are the same.
[0020] In another aspect, there is provided a method of preparing a crystalline material by contacting under crystallization conditions (1) at least one source of silicon oxide; (2) at least one source of aluminum oxide; (3) at least one source of an element selected from Groups 1 and 2 of the Periodic Table; (4) hydroxide ions; and (5) hexamethonium cations.
[0021] In yet another aspect, there is provided a process for preparing a crystalline material having, as made, the X-ray diffraction lines of Table 2, by:
(a) preparing a reaction mixture containing (1) at least one source of silicon oxide; (2) at least one source of aluminum oxide; (3) at least one source of an element selected from Groups 1 and 2 of the Periodic Table; (4) hydroxide ions; (5) hexamethonium cations; and (6) water; and (b) maintaining the reaction mixture under crystallization conditions sufficient to form crystals of the molecular sieve.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a powder X-ray diffraction (XRD) pattern of as-synthesized molecular sieve prepared in Comparative Example 1.
[0025] FIG. 2 is a scanning electron micrograph of as-synthesized molecular sieve prepared in Comparative Example 1.
[0026] FIG. 3 is a scanning electron micrograph of as-synthesized molecular sieve prepared in Comparative Example 2.
[0027] FIG. 4 is a scanning electron micrograph of as-synthesized molecular sieve prepared in Comparative Example 3.
[0028] FIG. 5 is a powder XRD pattern of as-synthesized molecular sieve SSZ-91 prepared in Example 7.
[0029] FIG. 6 is a scanning electron micrograph of as-synthesized molecular sieve SSZ-91 prepared in Example 7.
[0030] FIG. 7 is a scanning electron micrograph of as-synthesized molecular sieve prepared in Example 8.
[0031] FIG. 8 is a plot of several DIFFaX-generated simulated XRD patterns and a powder XRD pattern of the as-synthesized molecular sieve SSZ-91 prepared in Example 8.
[0032] FIG. 9 is a plot of several DIFFaX-generated simulated XRD patterns and a powder XRD pattern of the as-synthesized molecular sieve prepared in Example 11.
[0033] FIG. 10 is a plot of several DIFFaX-generated simulated XRD patterns and a powder XRD pattern of the as-synthesized molecular sieve prepared in Comparative Example 1.
[0034] FIG. 11 is a scanning electron micrograph of as-synthesized molecular sieve prepared in Example 13.
[0035] FIG. 12 is a plot of several DIFFaX-generated simulated XRD patterns and a powder XRD pattern of the as-synthesized molecular sieve prepared in Example 13.
DETAILED DESCRIPTION
Introduction
[0036] The term “active source” means a reagent or precursor material capable of supplying at least one element in a form that can react and which can be incorporated into the molecular sieve structure. The terms “source” and “active source” can be used interchangeably herein.
[0037] The term “molecular sieve” and “zeolite” are synonymous and include (a) intermediate and (b) final or target molecular sieves and molecular sieves produced by (1) direct synthesis or (2) post-crystallization treatment (secondary modification). Secondary synthesis techniques allow for the synthesis of a target material from an intermediate material by heteroatom lattice substitution or other techniques. For example, an aluminosilicate can be synthesized from an intermediate borosilicate by post-crystallization heteroatom lattice substitution of the Al for B. Such techniques are known, for example as described in U.S. Pat. No. 6,790,433 to C.Y. Chen and Stacey Zones, issued Sep. 14, 2004.
[0038] The term “*MRE-type molecular sieve” and “EUO-type molecular sieve” includes all molecular sieves and their isotypes that have been assigned the International Zeolite Association framework, as described in the Atlas of Zeolite Framework Types , eds. Ch. Baerlocher, L. B. McCusker and D. H. Olson, Elsevier, 6 th revised edition, 2007 and the Database of Zeolite Structures on the International Zeolite Association's website (http://www.iza-online.org).
[0039] The term “Periodic Table” refers to the version of IUPAC Periodic Table of the Elements dated Jun. 22, 2007, and the numbering scheme for the Periodic Table Groups is as described in Chem. Eng. News, 63(5), 26-27 (1985).
[0040] For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained. It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural references unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items. As used herein, the term “comprising” means including elements or steps that are identified following that term, but any such elements or steps are not exhaustive, and an embodiment can include other elements or steps.
[0041] Unless otherwise specified, the recitation of a genus of elements, materials or other components, from which an individual component or mixture of components can be selected, is intended to include all possible sub-generic combinations of the listed components and mixtures thereof. In addition, all number ranges presented herein are inclusive of their upper and lower limit values.
[0042] The patentable scope is defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. To an extent not inconsistent herewith, all citations referred to herein are hereby incorporated by reference.
Reaction Mixture and Crystallization
[0043] In preparing SSZ-91, at least one organic compound selective for synthesizing molecular sieves from the ZSM-48 family of zeolites is used as a structure directing agent (“SDA”), also known as a crystallization template. The SDA useful for making SSZ-91 is represented by the following structure (1):
[0000]
[0044] The SDA cation is typically associated with anions which may be any anion that is not detrimental to the formation of the molecular sieve. Representative examples of anions include hydroxide, acetate, sulfate, carboxylate and halogens, for example, fluoride, chloride, bromide and iodide. In one embodiment, the anion is bromide.
[0045] In general, SSZ-91 is prepared by:
(a) preparing a reaction mixture containing (1) at least one source of silicon oxide; (2) at least one source of aluminum oxide; (3) at least one source of an element selected from Groups 1 and 2 of the Periodic Table; (4) hydroxide ions; (5) hexamethonium cations; and (6) water; and (b) maintaining the reaction mixture under crystallization conditions sufficient to form crystals of the molecular sieve.
[0048] The composition of the reaction mixture from which the molecular sieve is formed, in terms of mole ratios, is identified in Table 1 below:
[0000]
TABLE 1
Components
Broad
Exemplary
SiO 2 /Al 2 O 3
50-220
85-180
M/SiO 2
0.05-1.0
0.1-0.8
Q/SiO 2
0.01-0.2
0.02-0.1
OH/SiO 2
0.05-0.4
0.10-0.3
H 2 O/SiO 2
3-100
10-50
wherein
(1) M is selected from the group consisting of elements from Groups 1 and 2 of the Periodic Table; and
(2) Q is the structure directing agent represented by structure 1 above.
[0049] Sources useful herein for silicon include fumed silica, precipitated silica, silica hydrogel, silicic acid, colloidal silica, tetra-alkyl orthosilicates (e.g., tetraethyl orthosilicate), and silica hydroxides.
[0050] Sources useful herein for aluminum include aluminates, alumina, and aluminum compounds such as AlCl 3 , Al 2 (SO 4 ) 3 , Al(OH) 3 , kaolin clays, and other zeolites. An example of the source of aluminum oxide is LZ-210 zeolite (a type of Y zeolite).
[0051] As described herein above, for each embodiment described herein, the reaction mixture can be formed containing at least one source of an elements selected from Groups 1 and 2 of the Periodic Table (referred to herein as M). In one sub-embodiment, the reaction mixture is formed using a source of an element from Group 1 of the Periodic Table. In another sub-embodiment, the reaction mixture is formed using a source of sodium (Na). Any M-containing compound which is not detrimental to the crystallization process is suitable. Sources for such Groups 1 and 2 elements include oxide, hydroxides, nitrates, sulfates, halides, oxalates, citrates and acetates thereof.
[0052] For each embodiment described herein, the molecular sieve reaction mixture can be supplied by more than one source. Also, two or more reaction components can be provided by one source.
[0053] The reaction mixture can be prepared either batch wise or continuously. Crystal size, morphology and crystallization time of the molecular sieve described herein can vary with the nature of the reaction mixture and the crystallization conditions.
[0054] The reaction mixture is maintained at an elevated temperature until the crystals of the molecular sieve are formed. In general, zeolite hydrothermal crystallization is usually conducted under pressure, and usually in an autoclave so that the reaction mixture is subject to autogenous pressure and optionally stirring, at a temperature between 125° C. and 200° C., for a period of 1 to more than 18 hours.
[0055] As noted herein above, SSZ-91 is a substantially phase pure material. As used herein, the term “substantially phase pure material” means the material is completely free of zeolite phases other than those belonging to the ZSM-48 family of zeolites, or are present in quantities that have less than a measureable effect on, or confer less than a material disadvantage to, the selectivity of the material. Two common phases that co-crystalize with SSZ-91 are EUO-type molecular sieves such as EU-1, as well as Magadiite and Kenyaite. These additional phases may be present as separate phases, or may be intergrown with the SSZ-91 phase. As demonstrated in the Examples below, the presence of high amounts of EU-1 in the product is deleterious to the selectivity for hydroisomerization by SSZ-91.
[0056] In one embodiment, the SSZ-91 product contains an additional EUO-type molecular sieve phase in an amount of between 0 and 3.5 percent by weight. In one subembodiment, SSZ-91 contains between 0.1 and 2 wt. % EU-1. In another subembodiment, SSZ-91 contains between 0.1 and 1 wt. % EU-1.
[0057] It's known that the ratio of powder XRD peak intensities varies linearly as a function of weight fractions for any two phases in a mixture: (lα/lβ) 32 (RIRα/RlRβ)* (xα/xβ), where the RIR (Reference Intensity Ratio) parameters can be found in The International Centre for Diffraction Data's Powder Diffraction File (PDF) database (http://www.icdd.com/products/). The weight percentage of the EUO phase is therefore calculated by measuring the ratio between the peak intensity of the EUO phase and that of the SSZ-91 phase.
[0058] The formation of amounts of the EUO phase is suppressed by selecting the optimal hydrogel composition, temperature and crystallization time which minimizes the formation of the EUO phase while maximizing the SSZ-91 product yield. The Examples below provide guidance on how changes in these process variables minimize the formation of EU-1. A zeolite manufacturer with ordinary skill in the art will readily be able to select the process variables necessary to minimize the formation of EU-1, as these variables will depend on the size of the production run, the capabilities of the available equipment, desired target yield and acceptable level of EU-1 material in the product.
[0059] During the hydrothermal crystallization step, the molecular sieve crystals can be allowed to nucleate spontaneously from the reaction mixture. The use of crystals of the molecular sieve as seed material can be advantageous in decreasing the time necessary for complete crystallization to occur. In addition, seeding can lead to an increased purity of the product obtained by promoting the nucleation and/or formation of the molecular sieve over any undesired phases. However, it has been found that if seeding is employed, the seeds must be very phase-pure SSZ-91 to avoid the formation of a large amount of a EUO phase. When used as seeds, seed crystals are added in an amount between 0.5% and 5% of the weight of the silicon source used in the reaction mixture.
[0060] The formation of Magadiite and Kenyaite is minimized by optimizing the hexamethonium bromide/SiO 2 ratio, controling the hydroxide concentration, and minimizing the concentration of sodium as Magadiite and Kenyaite are layered sodium silicate compositions. The Examples below provide guidance on how changes in gel conditions minimize the formation of EU-1.
[0061] Once the molecular sieve crystals have formed, the solid product is separated from the reaction mixture by standard mechanical separation techniques such as filtration. The crystals are water-washed and then dried to obtain the as-synthesized molecular sieve crystals. The drying step can be performed at atmospheric pressure or under vacuum.
Post-Crystallization Treatment
[0062] The molecular sieve can be used as-synthesized, but typically will be thermally treated (calcined). The term “as-synthesized” refers to the molecular sieve in its form after crystallization, prior to removal of the SDA cation. The SDA can be removed by thermal treatment (e.g., calcination), preferably in an oxidative atmosphere (e.g., air, gas with an oxygen partial pressure of greater than 0 kPa) at a temperature readily determinable by one skilled in the art sufficient to remove the SDA from the molecular sieve. The SDA can also be removed by ozonation and photolysis techniques (e.g., exposing the SDA-containing molecular sieve product to light or electromagnetic radiation that has a wavelength shorter than visible light under conditions sufficient to selectively remove the organic compound from the molecular sieve) as described in U.S. Pat. No. 6,960,327.
[0063] The molecular sieve can subsequently be calcined in steam, air or inert gas at temperatures ranging from 200° C. to 800° C. for periods of time ranging from 1 to 48 hours, or more. Usually, it is desirable to remove the extra-framework cation (e.g., Na + ) by ion exchange and replace it with hydrogen, ammonium, or any desired metal-ion.
[0064] Where the molecular sieve formed is an intermediate molecular sieve, the target molecular sieve can be achieved using post-synthesis techniques such as heteroatom lattice substitution techniques. The target molecular sieve (e.g., silicate
[0065] SSZ-91) can also be achieved by removing heteroatoms from the lattice by known techniques such as acid leaching.
[0066] The molecular sieve made from the process disclosed herein can be formed into a wide variety of physical shapes. Generally speaking, the molecular sieve can be in the form of a powder, a granule, or a molded product, such as extrudate having a particle size sufficient to pass through a 2-mesh (Tyler) screen and be retained on a 400-mesh (Tyler) screen. In cases where the catalyst is molded, such as by extrusion with an organic binder, the molecular sieve can be extruded before drying, or, dried or partially dried and then extruded.
[0067] The molecular sieve can be composited with other materials resistant to the temperatures and other conditions employed in organic conversion processes. Such matrix materials include active and inactive materials and synthetic or naturally occurring molecular sieves as well as inorganic materials such as clays, silica and metal oxides. Examples of such materials and the manner in which they can be used are disclosed in U.S. Pat. Nos. 4,910,006 and 5,316,753.
[0068] The extrudate or particle may then be further loaded using a technique such as impregnation or ion-exchange, with one or more active metals selected from the group consisting of metals from Groups 8 to 10 of the Periodic Table, to enhance the hydrogenation function. It may be desirable to co-impregnate a modifying metal and one or more Group 8 to 10 metals at once, as disclosed in U.S. Pat. No. 4,094,821. In one embodiment, the at least one active metal is selected from the group consisting of nickel, platinum, palladium, and combinations thereof. After metal loading, the metal loaded extrudate or particle can be calcined in air or inert gas at temperatures from 200° C. to 500° C. In one embodiment, the metal loaded extrudate is calcined in air or inert gas at temperatures from 390° C. to 482° C.
[0069] SSZ-91 is useful for a variety of hydrocarbon conversion reactions such as hydrocracking, dewaxing, olefin isomerization, alkylation and isomerization of aromatic compounds and the like. SSZ-91 is also useful as an adsorbent for general separation purposes.
Characterization of the Molecular Sieve
[0070] Molecular sieves made by the process disclosed herein have SiO 2 /Al 2 O 3 mole ratio (SAR) of 40 to 200. The SAR is determined by inductively coupled plasma (ICP) elemental analysis. In one subembodiment, SSZ-91 has a SAR of between 70 and 160. In another subembodiment, SSZ-91 has a SAR of between 80 and 140.
[0071] SSZ-91 materials are composed of at least 70% polytype 6 of the total ZSM-48-type material present in the product, as determined by DIFFaX simulation and as described by Lobo and Koningsveld in J. Am. Chem. Soc. 2012, 124, 13222-13230, where the disorder was tuned by three distinct fault probabilities. It should be noted the phrase “at least X %” includes the case where there are no other ZSM-48 polytypes present in the structure, i.e., the material is 100% polytype 6. The structure of polytype 6 is as described by Lobo and Koningsveld. (See J. Am. Chem. Soc. 2002, 124, 13222-13230). In one embodiment, the SSZ-91 material is composed of at least 80% polytype 6 of the total ZSM-48-type material present in the product. In another embodiment, the SSZ-91 material is composed of at least 90% polytype 6 of the total ZSM-48-type material present in the product. The polytype 6 structure has been given the framework code *M RE by the Structure Commission of the International Zeolite Association.
[0072] Molecular sieve SSZ-91 has a morphology characterized as polycrystalline aggregates having a diameter of between about 100 nm and 1.5 μm, each of the aggregates comprising a collection of crystallites collectively having an average aspect ratio of between 1 and 8. As used herein, the term diameter refers to the shortest length on the short end of each crystallite examined. SSZ-91 exhibits a lower degree of hydrocracking than those ZSM-48 materials having a higher aspect ratio. In one subembodiment, the average aspect ratio is between 1 and 5. In another subembodiment, the average aspect ratio is between 1 and 4. In yet another subembodiment, the average aspect ratio is between 1 and 3.
[0073] Molecular sieves synthesized by the process disclosed herein can be characterized by their XRD pattern. The powder XRD lines of Table 2 are representative of as-synthesized SSZ-91 made in accordance with the methods described herein. Minor variations in the diffraction pattern can result from variations in the mole ratios of the framework species of the particular sample due to changes in lattice constants. In addition, sufficiently small crystals will affect the shape and intensity of peaks, leading to significant peak broadening. Minor variations in the diffraction pattern can also result from variations in the organic compound used in the preparation and from variations in the Si/AI mole ratio from sample to sample.
[0074] Calcination can also cause minor shifts in the XRD pattern. Notwithstanding these minor perturbations, the basic crystal lattice structure remains unchanged.
[0000]
TABLE 2
Characteristic Peaks for As-Synthesized SSZ-91
2-Theta (a)
d-spacing (nm)
Relative Intensity (b)
7.55
1.170
W
8.71
1.015
W
12.49
0.708
W
15.12
0.586
W
21.18
0.419
VS
22.82
0.390
VS
24.62
0.361
W
26.39
0.337
W
29.03
0.307
W
31.33
0.285
W
(a) ±0.20
(b) The powder XRD patterns provided are based on a relative intensity scale in which the strongest line in the X-ray pattern is assigned a value of 100: W = weak (>0 to ≦20); M = medium (>20 to ≦40); S = strong (>40 to ≦60); VS = very strong (>60 to ≦100).
[0075] The X-ray diffraction pattern lines of Table 3 are representative of calcined SSZ-91 made in accordance with the methods described herein.
[0000]
TABLE 3
Characteristic Peaks for Calcined SSZ-91
2-Theta (a)
d-spacing (nm)
Relative Intensity (b)
7.67
1.152
M
8.81
1.003
W
12.61
0.701
W
15.30
0.579
W
21.25
0.418
VS
23.02
0.386
VS
24.91
0.357
W
26.63
0.334
W
29.20
0.306
W
31.51
0.284
W
(a) ±0.20
(b) The powder XRD patterns provided are based on a relative intensity scale in which the strongest line in the X-ray pattern is assigned a value of 100: W = weak (>0 to ≦20); M = medium (>20 to ≦40); S = strong (>40 to ≦60); VS = very strong (>60 to ≦100).
[0076] The powder X-ray diffraction patterns presented herein were collected by standard techniques. The radiation was CuK α radiation. The peak heights and the positions, as a function of 2θ where θ is the Bragg angle, were read from the relative intensities of the peaks (adjusting for background), and d, the interplanar spacing corresponding to the recorded lines, can be calculated.
EXAMPLES
[0077] The following illustrative examples are intended to be non-limiting.
SUMMARY OF THE EXAMPLES
[0078] The Examples below demonstrate that a ZSM-48 material lacking any one of the three uniquely combined characteristics of SSZ-91 (low aspect ratio, low EU-1 content, high polytype 6 composition) will exhibit poor catalytic performance. Table 4 below summarizes the hydroprocessing performance for various Examples outlined below. Only Example 8 (SSZ-91) exhibited superior performance, namely superior selectivity and low gas make as compared to the other three Examples. The remaining materials tested in the other three Examples exhibited poor performance because each lacked at least one of the three uniquely combined characteristics that define SSZ-91.
[0000]
TABLE 4
Isomerization
%
Selectivity
Polytype
%
Aspect
at 96% (n-C 16
C 4 −
Examples
6
EU-1
Ratio
Conversion)
Cracking
Comparative
80
<1
7-12
78%
2.8%
Example 1
Example 8
>90
3.20
1-4
87%
1.5%
Example 11
>90
6.82
2-6
82%
2.6%
Example 13
>90
3.16
9-15
78%
2.2%
Comparative Example 1
[0000]
Synthesis of ZSM-48
[0080] The product in this Example was prepared according to the teachings of U.S. Pat. No. 5,075,269 to Thomas F. Degnan and Ernest W. Valyocsik (Mobil Oil Corp.) issued Dec. 24, 1991, using available reagents.
[0081] Into a 1-gallon autoclave liner were added 76.51 g of NaOH (50%), 846 g of de-ionized water, 124.51 g of HI-SIL 233 silica (PPG Industries), and 63 g of hexamethonium bromide (“HMB,” Sigma Aldrich). After all the solids had dissolved, 396 g of aluminum stock solution prepared by dissolving 4.35 g Al 2 (SO 4 ) 3 18H 2 O and 63 g conc. H 2 SO 4 in 733.52 g de-ionized water, was added. Finally, 0.45 g of SSZ-91 seed crystals from Example 7 was added. The mixture was stirred until homogeneous. The composition of the aluminosilicate gel produced had the following mole ratios:
[0000]
TABLE 5
SiO 2 /Al 2 O 3
220
H 2 O/SiO 2
39.9
OH − /SiO 2
0.21
Na + /SiO 2
0.56
HMB/SiO 2
0.10
Seed
0.38%
[0082] The liner was transferred to a 1-gallon autoclave, which was heated to 160° C. over a period of 8 hours, and stirred at a rate of 150 rpm at autogenous pressure. After 80 hours, the product was filtered, washed with de-ionized water and dried. The resulting solids were determined by XRD to be a ZSM-48 material ( FIG. 1 ). The XRD indicated there was an immeasurable amount of EU-1 in the product (likely less than 1% EU-1). The SEM shows agglomerated long needles of ZSM-48 crystals ( FIG. 2 ), with an aspect ratio of 7-12.
Comparative Examples 2 AND 3
[0083] As noted above, the Lobo and Koningsveld paper describes their analysis of three ZSM-48 samples provided by Dr. Alexander Kuperman of Chevron
[0084] Corporation. Each of the three samples, Samples A, B and C, respectively, were prepared using three different structure directing agents. The Lobo and Koningsveld paper describes Sample A as being polytype 6, and Sample B as being a faulted polytype 6. The paper further describes the morphology of Sample A ( FIG. 3 ) of consisting of thin needle-like crystals having a diameter of ˜20 nm and a length of ˜0.5 μm. The morphology of Sample B ( FIG. 4 ) consisted of long, narrow crystals having a diameter of ˜30 nm and a length of 4-8 μm. Even though Dr. Kuperman's materials were reported as having a high concentration of polytype 6, the samples are characterized as having aspect ratios (length/diameter) of 25 for Sample A, and an aspect ratio ranging between 133 and 266 for Sample B.
Examples 4-11
Synthesis of SSZ-91 with Varying EU-1 Concentrations in the Product
[0085] Each of Examples 4 through 11 were prepared by adding NaOH (50%), de-ionized water, HI-SIL 233 silica (PPG Industries), hexamethonium bromide (Sigma Aldrich) to an autoclave liner. After all the solids had dissolved, an aluminum stock solution prepared by dissolving 4.18 g Al 2 (SO 4 ) 3 . 18H 2 O and 45.58 g conc. H 2 SO 4 in 540.6 g de-ionized water, was added. The mixture was stirred until homogeneous. The mole ratios for the aluminosilicate gels and heating periods are listed in Table 6 below.
[0000]
TABLE 6
Example No.
4
5
6
7
8
9
10
11
SiO 2 /Al 2 O 3
218.6
113.6
177.8
180
177.7
177.7
177.7
170.0
H 2 O/SiO 2
40.0
23.0
40.3
40.0
40.3
40.3
40.3
40
OH − /SiO 2
0.21
0.17
0.27
0.28
0.27
0.27
0.27
0.27
Na + /SiO 2
0.56
0.17
0.21
0.71
0.71
0.71
0.71
0.46
HMB/SiO 2
0.10
0.02
0.10
0.10
0.10
0.10
0.10
0.10
Crystallization
38
48
30
34
30
30
30
30
Period (hrs)
[0086] The liner was transferred to an autoclave, which was heated to 160° C. over a period of 8 hours, and stirred at a rate of 150 rpm at autogenous pressure. After the crystallization period, the product was filtered, washed with de-ionized water and dried. The resulting solids were analyzed by XRD to determine the product and the level of EU-1 in the product. The bulk SiO 2 Al 2 O 3 mole ratio and EU-1 content are listed in Table 7 below.
[0000]
TABLE 7
Example No.
4
5
6
7
8
9
10
11
Percent EU-1
0.25
0.30
2.09
3.13
3.20
3.22
3.56
6.82
Bulk
155
88
101
140
130
125
123
118
SiO 2 /Al 2 O 3
mole ratio
[0087] The products from Examples 1 and 4-11 were analyzed by XRD and SEM. The XRD pattern for Example 7 is shown in FIG. 5 , and is illustrative of the XRD patterns collected for the remaining Examples 4-11.
[0088] The SEM image for Examples 7 and 8 are shown in FIGS. 6 and 7 , respectively, and are illustrative of the SEM images for the remaining Examples 4-11. FIGS. 6 and 7 show the SSZ-91 material consists of polycrystalline aggregates, each of the aggregates composed of crystallites, wherein each crystallite has characteristic average aspect ratio of less than 8. In contrast, the ZSM-48 materials of Comparative Examples 1-3 ( FIGS. 2-4 ) contained long needles and fibrous morphologies, the presence of which have consistently showed poor catalytic performance.
Calcination and Ion-Exchange of Molecular Sieves
[0089] The as-synthesized products from Comparative Example 1 and Examples 4-11 were converted into the sodium form under an atmosphere of dry air at a heating rate of 1° C./min. to 120° C. and held for 120 min followed by a second ramp of 1° C./min. to 540° C. and held at this temperature for 180 min and lastly a third ramp of 1° C./min. to 595° C. and held at this temperature for 180 min. Finally, the sample was cooled down to 120° C. or below. Each of these calcined samples was then exchanged into the ammonium form as follows. An amount of ammonium nitrate equal to the mass of the sample to be exchanged was fully dissolved in an amount of deionized water ten times the mass of the sample. The sample was then added to the ammonium nitrate solution and the suspension was sealed in a flask and heated in an oven at 95° C. overnight. The flask was removed from the oven, and the sample was recovered immediately by filtration. This ammonium exchange procedure was repeated on the recovered sample, washed with copious amount of deionized water to a conductivity of less than 50 μS/cm and finally dried in an oven at 95° C. for three hours.
Hydroprocessing Tests
[0090] Palladium ion-exchange was carried out on the ammonium-exchanged samples from Examples 1 and 4-11 using tetraamminepalladium(II) nitrate (0.5 wt % Pd). After ion-exchange, the samples were dried at 95° C. and then calcined in air at 482° C. for 3 hours to convert the tetraamminepalladium(II) nitrate to palladium oxide.
[0091] 0.5 g of each of the palladium exchanged samples from Example 11 was loaded in the center of a 23 inch-long by 0.25 inch outside diameter stainless steel reactor tube with alundum loaded upstream of the catalyst for pre-heating the feed (total pressure of 1200 psig; down-flow hydrogen rate of 160 mL/min (when measured at 1 atmosphere pressure and 25° C.); down-flow liquid feed rate of 1 mL/hour. All materials were first reduced in flowing hydrogen at about 315° C. for 1 hour. Products were analyzed by on-line capillary gas chromatography (GC) once every thirty minutes. Raw data from the GC was collected by an automated data collection/processing system and hydrocarbon conversions were calculated from the raw data.
[0092] The catalyst was tested at about 260° C. initially to determine the temperature range for the next set of measurements. The overall temperature range will provide a wide range of hexadecane conversion with the maximum conversion just below and greater than 96%. At least five on-line GC injections were collected at each temperature. Conversion was defined as the amount of hexadecane reacted to produce other products (including iso-nC 16 isomers). Yields were expressed as weight percent of products other than n—C 16 and included iso-C 16 as a yield product. The results are included in Table 8.
[0000]
TABLE 8
Isomerization
Selectivity
Percent
at 96% (n-
Temperature
C 4 −
Examples
EU-1
C 16 Conversion)
(° F.)
Cracking
Example 4
0.25
88%
606
1.3%
Example 5
0.30
88%
565
1.2%
Example 6
2.09
85%
584
1.7%
Example 7
3.13
85%
598
1.7%
Example 8
3.20
87%
601
1.5%
Example 9
3.22
87%
597
1.6%
Example 10
3.56
86%
600
1.6%
Example 11
6.82
82%
593
2.6%
[0093] The desirable isomerization selectivity at 96% conversion for the preferred materials of this invention is at least 85%. A good balance between isomerization selectivity and temperature at 96% conversion is critical for this invention. The desirable temperature at 96% conversion is less than 605° F. The lower the temperature at 96% conversion the more desirable is the catalyst whilst still maintaining isomerization selectivity of at least 85%. The best catalytic performance is dependent on the synergy between isomerization selectivity and temperature at 96% conversion. A large amount of impurity results in undesirable catalytic cracking with concomitant high gas make reflected in Table 8 by increased level of C 4 − cracking. The desirable C 4 − cracking for the materials of this invention is below 2.0%. Note the selectivity begins to decrease at 6.82% EU-1, because increasing concentrations of EU-1 promotes catalytic cracking.
Polytype Distribution
[0094] Using DIFFaX, simulated XRD patterns for ZSM-48 materials having between 70 and 100% polytype 6 were generated and compared to the XRD pattern collected for the molecular sieve product from Examples 8 and 11. The simulated and product XRD patterns are presented in FIGS. 8 and 9 herein, respectively. A comparison of the product XRD pattern to the simulated patterns indicates the product synthesized in Examples 8 and 11 contained greater than 90% polytype 6.
[0095] Using DIFFaX, simulated XRD patterns for ZSM-48 materials having between 70 and 100% polytype 6 were generated and compared to the XRD pattern collected for the molecular sieve product from Comparative Example 1. The simulated and product XRD patterns are presented in FIG. 10 herein. A comparison of the product XRD pattern to the simulated patterns indicates the product synthesized in Comparative Example 1 contained 80% polytype 6.
[0096] The material synthesized in Comparative Example 1 was subjected to the hexadecane hydroprocessing test as outlined for Examples 4-11 above. The material from Comparative Example 1 exhibited an isomerization selectivity of 78% at 96% conversion at a temperature of 614° F. As indicated in Table 9 below, the C 4 − cracking was 2.8%. The isomerization selectivity at 96% conversion for the Comparative Example 1 material, having a polytype 6 content of only 80%, was inferior to those described in Examples 4 through 10, as shown in Table 7 above, even though the material of Comparative Example 1 contained an immeasurable (<1%) amount of EU-1. This indicates that although the material of Comparative Example 1 and Example 11 exhibited two of the three characteristics of SSZ-91 (low aspect ratio, low EU-1 content, high polytype 6 content), the lack of the third characteristic contributed to the material's poor catalytic performance.
[0000]
TABLE 9
Isomerization
%
Selectivity
Polytype
%
Aspect
at 96% (n-C 16
C 4 −
Examples
6
EU-1
Ratio
Conversion)
Cracking
Comparative
80
<1
7-12
78%
2.8%
Example 1
Example 8
>90
3.20
1-4
87%
1.5%
Example 11
>90
6.82
2-6
82%
2.6%
Example 12-13
Synthesis of SSZ-91 with Alternate Silica Source
[0097] The material of Example 12 was prepared by adding NaOH (50%), de-ionized water, CAB-O-SIL M-5 silica (Cabot Corporation) and hexamethonium bromide (HMB) to an autoclave liner. After all the solids had dissolved, anhydrous, Riedel de Haen sodium aluminate was added. Lastly, slurry of SSZ-91 similar to the slurry from Example 4 was added. The mixture was stirred until homogeneous. The composition of the aluminosilicate gel produced possessed the following mole ratios:
[0000]
TABLE 10
SiO 2 /Al 2 O 3
113.6
H 2 O/SiO 2
23.0
OH − /SiO 2
0.17
Na + /SiO 2
0.17
HMB/SiO 2
0.02
Seed
2.92%
[0098] The liner was transferred to an autoclave, which was heated to 160° C. over a period of 8 hours, and stirred at a rate of 150 rpm at autogenous pressure. After 48 hours, the product was filtered, washed with de-ionized water and dried. The resulting solids were determined by XRD to be SSZ-91 and contained a 0.30 wt % of EUO. The bulk SiO 2 /Al 2 O 3 mole ratio was found to be about 102.
[0099] The material of Example 13 was prepared by adding NaOH (50%), de-ionized water, commercially available NALCO 2327 colloidal silica (40.3% SiO 2 ) and hexamethonium bromide to an autoclave liner. After all the solids had dissolved, Al 2 (SO 4 ) 3 . 18H 2 O previously dissolved in some of the water was added. The mixture was stirred until homogeneous. The composition of the aluminosilicate gel produced possessed the following mole ratios:
[0000]
TABLE 11
SiO 2 /Al 2 O 3
177.7
H 2 O/SiO 2
20.0
OH − /SiO 2
0.13
Na + /SiO 2
0.17
HMB/SiO 2
0.05
[0100] The liner was transferred to an autoclave, which was heated to 160° C. over a period of 8 hours, and stirred at a rate of 150 rpm at autogenous pressure. After 35 hours, the product was filtered, washed with de-ionized water and dried. The resulting solids were determined by XRD to be SSZ-91 and contained a 3.16 wt % of EU-1. The bulk SiO 2 /Al 2 O 3 mole ratio was found to be about 155. The material of Example 13 was analyzed by scanning electron microscopy, and an SEM image from that analysis is shown in FIG. 11 .
Hydroprocessing Tests
[0101] For the SSZ-91 materials synthesized in Examples 12 and 13, palladium loading and catalytic tests were carried out as described with respect to the Examples above. The results of the catalytic tests are shown below in Table 12. These two examples prepared by varying the raw materials used show the versatility of SSZ-91 preparations. Example 12 showed another good example of desirable isomerization selectivity, 88% at significantly lower temperature at 96%. Example 13, although phase pure, but showed inferior catalytic performance, a result of the crystal habit with poor aspect ratio of the crystals.
[0000]
TABLE 12
Isomerization
Selectivity at
Percent
Aspect
%
96% (n-C 16
Temperature
C 4 -minus
Example
EUO
Ratio
Polytype 6
Conversion)
(° F.)
Cracking
Example 12
0.30
1-3
>90
88%
559
1.3%
Example 13
3.16
>10
>90
78%
587
2.2%
[0102] Using DIFFaX, simulated XRD patterns for ZSM-48 materials having between 70 and 100% polytype 6 were generated and compared to the XRD pattern collected for the molecular sieve product from Example 13. The simulated and product XRD patterns are presented in FIG. 12 herein. An SEM image from that analysis is shown in FIG. 11A comparison of the product XRD pattern to the simulated patterns indicates the product synthesized in Comparative Example 1 contains greater than 90% polytype 6. This indicates that although the material of Example 13 had the requisite low EU-1 content and desired polytype distribution, the high aspect ratio contributed to the material's poor catalytic performance. Example 13 again demonstrates that the lack of any one of the three characteristics of SSZ-91 (low aspect ratio, low EU-1 content, high polytype 6 content) contributes to the material's poor catalytic performance.
|
Uses for a family of new crystalline molecular sieves designated SSZ-91 are disclosed. Molecular sieve SSZ-91 is structurally similar to sieves falling within the ZSM-48 family of molecular sieves, and is characterized as: (1) having a low degree of faulting, (2) a low aspect ratio that inhibits hydrocracking as compared to conventional ZSM-48 materials having an aspect ratio of greater than 8, and (3) is substantially phase pure.
| 2
|
BACKGROUND OF THE INVENTION
1 Field of the Invention
The present invention relates to a method for efficiently manufacturing a compact from powders which contracts only a little anisotropically.
2 Description of the Prior Arts
In the prior art cold isostatic press method, a resilient mold is filled up with powders such as metallic powder, ceramic powder or the like and sealed. Then, an isostatic press is applied to the resilient mold by the use of a pressure medium at the normal temperature whereby a homogeneous compact is prepared. Hereinafter, the cold isostatic press method is abbreviated as a C.I.P. method. In the forgoing C.I.P. method, however, some idea is required to obtain a compact of desirable shape so that the resilient mold cannot be deformed by the weight of the powders. In this connection, a method wherein a thickness and a strength of the resilient mold are made large to some extent is known. In this method, however, a degree of contraction of the resilient mold relative to a pressure applied thereto is different from a degree of contraction of a fill-up of powders inside the resilient mold, to which a pressure is applied. Due to the difference in the degrees of the contraction, the resilient mold and fill-up do not contract isotropically. Accordingly, the compact is required to be subjected to considerable machining in order to obtain a desired shape and a dimensional accuracy.
A method disclosed in a Japanese Examined Patent Publication No. 297402/87 is pointed out as another method. This method is executed as follows:
(a) A thin-wall resilient mold of a predetermined shape and a ventilative mold support having an inside shape similar to the shape of the resilient mold are prepared;
(b) The resilient mold is inserted into the mold support;
(c) The resilient mold is put close to the inner surface of the mold support;
(d) The resilient mold, which has been put close to the inner surface of the mold support and whose shape is kept, is filled up with powder materials. Then, after air in the resilient mold has been exhausted, the resilient mold is sealed;
(e) The ventilative mold is removed from the thin-wall resilient mold; and
(f) The thin-wall resilient mold is subjected to a cold isostatic press treatment and is removed whereby a compact is prepared.
A great progress in an increase of dimensional accuracy is seen in the method disclosed in the Japanese Patent Application Laid Open No. 297402/87 in comparison with the method wherein the thickness and strength of the resilient mold are made large to some extent. However, since the resilient mold is expanded by the use of the pressure difference and put close to the inner surface of the ventilative mold support, there occurs a phenomenon such that the resilient mold expands, not moving to positions corresponding to due positions of the inner surface of the mold support similar in shape to the resilient mold. When the resilient mold, in which said phenomenon takes place, is subjected to the C.I.P. treatment as it is, there occurs an anisotropic contraction and creases of the resilient mold. The more a desired shape of a compact becomes complicated, the greater this problem is posed.
SUMMARY OF THE INVENTION
It is an object of the the present invention to manufacture a compact of high dimensional accuracy with good repeatability. To accomplish the foregoing object, the present invention provides a method for molding powders, comprising the steps of:
forming a thin-wall resilient mold having at least one opening on a surface of a model of a desired shape;
forming a mold support so that said mold support can be put close to an outer surface of said thin-wall resilient mold;
removing said model from said thin-wall resilient mold, a cavity being formed in a portion, from which said model is removed;
charging powders as a forming material from said opening into the cavity of the thin-wall resilient mold;
sealing said opening of the thin-wall resilient mold after having removed air in the thin-wall resilient mold;
removing the mold support from the thin-wall resilient mold; and
subjecting the thin-wall resilient mold filled up with powders to a cold isostaitic press treatment.
The above objects and other objects and advantages of the present invention will become apparent from the detailed description which follows, taken in conjunction with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational sectional view illustration of a state such that a model, on a surface of which a thin-wall resilient mold is formed, is put into a crate, thereby a mold support being formed, according to the present invention;
FIGS. 2 and 3 are elevational sectional view illustrations such that a mold support is formed by applying a liquid on a thin-wall resilient mold according to the present invention; and
FIG. 4 is an elevational sectional view illustrations such that the thin-wall resilient mold, on which a mold support is formed and which has a cavity, is put on a vibration table and filled up with powders.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A model of a desired shape can be made of materials not easily deformed in the case of being capable of taking the model out of the thin-wall resilient mold as a single body or by means of dividing. A wide range of materials can be selected as the materials for the mode. Metal, ceramics, plastic, wood or the like are used for the materials for the model. On the other hand, in case the model is hard to take out even by means of dividing it, materials capable of being taken out of the thin-wall resilient mold or being made to disappear by means of melting, dissolving or sublimating the materials are selected within a range, in which the functions of the thin-wall resilient mold and mold support are not impaired. Wax or the like is pointed out as a material capable of being removed from the thin-wall resilient mold by means of melting. PVA, PVB, PEG, MC, CMC, urea or the like are pointed out as materials capable of being removed by dissolving into water or an organic solvent. Napthalene or the like is pointed out as a material capable of being removed by means of sublimating. Out of those materials, wax easy to form is particularly desirable. Powders of metal, ceramics, plastic, wood or the like can be mixed with the above-mentioned materials to adjust the strength, rigidity or the like.
Methods of making a model of a desired shape are not particularly limited. A large lump of material can be machined. Material can be melted and cast into a mold of a desired shape. An injection molding of material in the state of being melted or semi-coagulated can be made.
The thin-wall resilient mold is a mold made of natural rubber or synthetic rubber and high in elasticity. Styrene-butadiene rubber, polyisoprene rubber, isobutylene rubber, isoprene rubber, silicone rubber and urethane rubber or the like is used as the synthetic rubber. A wall thickness of the thin-wall resilient mold varies dependent on sizes and shapes of the mold. The wall thickness of the mold are usually within a range of 50 to 2000 μm. Materials for rubber in the state of liquid or paste are applied on the whole surfaces of the model except for portions corresponding to portions to be filled up with powders. Applied materials are converted to the thin-wall resilient mold, being cured. There can be a plurality of positions which are to be filled up with powders. Means for applying the materials on the surfaces of the mold are not particularly limited. Applying the materials on the surfaces of the model by the use of a brush, dipping the model in the materials or spraying the materials on the model or the like can be applied. A mold releasing agent or an adhesive agent can be applied in advance on the thin-wall resilient mold in order to control the adhesive property of the model with the mold support. A function of the thin-wall resilient mold is to transfer a pressure applied to a liquid from the outside to a compact inside the resilient mold and to enable the compact to contract isostatically, following a contraction of the compact.
The mold support is made by a cast molding or an application of materials. Means for the application of materials are not particularly limited. The application of materials by the use of a brush, dipping into materials and spraying materials or the like can be applied. In the case of the use of cast molding, liquid polyurethane resin, liquid epoxy resin and liquid gypsum are applied. The mold support is formed by curing those materials. Metallic powder, ceramic powder, plastic powder or the like can be mixed with the materials to control strength and rigidity of the mold support. On the other hand, in the case of using the application of materials, water-glass, hydrolysis liquid of metal alkoxide, liquid polyurethane resin, liquid epoxy resin and liquid gypsum can be applied. In the case of using the application of materials also, powders can be mixed with the materials.
The mold support plays the role of preventing the thin-wall resilient mold from being deformed. Therefore, an appropriate adhesive property between the thin-wall resilient mold and the mold support except for sufficient rigidity and strength of the mold support is required. In many cases, the mold is vibrated when a cavity is filled up with material powders. When the thin-wall resilient mold is separated from the mold support under the influence of vibrations of the mold and friction working between powders and the thin-wall resilient mold in connection with movement of filled powders, a predetermined shape of a compact cannot be obtained due to an insufficient fill-up.
After the mold support has been formed, the model is removed. The model is removed dependent on the sort of the model used. For example, in case it is possible to take the model out of the thin-wall resilient mold as a single body or by dividing the model, the model is taken out of the mold as a single body or by dividing the model into several parts. In the case of removing the model by melting, the model is melted by heating and made to flow out of the thin-wall resilient mold. In the case of removing the model by dissolving, the model is dissolved by a solvent. In the case of removing the model by dissolving, the model can be heated if necessary. The model is sublimated by heating or reduction of pressure. Melting, dissolving or sublimating the model as described above does not need to be completely carried out. The model can be melted, dissolved or sublimated to the extent that the thin-wall resilient mold and mold support are not impaired. A cavity is formed in a portion of the mold, out of which the model has been taken.
The cavity formed in such a manner is filled up with powders such as metallic powder, ceramic powder or the like which are used for molding materials. The powders such as metallic powder, ceramic powder or the like can be any material, which can be molded by means of the C.I.P. For example, stainless steel powder, high-speed tool steel powder, a mixed powder of tungsten carbid-cobalt, alumina powder, silicon nitride powder, silicon carbide powder, titanium diboride powder or the like are pointed out. Those powders can be used by mixing two sorts of powders or more out of those powders. Powders of about 10 to 1000 μm in particle size are preferable. Spherical powders are desired. Powders can be pelletized to obtain the spherical powders. Various sorts of additives can be added to the powders responsive to properties required for the compact. In case the powder is silicon nitride powder, for example, alumina, yttria or the like is added to the powder. The cavity is filled up with powders through an opening of the thin-wall resilient mold.
Air inside the thin-wall resilient mold can be exhausted after the cavity of the thin-wall resilient mold has been filled up with powders. Air is easily exhausted when the cavity of the thin-wall resilient mold is filled up with powders. A degree of air exhaustion is determined in accord with purposes of the use of the compact. A high degree of vacuum is desired if it is economically allowable.
On the other hand, it is necessary to exhaust air inside the thin-wall resilient mold and to remove the mold support after the thin-wall resilient mold has been sealed. When the mold support is removed, the mold support is desired to be separated from the thin-wall resilient mold without breaking it. A fill-up contracts slightly when the air inside the thin-wall resilient mold is exhausted. The mold support is most desired to separate from the thin-wall resilient mold with this contraction. Accordingly, the mold support is desired to have a weak adhesive property. A mold releasing agent or an adhesive agent can be applied in advance on the surfaces of the thin-wall resilient mold in order to control the adhesive property.
The powders charged into the thin-wall resilient mold in a vacuum can easily hold a shape of a compact thanks to the difference in pressures from the inside and outside. Therefore, the powders can be subjected to C.I.P. treatment by the use of publicly-known methods. When the thin-wall resilient mold is removed after the C.I.P. treatment has been carried out, a compact having been contracted isostatically can be obtained. Since an excessive protrusion is usually formed in a portion of an opening, through which the powders are charged into the thin-wall resilient mold, this protrusion is removed.
As described above, according to the present invention, after the thin-wall resilient mold has been formed, a weakly adhesive mold support is formed successively, the shape of the thin-wall resilient mold being left as it is. Therefore, it is unnecessary to take the thin-wall resilient mold apart and to fit it to the mold support. Accordingly, any crease and any stress distribution do not occur on the surfaces of the thin-wall resilient mold. In consequence, any anisotropic contraction of a compact is hard to occur in comparison with that made by the use of the prior art method and transcription of a model is made very well.
EXAMPLE 1
An example of the present invention will be described with specific reference to FIG. 1. Model 1 was made by carving a lump having a paraffin wax of melting point of 48° to 50° C. Model 1 had a shaft of 40 mm in diameter and a length of 160 mm, a disk of 120 mm in diameter and 40 mm in thickness and a disk of miscellaneous shapes of 40 to 60 mm in thickness. A cylindrical Cylindrical wood spacer 2 of 40 mm in diameter and 40 mm in length was made to adhere to an upper portion of the model 1. A latex of natural rubber was applied on the whole surface of the model 1 except for an upper portion of the spacer 2 by the use of a brush. The model 1 was left as it was at room temperature for three hours. As a result, a film of 0.5 to 1 mm in thickness was made. The film formed in this way was a thin-wall resilient mold 3. The model 1, by the use of which a thin-wall resilient mold had been made, was set inside crate 5. Material made by kneeding burnt gypsum with water was poured between the model 1 and the crate 5 up to an upper end of the model 1 and was left as it was for 24 hours. The material made by kneading burnt gypsum with water was cured whereby mold support 4 was obtained. Then, the spacer 2 was taken out of the thin-wall resilient mold 3. The thin-wall resilient mold 3 was put into a heating furnace and held there at 55° C. for three hours. Paraffin wax inside the thin-wall resilient mold melted. Molten wax was discharged out of the thin-wall resilient mold. As a result, a cavity to be filled up with powders was formed.
The thin-wall resilient mold, in which the cavity to be filled up with powders had been formed, was put on a vibration table. The cavity was filled up with granulated powder of alumina up to about 10 mm above a level corresponding to an upper end of the model, the thin-wall resilient mold being vibrated. Subsequently, an adapter connected to a vacuum pump was fitted to the thin-wall resilient mold and the inside of the thin-wall resilient mold was evacuated to 40 Torr. After the evacuation of air, a rubber just under the adapter was squeezed and clamped from the outside. During the evacuation of air, separation of rubber from gypsum due to a slight contraction of a fill-up was observed. As a result, the fill-up was taken out without damage by breaking gypsum. The fill-up was subjected to the C.I.P. treatment at a pressure of 5000 kg/cm 2 . A rubber film of the thin-wall resilient mold was separated and a compact was obtained. Obtained compact had been contracted by 28.6% smaller than the model. The compact, however, had contracted uniformly and its transcription of the model was good. The above-described operation was repeated ten times, but there was not any failure and repeatability was good.
EXAMPLE 2
An example of the present invention will be described with specific reference to FIG. 2. Thin-wall resilient mold 3 of natural rubber was formed on model 1 made of paraffin wax by the same procedure as that in Example-1. Slurry was applied on the surfaces of the thin-wall resilient mold 3 in ten layers. Applied liquid was made into a slurry by dispersing 10 wt.% of alumina particles of 0.3 to 0.6 mm in particle size in colloidal silica. Mold support 4 of 2 to 4 mm in thickness was formed by repeatedly applying and drying liquid. Subsequently, spacer 2 was taken out of the thin-wall resilient mold 3. The thin-wall resilient mold 3, by the use of which the mold support was formed, was heated and held in a heating furnace at 55° C. for three hours. The thin-wall resilient mold was taken out of the heating furnace and molten wax was discharged. In this way, a cavity to be filled up with powders was formed.
The thin-wall resilient mold, in which the cavity to be filled up with powders was formed, was put on a vibration table as shown in FIG. 4 and was filled up with granulated alumina 6. Thanks to a separation of the thin-wall resilient mold 3 from the mold support 4 during evacuation of the inside of the mold support, the thin-wall resilient mold could be removed without impairing the thin-wall resilient mold 3 by breaking hardened layers of the mold support 4. A fill-up was subjected to C.I.P. treatment. A rubber film of the thin-wall resilient mold was separated and a compact was obtained. Isostatic contraction and a transcription property of the obtained compact were good. Even though preparation of the compact was repeated ten times, there was no failure and repeatability was good.
EXAMPLE 3
An example of the present invention will be described with specific reference to FIG. 3. Cylindrical model 1 of 40 mm in diameter and 280 mm in length which was made of nylon was used. Thin-wall resilient model 3 of 0.5 to 1 mm in thickness was formed by dipping the model 1 into latex of natural rubber and drying it. Mold support 4 was formed by applying a liquid consisting of colloidal silica and alumina on the surfaces of the thin-wall resilient mold 3. Subsequently, when the model 1 was taken out of the thin-wall resilient mold 3, a cavity, whose shape was similar to the shape of the inside of the thin-wall resilient mold and whose shape was held by the mold support 4 was not deformed, was formed. After the cavity to be filled up with powders has been filled up with granular particles of alumina in accordance with the same procedure as that of Example-1, evacuated and sealed, a fill-up was subjected to the C.I.P. treatment. As a result, a compact good in an isostatic contraction and a transcription property was obtained. Even though the operations were ten times repeated, there was not any failure and repeatability was good.
|
A method for molding powders to form a shaped compact comprising the steps of
forming a thin-wall resilient mold having an outer surface and having at least one opening adjacent a surface of a model of a desired shape, forming a mold support on the outer surface of the thin-wall resilient mold, so that the mold support adheres to the outer surface of the thin-walled resilient mold,
removing the model from the thin-wall resilient mold whereby a cavity is formed in a portion of the thin-wall resilient mold, from which the model is removed, filling up the cavity of the thin-wall resilient mold with a powder as a forming material through the opening,
sealing the opening of the thin-wall resilient mold after having evacuated air from the inside of the thin-wall resilient mold,
removing the mold support from the thin-wall resilient mold,
subjecting the thin-wall resilient mold filled with the powder to a cold isostatic press. The mold support can be made by cast molding or by applying a material such as water-glass, a hydrolysis liquid of metal alkoxide, liquid polyurethane resin, liquid epoxy resin or liquid gypsum.
| 1
|
RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 13/871,642 filed Apr. 26, 2013 by the same inventors and entitled PLUNGER LIFT APPARATUS, which claims priority to U.S. Provisional Patent Application Ser. No. 61/720,451 filed Oct. 31, 2012 by the same inventors and entitled PLUNGER LIFT APPARATUS.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to oil and gas production operations, and more particularly to gas-lift plunger devices for lifting production fluids to the surface to restore production to shut in wells.
2. Description of the Prior Art
Gas lift plunger apparatus has been in use for many decades and has a long history of development. In one recent example, U.S. Pat. No. 7,438,125, Victor, a bypass assembly of a plunger lift device employs a bypass valve assembly having both an internal cage and an outer cage. The internal cage, when rotated using an adjustment performed with tools at the surface, operates to vary the size of the bypass orifices of the bypass valve and thus vary the bypass fluid volume. In addition a clutch within the lower part of the outer cage is used to maintain the valve push rod in a fixed position within the valve assembly until the push rod is forced to change the valve from an open (bypass) configuration to a closed (no bypass) configuration. The clutch tension is provided by a plurality of small metal coil springs wrapped around the clutch bobbin that surrounds the push rod. Some disadvantages of this design are its complexity that increases its cost and the effects of corrosion which predisposes the clutch assembly to premature failure. Another drawback is that the bypass orifices are cut at right angles through the inner and outer cages, which impedes the flow of fluid through the plunger as it descends through the tubing.
In another example, U.S. Patent Application Publication No. 2010/0294507, Tanton (See also U.S. Pat. No. 6,467,541, Wells) discloses two different free piston embodiments in which one or both of their components are made of materials that are at least partly buoyant. One embodiment is a simple combination of a sleeve having a seat to receive a ball at its lower end, as in a ball-check valve. In operation the ball is allowed to fall through the fluid in the well bore, followed by the sleeve at some time interval. The ball reaches the bottom of the well first. When the sleeve arrives it contacts the ball, which seals the well bore. Gas pressure can then lift the ball and sleeve together to the surface, pushing the production fluid ahead of them upward through the well bore. The other embodiment eliminates the separate ball or plug and closes the lower end of the sleeve, thus presenting a closed face to whatever material is in the well casing during descent. While simple in configuration, the first lacks predictability because the sleeve and ball operate independently until they reach the bottom of the well bore, and the second lacks broad utility because of its buoyancy and is not able to bypass fluids as it descends to the bottom of the well. Variations in the ball-check valve concept have been in the art for decades, as for example is illustrated in U.S. Pat. No. 2,001,012 patented May 14, 1935.
What is needed is an improved plunger bypass valve mechanism for a gas lift plunger device that is simple and durable, as well as reliable in operation and low in cost to manufacture.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a clutch assembly for a plunger lift bypass valve having an axial valve stem slidingly disposed within a valve cage attached to a plunger lift, the clutch assembly comprising a split bobbin sized to surround less than 360 degrees of the perimeter of the valve stem; a resilient tension band formed of synthetic rubber and surrounding the split bobbin; and a predetermined surface roughness applied to the valve stem. In another aspect the tension band may be configured as two or more tension bands used together.
In another embodiment there is provided an improved bypass valve assembly for a plunger lift apparatus, comprising a bypass valve cage with at least one elongated opening or port formed through a side wall of the bypass valve cage, the opening outwardly relieved at a lower end thereof; a valve stem disposed within a longitudinal bore of the valve cage and having a predetermined surface roughness; and a split bobbin clutch assembly including a resilient tension band formed of a synthetic rubber having an A Scale durometer characteristic between 60 and 90, the clutch assembly disposed around the valve stem.
In yet another embodiment of the invention there is provided a plunger lift apparatus having an improved bypass valve assembly, comprising a plunger body having a plurality of annular sealing rings and a full diameter upper body portion with shortened taper at an upper end thereof, the plunger body configured at a lower end thereof for threadable engagement with the bypass valve assembly; and a bypass valve assembly comprising a valve cage and a valve stem having a clutch assembly disposed there around, the valve stem disposed within a longitudinal bore of the valve cage, the clutch assembly configured as a split bobbin having a synthetic rubber or elastomer tension band disposed around the split bobbin, and the valve stem surface configured with a predetermined surface roughness.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of one embodiment of a plunger lift apparatus—a rotary bypass plunger—according to the present invention;
FIG. 2 illustrates a cross section view along a longitudinal axis of the embodiment of FIG. 1 ;
FIG. 3A illustrates a side view of an embodiment of a bypass valve cage portion of the embodiment of FIGS. 1 and 2 ;
FIG. 3B illustrates an end view of the embodiment depicted in FIG. 3A ;
FIG. 3C illustrates a cross section view of the embodiment of FIGS. 3A and 3B along the line 3 C- 3 C as shown;
FIG. 4 provides a perspective view of a bypass valve cage 30 as it may appear in one embodiment of the present invention;
FIG. 5 illustrates a perspective view of one embodiment of a clutch assembly used in the rotary bypass plunger according to the present invention;
FIG. 6 illustrates a perspective view of a resilient tension band for use in the clutch assembly embodiment depicted in FIG. 5 ;
FIG. 7 illustrates a perspective view of a bypass valve stem and clutch assembly for use in the embodiment of FIGS. 1 through 5 of the present invention;
FIG. 8 illustrates a perspective view of an alternate embodiment of a clutch assembly used in the rotary bypass plunger according to the present invention; and
FIG. 9 illustrates a perspective view of a resilient tension band for use in the clutch assembly embodiment depicted in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
The drawings that accompany the following description depict several views of a bypass valve assembly for a gas lift plunger apparatus according to one embodiment of the rotary bypass plunger apparatus provided by the present invention. It has been discovered that significant improvements can be made to the bypass valve assembly that utilizes a clutch-controlled “dart” or valve stem that reciprocates within a bypass valve “cage” and provides a mechanism for sealing the fluid passages through the bypass valve. One of the functions of the bypass valve is to allow fluid to flow through the valve in a controlled manner to control descent of the plunger assembly to the bottom of the well. Another function of the bypass valve assembly is to switch the valve configuration to seal the passages that allow the flow-through of fluid so that the plunger acts as a piston to seal the well bore and permit the gas pressure in the well to force the piston and accumulated fluids above it to the surface so that production from the well can resume.
The present invention incorporates design features that substantially improve the performance and durability of the bypass valve assembly in a gas lift plunger. Descent of the plunger assembly is faster and better controlled, which cuts the shut-in time approximately in half, thus more quickly restoring the well to production. Moreover, the superiority of the valve stem and clutch assembly configuration that is disclosed herein, which enables the switch from plunger bypass/descent to gas lift/ascent at the bottom of the well, is confirmed by performance in the field. The success of the improved design of the present invention is demonstrated by sales volume exceeding 1200 units during the first six months of its availability, without a single reported instance of failure. In addition, the reliability and durability of the plunger and the bypass valve assembly is extended by the features to be described herein, thereby reducing downtime and maintenance costs.
To achieve the aforementioned advantages, the following features are preferably and most advantageously used in combination in the bypass valve assembly described herein: (a) elongated bypass openings or ports that are relieved at the upper and lower ends at an angle to reduce turbulence and improve flow as the plunger descends, providing a smoother and a more rapid descent; (b) helical disposition of the bypass openings around the body of the bypass valve assembly to impart a torque to the plunger, causing it to spin within the well casing as it descends, ensuring more uniform wear and longer life while providing a smoother descent; (c) a valve stem clutch with an elastomeric tension band (or bands) that is more resistant to high temperatures and corrosive chemicals than metal and thus much less prone to failure; (d) calibrated surface roughness of the valve stem surface to improve the friction characteristics of the valve stem clutch as it arrives at the bottom of the well and configures the plunger for its ascent to the surface; (e) machined grooves on the inner surface of the clutch bobbin to allow sand particles to be flushed away from within the clutch, thereby preventing undesired lock-up; and (f) shortened taper of the upper end of the plunger body that utilizes the improved bypass valve assembly, to ensure a more complete seal with minimum leakage of production fluids during ascent of the plunger to the surface.
Variations in the above features are contemplated to adapt the bypass valve assembly to different well circumstances. For example, the number of bypass openings or slots may be varied to provide different flow rates. The tension in the tension band (or bands) of the clutch assembly may be varied or adjusted to adapt the clutch clamping force to different descent velocities as the plunger contacts the bumper at the well bottom. The helical pitch may be varied within narrow limits to control the amount of spin imparted to the plunger. The profile of the machined grooves in the clutch bobbin may be varied to accommodate different sand particle sizes. The surface roughness of the valve stem may be varied to optimize the friction applied by the clutch. The tapered profile of the plunger body at the upper end may be varied to optimize ascending performance with different fluid viscosities, etc. Persons skilled in the art will understand that the bypass valve assembly described herein—the assembly of the cage, valve stem and clutch—may be constructed in a variety of combinations of the above features and interchanged with other combinations to suit particular conditions of individual oil or gas wells. For example, the plunger and bypass valve assembly may be produced in several diameters for use in different size well tubing. Also, different length plungers may be provided. For example, a shorter bypass plunger is better able to negotiate well tubing that have curves or elbows, and because of its lower weight, it places less stress on the bumper spring at the bottom in wells that are relatively dry. A longer casing falls more easily through more fluid and provides a better sealing action. This adaptability is yet another advantage of the present invention. As is well known, performance of a gas lift plunger may be reduced if the configuration of the plunger is not well-matched to the conditions of a particular well.
One important component of the clutch assembly to be described herein is the elastomer tension band. In this description the use of the singular form of the term “tension band” is intended to mean that the tension band may be composed of one such band or a plurality of individual bands used together. The tension band (or bands) may be fabricated of an elastomeric material, a broad category of synthesized polymer materials that are commonly known as synthetic rubber. Among the properties required in the tension band is resistance to high temperatures and corrosion, elasticity, reversibility—ability to return to and maintain its unstressed or relaxed configuration after being stressed, and excellent stability. Some examples of such materials include neoprene, buna-N, respectively polychloroprene and acrylonitrile butadiene. An alternative is hydrogenated nitrile rubber. Another example, preferred for the present invention, is a fluoroelastomer such as a fluoronated hydrocarbon better known as Viton®, a registered trademark of the E. I. DuPont de Nemours and Company or its affiliates of Wilmington, Del., USA. In particular, the preferred material will have a Shore A durometer of 60 to 90, and for most applications a Shore durometer of 75 on the A scale is preferred. In some applications where the tension band needs to be thicker or wider (greater cross sectional area), the durometer figure may be reduced. Similarly, if the tension band needs to be thinner or narrower (lesser cross sectional area), the durometer figure should be increased.
When installed on the valve stem, the split bobbin segments are disposed around the valve stem shaft, held in a clamping action against the valve stem shaft by the action of the elastomer tension band. The elastomer tension band has been found during tests to provide superior durability in down-hole conditions to other ways such as metal springs to provide the needed clamping force. The clamping force provided by the tension band resists by friction of the bobbin segment against the valve stem the movement of the valve stem through the clutch assembly. This friction arises because of the clamping force from the tension band and the predetermined surface roughness formed into the surface of the valve stem shaft along the greater portion of its length. The function of the clutch assembly is to ensure that the valve stem remains in either (a) the lower-most position within the valve cage during descent of the plunger so that the plunger will fall freely through the fluid in the well casing and cause it to rotate smoothly during the descent; and (b) the upper-most position within the valve cage during ascent of the plunger to seal the bypass valve assembly so that the gas pressure in the well will cause the plunger to rise through the well casing, pushing the production ahead of it. The clutch assembly enables the valve stem to be held in the appropriate position during descent and ascent, and also to change the position of the valve stem from the lower-most position to the upper-most position when the plunger reaches the bottom of the well to configure the plunger for its ascent.
In the drawings to be described each structural feature is identified with a reference number. A feature bearing the same reference number in more than one figure may be assumed to be the same feature. Turning now to FIG. 1 there is illustrated a perspective view of one embodiment of a plunger lift apparatus—a rotary bypass plunger—according to the present invention. The plunger 10 includes two main sections—the plunger section 12 and the rotary bypass valve assembly 14 . The plunger section 12 includes the plunger body 16 having an upper end 18 , a series of concentric outer rings 20 and a tapered portion 26 . The outer rings 20 around the plunger section 12 provide a seal against the well casing (not shown) and reduce friction (because of reduced surface area of the plunger section 12 ) as the plunger 10 descends or ascends through the well casing. The sloped surface 22 on the upper side of each ring facilitates ascent by reducing friction due to turbulence of the fluid. The underside 24 of the outer rings 20 may optionally be configured to serve a purpose such as minimizing drag, improving sealing, providing a flushing action upon descent, etc. In some applications the outer rings 20 may be formed as a continuous helix instead of concentric rings, for example.
The rotary bypass valve assembly 14 (also: bypass valve 14 ) includes a valve cage 30 , and end cap 34 , and a valve stem 102 . The body 32 of the valve cage 30 may be threaded (See FIG. 2 ) onto the lower end of the body 16 at threads 41 and may be secured with a set screw in a threaded hole 40 . The end cap 34 may be similarly threaded (See FIG. 2 ) into the lower end of the valve cage 30 at threads 43 and may also be secured with a set screw in a threaded hole 42 . An optional socket 44 for a spanner wrench for removing the bypass valve assembly 14 and the end cap 34 is shown in the outer surface of the end cap 34 . The valve cage 30 includes bypass ports 46 , to be further described below, which are disposed at equal radial intervals around the valve cage 30 .
FIG. 2 illustrates a cross section view along a longitudinal axis 60 of the embodiment of FIG. 1 . FIG. 2 is a side cross section view of the assembled bypass plunger 10 showing the sealing rings 20 formed along the axis 60 of the bypass plunger 10 . The bypass valve assembly 14 is shown to the left in the figure, and the upper end 18 of the plunger body 16 having the shortened taper 26 is shown at the right in the figure. The shortened taper 26 permits the upper portion of the plunger body 16 of the bypass plunger 10 to retain its full diameter over a maximum portion—at least 70% thereof—of its length. This feature provides improved sealing performance as the bypass plunger 10 rises within the well bore while lifting the production fluids to the surface. The plunger body 16 of the plunger section 12 is hollow—formed with a cylindrical bore 28 in this example to permit the flow of fluid through it during descent of the bypass plunger 10 . During descent, fluid flow enters the lower end of the bypass plunger 10 through the bypass ports 46 and the cylindrical bore 50 in the bypass valve cage 30 , and through the cylindrical bore 28 of the plunger body 16 . FIG. 2 also depicts a cross section view of the valve stem 102 with the clutch assembly 70 installed including the split bobbin 72 and the elastomer tension band 76 disposed around the split bobbin 72 , as these components appear when assembled in the bypass valve cage 30 . The clutch assembly 70 is further described in FIGS. 5, 6, and 7 .
Also clearly visible in FIGS. 1 and 2 is the bypass valve assembly 14 . As shown in the cross section view of FIG. 2 , the bypass valve assembly 14 includes the valve stem 102 disposed within a bore 36 through the end cap 34 , a clutch assembly 70 encircling the valve stem 102 , and an elongated bypass port 46 . Three such ports 46 are depicted in the preferred embodiment shown in the drawings, although for example without limitation other embodiments may include two or four such ports 46 . The details of the port 46 will be described in FIGS. 3A through 3C . The profile of the ports 46 features relieved areas to facilitate the flow of fluids during descent of the bypass plunger 10 . This relieved port configuration provides less resistance and turbulence to the flow of fluids as the bypass plunger 10 falls through the well bore. The valve stem 102 includes an enlarged head 68 at its upper end that includes a chamfered perimeter 66 formed to mate with a similarly beveled seat 64 formed in the lower end of the bore 28 through the plunger body 16 . This configuration provides a poppet-type valve to regulate the flow of fluid through it. The poppet valve configuration thus provides for sealing the bypass valve assembly 14 against the passage of fluids as the plunger 10 ascends through the well casing.
Continuing with FIG. 2 , the clutch assembly 70 to be described maintains the valve stem 102 in an extended, open-valve position during the descent of the bypass plunger 10 . The clutch assembly 70 is held in place in the lower end of the bypass valve cage 30 between a circumferential internal ridge 38 and the end cap 34 . When the plunger 10 reaches the bottom as the lower end of the valve stem 102 contacts a bumper at the well bottom, the inertia of the plunger 10 overcomes the frictional clamping force of the clutch assembly 70 , enabling the valve stem 102 to move upward (to the right in the figure) through the bore 50 in the bypass valve cage 30 and against the seat 64 in the plunger body 16 to seal the bypass valve assembly 14 . Thus sealed, the bypass plunger 10 functions like a piston, allowing the gas pressure in the well to lift the bypass plunger 10 upward, carrying accumulated fluids above it to the well surface.
Preferred materials for fabricating the rotary bypass plunger 10 described herein include the use of type 416 heat treated stainless steel for the bypass valve stem 102 and the clutch bobbin segments 72 A/ 72 B. The remaining parts—plunger body 16 , valve cage 30 , and end cap 34 may be fabricated of type 4140 heat treated alloy steel. In alternative embodiments, the 416 heat treated stainless steel may be used to fabricate all of these parts. Both materials are readily available as solid “rounds” in a variety of diameters, as is well known in the art.
FIGS. 3A, 3B, and 3C illustrate a bypass valve cage 30 of the present invention in several views to depict the profile of a bypass port 46 . The actual shape of the bypass port 46 is somewhat complex because of the tapered cylinder or conical configuration of the body 32 of the valve cage 30 and the helical alignment of a port 46 around the valve cage 30 . The views in FIGS. 3A and 3C illustrate the basic parameters of the profile of the port 46 . The port 46 is an elongated slot with rounded ends 54 , 56 cut through the wall of the body 32 of the valve cage 30 . As will be described, the port 46 may be substantially aligned with a continuous helix disposed around the tapered cylinder valve cage 30 . In addition, both ends 54 , 56 of the port 46 are cut at the same angle of approximately (but not limited to) 45° in the illustrated embodiment with the centerline 60 of the valve cage 30 as shown in FIG. 3C .
This nominal 45° angle results in an inward slope of the ends 54 , 56 of the port 46 with both ends 54 , 56 oriented toward the upper end 18 of the bypass plunger 10 as it is positioned within a well casing. This relief of the ends 54 , 56 of the port 46 facilitates the flow of fluid through the port(s) 46 as the bypass plunger 10 falls through the well casing by gravity. In alternate embodiments, this nominal angle of 45° may be varied to suit a particular implementation of the bypass valve assembly 14 . For example, the angle may be different at opposite ends of the port(s) 46 , they may be larger or smaller acute angles relative to the longitudinal axis 60 , the angled surfaces may be rounded in profile for even smoother flow through the port(s) 46 , etc. An additional relieved area, called ramp 58 , further smooths the path for fluid flow at the lower end 54 of each port 46 .
The surface of the ramp 58 shown in FIGS. 3A and 3C may be a flat or curved feature that is substantially parallel with the centerline or axis 60 of the valve cage 30 and, because of the conical outer shape of the valve cage 30 in the illustrated embodiment, forms an angle 52 of approximately 7° with the outer surface of the valve cage 30 . This angle 52 may typically vary from about 5° to 10° depending on the particular dimensions of the valve cage, but may be subject to other angles beyond this relatively small range in alternative embodiments. Persons skilled in the art will recognize that a variety of modifications to this port profile may be made to accommodate particular circumstances of manufacturing or application in the field, without departing substantially from the purpose of the profile shown in FIGS. 3A and 3C . The essential concept is to relieve the passage through which fluids are to flow by removing sharp angles, etc. to provide a smooth, obstruction-free passage. As a result, the plunger descends more rapidly and more predictably than conventional plunger designs.
Continuing with FIG. 3A , the port 46 is also oriented at a small angle relative to the length of the bypass plunger 10 . To illustrate, the length of the port 46 forms an angle of approximately 15° with respect to the axis 60 if the position of the port 46 is projected on to the plane of the centerline or axis 60 of the bypass plunger 10 . Thus, this angle may be substantially in alignment with a helical path around the body or wall 32 of the valve cage 30 . Orienting a port 46 in this way will cause the plunger 10 to rotate or spin as it descends within the well casing because the fluid flow through the angled port 46 exerts a torque on the plunger 10 . Further, to balance the effect of the helical orientation of the port 46 , the port 46 is preferably disposed at two, three, or four locations around the valve cage 30 and separated at uniform radial intervals around the body 32 of the valve cage 30 . The use of two or more ports 46 spaced at uniform intervals around the body 32 of the valve cage 30 also facilitates the passage of fluid through the plunger as it descends through the well tubing. FIG. 3B depicts a view of the lower end of the valve cage 30 to show the appearance of the valve cage 30 with three of the helically-oriented ports 46 disposed at even intervals around the body 32 of the valve cage 30 . The benefits of the helical orientation of the several, evenly separated ports 46 is to facilitate rotation of the bypass plunger 10 and provide a smooth descent and uniform wear of the bypass plunger 10 , thus extending its useful life through many gas lift cycles.
The combination of the helical orientation of the ports 46 , preferably disposed at several uniform radial positions around the body of the valve cage 30 , each having the relieved ends 54 , 56 , 58 , provides a rotary gas lift plunger that outperforms known bypass plungers by providing smoother, faster descent along with more uniform wear and extended life in the field. FIG. 4 provides a perspective view of a bypass valve cage 30 showing the appearance of two of the ports 46 when disposed at three evenly separated positions—120° apart—around the body 32 of the valve cage 30 .
FIGS. 5, 6, and 7 illustrate perspective views of one embodiment of a clutch assembly 70 used in the rotary bypass plunger 10 according to the present invention. In FIG. 5 the clutch assembly 70 includes a split bobbin 72 that surrounds the valve stem 102 . The split bobbin 72 is held in place by a tension band 76 that is placed around the two segments 72 A, 72 B of the split bobbin 72 , and within the space defined by the first and second rims 82 , 84 of the bobbin segments 72 A, 72 B, thus clamping the bobbin segments 72 A, 72 B against the outer surface of the valve stem 102 . The bobbin segments 72 A, 72 B are identical in this illustrated embodiment, each one resembling a semicircle except for being slightly shortened from a full 180° by the gap 78 , which may be provided by making a 0.063 to 0.125 inch saw cut, for example, through the diameter of a single formed circular bobbin 72 . In other embodiments, the bobbin may be split into three or more segments, although two segments are adequate for this purpose and somewhat simpler to manufacture and handle during assembly. The split bobbin 70 illustrated in FIG. 5 is shown with the segments 72 A and 72 B separated by the amount of the gap 78 even though the bobbin 70 is not installed on a valve stem 102 . When installed on the valve stem 102 , the gap 78 may typically be reduced under the effect of the tension band 76 .
Continuing with FIG. 5 , the tension band 76 is made of a resilient material and is configured to tightly press the bobbin segments 72 A, 72 B against the outer surface 104 of the valve stem 102 . In the present embodiment the inside diameter 86 of each half 72 A, 72 B of the split bobbin 72 is the substantially the same as the outside diameter of the valve stem 102 but is formed as slightly less than a full semicircle because of the small gap 78 provided between the proximate ends of the split bobbin 72 when it is in place around the valve stem 102 . This enables the inner surface of the bobbin halves 72 A, 72 B to fully contact the valve stem 102 to provide maximum friction to resist the movement of the valve stem 102 through the clutch assembly 70 except when the plunger 10 contacts the bottom of the well bore during a gas lift operation.
Also depicted in FIG. 5 is an additional feature of the split bobbin 72 , the series of grooves 80 formed on the inner surfaces of the split bobbin 72 . These grooves, preferably uniformly disposed around the circumference of the bobbin segments 72 A, 72 B, provide passages for fluids to flush particles of sand away from the contact area of the bobbin 72 with the outer surface of the valve stem 102 . The grooves 80 may be formed by machining or swaging, for example. In the illustrated example, four such grooves 80 are formed in each bobbin segment 72 A, 72 B, although the number may be varied, generally between two and six grooves 80 in each segment may be practical. However, the greater the number of grooves in the split bobbin 72 , the more the grooves 80 will be limited to trapping most grains rather than allowing them to be flushed out of the clutch assembly 70 .
FIG. 6 illustrates a perspective view of a resilient tension band 76 for use in the clutch assembly 70 embodiment depicted in FIG. 4 . The tension band 76 , which is formed as a ring having an inside diameter 90 about the same as or slightly smaller than the outer diameter of the central portion of the assembled split bobbin 72 A/ 72 B and an outside diameter 92 slightly less than the outer diameter of the rims 82 , 84 of the split bobbin 72 A/ 72 B, which in turn is only slightly less than the inner bore 50 of the valve cage 30 just below the internal ridge 38 . The tension band 76 preferably has a width 94 dimensioned to fill the full width between the first and second rims 82 , 84 of the split bobbin 72 A/ 72 B. It can further be seen that the resilient tension band 76 , which has a rectangular cross section to fit within the rims 82 , 84 of the split bobbin 72 , acts to form a very compact clutch assembly 70 . This configuration exerts a constant clamping force around the valve stem 102 . It has been found that the clamping force exerted by the elastomer tension band 76 does not diminish significantly over a great many gas lift cycles.
Moreover, the synthetic rubber material used in the tension band 76 is essentially impervious to the corrosive effects of most of the materials in the fluids found in oil and gas wells. These properties are unlike the use of small diameter coil springs, for example, which, being made of metal, are susceptible to such corrosion. Such corrosion requires additional maintenance—and down time—to replace and restore the tension of the springs or other metal components used to provide the necessary tension in the clutch 70 . The tension band 76 is preferably fabricated of a synthetic rubber material having a durometer of between 60 and 90 on the Shore “A” Scale. This requirement provides for sufficient tension when the tension band 76 is stretched over the rims 82 , 84 of the split bobbin 72 to secure the clutch assembly 70 around the valve stem 102 . In the embodiments described herein, the clutch assembly 70 is designed to resist a linear pull on the valve stem 102 of approximately 2.8 to 3.6 lb. in this example, although adjustments to the tension may generally vary from 1.0 to 6.0 lb. in other examples but are not so limited because some applications mat require the clutch to satisfy clamping forces beyond this range. The performance of the clutch assembly 70 is also dependent on the finish applied to the valve stem 62 , as will be described with FIG. 7 .
Suitable materials for the tension band 76 for the clutch assembly 70 include neoprene and buna-N, respectively polychloroprene and acrylonitrile butadiene. An alternative is hydrogenated nitrile rubber. Another example, preferred for the present invention, is a fluoroelastomer such as a fluoronated hydrocarbon better known as Viton®, a registered trademark of the E. I. DuPont de Nemours and Company or its affiliates of Wilmington, Del., USA. In particular, the preferred material will have a Shore A durometer of 60 to 90, and for most applications a Shore durometer of 75 on the A scale has been found to work the best.
FIG. 7 illustrates a perspective view of the assembly 100 of a bypass valve stem 102 and clutch assembly 70 for use in the embodiment of FIGS. 1 through 6 of the present invention. FIG. 7 also includes the details of the finish required on the surface 104 of the stem portion of the valve stem 102 that provides a surface roughness between 500 and 550 micro inches. This figure of 500 to 550 microinches describes the tolerance in the surface finish between the peak and valley portions of the roughened surface. In the illustrated embodiment the roughness of the surface 104 of valve stem 102 may be provided by a shallow continuous groove inscribed helically along the outer surface 104 of the portion of the valve stem 102 that is disposed within the clutch assembly 70 . The net effect of the clamping force provided by the tension band 76 combined with the surface roughness provided by the inscribed grooves 104 is to resist a pull on the lower end 108 of the valve stem 102 within the range of one to six lb. In one preferred embodiment the level of pull is set within the range of 2.8 to 3.6 lb. This surface roughness 104 thus forms an integral component of the friction effect of the clutch assembly 70 when it is installed on the valve stem 102 , improving its effectiveness and consistency.
FIGS. 8 and 9 depict an alternate embodiment 130 of the clutch assembly 70 that is shown in FIGS. 5 and 6 . Clutch assembly 130 may be used interchangeably with clutch assembly 70 . The clutch assembly 70 uses a single tension band 76 , whereas the clutch assembly 130 uses two tension bands and a split bobbin assembly 132 comprised of segments 132 A/ 132 B that has an additional rim 142 surrounding the bobbin. FIG. 8 thus illustrates a clutch assembly 130 that includes a split bobbin 132 that surrounds the valve stem 102 . The split bobbin 132 is held in place by a pair of tension bands 134 / 136 that are placed around the two segments 132 A, 132 B of the split bobbin 132 , and within the space defined by the first and second rims 140 and 142 , and 144 and 142 of the bobbin segments 132 A, 132 B, thus clamping the bobbin segments 132 A, 132 B against the outer surface of the valve stem 102 . The bobbin segments 132 A, 132 B are identical in this illustrated embodiment, each one resembling a semicircle except for being slightly shortened from a full 180° by the gap 146 , which may be provided by making a 0.063 to 0.125 inch saw cut, for example, through the diameter of a single formed circular bobbin 132 .
In other embodiments, the bobbin may be lengthened to cover a greater portion of the valve stem 102 . Further, the bobbin may be split into three or more segments (not shown), although two segments are adequate for this purpose and somewhat simpler to manufacture and handle during assembly. The split bobbin 130 illustrated in FIG. 8 is shown with the segments 132 A and 132 B separated by the amount of the gap 146 even though the bobbin 130 is not installed on a valve stem 102 . When installed on the valve stem 102 , the gap 146 may typically be reduced under the effect of the pair of tension bands 134 and 136 used together. In other similar embodiments, the number of tension bands such as the tension bands 134 , 136 may exceed two, an intermediate rim or rimes such as the rim 142 may or may not be used or needed, and the bobbin 132 may be split into more than two segments. In some embodiments the tension bands may simply be ordinary O-rings, such as those that are made of Viton®, as described herein above, which may be selected for size, thickness, or durometer to enable adjustment of the clamping force of the clutch assembly. Two or more such O-rings may be used to provide a particular adjustment to the tension—weaker or stringer—exerted on the bobbin segments of the clutch assembly.
Continuing with FIG. 8 , the tension bands 134 , 136 may be made of a resilient material and is configured to tightly press the bobbin segments 132 A, 132 B against the outer surface 104 of the valve stem 102 . In the present embodiment the inside diameter 138 of each half 132 A, 132 B of the split bobbin 132 is the substantially the same as the outside diameter of the valve stem 102 but is formed as slightly less than a full semicircle because of the small gap 146 provided between the proximate ends of the split bobbin 132 when it is in place around the valve stem 102 . This enables the inner surface of the bobbin halves 132 A, 132 B to fully contact the valve stem 102 to provide maximum friction to resist the movement of the valve stem 102 through the clutch assembly 130 except when the plunger 10 contacts the bottom of the well bore during a gas lift operation.
Also depicted in FIG. 8 is an additional feature of the split bobbin 132 , the series of grooves 150 formed on the inner surfaces of the split bobbin 132 . These grooves, preferably uniformly disposed around the circumference of the bobbin segments 132 A, 132 B, provide passages for fluids to flush particles of sand away from the contact area of the bobbin 132 with the outer surface of the valve stem 102 . The grooves 150 may be formed by machining or swaging, for example. In the illustrated example, four such grooves 150 are formed in each bobbin segment 132 A, 132 B, although the number may be varied, generally between two and six grooves 150 in each segment may be practical. However, the greater the number of grooves in the split bobbin 132 , the more the grooves 150 will be limited to trapping most grains rather than allowing them to be flushed out of the clutch assembly 130 .
FIG. 9 illustrates a perspective view of a pair of resilient tension bands 134 , 136 for use in the clutch assembly 130 embodiment depicted in FIG. 8 . The use of two or more tension bands instead of one may be preferred in some applications. For example, when it is necessary to provide a clutch assembly such as clutch assembly 70 or 130 to increase the effective clamping surface area against the valve stem 102 , the split bobbin may be lengthened along the longitudinal axis to accommodate additional tension bands. In the example illustrated in FIGS. 8 and 9 , the tension bands 134 , 136 , may each be formed as a ring having an inside diameter 120 about the same as or slightly smaller than the outer diameter of the central portion of the assembled split bobbin 132 A/ 132 B and an outside diameter 122 approximately the same (as shown in FIGS. 7 and 8 ) slightly less than the outer diameter of the rims 140 , 142 , 144 of the split bobbin 132 A/ 132 B, which in turn may only be slightly less than the inner bore 50 of the valve cage 30 just below the internal ridge 38 . The tension bands 134 , 136 preferably each have a width 124 , 126 dimensioned to fill the width between the first and second rims 140 , 142 and 142 , 144 respectively of the split bobbin 132 A/ 132 B. It can further be seen that the resilient tension bands 134 , 136 , which may have a rectangular cross section to fit within the respective rims 140 , 142 , 144 of the split bobbin 132 , act to form a very compact clutch assembly 130 . Alternately, the intermediate rim 142 may be deleted and a pair of tension bands placed side-by-side around the split bobbin as indicated by the dashed line 128 encircling the tension band 76 depicted in FIG. 7 . Either of these configurations exerts a constant clamping force around the valve stem 102 . It has been found that the clamping force exerted by the elastomer tension bands 134 , 136 do not diminish significantly over a great many gas lift cycles.
The materials suitable for the tension bands 134 , 136 in FIGS. 8 and 9 , or other embodiments thereof, are as described in FIG. 5 herein above. That is, the tension bands 134 , 136 are preferably fabricated of a synthetic rubber material having a durometer of between 60 and 90 on the Shore “A” Scale. This requirement provides for sufficient tension when the tension bands 134 , 136 are stretched over the rims 140 , 142 , 144 of the split bobbin 132 to secure the clutch assembly 130 around the valve stem 102 . In the embodiments described herein, the clutch assembly 130 is designed to resist a linear pull on the valve stem 102 of approximately 2.8 to 3.6 lb. in this example. Adjustments to the tension may generally vary from 1.0 to 6.0 lb. in other examples but are not so limited because some applications may require the clutch to satisfy clamping forces beyond this range as mentioned herein. The performance of the clutch assemblies 70 , 130 are also dependent on the finish applied to the valve stem 102 , as previously described with FIG. 7 .
Returning now to FIGS. 1 and 2 , the bypass valve assembly 14 may be assembled by first installing the valve stem 102 into the larger end of the valve cage 30 until it seats against the internal ridge 38 within the bore of the valve cage 30 . The valve cage may then be screwed onto the lower end of the plunger body 12 and secured with a set screw in the threaded hole 40 . Next, the clutch assembly 70 is installed over the lower end 108 of the valve stem 102 until it is seated against the opposite side of the internal ridge 38 within the valve cage 30 , followed by threading the end cap 34 into the lower end of the valve cage 30 to secure the clutch assembly 70 within the valve cage 30 . The end cap 34 may be tightened to a specified torque with the aid of a spanner wrench (not shown as it does not form part of the invention) inserted into the socket 38 , and secured using a set screw installed in the threaded hole 42 .
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
|
An improved bypass valve assembly for a plunger lift apparatus comprises a bypass valve cage having improved flow characteristics and a simplified clutch assembly having enhanced durability and low cost.
| 4
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the fabrication of stamps for microcontact printing using a master that contains surfaces of organic materials or composites of organic and inorganic materials, and more particularly a method of modifying the chemical nature of the surfaces of the master through a vapor phase treatment to improve the ease of separation of the stamp from the master.
2. Description of Related Art
Micromolding and microcontact printing as pattern transfer techniques are areas of significant interest for a wide range of applications, especially in the microelectronics industry. Microcontact printing, known as “stamping”, techniques are under development as low-cost alternatives to lithography for pattern definition on cost sensitive applications such as flat panel displays. Stamps made from siloxane polymers (such as poly(dimethylsiloxane) (PDMS)) are commonly used due to their ease of fabrication, conformal nature that allows stamping over topographical features, and potential for repeated use to pattern multiple substrates. Stamping has been demonstrated to transfer very thin coatings, down to monolayer coverage, of organics onto surfaces to act as etch barriers, plating seed layers, or ultra-thin patterns that can modify the interaction of the surface with subsequent coatings of organics—either enhancing or resisting deposition of materials in specific areas. Imaging with siloxane stamps has been demonstrated down to submicron dimensions.
In molding and stamping applications, a curable (thermosetting) material, such as PDMS, or a pliable (thermoplastic) material such as a resist is formed into the desired shape by bringing it in contact with a rigid pre-formed master. Thermoplastic materials are generally cast from a solvent or heated until pliable and conformal with the master. Thermosetting materials are generally composed of monomers or polymer precursors that generally have low viscosity prior to curing (crosslinking), and conform easily to the surface of the master. Curing at room or elevated temperatures or under exposure to an appropriate source of radiation causes crosslinking of the polymer precursors, which will be transformed into an elastic or inelastic solid. To achieve an accurate replication of the master, the polymeric material must be in intimate contact with the surfaces of the master.
After the thermosetting or thermoplastic stamp has been formed to replicate the shape of the master, it must be separated from the master without causing damage to either the stamp or the master. The cured/formed polymer will have reduced flexibility, and may adhere to, or even be chemically bonded to the surface of the master. Adhesion of the stamp to the master increases the difficulty in separating the stamp from the master, and may result in fractures or tears in the polymeric stamp, with the torn sections of the stamp adhering to the master. Tear-outs result in stamps that are imperfect replicas of the master, and are unusable in manufacturing applications that require defect free reproductions. Tear-outs also reduce the utility of the master for production of future articles.
The master itself may be fabricated from a range of materials, although they are generally composed of inorganic materials, such as glass or silicon, or composite structures of an organic material on a glass or silicon substrate, although all organic masters are also feasible. Inorganic masters are generally produced by lithographically patterning a photoresist that has been spun onto the substrate. The exposed and developed photoresist creates a relief pattern that is the inverse of the desired stamp pattern. The patterns on the master may be as small as micron or sub-micron dimensions in width, but are usually several microns deep. Creating relief structures in a silicon or glass substrate requires transferring the resist pattern via wet chemical or plasma etching of the substrate. Such substrates can easily be treated with standard silane or fluorosilane solutions to increase the hydrophobicity of the surface and improve the release of organic materials molded from the master, as described in U.S. Pat. Nos. 5,425,848, 5,817,242 and 6,027,595. Release layers such as the silanes used in these patents are applied in dilute solutions of appropriate nonpolar organic solvents such has alkanes, chlorinated or fluorinated solvents, etc. These solvents provide adequate wetting and minimal interaction with inorganic masters, such as those made of silicon or glass.
A less time-consuming and more cost-effective technique for preparation of masters, also in common usage, is the fabrication of composite masters with a permanent patterned photoresist layer on a glass or silicon substrate. Using this fabrication technique, the exposed and developed resist images form the topographical features that will be replicated in the elastomeric stamp. No mention is made in the literature of treating such masters with release agents. The common solvents for silane release agents produce swelling or distortion of organic films, such as photoresists. Interactions with the organic features on the master limit the utility of solvent applied silanes to produce release layers on organic or composite organic/inorganic masters.
Other examples of the fabrication and uses of microcontact printing stamps and masters include U.S. Pat. No. 5,512,131, which describes the fabrication of elastomeric stamps and the use of these stamps to transfer self-assembled monolayers (“SAM”) of molecular species onto a solid substrate; and U.S. Pat. No. 5,900,160 describes the etching of said substrates after transfer of the SAM using an elastomeric stamp. U.S. Pat. No. 5,817,242 describes the use of a deformable layer as part of the stamp to accommodate for unevenness of the substrate being stamped. Fabrication of stamps in this patent includes transfer of resist features from one inorganic substrate to another.
U.S. Pat. Nos. 5,425,848 and 6,027,595 demonstrate the use of stamps to produce patterned resist images using molding techniques; U.S. Pat. No. 5,925,259 employs stamps to provide patterned “microcontainers” for etchants or reactants/catalysts to interact with the substrate in selected areas.
SUMMARY OF THE INVENTION
The present invention comprises exposing a composite organic/inorganic master to alkylchlorosilanes in the vapor phase. Chlorosilanes participate in facile reactions with hydroxyl groups existing on the surface of inorganic oxides (such as glass or the native oxides on silicon, aluminum, tin, etc.); or those in organics-containing phenolic or alcoholic groups, such as photoresists. The alkyl group on the silane can be chosen from a large selection of aliphatic or aromatic organic groups that have substituents with varying polarity and reactivity. The preferred materials to increase the hydrophobicity of the master and minimize adhesion of the stamp are fluorinated aliphatic chlorosilanes with at least eight carbon atoms, or long chain alkyl silanes with at least twelve carbon atoms, although aromatic silanes, such as phenyl silane are also applicable. To avoid swelling or distortion of the organic features on the master that can be caused by exposure to solvents, the chlorosilanes were brought into contact with the master in an evacuated, heated chamber, resulting in reaction of the silanes with all surfaces of the master to produce uniform, hydrophobic surfaces. The temperature of the reaction chamber affects the rate of reaction of the silane with the organic and inorganic surfaces of the master. Since the silanes chemically bond to the surfaces of the master, the hydrophobicity of the surface is retained for preparation of multiple stamps, increasing the useful lifetime (and so lowering the effective cost) of the master.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 ( a-g ) illustrates the process of master and stamp formation using the disclosed method for vapor phase application of silanes to the master as a release layer prior to stamp fabrication.
FIGS. 2 ( a-c ) Scanning electron micrographs (SEMs) that illustrate PDMS tear-out associated with untreated masters.
FIGS. 3 ( a-f ) SEMs of resist images exposed to organic solvents commonly used for silane application that illustrate the swelling, distortion, and loss of adhesion of the resist features that can accompany this method of silane application.
FIGS. 4 ( a-d ) SEMs of resist features before and after vapor fluorosilane treatment that illustrate that no change occurs in the resist image due to the vapor silane treatment.
DETAILED DESCRIPTION OF THE INVENTION
The present invention describes a method for applying a self-assembled monolayer of a release agent to composite organic/inorganic substrates, specifically substrates used as masters for the preparation of elastomeric stamps for microcontact printing. The release layer aids in removal of the elastomeric stamp from the master by decreasing the interaction of the elastomer with the surfaces of the substrate. This reduces damage to both the stamp and the master during the process of separation.
Referring to FIG. 1, a schematic illustration of vapor treatment of a master as part of the process of stamp fabrication is presented. The substrate, 22 (FIG. 1 a ) is composed of glass, silicon, or a metal with oxide-containing hydroxyl groups on its surface 24 . This substrate could also be composed of a rigid or flexible organic or composite material that contains hydroxyl functionality. As illustrated in FIG. 1 b , a layer of photoresist 26 is spun on the surface 24 of the substrate, and the photoresist is exposed and developed to produce images that are the inverse of those desired in the final stamp.
The composite of the patterned photoresist on the substrate, which shall be referred to hereinafter as the “master”, is placed in a chamber that is then evacuated. The chamber may be heated above room temperature, with the temperature range generally limited to a maximum of 10-20° below the glass transition temperature of the photoresist to minimize deformation of the surfaces of resist images 28 . In certain cases, temperature induced deformation of resist images 28 may be desirable, such as to tailor the sidewall slopes of the resist. In these cases, increasing the chamber temperature above the glass transition temperature of the resist will allow a degree of controlled deformation.
Once the chamber with the master has been evacuated, silane vapor 30 is introduced into the chamber as illustrated in FIGS. 1 c-d , generally through opening a valve to a container of the liquid silane. The partial pressure of silane 30 in the chamber may be controlled by the inherent vapor pressure of the selected silane, the temperature of the container in which the silane is held, the vacuum in the chamber, and combinations thereof.
The specific silane may be chosen, according to the present invention, to optimize the desired properties of the surface and accommodate any limitations on processing conditions. The silanes are composed of a head, or reactive group, and a tail group that affects the hydrophobicity and surface free energy of the surfaces to which the silane is bound. For the purposes of this invention, desirable head groups include trichlorosilane, methyldichlorosilane, dimethylchlorosilane, trimethoxysilane, or triethoxysilane. The specified head groups will react with hydroxyl groups on the surface of inorganic substrate 24 and hydroxyl or phenolic groups on the surface of resist 28 . For the purposes of this invention, desirable tail groups include alkanes, especially linear alkanes with more than 12 carbons, aromatic groups, and aromatic or aliphatic groups with fluorine substitution, especially linear alkanes with the terminal hydrocarbon(s) completely fluorinated. Highly fluorinated alkanes such as (tridecafluoro-1,1,2,2-tetrahydrooctyl)trichlorosilane or (heptadecafluoro-1,1,2,2-tetrahydrodecyl)trichlorosilane produce particularly highly hydrophobic surfaces on both the organic and inorganic surfaces of the master.
The vapor phase silanes 30 undergo a facile reaction with the surfaces of photoresist 28 and substrate 24 producing monolayer coverage of the silane on the organic 32 and inorganic 34 surfaces of the master (FIG. 1 e ). The silanes form a covalent bond with the hydroxyls on the organic and inorganic surfaces, creating a stable hydrophobic surface. The isotropic nature of the contact of the silane vapor with all surfaces on the master produces uniform coverage independent on the orientation of, or features on the substrate. The contact time required to achieve full coverage of the surfaces varies with the choice of silane and the temperature of the chamber; but it has been measured to be anywhere from one minute to several hours. Once a uniform monolayer of silane has reacted with the surface, introduction of silane into the chamber ceases and the remaining silane is evacuated prior to removal of the master.
Elastomeric stamps for microcontact printing fabricated by coating the master as indicated in FIG. 1 ( f ) with polymeric precursors, such as siloxanes, and curing the precursors using heat or irradiation to form crosslinked structure 36 . The surface of elastomeric stamp 38 is in contact with the silane monolayer, which has minimal interactions with the cured polymer as compared with untreated resist or inorganic substrates. The limited interactions between the elastomer and the master result in minimal forces required to separate the stamp from the master (FIG. 1 g ), thus reducing defect formation due to adhesion of the elastomer to the master.
The invention herein disclosed eliminates several problems with the production of elastomeric stamps for microcontact printing that would otherwise limit their utility in manufacturing applications. As mentioned previously, tear-outs in the elastomer as it is removed from contact with the master often leave pieces of the elastomer adhering to the master (as shown in the SEMs in FIG. 2 ), which create defects in both the stamp and the master that render them useless. To date, most stamping demonstrations have been accomplished on small, laboratory scale parts where the manufacturing issues of defect free stamps, reproducibility, and reusability of masters have not been primary concerns. As larger stamps, up to 1 meter 2 in size, are being developed for flat panel applications the adhesion of the PDMS to the master, and the defects created by this adhesion severely limit manufacturability. The surface treatment disclosed in the present invention reduces the interaction between the elastomeric stamp and the master to a level that requires minimal force for separation, and eliminates tear-outs in the stamp. The process described in the present invention allows the production of stamps free of tear-out defects and improves the potential for reuse of masters.
The traditional solution-based silane treatments used for inorganic masters are incompatible with the less expensive organic/inorganic masters required for cost-effective manufacturing processes. FIG. 3 illustrates the deformation and swelling of photoresist features subjected to solution-based silane treatments. The vapor phase contact with silanes described in this invention avoids any deformation or distortion of the resist images, as demonstrated in the SEM's of untreated and vapor treated resist images depicted in FIG. 4
EXAMPLE 1
A master substrate having an exposed and developed photoresist pattern was fabricated by photolithography. The master was placed in a chamber that was heated to 40° C. and evacuated to 2 torr.
A valve to a container of liquid (tridecafluoro-1,1,2,2-tetrahydrooctyl)trichlorosilane (TFOTS) was opened, allowing vapor of the TFOTS to enter the evacuated chamber and react with the substrate. The chlorosilyl head group undergoes a facile reaction with hydroxyl groups on the surface of the glass as well as with the hydroxyl or phenyl groups in the resist. The fluorinated tail portion of the silane extends outward from the surface of the substrate, increasing the hydrophobicity of both inorganic and organic surfaces. The substrate remained in the evacuated chamber in contact with the TFOTS vapor for 60 minutes, after which the valve to the TFOTS container was closed, and the chamber was flooded with nitrogen. The chamber was evacuated again, and refilled with nitrogen before removing the master.
The contact angle of static drops of water on the surface of both the resist and the glass portions of the master were measured for untreated and fluorosilane-treated masters. Large contact angles with water indicate high hydrophobicity and low surface free energy, which are associated with reduced chemical interactions and adhesion. The contact angle of water on the resist increased from 75° on the untreated sample to 95° on the treated sample. The contact angle of water on the glass portions of the master increased from 40° on the untreated sample to 90° on the treated sample. The fluorosilane treatment significantly increases the hydrophobicity of the glass portions of the master, as well as moderately increasing the hydrophobicity of the resist portions. Perhaps more importantly, the fluorosilane treatment produces a uniform degree of hydrophobicity between the two disparate materials.
A 10:1 (w:w) mixture of PDMS-Sylgard Silicone Elastomer 184 and Sylgard Curing Agent 184, a poly(dimethyl siloxane) precursor and crosslinking agent (Dow Corning Corp. Midland, Mich.) was degassed under vacuum for about 10 minutes, then the mixture was poured over the master. The PDMS cured at 65° C. within 60 minutes to produce an elastomeric stamp. After cooling to room temperature, the PDMS stamp was peeled from the master. Very little, if any force was required to remove the stamp from the template after the master was treated with the fluorosilane vapor, and there was no evidence of PDMS adhering to the master or tear-outs in the stamp.
EXAMPLE 2
A master substrate having an exposed and developed photoresist pattern was fabricated by photolithography. The master was placed in a chamber that was heated to 80° C. and evacuated to 2 torr. A valve to a container of liquid TFOTS was opened. The substrate remained in the evacuated chamber in contact with the TFOTS vapor for 10 minutes, after which the valve to the TFOTS container was closed, and the chamber was flooded with nitrogen. The chamber was evacuated again, and refilled with nitrogen before removing the master. The contact angles of the resist and glass after this treatment averaged 94° and 92° respectively. The PDMS stamp was prepared as described in Example 1, and the stamp was easily removed from the master with no evidence of PDMS adhering to the master.
EXAMPLE 3
A master substrate having an exposed and developed photoresist pattern was fabricated by photolithography. The master was placed in a chamber at room temperature that contained 0.1 ml of octyltrichlorosilane in an open glass vial and the chamber was evacuated to about 10 torr. The substrate remained in the evacuated chamber in contact with the octyltrichlorosilane vapor overnight. The contact angle of water on the glass and the resist after this treatment averaged 98°. The PDMS stamp was prepared as described in Example 1, and the stamp was easily removed from the master with no evidence of PDMS adhering to the master.
|
A method of exposing a composite organic/inorganic master to alkylchlorosilanes in the vapor phase. Chlorosilanes participate in facile reactions with hydroxyl groups existing on the surface of inorganic oxides (such as glass or the native oxides on silicon, aluminum, tin, etc.); or those in organics-containing phenolic or alcoholic groups, such as photoresists. The alkyl group on the silane can be chosen from a large selection of aliphatic or aromatic organic groups that have substituents with varying polarity and reactivity.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Chinese Patent Application No. 2015103084200 filed on Jun. 9, 2015, the contents of which are incorporated by reference herein.
TECHNICAL FIELD
[0002] The invention relates to a floorboard and wallboard, in particular to a waterproof board and its manufacturing method.
BACKGROUND
[0003] In general, the wooden or composite boards are adopted as the indoor flooring or wall pavement materials. Although the wooden board materials have a more comfortable tactility, it is easy to absorb water and deform due to drying, and the strength of wooden board is insufficient to resist the tilting and delamination; and although composite board extruded of sawdust mixed with binder features good appearance and low cost, it easily absorbs water and releases the formaldehyde that is not environmentally friendly. Therefore, in modern construction, such as in the LEED green buildings, it is required to further reduce the impact on the natural environment and to maximize the use of recycled materials or waste. Therefore, the utilization of wood plastic composite material board in floorboard, wallboard and other technical field becomes more and more important. The utility model patent CN203742125U discloses a wood-plastic flooring symmetrically arranged with a balance layer, including UV coating, PVC sheet layer, PVC decorative layer, upper balance layer, substrate layer and lower balance layer. The utility model adopts hard sheets as the upper and lower balance layers and uses the multilayer structure to solve the strength problem of wood-plastic board. But the multilayer structure makes the binding between the layers need more processing steps and add layers of adhesive, making the wood plastic floor has a poor stability, be easily delaminated by temperature changes or water immersion factors and not environmentally friendly. And its substrate layer uses the existing wood plastic composite material which has an ordinary waterproof effect.
SUMMARY
[0004] Aiming at the shortages of the existing technology, the invention provides a kind of waterproof board with high strength, low water absorption rate, strong stability and environmental protection, and its manufacturing method.
[0005] In order to solve the above problems, the invention provides a technical scheme as follows: a waterproof board, comprising a waterproof layer and wear-resistant layer and the groove and tenon that are respectively arranged on both sides of the board. Said wear-resistant layer is affixed onto the waterproof layer and said waterproof layer is extruded via extrusion material with resin and bamboo-wood powder as main compositions. The density of said waterproof layer is 0.60 kg/cm 3 -0.95 kg/cm 3 .
[0006] The waterproof board has two layers of structure that is easy for processing. It uses the wear-resistant layer to improve the service life of the waterproof board and reach a certain static friction force to adapt to the tactility, and uses the waterproof layer formed of the wood plastic composite material to improve the waterproof performance of board. And the waterproof board is light in weight so that it has a comfortable foot feeling when it is used as the flooring and convenient transportation, and reduces the material and transportation costs in a certain extent.
[0007] As a preferred embodiment of the invention, said waterproof board can also comprise a decorative layer. Said wearing-resistant layer is hot-pressed onto said decorative layer and said decorative layer is affixed onto said waterproof layer. Alternatively, said waterproof board further comprises a bottom layer, said waterproof layer is affixed onto the bottom layer. Alternatively, said waterproof board also includes a decorative layer and a bottom layer. Said wear-resistant layer is hot-pressed onto the decorative layer, and said decorative layer is affixed onto said waterproof layer and said waterproof layer is affixed onto said bottom layer.
[0008] As a preferred embodiment of the invention, the extrusion materials used by said waterproof layer, include bamboo powder or wood powder or the mixture of both, accounting for 20%-40% of the total mass of extrusion materials; and the resin that accounts for 30%-40% of the total mass of extrusion materials.
[0009] As a preferred embodiment of the invention, the bamboo-wood powder refers to the bamboo powder, or the mixture of the bamboo powder and the wood powder, and said bamboo powder includes the tabasheer powder that accounts for at least 40% of the total mass of bamboo powder and the bamboo green powder that accounts for at most 60% of total mass of bamboo powder.
[0010] As a preferred embodiment of the invention, the particle size of resin and/or bamboo-wood powders in the waterproof layer ranges from 60 to 80 mesh.
[0011] As a preferred embodiment of the invention, the density of the waterproof layer further is 0.65 kg/cm 3 -0.75 kg/cm 3 .
[0012] As a preferred embodiment of the invention, the thickness of said waterproof layer is 3.8 mm-18.8 mm, and the tensile strength of said waterproof layer is 5.9 Mpa-12.5 Mpa.
[0013] As a preferred embodiment of the invention, the thickness of the wear layer is 0.085 mm-0.5 mm.
[0014] As a preferred embodiment of the invention, the static bending strength (MOR) of said waterproof layer is 21 Mpa-28 Mpa, and the elastic modulus (MOE) of said waterproof layer is 1490 Mpa-1580 Mpa.
[0015] The invention provides another technical scheme as follows: a waterproof board manufacturing method.
[0016] Step 1: Put the industrial waste with bamboo or wooden components into an extruder to obtain the bamboo-wood powder. Said bamboo-wood powder is bamboo powder or wood powder, or a mixture of both bamboo powder and wood powder. Said bamboo powder is mixed with said resin, wherein the bamboo powder shall be extruded for at least three times to finally make the bamboo-wood powder account for 20-40% of the total mass of extrusion materials, and the resin account for 30%-40% of the total mass of extrusion materials;
[0017] Step 2: The mixed bamboo-wood powder and resin added with additives are blended and modified in a blending machine, and then adding foaming agents into the machine. Said bamboo-wood powder, said resin, said additives and said foaming agents constitute the extrusion materials. The extrusion materials in the extruder are extruded into the waterproof layer via hot pressing under the temperature of 162 degrees C.-172 degrees C., and pressure of 20 Mpa-25 Mpa;
[0018] Step 3: The wear-resistant layer made of polyethylene or polyvinyl chloride is hot-pressed onto the decorative layer made of tile veneer or stone veneer or rubber veneer or decorative plastic veneer or linoleum veneer or decorative vinyl veneer under the temperature of 200 degrees C.-220 degrees C., and hot pressing pressure of 22-24 Mpa;
[0019] Step 4: Said decorative layer is affixed onto said waterproof layer under the temperature of at least 182 degrees C. by hot melt adhesive;
[0020] Step 5: Said waterproof layer is affixed onto said bottom layer at the temperature of 183 degrees C.-193 degrees C. by hot melt adhesive;
[0021] Step 6: Finish the tongue-and-groove processing and the Tu-edge processing of the waterproof board.
[0022] The waterproof board manufacturing method adopts the bamboo-wood powder and resin as the main compositions of the extruded material to form a waterproof layer with low density and good waterproof performance. The waterproof layer combines with the wear-resistant layer, decorative layer and the bottom layer together to form the main body of the board, making the board surface wear-resistant, beautiful, comfortable tactility. In this manufacturing method, a certain mass percentage of bamboo-wood powder and resin is added to form a waterproof board featured of low density and low bibulous rate and high strength, further improving the strength, stability and waterproof performance of the board.
[0023] The invention has the following beneficial effects:
[0024] (1) The waterproof board features simple structure and is easy to process and assemble.
[0025] (2) The waterproof layer uses a suitable weight of the wood powder or bamboo powder composition to mix with the resin to improve the wood plastic composite compatibility and is matched with the other layers, making better affinity and easy bonding between layer and layer. The entire waterproof board keeps consistent in the heat expansion and cold contraction. It has relatively high strength and stability, less susceptibility to deforming or delaminating due to the influences of temperature or water.
[0026] (3) It is light in weight, comfortable feeling under foot, and further reduces the cost of transportation and materials.
[0027] (4) The waterproof board is of great strength, tensile strength, and is not easy to break and deform.
[0028] (5) Environmentally friendly, passed the system certification of the FSC (Forest Stewardship Council).
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 illustrates a perspective view of a waterproof board according to the first embodiment disclosed herein;
[0030] FIG. 2 illustrates a perspective view of a waterproof board according to the second embodiment disclosed herein;
[0031] FIG. 3 illustrates a perspective view of a waterproof board according to the third embodiment disclosed herein; and
[0032] FIG. 4 illustrates a perspective view of a waterproof board according to the third embodiment disclosed herein.
DETAILED DESCRIPTION
[0033] In the Figures, the following numbers designate corresponding items:
1 —wear-resistant layer; 2 —decorative layer; 3 —waterproof layer; 4 —bottom layer; 5 —groove; 6 —tenon.
Example 1
[0035] In FIG. 1 , the waterproof board in this invention comprises: the wear-resistant layer 1 , the waterproof layer 3 , and groove 5 and tenon 6 respectively arranged on both sides of the board. Said wear-resistant layer 1 can be affixed onto the waterproof layer 3 via various bonding ways as hot melt adhesive. Profiles of said groove 5 and tenon 6 can be matched to form a fixation-connection between the adjacent boards. The fixation-connection can be mechanically clamping in a locking form or fastening with glue and other chemical methods.
[0036] The wear-resistant layer can be polyethylene or polyvinyl chloride material that features low absorption rate and good stability. When it is used as the surface of the waterproof board, it can exert the roles of waterproof, damp-proof and wear-resistant; and the wear-resistant layer has a certain friction, such as its static friction coefficient at least reaches to 0.62, it is conducive to slip-proof.
[0037] Said waterproof layer 3 contains the resin and the bamboo-wood powder. The polyvinyl chloride can be used as the resin. In the present invention, the bamboo-wood powder refers to a collective concept of the bamboo powder, or wood powder, or the mixture of bamboo powder or wood powder. Usually obtaining more environmentally friendly wood powder is not more convenient than obtaining the bamboo powder. The bamboo powder is easier in the extrusion molding than that of the wood powder; it is desirable to consider the use of the bamboo powder. The bamboo powder and wood powder that come from industrial waste materials can be recycled, are featured of low cost, and are beneficial to environmental protection.
[0038] In order to make the waterproof layer 3 have features of high strength, low water absorption rate and high stability, the extrusion materials in the waterproof layer 3 , include the bamboo powder, or wood powder, or a mixture of both bamboo powder and wood powder accounting for 20%-40% of the total mass of the materials and the resin that accounts for 30%-40% of the total mass of the materials. Considering the board to be more environmentally friendly and with reduced cost in a certain extent, the larger percentage of the bamboo powder accounted for the total mass of extrusion materials can be better. Because of limited practical extrusion process currently available, it is almost impossible to increase the percentage of the bamboo powder material accounting for the total mass of extruded materials to 50%, especially above 55%. If we want to increase the bamboo-wood powder content above 40%, it can be realized through adding similar forming agents and other additives, or increasing the temperature or increasing extrusion pressure, but the finished product rate is low, as the resources are wasted, the difficulty of processing goes up significantly and the production efficiency is reduced accordingly. And if the bamboo-wood powder content is lower than 20%, it can reduce the bamboo powder molding process difficulty, but the waterproof layer is insufficiently environmentally friendly, high cost, and the waterproof layer stability is insufficient. Using said materials, the formaldehyde emission from the waterproof layer 3 is 0.15 mg/L-0.45 mg/L, reaching to the E0 level standard.
[0039] In general, bamboo includes bamboo green (bamboo outer skin) and tabasheer; the strength of bamboo green is higher than that of tabasheer. Considering the board strength, it is necessary to add more extruded powder of bamboo green and the bamboo green powder is difficult to mix with resin independently due to the wax on its surface, adequate amount of tabasheer extrusion powder shall be added. The optimized design is that the bamboo-wood powder is bamboo powder, or a mixture of both the bamboo powder and the wood powder. Said bamboo powder includes tabasheer powder accounted for at least 40% of total mass of bamboo powder, and the bamboo green powder accounted for at most 60% of the total mass of bamboo powder. This makes the waterproof layer have certain strength, and can use the wax of the bamboo green surface to lubricate, reduce the use of additional lubricant additives, and reduce formaldehyde emissions.
[0040] In order to further improve the strength of the waterproof layer 3 , it is necessary to decrease the particle size. For example, the particle size of the resin or bamboo powder, or bamboo and wood powder and resin in the waterproof layer 3 , ranges from 60-80 mesh. The larger size of the particles within the board the more difficult for the particles move within the board. It is easier to break or generate defects at the interface, and the small size of the particles can improve the tensile strength of the board, especially the strength of the waterproof layer. At the same time, with the decrease of particle size, it can further reduce the density of the waterproof layer, which enhances the strength of the board and makes the board lighter.
[0041] Said waterproof layer is filled with foaming agent. Before foaming, the density of said waterproof layer 3 is about 1.1 kg/cm 3 -1.3 kg/cm 3 . When adding baking soda etc. foaming agents, the density of the waterproof layer 3 decreases; the density of said waterproof layer is about 0.60 kg/cm 3 -0.95 kg/cm 3 . If coupled with the controls on the particle sizes of the bamboo-wood powder and/or resin in the waterproof layer, it can also further reduce the waterproof layer density, which makes the overall weight of board light to have a more comfortable feeling when it is used as a floor and further and further reduce the cost of materials and transportation. The density of the board can be further reduced to 0.65 kg/cm 3 -0.75 kg/cm 3 or 0.60 kg/cm 3 -0.64 kg/cm 3 or 0.70 kg/cm 3 -0.80 kg/cm 3 .
[0042] In order to protect the board against the easy abrasion, the thickness of the wear-resistant layer 1 is 0.085 mm-0.5 mm, further is 0.085 mm-0.15 mm, or 0.25 mm-0.35 mm. Besides the waterproof layer adopting the extrusion materials that are mainly composed of bamboo powder and the resin in said certain percentage to improve the strength and stability of the waterproof layer, the higher thickness of the waterproof layer 3 further improves the stability of waterproof board. The thickness of the waterproof layer 3 of the waterproof board is 3.8 mm-18.8 mm, the board is not easy to deform, and the stampede sound feeling is thicker and heavier. The thickness of the waterproof layer 3 can be further adjusted to 10.5 mm-12.5 mm, or 13.2 mm-15.2 mm, or 15.5 mm-18.8 mm. And the measured tensile strength of the waterproof layer is 5.9 Mpa-12.5 Mpa. That is to say, per square meter cross section of the waterproof layer can withstand 59000N-125000N; the waterproof layer is not easy to break and demonstrates a high tensile strength when it bears the stress within this range.
[0043] The static bending strength of the waterproof layer 3 is 21 Mpa-28 Mpa, and the elastic modulus of the waterproof layer 3 is 1490 Mpa-1580 Mpa. The static bending strength is the ratio of the bending moment and the modulus of bending section when the maximum load is acting, and the larger the numerical value is, the stronger the bending resistance is. Said parameters mean that the internal bonding strength of the waterproof layer 3 has been improved and its water absorption rate has been decreased. Within static bending strength and elastic modulus range, the binding force between cellulose molecules has been reduced, the external resistance increases, making it difficult deform the waterproof layer.
[0044] The wood-plastic compatibility of the waterproof layer made of the extrusion materials has been improved after appropriate mass percentage of mixed bamboo-wood powder and resin is achieved, so that the waterproof layer features lower water absorption rate, stable thermal expansion and cold contraction, high strength, low density, and not easy to deform or delaminate due to changes in temperature and soaking factors. The size expansion of the waterproof layer exposed to the wet environment is not more than 0.0099%. At the same time, the waterproof board of this design is of low cost, environmentally friendly, and suitable for the United States LEED green building.
[0045] Said waterproof board also includes additives. The additives can contain stone powder and talcum powder. The content of the stone powder and talcum powder accounts for less than 40% of the total mass of the extrusion materials. If coloring, mildew proof, lubrication and other effects are considered, the additives can also contain anti UV agent, antioxidant, stabilizer, coloring agent, anti-mildew agent, coupling agent, reinforcing agent and lubricant.
[0046] The manufacturing process of the waterproof board: Step 1: Put the industrial waste containing the bamboo or wood components in the extruder to obtain the bamboo-wood powder, which is the bamboo powder, or wood powder or a mixture of both. The bamboo-wood powder is mixed with the resin; in general, it is more difficult for the bamboo powder extrusion than that of the wood powder. During the extrusion process, one-step extrusion cannot be achieved and multiple extrusions are required. Each time, the bamboo powder accounting for at most 5%-8% of the total mass of the extrusion materials can be extruded. The first 7% of the bamboo powder extruded is mixed with the resin, and another 7% of bamboo powder is added in the second time. It roughly needs 6 times for you to reach the required 40% of bamboo-wood powder. When 8% of the bamboo powder is extruded each time, you need to extrude 3 times to reach 20% of the bamboo-wood powder required. So, at least 3 times for bamboo power extrusion is required, making the final mass of the bamboo-wood powder account for 20%-40% of the total mass of the extrusion materials, and the resin account for 30%-40% of the total mass of the extrusion materials.
[0047] Step 2: Said mixture of the bamboo-wood powder and resin added with additives such as the stone powder and talcum powder are blended and modified in a blending machine, and then adding the foaming agent into the machine. Said bamboo-wood powder, said resin, said additives and said foaming agents constitute the extrusion materials. Said foaming agents can be soda or calcium bicarbonate. The extrusion materials in the extruder are extruded into the waterproof layer via hot pressing under the temperature of 162 degrees C.-172 degrees C., and pressure of 20 Mpa-25 Mpa. The gas evaporates after foaming, the volume of the waterproof layer gets larger and its thickness is about 3.8 mm-18.8 mm, while its density is minimized to about 0.60 kg/cm3-0.95 kg/cm 3 . In order to improve the forming rate of the waterproof board, especially the forming rate after adding the bamboo powder, the forming agent additives shall be added, or the processing temperature and extrusion pressure etc. shall be increased. With the increment of the process temperature, the water-swelling rate of the waterproof layer is decreased, and the internal bonding strength of the waterproof layer is improved. The static bending strength and the elastic modulus are improved, and the waterproof layer is stable and not easy to deform.
[0048] Step 3: The wear-resistant layer made of polyethylene or polyvinyl chloride is affixed onto the waterproof layer by hot melt adhesive at the temperature of at least 182 degrees C., where the upper surface of said wear-resistant layer is coated with wax or paint, the thickness of the wear-resistant layer is 0.085 mm-0.5 mm;
[0049] Step 4: Finish the tongue-and-groove processing and the Tu-edge processing of the waterproof board, i.e. setting the grooves 5 and tenons 6 on both sides of the waterproof board respectively.
[0050] The waterproof board is made according to the waterproof board manufacturing method. The following examples 2, 3 and 4, have the wear-resistant layer 1 and waterproof layer 3 made of same materials, and the groove 5 and tenon 6 that have the same structure of that in Example 1.
Example 2
[0051] As shown in FIG. 2 , the waterproof board in this invention comprises: the wear-resistant layer 1 , the decorative layer 2 , the waterproof layer 3 , and the groove 5 and the tenon 6 respectively arranged on both sides of the board. Said decorative layer 2 is set between the wear-resistant layer 1 and the waterproof layer 3 , the wear-resistant layer 1 and said decorative layer 2 are hot-pressed into one, and then affixed onto said waterproof layer 3 via bonding ways like hot melt adhesive. Said decorative layer 2 can be the tile veneer or stone veneer or rubber veneer or decorative plastic veneer or linoleum veneer or decorative vinyl veneer, which is not only beautiful but also waterproof. The profiles of groove 5 and tenon 6 can be matched to form a fixation-connection between the adjacent boards. The fixation-connection can be mechanically clamping in a locking form or fastening with glue and other chemical methods.
[0052] The manufacturing process of the waterproof board: Step 1: Put the industrial waste containing the bamboo or wood components in the extruder to obtain the bamboo-wood powder, which is the bamboo powder, or wood powder or a mixture of both. The bamboo-wood powder is mixed with the resin. In general, it is more difficult for the bamboo powder extrusion than that of the wood powder. During the extrusion process, the bamboo powders cannot be extruded in one step and multiple extrusions are required. For example, each time the bamboo powder accounting for at most 5%-8% of the total mass of the extrusion materials can be extruded, the first 7% of the bamboo powder extruded is mixed with the resin, and another 7% of bamboo powder is added in the second time. It roughly needs 6 times for you to reach the required 40% of bamboo-wood powder. When 8% of the bamboo powder is extruded each time, you need to extrude 3 times to reach 20% of the bamboo-wood powder required. So, at least 3 times for bamboo power extrusion is required, making the final mass of the bamboo-wood powder account for 20%-40% of the total mass of the extrusion materials and the resin account for 30%-40% of the total mass of the extrusion materials.
[0053] Step 2: Said mixture of the bamboo-wood powder and resin added with additives such as the stone powder and talcum powder can be blended and modified in a blending machine, and then adding the foaming agent into the machine. Said bamboo-wood powder, said resin, said additives and said foaming agents constitute the extrusion materials. Said foaming agents can be soda or calcium bicarbonate. The extrusion materials in the extruder are extruded into the waterproof layer via hot pressing under the temperature of 162 degrees C.-172 degrees C., and pressure of 20 Mpa-25 Mpa. The gas evaporates after foaming; the volume of the waterproof layer gets larger and its thickness is about 3.8 mm-18.8 mm, while its density is minimized to about 0.60 kg/cm 3 -0.95 kg/cm 3 . In order to improve the forming rate of the waterproof board, especially the forming rate after adding the bamboo powder, the forming agent additives shall be added, or the processing temperature and extrusion pressure etc. shall be increased. With the increment of the process temperature, the water-swelling rate of the waterproof layer is decreased, and the internal bonding strength of the waterproof layer is improved, the static bending strength and the elastic modulus are improved, and the waterproof layer is stable and not easy to deform.
[0054] Step 3: the wear-resistant layer made of polyethylene or polyvinyl chloride is affixed onto the decorative layer made of the tile veneer or stone veneer or rubber veneer or decorative plastic veneer or linoleum veneer or decorative vinyl veneer by hot melt adhesive at the temperature of 200-220 degrees C., the pressure of 22-24 Mpa. The upper surface of said wear-resistant layer is coated with wax or paint, the thickness of the wear-resistant layer is 0.085 mm-0.5 mm; the thickness of the decorative layer is 0.02 mm-0.08 mm.
[0055] Step 4: Said decorative layer is affixed onto the waterproof layer by hot melt adhesive at the temperature of at least 182 degrees C.
[0056] Step 5: Finish the tongue-and-groove processing and the Tu-edge processing of the waterproof board, i.e. setting the grooves 5 and tenons 6 on both sides of the waterproof board respectively.
Example 3
[0057] As shown in FIG. 3 , the waterproof board in this invention comprises: the wear-resistant layer 1 , the waterproof layer 3 , bottom layer 4 and groove 5 and tenon 6 respectively arranged on both sides of the board. Said waterproof layer 3 is set between the wear-resistant layer 1 and the bottom layer 4 . The wear-resistant layer 1 is affixed onto the waterproof layer 3 by bonding ways like hot melt adhesive, and said waterproof layer 3 is affixed onto said bottom layer 4 via bonding ways as hot melt adhesive. Said decorative layer 2 can be the tile veneer or stone veneer or rubber veneer or decorative plastic veneer or linoleum veneer or decorative vinyl veneer, which is not only beautiful but also waterproof. Said bottom layer 4 can be soft wood or rubber materials. The profile of groove 5 and tenon 6 can be matched to form a fixation-connection between the adjacent boards. The fixation-connection can be mechanically clamping in a locking form or fastening with glue and other chemical methods.
[0058] The manufacturing process of the waterproof board: Step 1: Put the industrial waste containing the bamboo or wood components in the extruder to obtain the bamboo-wood powder, which is the bamboo powder, or wood powder or a mixture of both; the bamboo-wood powder is mixed with the resin. In general, it is more difficult for the bamboo powder extrusion than that of the wood powder. During the extrusion process, the bamboo powder cannot be extruded in one step and multiple extrusions are required. Each time the bamboo powder accounting for at most 5%-8% of the total mass of the extrusion materials can be extruded. The first 7% of the bamboo powder extruded is mixed with the resin, and another 7% of bamboo powder is added in the second time. It roughly needs 6 times for you to reach the required 40% of bamboo-wood powder. When 8% of the bamboo powder is extruded each time, you need to extrude at 3 times to reach 20% of the bamboo-wood powder required. So, at least 3 times for bamboo power extrusion is required, making the final mass of the bamboo-wood powder account for 20%-40% of the total mass of the extrusion materials and the resin account for 30%-40% of the total mass of the extrusion materials.
[0059] Step 2: Said mixture of the bamboo-wood powder and resin added with additives such as the stone powder and talcum powder can be blended and modified in a blending machine, and then adding the foaming agent into the machine. Said bamboo-wood powder, said resin, said additives and said foaming agents constitute the extrusion materials. Said foaming agents can be soda or calcium bicarbonate. The extrusion materials in the extruder are extruded into the waterproof layer via hot pressing under the temperature of 162 degrees C.-172 degrees C., and pressure of 20 Mpa-25 Mpa. The gas evaporates after foaming, the volume of the waterproof layer gets larger and its thickness is about 3.8 mm-18.8 mm, while its density is minimized to about 0.60 kg/cm 3 -0.95 kg/cm 3 . In order to improve the forming rate of the waterproof board, especially the forming rate after adding the bamboo powder, the forming agent additives shall be added, or the processing temperature and extrusion pressure etc. shall be increased. With the increment of the process temperature, the water-swelling rate of the waterproof layer is decreased, and the internal bonding strength of the waterproof layer is improved, the static bending strength and the elastic modulus are improved, and the waterproof layer is stable and not easy to deform.
[0060] Step 3: the wear-resistant layer made of polyethylene or polyvinyl chloride is affixed onto the waterproof layer at the temperature of at least 182 degrees C. via hot melt adhesive. The upper surface of said wear-resistant layer is coated with wax or paint. The thickness of the wear-resistant layer is 0.085 mm-0.5 mm.
[0061] Step 4: Said waterproof layer is affixed onto the bottom layer by hot melt adhesive at a temperature of 183-193 degrees C. The thickness of said bottom layer is 1.2 mm-2.6 mm.
[0062] Step 5: Finish the tongue-and-groove processing and the Tu-edge processing of the waterproof board, i.e. setting the grooves 5 and tenons 6 on both sides of the waterproof board respectively.
Example 4
[0063] As shown in FIG. 4 , this invention comprises: the wear-resistant layer 1 , the decorative layer 2 , the waterproof layer 3 , the bottom layer 4 , and the groove 5 and the tenon 6 arranged respectively on both sides of the board. Said decorative layer 2 is set between the wear-resistant layer 1 and the waterproof layer 3 , and said bottom layer 4 is set under the waterproof layer 3 . Said wear-resistant layer 1 and said decorative layer 2 are pressed into one via hot pressing, and then affixed onto said waterproof layer 3 via bonding ways like hot melt adhesive. Said wear-resistant layer 1 , said decorative layer 2 and said waterproof layer 3 bonded together into one part, which is affixed onto the bottom layer 4 via bonding ways like hot melt adhesive. Said decorative layer 2 can be the tile veneer or stone veneer or rubber veneer or decorative plastic veneer or linoleum veneer or decorative vinyl veneer, which is not only beautiful but also waterproof. Said bottom layer 4 can be soft wood or rubber materials. The profile of groove 5 and tenon 6 can be matched to form a fixation-connection between the adjacent boards. The fixation-connection can be mechanically clamping in a locking form or fastening with glue and other chemical methods.
[0064] The manufacturing process of the waterproof board: Step 1: Put the industrial waste containing the bamboo or wood components in the extruder to obtain the bamboo-wood powder, which is the bamboo powder, or wood powder or a mixture of both; the bamboo-wood powder is mixed with the resin. In general, it is more difficult for the bamboo powder extrusion than that of the wood powder. During the extrusion process, the bamboo powder cannot be extruded in one step and multiple extrusions are required. Each time the bamboo powder accounting for at most 5%-8% of the total mass of the extrusion materials can be extruded. The first 7% of the bamboo powder extruded is mixed with the resin, and another 7% of bamboo powder is added in the second time. It roughly needs 6 times for you to reach the required 40% of bamboo-wood powder; when 8% of the bamboo powder is extruded each time. You need to extrude 3 times to reach 20% of the bamboo-wood powder required. So, at least 3 times for bamboo power extrusion is required, making the final mass of the bamboo-wood powder account for 20%-40% of the total mass of the extrusion materials and the resin account for 30%-40% of the total mass of the extrusion materials.
[0065] Step 2: Said mixture of the bamboo-wood powder and resin added with additives such as the stone powder and talcum powder can be blended and modified in a blending machine, and then adding the foaming agents into the machine. Said bamboo-wood powder, said resin, said additives and said foaming agents constitute the extrusion materials. Said foaming agents can be soda or calcium bicarbonate. The extrusion materials in the extruder are extruded into the waterproof layer via hot pressing under the temperature of 162 degrees C.-172 degrees C., and pressure of 20 Mpa-25 Mpa. The gas evaporates after foaming, the volume of the waterproof layer gets larger and its thickness is about 3.8 mm-18.8 mm, while its density is minimized to about 0.60 kg/cm 3 -0.95 kg/cm 3 . In order to improve the forming rate of the waterproof board, especially the forming rate after adding the bamboo powder, the forming agent additives shall be added, or the processing temperature and extrusion pressure etc. shall be increased. With the increment of the process temperature, the water-swelling rate of the waterproof layer is decreased, and the internal bonding strength of the waterproof layer is improved, the static bending strength and the elastic modulus are improved, and the waterproof layer is stable and not easy to deform.
[0066] Step 3: The wear-resistant layer made of polyethylene or polyvinyl chloride is hot-pressed onto the decorative layer made of the tile veneer or stone veneer or rubber veneer or decorative plastic veneer or linoleum veneer or decorative vinyl veneer at the temperature of 200-220 degrees C., the pressure of 22-24 Mpa. The upper surface of said wear-resistant layer is coated with wax or paint. The thickness of the wear-resistant layer is 0.085 mm-0.5 mm and the thickness of the decorative layer is 0.02 mm-0.08 mm.
[0067] Step 4: Said decorative layer is affixed onto the waterproof layer by hot melt adhesive at a temperature of at least 182 degrees C.
[0068] Step 5: Said waterproof layer is affixed onto the bottom layer by hot melt adhesive at a temperature of 183-193 degrees C. The thickness of said bottom layer is 1.2 mm-2.6 mm.
[0069] Step 6: Finish the tongue-and-groove processing and the Tu-edge processing of the waterproof board, i.e. setting the groove 5 and tenon 6 on both sides of the waterproof board respectively.
[0070] The examples described above are only a description of the preferred embodiments of the invention, and not limited to the conception and scope of the invention. Under the premise of not separating from the conception design of the invention, various variants and refinements made on technical scheme of the invention by the general staff of the field, shall be in the scope of protection of the invention, the technology contents requesting protection in the invention, have all recorded in the claims.
|
The present invention relates to a waterproof board and its manufacturing method, belongs to the technical field of floorboard and wallboards. The waterproof board includes waterproof layer and wear-resistant layer and the groove and ten on arranged on both side of said board respectively. Said wear-resistant layer is affixed onto said waterproof layer and said waterproof layer is made of the extrusion materials mainly including the resin and bamboo powder. The density of said waterproof layer is 0.60 kg/cm 3 -0.95 kg/cm 3 . The board of present invention is featured of high strength, good tensile strength, not easy to break; low water absorption rate, good waterproof performance; strong stability, less susceptible to deform due to changes in temperature or water immersion; light weight, more comfortable tactility, and further decreasing the material and transportation costs.
| 4
|
CROSS REFERENCE TO RELATED APPLICATION
This application claims benefit under 35 USC §119(e) of U.S. Provisional Patent Application Ser. No. 61/101,049 filed 29 Sep. 2008, which application is hereby incorporated fully by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fabric systems, and more specifically to bed coverings constructed of high gauge circular knitted fabrics that accommodate and maintain optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper, more restorative sleep.
2. Description of Related Art
Sleep problems in the United States are remarkably widespread, affecting roughly three out of four American adults, according to research by the National Sleep Foundation (NSF). Consequently, a great deal of attention has been paid to the circumstances surrounding poor sleep, along with strategies for how to improve it.
The implications are not merely academic. Sleep—not only the right amount of it but also the right quality—impacts not just day-to-day performance, but also “the overall quality of our lives,” according to the NSF. Addressing the causes of poor quality sleep, therefore, has ramifications for millions.
Though many factors contribute to sleep quality, the sleep environment itself plays a critical role, and sleep researchers routinely highlight temperature as one of the most important components in creating an environment for optimal sleep. As advised by the University of Maryland Medical Center, “a cool (not cold) bedroom is often the most conducive to sleep.” The National Sleep Foundation further notes that “temperatures above 75 degrees Fahrenheit and below 54 degrees will disrupt sleep,” with 65 degrees being the ideal sleep temperature for most individuals, according to the NSF.
A lower environmental temperature is not the only thermal factor associated with improved sleep. Researchers have noted a nightly drop in body temperature among healthy, normal adults during sleep. This natural cycle, when inhibited or not functioning properly, can disrupt sleep and delay sleep onset, according to medical researchers at Cornell University. Conversely, the researchers noted, a rapid decline in body temperature not only accelerates sleep onset but also “may facilitate an entry into the deeper stages of sleep.”
Therefore, maintaining an appropriately cool sleep environment and accommodating the body's natural tendency to cool itself at night should be a top priority for individuals interested in optimizing their sleep quality. Performance fabrics crafted into bedding applications would be uniquely capable of promoting cool, comfortable—and therefore better—sleep, as these advanced fabrics maximize breathability and heat transfer. Performance fabrics are made for a variety of end-use applications, and can provide multiple functional qualities, such as moisture management, UV protection, anti-microbial, thermo-regulation, and wind/water resistance.
There has been a long felt need in several industries to provide improved bedding to help individuals get better sleep. Such improved bedding would include beneficial wicking among other properties. For example, in marine, boating and recreational vehicle applications, bedding should resist moisture, fit odd-shaped mattresses and beds, and reduce mildew. Particularly with watercraft, there is a need to protect bedding, and specifically sheets, from moisture and mildew accumulation.
An additional problem with bedding, not just with marine and recreational vehicles, is the sticky, wet feeling that can occur when the bedding sheets are wet due to body sweat, environmental moisture, or other bodily fluids. In particular, when bedding is used during hot weather, or is continuously used for a long time by a person suffering from an illness, problems can arise in that the conventional bed sheet of cotton fiber or the like cannot sufficiently absorb the moisture. All of these issues lead to poor sleep.
To date, performance fabric bedding products are not known. There are width limitations in the manufacturing of high gauge circular knit fabrics, because the finished width of bedding fabrics are dictated by the machine used in its construction. At present, performance fabrics are manufactured with a maximum width of under 90 inches wide, given present manufacturing and technical limitations, along with the inability of alternate manufacturing processes to produce a fabric with identical performance attributes. Yet, normal bed sheet panels can be 102 by 91 inches or larger. Thus, performance fabrics cannot yet be used for bed sheets.
Some conventional solutions for the above issues that hinder a good night's sleep include U.S. Pat. No. 4,648,186, which discloses an absorbent wood pulp cellulose fiber that is provided in a variety of sizes and is placed under a mattress. The wood pulp is water absorbent and acts to capture moisture to prevent such moisture from being retained by the bedding or the bedding sheets. However, this proposed solution does not interact with the bedding or the bedding sheets, but merely acts as a sponge for moisture that is in proximity to the target bedding.
U.S. Pat. No. 5,092,088 discloses a sheet-like mat comprised of a mat cover, the inside of which is divided into a plurality of bag-like spaces, and a drying agent packed into a bag and contained in the bag-like spaces in such a manner that the drying agent cannot fall out of the bag-like spaces. A magnesium sulfate, a high polymer absorbent, a silica gel or the like can be used as the drying agent. As can be seen, this proposed solution to moisture in bedding is cumbersome and chemically-based.
In the athletic apparel industry, moisture wicking fabric has been used to construct athletic apparel. For example, U.S. Pat. No. 5,636,380 discloses a base fabric of CoolmaxQ high moisture evaporation fabric having one or more insulating panels of ThermaxB or ThermastatQ hollow core fiber fabric having moisture wicking capability and applied to the inner side of the garment for skin contact at selected areas of the body where muscle protection is desired. However, this application cannot be applied to bedding sheets due to the limitations of the size of the performance fabrics manufactured. Further, performance fabric such as this type cannot be easily stitched together as the denier is so fine that stitching this fabric results in the stitching simply falling apart.
Circular knitting is typically used for athletic apparel. The process includes circularly knitting yarns into fabrics. Circular knitting is a form of weft knitting where the knitting needles are organized into a circular knitting bed. A cylinder rotates and interacts with a cam to move the needles reciprocally for knitting action. The yarns to be knitted are fed from packages to a carrier plate that directs the yarn strands to the needles. The circular fabric emerges from the knitting needles in a tubular form through the center of the cylinder. This process is described in U.S. Pat. No. 7,117,695. However, the machinery presently available for this method of manufacture can only produce a fabric with a maximum width of approximately 90 inches. Therefore, this process has not been known to manufacture sheets, since sheets can have dimensions of 91 inches by 102 inches or greater.
Further, the machinery that is used for bedding is very different than for athletic wear. For example, bedding manufacturing equipment is not equipped to sew flatlock stitching or to provide circular knitting. Bed sheets typically are knit using a process known as warp knitting, a process capable of producing finished fabrics in the widths required for bedding. This method, however, cannot be employed to produce high-quality performance fabrics. Warp knitting is not capable of reproducing these fabrics' fine tactile qualities nor their omni-direction stretch properties, for example.
Circular knitting must be employed to produce a performance fabric that retains these fabric's full range of benefits and advantages. However, in order to produce a fabric of the proper width for bedding applications, a circular knit machine of at least 48 inches in diameter would be necessary. Manufacturing limitations therefore preclude the construction of performance fabrics at proper widths for bedding. The industry is unsure if it could actually knit and then finish performance fabrics at these large sizes, even if the machinery were readily available.
Further, athletic sewing factories are typically not equipped to sew and handle large pieces of fabrics so that equipment limitations do not allow for the manufacture of bedding sheets.
What is needed, therefore, is a bedding system that utilizes performance fabrics and their beneficial properties, the design of which acknowledges and addresses limitations in the manufacture of these fabrics. It is to such a system that the present invention is primarily directed.
BRIEF SUMMARY OF THE INVENTION
Briefly described, in preferred form, the present invention is a high gauge circular knit fabric for use in bedding, and a method for manufacturing such bedding. The bedding fabric has superior performance properties, while allowing for manufacture by machinery presently available and in use. In order to achieve a finished width of the size needed to create sheet-sized performance fabric, a high gauge circular knit machine of at least 48 inches in diameter is necessary. And while warp knitting machines are available that can produce wider fabrics, this method will not provide a fabric with the tactile qualities required, nor provide a fabric with omni-directional stretch.
In an exemplary embodiment, the present invention is a method of making a finished fabric comprising at least two discrete performance fabric portions, and joining at least two discrete performance fabric portions to form the finished fabric. Forming the at least two discrete performance fabric portions can comprise knitting at least two discrete performance fabric portions, and more preferably, circular knitting at least two discrete performance fabric portions. Joining the at least two discrete performance fabric portions to form the finished fabric can comprise stitching at least two discrete performance fabric portions together to form the finished fabric.
The at least two discrete performance fabric portions can have different fabric characteristics. Fabric characteristics as used herein include, among other things, moisture management, UV protection, anti-microbial, thermo-regulation, wind resistance and water resistance.
The finished fabric can be used in, among other applications, residential settings, or in marine, boating and recreational vehicle environments.
The present sheets offer enhanced drape and comfort compared to traditional cotton bedding, and are as fine as silk, yet provide the benefits of high elasticity and recovery along with superior breathability, body-heat transport, and moisture management as compared to traditional cotton bedding.
Conventional fitted sheets can bunch and slide on standard mattress sizes. Furthermore, if the fitted bed sheets do not fit properly, they do not provide a smooth surface to lie on. The present invention overcomes these issues.
The present high gauge circular knit fabrics stretch to fit and offer superior recovery on the mattress allowing the fabric to conform to fit the mattress without popping off the corners of the mattress or billowing. The performance fabric can include spandex, offers a better fit than conventional bedding products, can accommodate larger or smaller mattress sizes with a single size sheet, and can conform to mattresses with various odd dimensions.
Spandex—or elastane—is a synthetic fiber known for its exceptional elasticity. It is stronger and more durable than rubber, its major non-synthetic competitor. It is a polyurethane-polyurea copolymer that was invented by DuPont. “Spandex” is a generic name, and an anagram of the word “expands.” “Spandex” is the preferred name in North America; elsewhere it is referred to as “elastane.” The most famous brand name associated with spandex is Lycra, a trademark of Invista.
The present high gauge circular knit fabric offers durability in reduced pilling and pulling when compared to other knit technologies, and offer reduced wrinkles and enhanced color steadfastness
In a preferred embodiment, the present performance fabric can allow for a one-size fitted sheet that can actually fit two different size mattresses. For example, the full fitted sheet of the present invention can fit on both the full and queen size bed. The twin fitted sheet of the present invention will also fit an XL twin. In a boating application, the present invention can be produced to fit almost every custom boat mattress.
Testing of the present invention conducted at the North Carolina State University (NCSU) Center for Research on Textile Protection and Comfort confirms that the present performance fabrics provide a cooler sleeping environment than cotton. Performance bedding was tested side-by-side with commercially available cotton bed sheets in a series of procedures designed to measure each product's heat- and moisture-transport properties, as well as warm/cool-to-touch thermal transport capabilities.
Across all tests, the present performance fabrics in bedding outperformed cotton, demonstrating the performance fabric's superiority in establishing and maintaining thermal comfort during sleep. This advantage is evident to users from the very onset, as NCSU testing indicates that, on average, performance bedding of the present invention offers improved heat transfer upon initial contact with the skin, resulting in a cooler-to-the-touch feeling.
During sleep, high gauge circular knit performance bedding of the present invention helps to maintain thermal comfort by trapping less body heat and breathing better than cotton. Testing has demonstrated that performance bedding made out of performance fabrics transfers heat away from the body up to two times more effectively than cotton. This is critically important not only for sustained comfort during sleep, but also in terms of enabling the body to cool itself as rapidly as possible to facilitate sleep onset. In addition to trapping less heat, performance bedding breathes better than cotton—up to 50% better, giving performance bedding a strong advantage in terms of ventilation and heat and moisture transfer.
The performance advantage over cotton holds true for simulated dry and wet skin conditions, confirming that certain performance fabrics in bedding are better suited than cotton at managing moisture (e.g., sweat) to maintain thermal comfort. In addition to wicking moisture away from the skin through capillary action, the performance fabric's advanced breathability further enables heat and moisture transfer through evaporative cooling. As a result, the user is kept cooler, drier and more comfortable than with cotton.
The present performance bedding holds a distinct advantage over cotton in enabling, accommodating and maintaining optimum thermal conditions for sleep, which in turn can lead to faster sleep initiation and deeper, more restorative sleep.
These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates a preferred embodiment of the present invention.
FIG. 2 illustrates another preferred embodiment of the present invention.
FIG. 3A illustrates a further preferred embodiment of the present invention.
FIG. 3B illustrates pull ties useful with a preferred embodiment of the present invention.
FIG. 3C illustrates a cinched pull tie of FIG. 3B .
FIGS. 3D-3E illustrate stitching embodiments useful for securing portions of the present invention together.
FIG. 4 illustrates another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Although preferred embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the preferred embodiments, specific terminology will be resorted to for the sake of clarity.
It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. For example, reference to a sheet or portion is intended also to include the manufacturing of a plurality of sheets or portions. References to a sheet containing “a” constituent is intended to include other constituents in addition to the one named.
Also, in describing the preferred embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value.
By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.
It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a fabric or system does not preclude the presence of additional components or intervening components between those components expressly identified.
Referring now in detail to the drawing figures, wherein like reference numerals represent like parts throughout the several views, the present invention of FIGS. 1 and 4 provides a sheet 10 shown having dimensions of 102 inches in length and 91 inches in width. The material is manufactured from performance fabric, which can include, for example, varying amounts of one or more of Lycra, Coolmax, Thermax and Thermastat. In a preferred embodiment, the fabric is treated so that the fabric has antimicrobial properties. By using circular-knit performance fabric, the fabric is able to provide elasticity in all four directions. This property allows for the sheet to fit extraordinary mattress, cushion and bedding shapes, as well as providing better fits for traditional rectangular sheets. By using performance fabrics, the sheet has elastic properties that allow stretching in the directions shown as 30 . In addition, by using circular-knit performance fabric, the resulting bedding retains an exceptionally fine tactile quality critical for providing maximum levels of enhanced comfort.
An alternative to circular knitting is non-circular knitting—for example, warp knitting. This method can achieve widths greater than circular knitting. Industrial warp knit machines, for example, can produce tricote warp knit fabrics up to 130-140 inches in width. Circular knitting, however, is less expensive, as it requires less set-up time. Circular knitting also provides greater multidirectional stretch.
In order to provide a sheet that exceeds the maximum dimensions of fabric that can be produced by available circular knitting machines, flat lock stitching 12 is used to join a plurality of portions resulting in a sheet that is 91 inches wide (as shown). In an exemplary embodiment, piping 11 can be included in close proximity to the stitching. The stitching can be the same color as the fabric of the sheet portions, or different color(s). The piping can be ¾ inch straight piping without a cord or other filler. In one preferred embodiment, the stitching is 16 stitches per inch. Piping 11 can be included at one end of the sheet and can be the same or a different color as the sheet fabric.
For a fitted sheet, the sheet can include an elastic portion surrounding the edge of the fitted sheet to better keep the fitted sheet in place when placed on a mattress or other sleeping surface. A cord can be sewn into the edge of the fitted sheet and cinched around the mattress or other sleeping surface to better hold the fitted sheet in place.
Referring to FIG. 2 , a sheet is shown having dimensions of 91 inches wide and 102 inches in length. In this embodiment, stitching 14 is shown 34 inches from an interior edge 18 of a main portion 16 and another stitch 14 at edge 20 of the sewn-on portion. Flat lock stitching can be used for the stitching. Piping can be applied at or in proximity to the stitching.
Referring to FIGS. 3A-E , a non-rectangular shaped sheet is shown in FIG. 3A . In this exemplary embodiment, elastic can be included around the edge of the fitted sheet to better maintain the fitted sheet in position when placed on a sleeping surface. In one embodiment, pull ties 24 ( FIG. 3B ) can be installed at various locations around the edge of the fitted sheet in order to assist in maintaining the fitted sheet secured to the sleeping surface. The pull tie can be cinched to increase tension around the edge of the fitted sheet as shown by 26 ( FIG. 3C ).
Stitching used for securing the portions of the sheet together can include that shown in FIGS. 3D-3E , for example as 28 a . In another embodiment, the stitching used for securing the portion of fabric together is shown as 28 b .
Referring to FIG. 4 , yet another preferred embodiment of the invention is shown. In this embodiment, the sheet can be assembled through stitching of differing fabrics for generating performance zones in the sheet. For example, zone 32 can have higher wicking properties than the other zones since this area is where the majority of the individual body rests. Areas 34 a through 34 d can have higher spandex or other elastic fabric properties so that the fit around a sleeping surface is improved. Area 36 may have thermal properties such as increased cooling since this area is generally where the individual's head lies. In an exemplary embodiment, the pillow covers of pillows used by the individual also have differing properties from the remainder of the sheet, e.g., thermal properties.
The present invention encompasses the construction of bedding materials that have superior performance properties while allowing for manufacture by machinery presently available and in use. More specifically, the invention is related to a new method for fabricating a covering and or sheets in bedding. When using the circular knitting machine, the high gauge performance fabrics can only be made to a maximum size of 72.5 inches without losing the integrity of the spandex in the fabric. Yet, normal sheet panels are 102×91 inches. This presents problems when manufacturing sheets from performance fabrics.
Additionally, special stitching techniques must be used given the thread density of the fabric. Using this special stitching, panels are sewn together to produce bedding or a sheet that is the proper size for standard bed sheets. Because discrete portions/panels are used in the manufacture of the present fabrics, panels can be selected that provide different properties for different areas of the bedding ( FIG. 4 ). Stitching or seams on the sheet can also allow for the ease of making the bed. Because the bedding is made from performance fabric with spandex, it stretches to permit multiple and custom sizing for applications in cribs, recreational vehicles and boats.
Circular knitting machines used for high gauge performance bedding fabrics are called high-gauge circular knitting machines, because of dense knitting with thin yarn. High gauge generally denotes 17 gauges or more. Seventeen gauges indicate that 17 or more cylinder needles are contained in one inch. Circular knitting machines of less than 17 gauges are referred to as low-gauge circular knitting machines. The low-gauge circular knitting machines are often used to knit outerwear.
“Yarn count” indicates the linear density (yarn diameter or fineness) to which that particular yarn has been spun. The choice of yarn count is restricted by the type of knitting machine employed and the knitting construction. The yarn count, in turn, influences the cost, weight, opacity, hand and drape of the resulting knitted structure. In general, staple spun yarns tend to be comparatively more expensive the finer their count, because finer fibers and a more exacting spinning process are necessary in order to prevent the yarn from showing an irregular appearance.
A top width in the 90-inch range is currently possible using a circular knit fabric formed on a 36-38-inch diameter machine, although higher levels of spandex in the performance fabric tend to pull the width in. In just one example, on a 30-inch diameter machine, the spandex can reduce an otherwise 94-inch circumference fabric tube to one with a 60-65 inch finished width.
A major limitation in finished width is not strictly a knitting concern but also concerns finishing. With performance fabric, it tends to sag in the middle—increasingly so with greater widths—making finishing difficult to impossible above a certain threshold. A possible 90-inch finished width is contingent upon having a good finishing set-up capable of handling the present performance fabric. This potential for difficulties would only become compounded at the larger widths required for bed sheets.
In a preferred process, the present fabric undergoes a heat setting finishing process. Applying a moisture-wicking finish to another fabric—like cotton—that can be produced at larger widths appears unlikely to match the moisture-control properties of the present fabric, as polyester itself is naturally moisture-resistant and there are physical actions (e.g. capillary action) at play. Further, the use of cotton comes at the expense of breathability and heat-transfer capabilities (as confirmed by laboratory testing) and stretchability.
Numerous characteristics and advantages have been set forth in the foregoing description, together with details of structure and function. While the invention has been disclosed in several forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions, especially in matters of shape, size, and arrangement of parts, can be made therein without departing from the spirit and scope of the invention and its equivalents as set forth in the following claims. Therefore, other modifications or embodiments as may be suggested by the teachings herein are particularly reserved as they fall within the breadth and scope of the claims here appended.
|
Bedding material including a first fabric section manufactured from performance fabric and having a first and second side; and, a second fabric section attached to the first side of the first fabric section. Additionally, a third fabric section can be attached to the second side of the first fabric section. The first fabric section can be attached to the second fabric section through a flatlock stitch. The first fabric section can include a first zone and a second zone wherein the first zone contains different performance properties from the second zone and the first zone can have thermal or moisture wicking properties.
| 3
|
FIELD OF THE INVENTION
This invention relates to telecommunications apparatus and methods. More particularly, this invention relates to apparatus and methods for transmitting signals (specifically signals with information or a data content) in multiple different formats.
RELATED ART
The formats may simply be alternative technical representations of the same information; for example, different graphics formats. Alternatively, each format may be in a different medium; for example, image, text and audio formats. Further, the formats may represent something of the same information content but using different volumes of data; for example, a text file and a facsimile image made up of the characters of the text represent different formats for the same text information.
In conventional telecommunications, a given user is associated with a given telecommunications terminal (e.g. a conventional telephone, or a computer with a modem, or a facsimile unit). However, more recently, users have become mobile. In addition to mobile telephones (for example digital cellular telephones such as those conforming to the GSM standard) other types of portable terminal include pagers (either tone pagers or message pagers which can receive short textual messages and display them); so called “personal digital assistants” (PDA's) and portable facsimile or computer units adapted to communicate via cellular networks using dedicated modems.
At the same time, the volume of different types of formats within which information can be transmitted is increasing, and new, so called “multi-media” formats, consisting of single sets of information presented in multiple media (such as for example image, text and audio files) are entering use.
The telecommunications channels through which information is delivered comprise channels of varying bandwidth, including optical fibre links; coaxial copper links; conventional subscriber telephone lines; infra-red local area networks; and radio transmission channels. Of these, radio frequency channels are used for mobile communications. However, radio frequency channels generally have available the lowest bandwidth due to demands on the RF spectrum and to the channel conditions within the RF spectrum.
It is becoming increasingly common for large organisations to provide local area networks within a building or group of buildings, at which a number of different terminals of different types are provided. For example, powerful workstations such as Sun (TM) workstations, may be connected on the same network as less powerful personal computers, advanced telephones, and conventional telephones. Depending on the access conditions, different users may have access to a number of different terminals within such a network, each with different capabilities of receiving information in different formats.
Various prior proposals have been made to attempt to meet the needs of mobile users dealing with data in different formats. For example, our earlier application WO 95/30317 (U.S. application Ser. No. 08/732,321 filed Jan. 22, 1997)describes an “agent based” telecommunications system in which the position of a mobile user is tracked and, when he is in a cell which permits only low bandwidth information transfer, the incoming signal is either cached for later retrieval or the link is down graded (e.g. from video to voice).
Similarly, the article “The network with smarts, new agent—based WANs presage the future of connected computing”, Andy Reinhardt, BYTE October 1994, pages 51-64, describes the proposed IBM ‘Intelligent Communications’ service (apparently intended to be marketed in late 1995) which allows a user to set up a routing profile so that when a fax is received for the user it may be converted to text using optical character recognition, and then converted to speech and read into a voice mailbox.
Our earlier application WO 95/15635 (U.S. application Ser. No. 08/652,433 filed Nov. 1, 1996), describes an agent based telecommunications system for use in a multiple services network.
Our earlier application WO 96/25012 (U.S. application Ser. No. 08/875,890, filed Oct. 14, 1997) describes a multimedia telecommunications system employing reconfigurable agents. Aspects of this document are incorporated by reference herein.
Our earlier international application WO 94/28683 (U.S. application Ser. No. 08/233,631 filed Apr. 26, 1994, now U.S. Pat. No. 5,802,502 issued Sep. 1, 1998) includes an embodiment in which, within a single network, parts of the network set up a service by obtaining prices from other parts of the network. Thus, when a user desires to transmit through the network, he polls a first part of the network, and which polls further downstream parts of the network, and so on, each part of the network then transmitting back a price. Whilst this arrangement is suitable in many applications, as networks grow in size the amount of signalling generated within the network may be substantial.
U.S. Pat. No. 5,446,553 (Motorola) discloses a fax messaging system in which, when a user is unavailable, incoming messages are stored for later access.
According to the invention we provide a telecommunications system which routes messages therethrough, in which bidding takes place in two stages; a first stage in which an estimated bid is made prior to derivation of the route, and, if accepted, a second stage in which the route is set up by a further bidding process. This has the advantage of reducing the number of bidding (and therefore signalling) entities at any time whilst maintaining a reasonable response time in setting up the route.
Furthermore, in a preferred embodiment, multiple passes may be employed corresponding to successive layers of a hierarchical organisation of bidding entities, those entities in the middle layers acting as resource suppliers to entities in layers above them and as resource purchasers to entities in layers below them. This enables further increases in the size of the network without vastly increasing the volume of signalling traffic across the network, particularly if (as preferred) the entities in each layer are geographically distributed.
For example, the arrangement adopted may consist of an entity storing data relating to each customer and arranged to decide whether or not to accept a service on behalf of that customer; a number of service offering entities each of which is arranged to offer a service at a price in the first pass; and, for each service offering entity, a number of resource entities each corresponding to an available network resource (such as a signal format converter or a signal path).
In the preferred embodiment the present invention provides a telecommunication system in which, as in some of the above proposals, a user is tracked, and the identity of a terminal which he may at any time be using is stored. Further, the present invention provides, in one aspect, storage of the capabilities (i.e. formats in which signals can be accepted and/or output) of terminal equipment in the vicinity of the user.
Therefore, rather than attempting (unsuccessfully) to deliver a high bandwidth signal to a low bandwidth mobile terminal, the system of the present invention directs the signal to a nearby terminal which can support a better representation of the signal. The nearby terminal may accent and output the signal in its original form, or the network may convert the signal to a different format which can be accepted by the nearby terminal.
Thus, according to this embodiment of the invention, the network supports a number of different signal format conversions, and is able to choose between the different terminals and associated different format capacities in the neighbourhood of a given mobile user.
It may at this point be mentioned that in so-called ‘Computer-Telephony Integration’ (CTI), it has been proposed to group a computer and a telephone on the same desktop together; to note when a particular user logs onto the computer, and to route all that user's telephone calls to the telephone with which the computer shares a desktop, thus effectively tying together a particular telephone and a particular computer in a pair.
This differs fundamentally from the above embodiment, in which the nature of each terminal in an area is stored and a given terminal is selected depending on the format of the input signal.
For this aspect of the invention to be useful, the signal must not be delivered to a terminal which is too distant to the user. Accordingly, the system must maintain accurate information of a large number of terminals, so as to establish a “communications neighbourhood” around any position at which a mobile user might be located. Thus, fairly frequent position update messages tracking the position of the user, and terminal update messages tracking changes to the capabilities of the terminals may take place.
In order to avoid the possibility of such messages swamping the signalling capacity of the network, in a preferred embodiment the present invention provides for a hierarchical arrangement of location data storage, with distributed local databases (e.g. one per LAN, or one per building, or one per cell, microcell or picocell) storing details of the terminals provided therein and the users located close by, and at least one higher layer of databases each covering an area corresponding to plurality of the local databases and containing, for each user within the wider area, a pointer to the local database within which the user is located.
Thus, when a user changes position, the position change signal need be transmitted only as far as the local database within the area in which he moves or, if he changes from the area of one local database to another, to the new local database and to the next database up in the hierarchy containing both local databases. Likewise, changes in terminal equipment need only be signalled within the area of a local database or to the layer above.
Other aspects and embodiments are described below, with advantages which will be apparent hereafter.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be illustrated, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 is a schematic diagram illustrating the physical, or transport, layer of a telecommunications system according to the invention;
FIG. 2 is a schematic block diagram illustrating the components of the network control layer of the system of FIG. 1;
FIG. 3 is a schematic diagram illustrating the components of a position tracking system forming part of FIG. 2 and the logical relationships between them;
FIG. 4 is a schematic diagram showing the elements stored within a local database forming part of FIG. 3 and the logical relationships between them;
FIGS. 5 a to 5 c show schematically the content of records held within the databases of FIG. 3;
FIG. 6 shows schematically the process of obtaining information from the storage system of FIG. 3;
FIG. 7 shows schematically a first process of routing information through the network of FIG. 1 according to an embodiment of the invention;
FIG. 8 (comprising FIGS. 8 a and 8 b ) is a flow diagram showing schematically the process of updating information held within the databases of FIG. 3;
FIG. 9 is a block diagram illustrating the structure of signal format converters comprised within the network of FIG. 1;
FIG. 10 is a schematic diagram showing the software components making up the routing logic of the control layer of FIG. 2;
FIG. 11 shows the structure of a service request record message utilised in setting up a service in this embodiment;
FIG. 12 is a flow diagram showing schematically the process of operation of a customer agent comprised within the embodiment of FIG. 10;
FIG. 13 (comprising FIGS. 13 a and 13 b ) is a flow diagram showing schematically the process performed by a network managing agent forming part of the embodiment of FIG. 10;
FIG. 14 is a flow diagram showing schematically the process performed by a resource agent forming part of the embodiment of FIG. 10;
FIG. 15 is an explanatory diagram showing the distribution of a number of components through which a signal is routed according to the process of FIGS. 12 to 14 ; and
FIG. 16 (comprising FIGS. 16 a and 16 b ) is a flow diagram showing schematically, in greater detail, the process of selection of a route to a terminal forming part of the process of FIG. 13 .
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
General Overview of Physical Layer
Referring to FIG. 1, at the physical or bearer level the telecommunications environment of a user U 1 comprises a cellular telephone T 1 and a personal digital assistant T 2 carried by the user; a facsimile apparatus T 3 and conventional telephone T 4 at a desk a few feet from the user; and a computer workstation T 5 including a modem at a desk top some meters away from the user, all within a single building.
The workstation T 5 in this case comprises a local area network (LAN) server, connected to further terminals T 6 -T 9 (not shown) at different distances from the user.
The various terminals T 1 -T 9 are each capable of receiving different signal formats, as follows:
T 1 —voice or low bit rate data.
T 2 —low bit rate data (receive only).
T 3 —facsimile image signals.
T 4 —narrow bandwidth audio.
T 5 —high bit rate data in various formats.
In communication with the various terminals are a number of different communications channels forming parts of different notional networks (although some or all may be commonly owned).
A public switched telephone network (PSTN) N 1 is connected via a local line L 3 to terminal T 3 , and via local line L 4 to terminal T 4 .
An integrated services digital network (ISDN) N 2 is interconnected with the PSTN N 1 via a gateway G 1 (e.g. a local or international switching centre), and is connected via an ISDN line L 5 to terminal T 5 , and hence to local area network N 3 .
A public land mobile network (PLMN) (e.g. a GSM—compatible digital cellular network) N 4 is connected via a gateway G 2 to the PSTN N 1 and ISDN N 2 . A base station B 1 of the PLMN provides a picocell in the environment of the building within which the user U 1 is located, and a base station B 2 provides a cell within the same general area.
Thus, the networks N 1 -N 4 are capable of delivering data at different rates to the various terminal T 1 -T 9 ; low speed data via the PLMN N 4 , higher speed data via the PSTN N 1 , and yet higher speed data via the ISDN N 2 or LAN N 3 .
The user U 1 carries a tracking device P 1 via which his position within the telecommunications environment may be tracked. For example, in this embodiment the tracking device P 1 comprises a chip carrying card or “smart card” carrying data identifying the user, and some or all of the terminals T 1 -T 9 carrying a card reader arranged to read the card. Alternatively, it could comprise a ‘smart badge’ device, the location of which is tracked within the building.
Specifically, the workstations T 5 -T 9 and the cellular telephone T 1 carry such smart card readers. Additional smart card readers are installed at access doors within the building, and are connected to the LAN N 3 to signal thereon.
Further, preferably, the celiphone T 1 comprises, in addition to cellphone communicating components, a global positioning system (GPS) receiver and is arranged to derive and signal its position periodically as disclosed in EP 0467651 (Motorola).
Thus, the position of the user U 1 is known by one or more of several means; firstly, it is known to which terminal he has logged in by the insertion of his smart card; secondly, the position of his mobile phone is known; and thirdly, his position within the building is known (from the access door system).
General Overview of Control Layer
Referring to FIG. 2, the routing of calls to and from the user U 1 via the networks is performed in accordance with routing decision logic 100 and geographical and terminal storage 200 . The storage 200 (which, as described in greater detail below, takes the form of a distributed database) receives user position information and terminal information via signalling channels of the networks N 1 -N 4 , and supplies this information on request to the routing logic 100 .
The routing logic 100 (comprising, as discussed in greater detail below, distributed control programs) sets up the switches through the networks to route the message as desired to or from the user U 1 .
Position and Terminal Databases 200
Referring to FIG. 3, the storage 200 comprises a distributed hierarchical database comprising a home layer 201 consisting of, for each user U 1 , a unique database station where details of that user are registered (similarly to the home location register (HLR) of GSM); a local layer 220 consisting of a plurality of localised databases 221 - 224 , each storing details of users and terminals within its local area, and (in this embodiment) one or more intermediate layers 210 comprising a plurality of regional databases 211 - 213 storing records of users in a wider geographical area covering that of several local databases 221 - 224 .
For example, the regional databases 211 - 213 might each be associated with a coverage area approximately equal to the coverage area of a mobile switching centre (MSC) or local exchange, whereas the local databases 221 - 224 each relate to a small area (e.g. a floor of a building, a single local area network, or a picocell).
Referring to FIG. 4, each local database (which is conveniently provided by a large volume random access memory, or high speed off-line storage device such as a RAID disk array) comprises a first set of user records 251 , 252 . . . each relating to a single user in the locality, and a plurality of terminal records 261 , 262 . . . each relating to an item of terminal equipment in the locality (e.g., in this case, building).
Each user record 251 , 252 . . . contains data recording the position of the user. Each terminal record 261 , 262 contains data identifying the technical characteristics of the respective terminal to which it corresponds.
Where a user is logged on to a terminal (e.g. U 1 with T 5 or U 2 with T 6 ) the corresponding user record includes a pointer to the relevant terminal record (e.g. 251 to 261 and 252 to 262 ).
Referring to FIG. 5 a , in greater detail, a user record 251 , 252 . . . comprises a field 2521 for storing the users position (e.g. his three dimensional position in space, defined in altitude, latitude and longitude); a field 2522 specifying the terminal (if any) to which he is currently logged on (and containing a pointer to that terminal); and, optionally, other user information ( 2523 ) such as the access rights of the user (i.e. whether he can use all terminals or only one).
Referring to FIG. 5 b , each terminal record ( 261 , 262 . . . ) comprises a field 2611 identifying the geographical position of the terminal (e.g. in latitude, longitude and altitude); and a field 2612 indicating the technical characteristics of the terminal.
This latter field may consist of a list of format type records 2613 , 2614 . . . each itemising a signal format which the terminal can receive.
Alternatively, the field 2612 could comprise a pointer to a separate record of the technical specification of the terminal, or a generic record specifying the capabilities of all terminals of that type.
A field 2620 specifies the access rights (i.e. any limitations on users who can access the terminal, or classes of user who are permitted to do so).
Finally, a field 2625 specifies the dial number, network user address or other routing data which will enable a call to be routed through to the terminal, and consequently specifying the part of the network to which it is attached.
Referring to FIGS. 3 and 5 c , a given regional database 210 will contain a user position field ( 271 , 272 , 273 . . . ) for each of the users within its region, comprising the union of all the users in all the localities making up the region. Each user field 271 ( 272 , 273 . . . ) simply comprises a pointer to the local database 221 , 222 , 223 , 224 . . . in which the position record for that user is stored (and within the locality of which that user is last detected).
Likewise, in the home database station 201 for the user concerned, a further user field 271 is present for that user, containing a pointer to the identity of the regional database 211 , 212 , 213 . . . within which a field for that user is stored.
Thus, each user record is duplicated n times, where there are n layers present in the position tracking distributed database (in this case, 3).
Locating a User
Referring to FIG. 6, when it is desired to determine a user's location, his home database 201 is accessed (based on his dial number, his international mobile subscriber identity, network user identity or some other identifier associated with the user) in a step 300 . In a step 302 , the region database ( 211 - 213 ) is determined from the user field within the home database 201 , and in a step 304 this regional database is accessed. If there are further intermediate layers in the hierarchical database, steps 302 and 304 are repeated as necessary to move down through the layers of the hierarchy.
Ultimately, in a step 306 , in a regional database the identity of the local database associated with the locality in which the user is presently to be found is read, and in a step 308 the local database ( 221 - 224 ) is interrogated via an interrogation signal, and replies in step 310 with a message including the current user position, and the terminal records of all nearby terminals, including the positions and technical characteristics thereof.
Each local database station 221 - 224 may comprise a processor 2211 arranged to calculate the range from the user to each terminals and to exclude those terminal which are beyond a certain distance from user; it may also be arranged to compare authorisation data for each terminal with authorisation data stored for the user and to transmit details of only those terminals for which the user is not denied access.
The distributed databases are interconnected via signalling channels forming part of the signalling layer carried over the physical layer of FIG. 1, to permit the databases to be interrogated, read and written to.
Routing an Incoming Call
Referring to FIG. 7, the process performed by the routing logic 100 in routing an incoming call to a user will now be described. In a step 320 , an incoming signal in a particular format for the user is received in some portion of the physical layer of FIG. 1 and the identity of the user is determined and relayed to the routing logic 100 .
In a step 330 , the routing logic 100 interrogates the position tracking system 200 by performing the process of FIG. 6, to obtain thereby the position of the user and the list of nearby terminals and their corresponding technical capabilities.
In a step 340 , the routing logic 100 selects one of the nearby terminals, on the basis of its technical characteristics. For example, if the incoming signal is a facsimile signal, but the nearest terminal to the user U 1 is his mobile phone T 1 or pager T 2 , neither of which can receive an incoming facsimile signal, then the nearby facsimile terminal T 3 may be selected and the signal routed thereto in a step 350 .
Having selected the terminal to which a signal should be routed, in a step 360 an alerting signal is generated and transmitted to the user; for example, the alerting signal could be an alphanumeric message to his PDA terminal T 2 stating “FAX ROUTED TO TERMINAL T3 AT POSITION . . . ”, and accompanied by an alerting signal.
Equally, the message could comprise a recorded call announcement delivered as a call to his cellular telephone T 1 .
Thus, to sum up, according to the process of FIG. 7, the format of the call is inspected and it is delivered to a terminal nearby in which it is suitable to receive that format, and the terminal nearest the user (preferably his pager or cellphone) is alerted to the destination terminal of the signal.
Position Updating
The updating of a user position will now be described with reference to FIG. 8 (comprising FIGS. 8 a and 8 b ).
In a step 400 , a user position update signal is transmitted; either from one of the terminals T 1 -T 9 on registration of the user therewith, or from a position sensing element in the building (for example a door containing a card reader), or from the mobile telephone terminal T 1 (where this is equipped with some position determination means), or from the PLMN N 4 (where this determines the relative position for the user by ranging measurements from several base stations B 1 , B 2 . . . ).
A position change signal (containing the identity of the user and either a new latitude, longitude position or the identity of a new terminal with which he is registered), is transmitted in step 400 , from whichever of these sources originated the message, to the local database for the locality.
For example, in the case shown in FIG. 1, the terminals and door card readers transmit the position update signal via the LAN N 3 to the LAN server T 5 , at which the local database station is located.
On receiving the position update signal (step 402 ) the LAN server T 5 or other element of the physical layer signals to the local database (step 404 ).
The local database determines whether the user is one for which a record is already stored (step 406 ). If so, the stored record for the user is updated (step 408 ) to reflect the users new position; if a new position is received, the position is written to the record, whereas if the signal indicates that the user has registered at a door or on a terminal, the position data of the door or terminal is written to the user record.
If the user is not already present in the local database, a record is created (step 410 ) and his position is added. Then (step 412 ) a signal is transmitted up to the regional database within the region of which the local database falls.
The regional database examines whether a record is already stored for the user (step 414 ). If not, the regional database now executes steps 410 - 414 , to create a record for the user including a pointer to the local database the user is now in, and to signal up to the database in the next layer above (i.e. the database responsible for a wider area within which the region falls).
If multiple such intermediate layers exist, this process is repeated until, at some database, a record is found for the user in step 414 , in which case that database updates (step 416 ) the record to point to the new database in the layer below within which the user lies.
It now remains to remove the previous, erroneous, records of the user from areas where he has previously been located; accordingly, the database which has updated its record signals down to the database in the layer below to which the record previously pointed (the pointer now being inaccurate) in step 418 .
This database in the layer below then deletes the user from its record in step 420 . If (step 422 ) it is not a local database (i.e. if its user record points to another database in a layer below it, rather than defining the position of the user), then the database repeats steps 418 and 420 , and so on until the original local database within which the user was previously recorded is reached.
Thus, it will be seen that, by the updating process of FIG. 8, location information is updated within a localised area, due to the hierarchical organisation of the databases. That is, if a user moves within a single database then mobility management signals travel no further than that local database (which in practice is confined to a small area).
If a user moves from one locality to another nearby but within the same region (i.e. so that his record remains within the same regional database) then signalling is confined within that region, and so on.
Thus, increasing the size of the network does not lead to exponential increases in the volume of mobility signalling traffic, since such traffic remains localised.
On each occasion when a new terminal is added, or the position or the technical characteristics of a terminal change, this is reported to the local database.
Format Conversion
Referring to FIG. 9, in this embodiment there are preferably provided a plurality of format converters C 1 , C 2 . . . C 3 within the network. The physical location of the format converters is unimportant, but some means for routing signals to and from the format converters (shown here as a pair of routing switches R 1 , R 2 ) is provided, under control of the routing circuit 100 , which can therefore route an incoming signal via one, or a succession, of the converters C 1 -C 3 on route to the user.
Format Conversion Types
The converters may perform one of the following format conversions (but the following is not intended to be a limiting list):
3D graphics to 2D graphics and vice versa;
Image graphics to facsimile and vice versa;
Facsimile to text (e.g. optical character recognition) and vice versa;
First application output (e.g. spreadsheet) to second application output (e.g. wordprocessor);
Wordprocessor output to text and vice versa;
Text to speech and vice versa (speech recognition);
First video format to second video format (e.g. full rate video to MPEG compressed video);
Text to summary (i.e. automatic document abstracting);
Picture to text (i.e. image recognition);
First human language to second human language (i.e. machine translation);
First speech coder format to second speech coder format (e.g. ADPCM to GSM and vice versa);
First database search query language to second database search query language.
From the foregoing, it will be apparent that the format conversions may be grouped into one or more of the following subgroups:
1. Lossless format translation;
2. Lossy compression;
3. Translation from one medium to another (e.g. from a format recognisable by a first human sense to a format-recognisable by a second human sense).
In this embodiment (and as will be described in greater detail), the routing logic 100 is arranged to determine whether the received signal may be delivered to a terminal near the user.
If no nearby terminal can support the incoming signal format, the routing logic 100 is operative to determine whether, after conversion by one or more of the converters C 1 -C 3 , the message could be delivered in a format receivable by one or more of the terminals near to the user and, if so, routes the signal via that converter or those converters to such a terminal.
Routing Logic 100
It will be apparent that many ways of implementing the control logic 100 to achieve the above functionality are possible. However, for the reasons described in the above referenced prior art, it is advantageous to employ a so called “agent based” control mechanism. The term “agent” is used with a number of different senses in the literature; here, except where the context makes it clear that this is unnecessarily limiting, it will be understood to mean an independently executing control program under control of which a computer or computer controlled switching centre performs the functions attributed to the “agent”. The term is not necessarily limited to control programs which monitor their environment and adapt their behaviour and response thereto, but encompasses such programs.
Each agent makes use of data, and it is convenient that the agents should therefore operate in “object-oriented” fashion; that is to say, that the data should be “encapsulated” so as to be accessible alterable only by associated control programs, acting in response to “messages” (which need not, however, be physically transmitted but could simply be data passed via the stack of a single computer). It will, however, be understood that the object oriented format is inessential to the invention.
Referring to FIG. 10, the routing logic comprises at least one computer 100 connected via a signalling link to the physical layer of the network, and including storage areas storing data and control programs defining a plurality of customer agents 101 - 106 . . . ; a plurality of network manager agents 111 - 113 ; and a plurality of network resource agents 121 - 132 .
Conceptually, and as will be described in greater detail below, each customer agent 101 - 110 represents an actual customer, and comprises stored data relating to the customer to enable the network to carry out activities in relation to the customer even when the customer is not connected to the network. The number of customer agents is therefore very large.
Each comprises a section of random access memory storing fields containing the following data:
User name;
Identity of home database 201;
Billing point;
Customer format preferences;
Customer billing preferences;
Selection algorithm.
The customer agent further contains stored programs for executing the following processes:
1. Request outgoing service;
2. Select outgoing service;
3. Select incoming service format;
4. Update customer data.
5. Update selection algorithm.
The network management agents 111 - 113 comprise random access memory storing:
Data specifying the input and output formats between which the converters present in the network can convert;
Anticipated price data for each such type of conversion, and for standard types of service;
Data on current high-level network conditions (for example, time of day, and general level of traffic).
A pricing algorithm.
Each network managing agent is also associated with program code to perform the following functions.
1. Receive service request;
2. Price service request;
3. Set up service through network;
4. Update data;
5. Update pricing algorithm.
Each network managing agent is associated with a particular area of the physical layer; for example, in FIG. 1, separate network managing agents may be provided for the PSTN N 1 , ISDN N 2 and PLMN N 4 ; and more specifically, within each of these networks a separate managing agent may be provided for each major region (for example one network managing agent may be associated with each mobile switching centre of the PLMN N 4 and major exchanges of the PSTN N 1 ).
Resource agent
Each resource agent 121 - 132 relates to a specific hardware structure within the physical layer of the network, such as a converter (C 1 -C 3 ); a routing switch (R 1 , R 2 ), e.g. an exchange or mobile switching centre; a transport component such as a cable, base station or satellite channel; or the like. Each resource agent therefore stores data representing the following:
Physical characteristics of the resource (input and output formats);
Current state of loading of the device;
Time of day.
The resource agents also comprise random access memory storing code for performing the following functions:
1. Receive service request;
2. Price service request;
3. Set up service through resource;
4. Update data;
5. Update pricing algorithm
Heirarchical Arrangement
Although only a single layer of network managing agents 111 - 113 is shown here, it is envisaged that in larger systems, each network managing agent may act as a network resource agent to a higher level of managing agents, so as to produce a hierarchical structure. For simplicity, however, only a single layer of network managing agents will be described hereafter.
Geographical Arrangement
The routing logic 100 may be provided by a single large computer including processor and storage capacity for all the above described data and processes.
However, in order to avoid bottlenecks of signalling traffic, it is more convenient in this embodiment to distribute the various agent functions.
Conveniently, the resource agents 121 - 132 are located at or close to the resources to which they relate (e.g. are provided as software running on local or regional exchange control computers), whereas the network management agents are located centrally within the segment of the network which they control (for example at a network control station or major switch, as software running on the control computer thereof).
Customer agents 101 - 105 may conveniently be co-located with network managing agents 111 - 113 , or with the home database 201 for the customer concerned.
Overview of Outgoing Call Process
The process of setting up a communication initiated by a first mobile party will now be described. Broadly, the first party gives an indication of the format in which it will transmit (and, if necessary, receive) and the party for whom the transmission is intended.
Each network managing agent then assesses whether it can deliver a broadly corresponding service to the vicinity of the remote party and the initiating party by assessing the position database, and replies accordingly with a proposed service and a corresponding price.
The initiating party customer agent selects one of the proposals and the call is set up in accordance with the proposal. To set up the call, the network managing agent which has made the successful proposal negotiates with the resource agents within its region to provide the service at a price within the specified constraints. Each resource agent assesses whether it can offer a service in setting up the required service and, if so, submits a price.
The network managing agent then selects the combination or resource agent which gives the best price whilst meeting the necessary format and other constraints and sets up the call accordingly.
In the process, a description of the service to be offered is built up during the negotiation between the customer agent, the network managing agent and each resource agent. The customer agent initially provides a partial service description specifying its requirements, and the remaining details and price are supplied by the network managing agent and resource agents.
Referring to FIG. 11, the service description is provided as a data record which can be amended by the customer agents, network managing agents and resource agents. The record comprises the following fields.
Initiating ID ( 502 )—this field specifies the user who is initiating the service request.
Remote ID ( 504 )—this field specifies the user to whom the service is to be connected.
Transmit supply format ( 506 )—this field specifies the signal format which the initiating user will actually be supplying (e.g. speech, text or image).
Transmit delivery format ( 508 )—this field specifies the format in which the signal will actually reach the remote party, after conversion (if necessary). Whereas all the preceding fields are filled in initially by the initiating party customer agent, this field may be left blank, or may contain a number of different possible supply formats.
Receive delivery format ( 510 )—if the service is bi-directional (for example a telephone conversation, or text, video or audio conference) then this field contains one or more formats specified by the initiating party in which it would prefer to receive data from the remote party.
TX terminal ( 512 )—this field is initially blank.
RX terminal ( 514 )—this field is initially blank.
Price ( 516 )—this field is initially blank.
Delivery time ( 518 )—this field may be completed by the originating customer agent to specify a maximum delay in communication. For example, for voice communications, a maximum delay of M second might be set; for fax or data delivery, a maximum delivery time of 1, 10 or 20 hours might be set.
Distortion ( 520 )—this field may be set by the customer agent to specify some maximum acceptable level of distortion of the signal; for example, for an image signal, conversion between different image formats may be distortion free but image compression will involve some loss of detail, corresponding to some notional distortion level of 10% or 20%.
Routing fields ( 530 )—these fields are initially left blank.
Referring to FIGS. 12 to 14 , (relating to the processes performed by the customer agent, network agents and resource agent respectively), this process will be described in greater detail.
The service initiating user indicates the service he wishes to receive, by taking a phone (T 1 ) off hook, or entering data into a terminal (T 3 ). The network (N 1 -N 4 ) to which he is connected forwards this event to the customer agent (e.g.) which receives it (in FIG. 12 step 602 ). In step 604 , the customer agent broadcasts a partially complete service request record 500 (as described above) to each network managing agent in the network.
In FIG. 13 step 620 , each network agent receives the service request and (step 622 ) interrogates the home database for the originating and destination users, and receives back (as in FIG. 6) a list of nearby terminals (together with their available signal formats) for the originating and destination users, which are filled into the terminal fields 512 , 514 .
In step 624 , each network managing agent determines whether there is any path via its available convertors (C 1 -C 3 ) which would convert a signal in the transmit source format to one receivable at one of the destination terminals (and vice versa if the service is bi-directional). If so, it selects the path which gives the shortest transmission time, and/or least distortion in reproduction (step 626 ), together with the terminals to be used by the initiating and destination users.
It then calculates a price for this service (step 628 ) based on its stored pricing algorithm, and transmits back the completed service request record 500 to the originating customer agent, including data in the field for the proposed terminals, formats, price, delivery time and distortion.
Referring back to FIG. 12, in step 606 , the customer agent receives the first bid (i.e. completed service request) and determines (step 608 ) whether the bid is acceptable in price, quality, time and terminal proximity. The determination could simply involve relaying all details to the user for a decision, but preferably the customer agent, in this embodiment, calculates a weighted sum
a 1 (p)+a 2 (t)+a 3 (q);
where a 1 −a 3 are constants or functions and p, t and q are price, time and distortion respectively if the sum exceeds a threshold, the bid is rejected and the customer agent awaits the next bid (step 606 ) from another network managing agent. (If all bids are rejected, the customer agent may issue a new service request).
When a bid is accepted, the customer agent signals back acceptance (step 609 ) and signals the accepted service to the user (step 610 ) in a message (as discussed above) advising him which terminal to use.
On acceptance (step 632 ), the accepted network managing agent then issues a service request record to resource agents (step 634 ) within the network with which it is associated.
Referring to FIG. 15, the resources within this network will be distributed throughout the area of the network; in FIG. 15 a set of resources R 1 -R 10 are illustrated.
A signal to be delivered arrives at a port P 1 of the network in the source format determined by the network managing agent, and is delivered at the destination terminal T 1 in the delivery format determined by the network managing agent (and agreed by the customer agent).
To cross the network, the signal must traverse at least one resource (which may simply be a land line or other single channel) and may require conversion (e.g. from a wordprocessing document source format to a speech delivery format).
Comprised within the resources R 1 -R 10 are a wordprocessor (document)-to-ASCII text converter resource R 3 , and a text-to-speech converter R 10 . The other resources in this case may either be transparent transport devices or other converters.
Thus, the path taken by the signal should include, in order, the converters R 3 and R 10 , linked by suitable transport resources.
From inspection of FIG. 15 it will be clear that the shortest routes are R 1 -R 3 -R 6 -R 10 -R 9 or R 1 -R 3 -R 7 -R 10 -R 9 . Longer routes are equally possible, however.
Referring to FIG. 14, in a step 660 , the service request is received from the network managing agent by the resource to which the input port at which the source signal is received is connected. In this case, this resource may for example be a switch connected to one of several further resources R 2 , R 3 or R 4 .
The first resource R 1 inserts into one of the routing fields 530 its identity and price in step 662 .
In step 664 , it determines whether it is connected to the destination terminal specified in field 514 and whether the signal output format it generates (which in this case is the same as the input format) is that required by the delivery format field 510 . In this case, neither test is satisfied in step 664 , and accordingly the resource agent proceeds to step 674 .
At step 674 , the resource agent reviews the list of resources to which it is connected (in this case, R 2 , R 3 , R 4 ) If (step 676 ) none of these connected resources is relevant (because, for example, all are connected to gateway points out of the network) the possible route has reached a dead end, and the service request is passed back; in general, the service request is passed back to the preceding resource but where, as here, the resource is the first encountered in the network the service request is passed back to the network managing agent (which is therefore unable to provide the service).
Where one or more of the following resources is not a dead end (step 676 ), the initial resource selects a following resource so as to define a path through the network. The selection may simply proceed on the basis of the first resource listed (e.g. R 2 in this case). The service request is then passed to this next resource in step 682 , but now including the details of the first resource R 1 .
The next resource R 2 then begins execution at step 660 , and the process continues, adding successive resources sequentially in a list defining the path through the network, until the list includes R 3 and R 10 in the correct order and terminals at resource R 9 .
At this point, at step 664 , it will be observed that the service request is complete since the signal has arrived in the correct format at R 9 where it can be delivered to terminal T 1 . Accordingly, at this point the resource R 9 sends the completed service request back to the network managing agent (step 666 ) and awaits its response.
Referring back to FIG. 13 b , in step 636 the network managing agent receives the completed service request, adds up the price elements added by each resource and compares then with the agreed price recorded in the price field 516 .
The network managing agent may also determine a likely level of distortion by adding up progressive increments of distortion for each resource in the list of resources in the fields 530 , and may derive a total delivery time by adding up the time delays associated with each resource in the list of resources in the fields 530 , and compare these with the target delivery time in field 518 and distortion in field 520 .
If each such comparison is acceptable (step 637 ), the network managing agent signals acceptance in step 638 to the resource agents in the list of resource agents in the completed service request, each of which then executes step 670 of FIG. 14 to configure issue command signals causing the corresponding physical network structure to connect the call.
In step 640 , the network managing agent signals to the customer agent for the destination customer to expect the message in the stated format at the stated terminal specified in field 514 (this message may be delivered as a voice announcement to the destination user's mobile phone or a pager message to his pager).
In step 642 , the network managing agent compares the cost calculated in step 637 with the quoted price in field 516 and, in step 644 , the network managing agent updates its pricing algorithm in accordance with the differences, as will be discussed in greater detail below.
If in step 637 the network managing agent determines that either the quality of the proposed service is unacceptable or the cost is too high, it returns to step 634 and transmits back the service request to the last resource agent (in this case R 9 ).
This is interpreted (step 688 ) as a rejection of the resource request by resource agent R 9 , and accordingly R 9 executes step 678 to pass the service request back to the immediately preceding resource agent in the list within the service request and deletes itself (and its price) from the list.
The preceding resource agent notes that it received the service request from R 9 and accordingly does not attempt to forward the service request again to R 9 but instead, if there is an alternative resource to which it is connected which is relevant (step 676 ) selects the next alternative resource in step 680 .
It will thus be seen that FIGS. 13 and 14 together define a depth-first tree-following algorithm which attempts to define a route through the resources and, where a particular route is unsuccessful, reverse back to the preceding node of the tree and attempt to follow a different route.
In practice, at step 676 , each resource agent could determine additional tests; for example, the resource agents could each test the cumulative delay time associated with the list of resources recorded in the field 530 , and/or the cumulative sum of all the distortion measurements therein, and when this exceeds the delivery time and distortion amounts specified in fields 518 and 520 , there is then no further point in traversing the remainder of the path and step 678 may be executed immediately, to reverse back to the preceding resource agent and attempt to find a new path on from there.
Rather than merely following a path from the signal source P 1 , it is equally possible to attempt to construct a path from both the signal source P 1 and the destination terminal T 1 simultaneously, so as to reduce the path search time.
Terminal and Route Selection (steps 624 and 626 )
The process of selection of delivery terminal and format conversion described briefly above in relation to steps 624 and 626 will now be described in greater detail with reference to FIG. 16 .
In step 6242 , the network managing agent reads the source format field 506 from the service request and in step 6244 the network managing agent reads any delivery preference format data from the customer agent for the destination user; such information may, for example, specify that an incoming facsimile signal is to be delivered as an image signal or vice versa.
From the source format and the delivery format data (if any), in steps 6246 , the network managing agent derives a preferred delivery format.
Next, the network managing agent determines, for each terminal reported to be adjacent to the destination user, whether the network includes a resource (a converter or a transparent link) which can convert between the source format and a format recognisable by the terminal. Accordingly, in step 6248 , a first terminal is picked (this may be the terminal closest to the user) and in step 6250 a first conversion resource is picked.
In step 6252 , the input and output formats required by the conversion resource (which may, as mentioned above, be identical where the resource is a transport resource) are compared with the source format and the list of formats which the terminal can accept. If they match, the stored price, distortion and time delay data (P, Q, T) for the resource are derived (step 6254 ) and the resource is added to a list of possible paths (step 6256 ).
If the converter input and output formats do not match the source format and or one of the formats the terminal can accept, and if not all resources have yet been tried (step 6258 ), the next conversion resource is substituted in step 6260 and the process is repeated. Once all conversion resources have been attempted using the first such terminal in the area of the user, then if the last terminal has not yet been tried (step 6262 ), the next terminal is picked and the cycle is repeated.
Once all resources have been matched against all terminals (step 6262 ) if in step 6256 any possible delivery routes have been added to the list (step 6266 ), step 626 is executed. Specifically, if there is more than one route the network managing agent selects one of the routes by examining the price, delivery time and distortions calculated (step 6254 ) and comparing these against the price, delivery time and distortion values filled in fields 516 , 518 and 520 (if any) by the originating customer agent, and (if any) by the destination customer agent.
If multiple different routes in the list meet all these criteria, the network managing agents selects one, on the basis of price, quality or delivery time, or on the basis of awaited combination of these three. This forms the basis of the bid output in step 630 .
If, after this first pass, no single resource suffices to convert the signal from the source format to a format which one of the destination terminals can support (step 6268 ), then a further pass is executed to determine whether a combination of two successive resources will convert the source format to one which a terminal can recognise (e.g. fax to text, followed by text to speech). This is achieved by setting a first conversion resource following the source format to convert it into a converted format, and then testing all other resources to determine whether any of them can convert the converted format into a format which can be recognised by one of the destination terminals.
Accordingly, in step 6270 , a resource is added as an extra conversion stage to the source format (or any conversion resource which follows it). The selected resource must, of course, be able to convert the format on which acts (the source format or a converted format produced by a preceding stage), and must convert this to a different format (i.e. must not be a transport link).
After having added the extra stage (step 6270 ) a first terminal is selected (step 6248 ) and the first pass is repeated. If this first resource, when followed by any other resource, still does not lead to an acceptable path (step 6266 ), it is substituted by another resource (step 6270 ).
Where all such resources have been tested as a first stage, and no successful two stage conversion process has been identified (step 6268 ), one resource is retained in the first stage and a further resource is added as a second stage, and the process is repeated to test for the presence of three stage conversions. If this too is unsuccessful, a further stage is added, and so on until either a successful result is achieved, or another network managing agent is successful, or a time-out is reached.
Thus, the process corresponds to a breadth-first tree search, searching for the shortest solutions first.
On transmission of a service request by a first network managing agent, all network managing agents halt the search for paths pending the acceptance or otherwise from the customer agent. If the service is rejected, the network managing agents therefore recommence searching for conversion paths where they left off.
Pricing
The pricing performed by the network managing agent in step 630 may be performed in one of two ways.
Firstly, where the service type is common (for example a voice called to be delivered to a voice terminal), the network managing agent may simply maintain a stored price for each such commonly called type, or several prices relating to different times of day (corresponding to lesser or greater load on the network) and may simply output the relevant price for the time of day.
On the other hand, where the service is less common and the network managing agent proposes to deliver the service by a succession of signal format conversions provided by corresponding resources, the network managing agent is arranged to read a stored price for each resource (or, as discussed above, a number of different prices for different times of day) and add the prices for the various resources to derive a total.
Each resource agent likewise issues a pricing signal at step 662 . This is a function of a stored constant and the current utilisation factor (in other words, the percentage of the capacity of the resource which is current free, if any). The function may simply be A/C, where A is a constant and C is the percentage spare capacity. Thus, when the resource is under utilised (i.e. the spare capacity is close to 100%) the price tends to the value of the constant A, whereas when there is little spare capacity, the price rises sharply.
Price Updating
At steps 644 , 646 and 672 the network managing agent and the resource agent update their prices. On each occasion when a resource agent is selected, it examines the ratio of the number of occasions on which it has been selected to the number of occasions on which it has bid and compares this with a predetermined constant K.
In the event that the ratio exceeds the predetermined constant K (i.e. the resource agent is begin selected relatively frequently), the stored constant A is increased by an amount which may either be a fixed increment or a function of the difference between the ratio and the predetermined constant K.
Likewise, when the ratio falls below the predetermined constant this indicates that the resource is being selected relatively infrequently and the stored constant A is decremented (by a fixed amount or a function of the difference between the ratio and the predetermined constant K).
Naturally, other procedures for adjusting the price depending upon the relative frequency of selection of the resource could be utilised.
In step 644 , the network managing agent is able to update more accurately its model of the costs which will be charged each resource agent, by comparing the prices listed in the route fields 530 with those it currently has stored for resources of the same type; for example, where the path includes five leased line links, the network managing agent may calculate the average of the five and store this as a new price datum for resources of the fixed leased line type (or combine it with the existing stored measurement to maintain a running average price).
Naturally, these stored constant cost levels will affect future prices calculated by the network managing agent for services assembled from a plurality of conversion resources.
Additionally, the network managing agent adapts its price level in the same manner as each resource agent to depend upon the relative ratio of the number of times it has been selected to the number of times it has bid (in steps 646 ).
The extension of the above described processes to a more hierarchical arrangement, where entities may act as a network managing act to resources below them and as a resource to further network managing agents above them, will be apparent to the skilled person:
Separate Networks
In the foregoing, the behaviour of network managing agents in pricing services utilising resources within their own network has been described.
However, it will sometimes be necessary for a network managing agent to deliver services utilising another network (for example, utilising a pager network to deliver a message to a pager or a long distance carrier to carry a transatlantic message).
Accordingly, the network managing agent also stores records, corresponding to those of the resources within its associated network, for each other network, and stores a predetermined price constant for each such other network.
The network managing agent then adds the details of the other network within the path fields 530 of the service request before transmitting the service request to its own resource agents, so that the resource agents bid only for that portion of the path which lies through the network associated with the network managing agent concerned.
Structure of Each Agent
To some extent, the structure of the agents may be made compatible so as to increase the ease with which they may integrated into a hierarchy, and increase the possibilities for re-use of the same program code.
Accordingly, each agent may be regarded as being comprised of code defining a buying function (this is, of course, not necessary for the resource agents) and a selling function (this is, of course, not necessary for the customer agents) together with a communications function (for signalling either between different programs executing on the same processor in time sharing mode, or for signalling across network signalling channels between processors).
Further, the data held in relation to the capabilities of each terminal may be held in object oriented form, as a terminal object, or as a “terminal agent”. Where the terminal contains computer processing equipment, the terminal agent program may reside on the terminal and communicate chances to the capabilities of the program via the communications network. The terminal agent may, in this case, be downloaded to the terminal on first connection of the terminal to the network.
Summary
It will be seen that the particular manner of operation of the agents in this embodiment is advantageous in several respects. Firstly, it will be observed that in general the number of agents simultaneously communicating with each other is kept low; this is advantageous since it enable the size of the network to be increased without the inter-agent messages swamping the network. With ten million users or more, this is a very real risk.
Secondly, the behaviour of each agent may be relatively simple.
Thirdly, since network managing agents bid prices in a first pass of operation, before making a detailed investigation of the availability or price of the services in a more detailed second pass, relatively few agents are active during each stage of operation (in the first pass, all the network managing agents are active, whereas in the second pass, only the resource agents of the successful network managing agents are active). This conserves computing and signalling resources further.
Other Aspects of the Invention
Terminals
Particular terminals have been discussed above as examples. A more complete (though non limiting) list would include:
telephones,
video cameras,
3D displays,
personal digital assistants,
cellular telephones,
satellite telephones,
pagers,
video phones,
facsimiles
payphones,
qwertyphones,
personal computers,
lap top portable computers,
engineering workstations,
audio microphones,
video conference suites,
telemetry equipment.
Network and Links
Likewise, although examples of networks have been given the range of networks links available includes:
terrestrial cellular networks (analog or digital),
callpoint wireless systems,
microcellular or picocellular systems,
satellite cellular systems,
the Internet,
packet switching data services (PSS),
leased lines,
the PSTN,
optical networks,
Ethernet or the like area networks,
line of sight infrared links,
video to home links,
radio paging networks.
User Location
Whilst particular techniques for location tracking have been described, it will of course be understood that any method of tracking the approximate user position may be used; for example, tracking the terminals at which a user logs on. Accordingly, no specific position tracking device is essential to the invention.
Pricing and Charging
It will be understood that the prices accepted by the customer agent may correspond to prices actually to be paid by the customer. Equally, the price charged by one network resource may reflect an actual financial transaction within the network or between two networks. However, it is equally possible for the price mechanism to operate simply as a routing procedure, without implications for the actual prices paid by the user or any part of any network.
Naturally, many other modifications and variations may be made the above described embodiments without departing from the invention.
|
Routing apparatus for a telecommunication system includes a telecommunications user apparatus arranged to generate a request for a telecommunications delivery service, to receive a plurality of telecommunications delivery service offers and to select one of them. The system also intends a plurality of telecommunication service supply apparatuses each arranged to receive one of the request to generate an offer signal specifying a proposed delivery service and to receive an acceptance signal indicating acceptance thereof and, on receipt thereof, to generate a service provision invitation. The system further provides a plurality of resource supplier apparatuses each representing a communications resource arranged to communicate with each of said service supply apparatuses. The resource supplier apparatus is arranged to receive an invitation to determine whether the telecommunications resource they represent would contribute to the provision of the corresponding service; and, if so, to signal this to the service supply apparatus. The service supply apparatus is arranged, on the basis of signals from the resource supplier apparatus to select the route subsequent to the offer of the service.
| 7
|
TECHNICAL FIELD
This invention relates to wire and cable and the insulation and jacketing therefor and, more particularly, to telephone cable.
BACKGROUND INFORMATION
A typical telephone cable is constructed of twisted pairs of metal conductors for signal transmission. Each conductor is insulated with a polymeric material. The desired number of transmission pairs is assembled into a circular cable core, which is protected by a cable sheath incorporating metal foil and/or armor in combination with a polymeric jacketing material. The sheathing protects the transmission core against mechanical and, to some extent, environmental damage.
Of particular interest are the grease-filled telephone cables. These cables were developed in order to minimize the risk of water penetration, which can severely upset electrical signal transmission quality. A watertight cable is provided by filling the air spaces in the cable interstices with a hydrocarbon cable filler grease. While the cable filler grease extracts a portion of the antioxidants from the insulation, the watertight cable will not exhibit premature oxidative failure as long as the cable maintains its integrity.
In the cable transmission network, however, junctions of two or more watertight cables are required and this joining is often accomplished in an outdoor enclosure known as a pedestal (an interconnection box). Inside the pedestal, the cable sheathing is removed, the cable filler grease is wiped off, and the transmission wires are interconnected. The pedestal with its now exposed insulated wires is usually subjected to a severe environment, a combination of high temperature, air, and moisture. This environment together with the depletion by extraction of those antioxidants presently used in grease-filled cable can cause the insulation in the pedestal to exhibit premature oxidative failure. In its final stage, this failure is reflected in oxidatively embrittled insulation prone to cracking and flaking together with a loss of electrical transmission performance.
To counter the depletion of antioxidants, it has been proposed to add high levels of antioxidants to the polymeric insulation. However, this not only alters the performance characteristics of the insulation, but is economically unsound in view of the high cost of antioxidants. There is a need, then, for antioxidants which will resist cable filler grease extraction to the extent necessary to prevent premature oxidative failure and ensure the 30 to 40 year service life desired by industry.
DISCLOSURE OF THE INVENTION
An object of this invention, therefore, is to provide a grease-filled cable construction containing antioxidants, which will resist extraction and be maintained at a satisfactory stabilizing level. Other objects and advantages will become apparent hereinafter.
According to the invention, an article of manufacture has been discovered which meets the above object.
The article of manufacture comprises, as a first component, a plurality of electrical conductors, each surrounded by one or more layers of a composition comprising (a) one or more polyolefins and, bonded thereto or blended therewith, (b) a linear or cyclic organopolysiloxane containing one or more functionalized hindered amine moieties; and, as a second component, hydrocarbon cable filler grease within the interstices between said surrounded conductors.
In one other embodiment, the article of manufacture comprises first and second components; however, the mixture of the first component contains absorbed hydrocarbon cable filler grease or one or more of the hydrocarbon constituents thereof and, in another embodiment, the article of manufacture is comprised only of the first component wherein the mixture contains hydrocarbon cable filler grease or one or more of the hydrocarbon constituents thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The polyolefins used in this invention are generally thermoplastic resins, which are crosslinkable. They can be homopolymers or copolymers produced from two or more comonomers, or a blend of two or more of these polymers, conventionally used in film, sheet, and tubing, and as jacketing and/or insulating materials in wire and cable applications. The monomers useful in the production of these homopolymers and copolymers can have 2 to 20 carbon atoms, and preferably have 2 to 12 carbon atoms. Examples of these monomers are alpha-olefins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene; unsaturated esters such as vinyl acetate, ethyl acrylate, methyl acrylate, methyl methacrylate, t-butyl acrylate, n-butyl acrylate, n-butyl methacrylate, 2-ethylhexyl acrylate, and other alkyl acrylates; diolefins such as 1,4-pentadiene, 1,3-hexadiene, 1,5-hexadiene, 1,4-octadiene, and ethylidene norbornene, commonly the third monomer in a terpolymer; other monomers such as styrene, p-methyl styrene, alpha-methyl styrene, p-chloro styrene, vinyl naphthalene, and similar aryl olefins; nitriles such as acrylonitrile, methacrylonitrile, and alpha-chloroacrylonitrile; vinyl methyl ketone, vinyl methyl ether, vinylidene chloride, maleic anhydride, vinyl chloride, vinylidene chloride, vinyl alcohol, tetrafluoroethylene, and chlorotrifluoroethylene; and acrylic acid, methacrylic acid, and other similar unsaturated acids.
The homopolymers and copolymers referred to can be non-halogenated, or halogenated in a conventional manner, generally with chlorine or bromine. Examples of halogenated polymers are polyvinyl chloride, polyvinylidene chloride, and polytetrafluoroethylene. The homopolymers and copolymers of ethylene and propylene are preferred, both in the non-halogenated and halogenated form. Included in this preferred group are terpolymers such as ethylene/propylene/diene monomer rubbers.
Other examples of ethylene polymers are as follows: a high pressure homopolymer of ethylene; a copolymer of ethylene and one or more alpha-olefins having 3 to 12 carbon atoms; a homopolymer or copolymer of ethylene having a hydrolyzable silane grafted to their backbones; a copolymer of ethylene and a hydrolyzable silane; or a copolymer of an alpha-olefin having 2 to 12 carbon atoms and an unsaturated ester having 4 to 20 carbon atoms, e.g., an ethylene/ethyl acrylate or vinyl acetate copolymer; an ethylene/ethyl acrylate or vinyl acetate/hydrolyzable silane terpolymer; and ethylene/ethyl acrylate or vinyl acetate copolymers having a hydrolyzable silane grafted to their backbones.
With respect to polypropylene: homopolymers and copolymers of propylene and one or more other alpha-olefins wherein the portion of the copolymer based on propylene is at least about 60 percent by weight based on the weight of the copolymer can be used to provide the polyolefin of the invention. The polypropylene can be prepared by conventional processes such as the process described in U.S. Pat. No. 4,414,132. The alpha-olefins in the copolymer are preferably those having 2 or 4 to 12 carbon atoms.
The homopolymer or copolymers can be crosslinked or cured with an organic peroxide, or to make them hydrolyzable, they can be grafted with an alkenyl trialkoxy silane in the presence of an organic peroxide which acts as a free radical generator or catalyst. Useful alkenyl trialkoxy silanes include the vinyl trialkoxy silanes such as vinyl trimethoxy silane, vinyl triethoxy silane, and vinyl triisopropoxy silane. The alkenyl and alkoxy radicals can have 1 to 30 carbon atoms and preferably have 1 to 12 carbon atoms. The hydrolyzable polymers can be moisture cured in the presence of a silanol condensation catalyst such as dibutyl tin dilaurate, dioctyl tin maleate, stannous acetate, stannous octoate, lead naphthenate, zinc octoate, iron 2-ethyl hexoate, and other metal carboxylates.
The homopolymers or copolymers of ethylene wherein ethylene is the primary comonomer and the homopolymers and copolymers of propylene wherein propylene is the primary comonomer may be referred to herein as polyethylene and polypropylene, respectively.
For each 100 parts by weight of polyolefin, the other components of the insulation mixture can be present in about the following proportions:
______________________________________ Parts by WeightComponent Broad Range Preferred Range______________________________________(i) organopoly- 0.01 to 5 0.1 to 1 siloxane containing hindered amine(ii) grease 3 to 30 5 to 25______________________________________
The organopolysiloxane, mentioned above, can contain 2 to about 200 siloxane units and preferably contains about 3 to about 100 siloxane units. At least one of the siloxane units must contain at least one functionalized hindered amine moiety; however, all of the siloxane units can contain one or more functionalized hindered amine moieties. Aside from the siloxane units containing the functionalized hindered amine moiety, generally, any of the known siloxane units can make up the organopolysiloxane.
A typical siloxane unit, which does not contain the functionalized hindered amine moiety has the following structural formula: ##STR1## wherein R is an alkyl, aryl, alkaryl, alkoxy, alkenyl or aralkyl, each having 1 to 20 carbon atoms, and each R can be the same or different.
The siloxane unit containing the functionalized hindered amine moiety can be represented by the following structural formula: ##STR2## wherein R 1 =alkyl, alkoxy, or mixtures thereof;
X=oxygen; a linear or branched chain alkylene; alkylene oxy; alkylene amine (CH 2 ) a CONH; or (CH 2 ) a COO wherein a is at least one;
Y=C or N;
p=0, 1, or 2;
R 2 =hydrogen or alkyl and each R 2 can be the same or different, or the R 2 s together can be one oxygen atom;
R 3 =hydrogen or alkyl and each R 3 can be the same or different; and
R 4 =hydrogen, alkyl, alkoxy, hydroxy, or oxyl.
In one preferred embodiment of the above:
With respect to R 1 , the alkyl and alkoxy can be 1 to 20 carbon atoms; the alkylene in the X moiety can have 1 to 6 carbon atoms; the alkyl in the R 2 moiety can have 1 to 3 carbon atoms; the alkyl in the R 3 moiety can have 1 to 4 carbon atoms; and the alkyl and alkoxy in the R 4 moiety can have 1 to 20 carbon atoms.
In a more preferred embodiment:
R 1 ==alkyl, alkoxy, or mixtures thereof wherein the alkyl and alkoxy have 1 to 20 carbon atoms;
X=oxygen or alkylene oxy having 1 to 6 carbon atoms;
Y=C;
p=0, 1, or 2;
R 2 =hydrogen;
R 3 =methyl; and
R 4 =hydrogen or alkyl having 1 to 6 carbon atoms.
In the most preferred embodiment, everything is the same as in the preceding more preferred embodiment except that R 1 =methyl; p=1; and R 4 =hydrogen.
The organopolysiloxane can contain one or two of the following terminal units: R 3 SiO--; R 3 Si--; R 5 O 0 .5 --; or a functionalized hindered amine moiety such as that depicted in the above structural formula. R is as defined above; each R can be the same or different;
and R 5 can be hydrogen, an alkyl having 1 to 20 carbon atoms, or a substituted or unsubstituted phenyl group.
The organopolysiloxane may also contain small amounts of the following siloxane units (known as T and Q units in the silicone nomenclature): R 1 SiO 3/2 ; functionalized hindered amine* --SiO 3/2 (*such as that depicted in the above structural formula); and/or SiO 4/2 .
Examples of suitable functionalized hindered amines follow: ##STR3##
Hydrocarbon cable filler grease is a mixture of hydrocarbon compounds, which is semisolid at use temperatures. It is known industrially as "cable filling compound". A typical requirement of cable filling compounds is that the grease has minimal leakage from the cut end of a cable at a 60° C. or higher temperature rating. Another typical requirement is that the grease resist water leakage through a short length of cut cable when water pressure is applied at one end. Among other typical requirements are cost competitiveness; minimal detrimental effect on signal transmission; minimal detrimental effect on the physical characteristics of the polymeric insulation and cable sheathing materials; thermal and oxidative stability; and cable fabrication processability.
Cable fabrication can be accomplished by heating the cable filling compound to a temperature of approximately 100° C. This liquefies the filling compound so that it can be pumped into the multiconductor cable core to fully impregnate the interstices and eliminate all air space. Alternatively, thixotropic cable filling compounds using shear induced flow can be processed at reduced temperatures in the same manner. A cross section of a typical finished grease-filled cable transmission core is made up of about 52 percent insulated wire and about 48 percent interstices in terms of the areas of the total cross section. Since the interstices are completely filled with cable filling compound, a filled cable core typically contains about 48 percent by volume of cable filling compound.
The cable filling compound or one or more of its hydrocarbon constituents enter the insulation through absorption from the interstices. Generally, the insulation absorbs about 3 to about 30 parts by weight of cable filling compound or one or more of its hydrocarbon constituents, in toto, based on 100 parts by weight of polyolefin. A typical absorption is in the range of a total of about 5 to about 25 parts by weight per 100 parts by weight of polyolefin.
It will be appreciated by those skilled in the art that the combination of resin, cable filling compound constituents, and antioxidants in the insulation is more difficult to stabilize than, an insulating layer containing only resin and antioxidant, and no cable filling compound constituent.
Examples of hydrocarbon cable filler grease (cable filling compound) are petrolatum; petrolatum/polyolefin wax mixtures; oil modified thermoplastic rubber (ETPR or extended thermoplastic rubber); paraffin oil; naphthenic oil; mineral oil; the aforementioned oils thickened with a residual oil, petrolatum, or wax; polyethylene wax; mineral oil/rubber block copolymer mixture; lubricating grease; and various mixtures thereof, all of which meet industrial requirements similar to those typified above.
Generally, cable filling compounds extract insulation antioxidants and, as noted above, are absorbed into the polymeric insulation. Since each cable filling compound contains several hydrocarbons, both the absorption and the extraction behavior are preferential toward the lower molecular weight hydrocarbon wax and oil constituents. It is found that the insulation composition with its antioxidant not only has to resist extraction, but has to provide sufficient stabilization (i) to mediate against the copper conductor, which is a potential catalyst for insulation oxidative degradation; (ii) to counter the effect of residuals of chemical blowing agents present in cellular and cellular/solid (foam/skin) polymeric foamed insulation; and (iii) to counter the effect of absorbed constituents from the cable filling compound.
The polyolefin can be one polyolefin or a blend of polyolefins. The organopolysiloxane containing the functionalized hindered amine can either be bonded to the polyolefin and/or blended with the polyolefin. The composition containing the foregoing can be used in combination with disulfides, phosphites or other non-amine antioxidants in molar ratios of about 1:1 to about 1:6 for additional oxidative and thermal stability, but, of course, it must be determined to what extent these latter compounds are extracted by the grease since this could affect the efficacy of the combination.
The following conventional additives can be added in conventional amounts if desired: ultraviolet absorbers, antistatic agents, pigments, dyes, fillers, slip agents, fire retardants, stabilizers, crosslinking agents, halogen scavengers, smoke inhibitors, crosslinking boosters, processing aids, e.g., metal carboxylates, lubricants, plasticizers, viscosity control agents, and blowing agents such as azodicarbonamide. The fillers can include, among others, magnesium hydroxide and aluminum trihydrate. As noted, other antioxidants and/or metal deactivators can also be used, but for these or any of the other additives, resistance to grease extraction must be considered. 1,2-bis(3,5-di-tert-butyl-4-hydroxy-hydrocinnamoyl)hydrazine added as an adjunct metal deactivator and antioxidant is desirable.
Additional information concerning grease-filled cable can be found in Eoll, The Aging of Filled Cable with Cellular Insulation, International Wire & Cable Symposium Proceeding 1978, pages 156 to 170, and Mitchell et al, Development, Characterization, and Performance of an Improved Cable Filling Compound, International Wire & Cable Symposium Proceeding 1980, pages 15 to 25. The latter publication shows a typical cable construction on page 16 and gives additional examples of cable filling compounds.
Additional examples of various polyolefins, organopolysiloxanes, and hindered amines useful in the invention can be found in U.S. Pat. Nos. 4,167,512; 4,190,571; 4,292,240; 4,297,497; 4,684,726; 4,895,885; 4,927,898; 4,935,063; 4,946,880; 4,948,888; and 4,952,619; and in European Patent applications 89201239.4 and 90420051.6.
The patents, patent applications, and other publications mentioned in this specification are incorporated by reference herein.
The invention is illustrated by the following examples.
EXAMPLES
Examples 1 to 4 are carried out under an atmosphere of dry nitrogen using conventional techniques.
Example 1
A three neck flask equipped with a Dean-Stark™ trap, a thermometer, an overhead mechanical stirrer, and a drop-wise addition funnel is charged with 484 grams of xylene and 430.2 grams of 2,2,6,6-tetramethyl-4-hydroxypiperidine and the mixture is dried by removal of a small amount of azeotrope. With the pot temperature at 100° C., three grams of a silicone fluid having the average structure: ##STR4## wherein x=5
y=15
are added followed by the addition of a slurry containing one gram of xylene and 201 milligrams of diiodo(2,5-cyclooctadiene)platinum(II). Over a one hour period, an additional 272 grams of the aforementioned silicone fluid are added drop-wise (caution: hydrogen evolution). The mixture is then allowed to stir for an additional 10 hours at 135° C. by which time infrared spectroscopy indicates an absence of the Si--H absorbance. Activated carbon is added, the mixture is allowed to cool to room temperature, and the mixture is pressure filtered through a small plug of diatomaceous earth. Solvent and the unreacted piperidine compound are removed under vacuum affording 684.5 grams of antioxidant A.
Example 2
Example 1 is repeated using 571 grams of xylene; 577.6 grams of the piperidine compound; 236 milligrams of the platinum compound; and a total of 250 grams of a silicone fluid (see above) wherein x=0 and y=20. The product is 812 grams of antioxidant B.
Example 3
The allyl ether of the piperidine compound referred to in Example 1 is prepared by reacting its potassium salt with allyl chloride in dimethoxyethane.
This ether (85.89 grams) and 109 grams of toluene are charged to a three neck flask fitted with a condenser, dropping funnel, mechanical stirrer, and thermometer. With the temperature held at 85° C., three grams of a silicone fluid (see above) wherein x=0 and y=30 are added followed by the addition of 0.54 milliliter of isopropanol containing 13 milligrams of chloroplatinic acid. An additional 20.1 grams of the silicone fluid are added drop-wise. After stirring at 85° C. for an hour, an additional 0.26 milliliter of the chloroplatinic acid solution is added. The mixture is allowed to react until infrared analysis indicates disappearance of the Si--H absorbance. Activated carbon is added, the mixture is allowed to cool to room temperature, and the mixture is pressure filtered through a small plug of diatomaceous earth. Solvent is removed under vacuum. The product is 98.6 grams of antioxidant C.
Example 4
Using conventional procedures, a silicone resin is prepared by partial hydrolysis of methyl triethoxy-silane with a quantity of water sufficient to afford a product containing 43.85 percent by weight ethoxy groups after removal of volatiles under vacuum. In a three neck flask equipped with a thermometer, a magnetic stirrer, and a distillation head, 513 grams of the silicone resin is combined with 571 grams of toluene, 629 grams of the piperidine compound referred to in Example 1, and 1.14 grams of sodium ethoxide in 4.3 grams of ethanol.
The mixture is then refluxed until a total of 4.1 moles of ethanol is removed as an azeotrope with toluene. After allowing the mixture to cool to room temperature, the mixture is treated with 1.26 grams of acetic acid. The volatiles are stripped by heating the crude mixture at 150° C. and 45 Torr. After treatment of the resulting fluid with 0.5 gram of activated carbon and 0.5 gram of diatomaceous earth at 150° C., filtration afforded 854 grams of antioxidant D.
Examples 5 to 10
Various materials used in the examples are as follows:
Polyethylene I is a copolymer of ethylene and 1-hexene. The density is 0.946 gram per cubic centimeter and the melt index is 0.80 to 0.95 gram per 10 minutes.
Antioxidants A to D are prepared in Examples 1 to 4, respectively.
Antioxidant E is an organopolysiloxane containing functionalized hindered amine moieties. It is prepared by the hydrolysis of the hydrosilylation product of methyldiethoxysilane with the allyl ether of 2,2,6,6-tetramethyl-4-hydroxypiperidine, as described in U.S. Pat. No. 4,946,880. Antioxidant E has a number average molecular weight of 1800.
Antioxidant F is 1,2-bis(3,5-di-tert-butyl-4-hydroxy-hydrocinnamoyl)hydrazine.
For examples 5 to 10, 10 mil polyethylene plaques are prepared for oxidation induction time (OIT) testing. The plaques are prepared from a mixture of polyethylene I and the antioxidants mentioned above.
A laboratory procedure simulating the grease filled cable application is used to demonstrate performance. Resin samples incorporating specified antioxidants are prepared. The samples are first pelletized and then formed into approximately 10 mil (0.010 inch) thick test plaques using ASTM D-1928 methods as a guideline. There is a final melt mixing on a two roll mill or laboratory Brabender™ type mixer followed by preparation of the test plaques using a compressor molding press at 150° C. Initial oxygen induction time is measured on these test plaques.
A supply of hydrocarbon cable filler grease is heated to about 80° C. and well mixed to insure uniformity. A supply of 30 millimeter dram vials are then each filled to approximately 25 millimeters with the cable filler grease. These vials are then cooled to room temperature for subsequent use. An oil extended thermoplastic rubber (ETPR) type cable filler grease is the hydrocarbon cable filler grease used in these examples. It is a typical cable filling compound.
Each ten mil test plaque is then cut to provide about twenty approximately one-half inch square test specimens. Before testing, each vial is reheated to about 70° C. to allow for the easy insertion of the test specimens. The specimens are inserted into the vial one at a time together with careful wetting of all surfaces with the cable filler grease. After all of the specimens have been inserted, the vials are loosely capped and placed in a 70° C. circulating air oven. Specimens are removed after 2 and 4 weeks, the surfaces are wiped dry with tissue, and the specimens are tested for OIT. After 4 weeks, the remaining specimens are removed, wiped dry, and placed in a static air chamber at 90° C. At various intervals, specimens are removed and tested for OIT.
OIT testing is accomplished in a differential scanning calorimeter with an OIT test cell. The test conditions are: uncrimped aluminum pan; no screen; heat up to 200° C. under nitrogen, followed by a switch to a 50 milliliters per minute flow of oxygen. Oxidation induction time (OIT) is the time interval between the start of oxygen flow and the exothermic decomposition of the test specimen. OIT is reported in minutes; the greater the number of minutes, the better the OIT. OIT is used as a measure of the oxidative stability of a sample as it proceeds through the cable filler grease exposure and the oxidative aging program. Relative performance in the grease filled cable applications can be predicted by comparing initial sample OIT to OIT values after 70° C. cable filler grease exposure and 90° C. oxidative aging.
Variables and results are set forth in the following Table.
TABLE______________________________________Example 5 6 7 8 9 10______________________________________Formulation(% by wt):Polyethylene 99.40 99.40 99.40 99.40 99.40 99.60Antioxidant A 0.20 -- -- -- -- --Antioxidant B -- 0.20 -- -- -- --Antioxidant C -- -- 0.20 -- -- --Antioxidant D -- -- -- 0.20 -- --Antioxidant E -- -- -- -- 0.20 --Antioxidant F 0.40 0.40 0.40 0.40 0.40 0.40OIT (minutes):Initial 214 198 173 218 196 1402 Weeks 193 174 157 171 183 984 Weeks 180 173 172 179 179 878 Weeks 154 150 146 126 152 6612 Weeks 140 136 119 115 -- 6816 Weeks 118 119 -- -- -- 65______________________________________
|
An article of manufacture comprising (i) a plurality of electrical conductors, each surrounded by one or more layers of a composition comprising (a) one or more polyolefins and, bonded thereto or blended therewith, (b) a linear or cyclic organopolysiloxane containing one or more functionalized hindered amine moieties; and (ii) hydrocarbon cable filler grease within the interstices between said surrounded conductors.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an LCD panel of large cell gap tolerance and an LCD projector using it, and more particularly, to an LCD panel of large cell gap tolerance and an LCD projector using it, in which a brightness change in each gray level and a transmittance rate change due to an alignment error are small by compensating a cell gap change.
2. Background of the Related Art
Recently, an Liquid Crystal Display(LCD) projector is utilized in a large display device for an HDTV or a large display device used for an announcement conference such as a seminar because of being small in its volume and easily adjusted in its projection screen size. In general, the LCD projector includes dichroic mirrors for dividing white light outputted from a light source into red, green and blue lights colors, LCD panels for modulating the divided lights with the dichroic mirrors and a projection lens for adding and magnifying lights outputted from the LCD panels.
A conventional LCD panel used in the LCD projector includes an Liquid Crystal (LC), of which properties are changed according to input voltage, pixel electrodes and a-common electrodes for applying the input voltage to the LC, and base plates on which the electrodes are formed. Furthermore, the base plates, on which the pixel electrodes are formed, further include TFTs (Thin Film Transistors) for applying/blocking voltage to/from LC layers every pixel. Here, the TFT is most used in the LCD panel of the LCD projector as being easy in multi-gray and fast response.
However, such LCD panel shows different properties according to its thickness. That is, according to the LCD panel thickness, a cell transmittance rate is changed small in high gray level but large in low gray level. Additionally, the LCD panel brightness is gradually lowered because an aperture ratio is lowered when the resolution of the LCD panel becomes gradually high.
Even though the LCD is manufactured by highly controlled processes, the LCD thickness is not uniform to depending on the position even in the same LCD panel. Furthermore, the different LCD panel thickness causes a different thermal expansion to depending on the position (or point) in the same LCD panel because the LCD panel receives lots of infrared rays and visible rays from the light source. For example, if there is a difference of temperature of 1° C. between glass base plates of the LCD panel, the cell gap is changed about 0.1 μm.
FIG. 1 illustrates a cross-sectional view of an LCD panel on which a conventional microlens is attached.
As shown in FIG. 1 , the LCD panel, on which the micro lens is attached, includes a first glass base plate 1 , TFTs 2 and pixel electrodes 3 formed on the first glass base plate 1 , a second glass base plate 6 formed in a predetermined interval from the first glass base plate 1 , a common electrode 5 directing the TFTs 2 and the pixel electrodes 3 and formed on the second glass base plate 6 , an LC layer 4 filled with LC and formed between the pixel electrodes and the common electrode 5 , and a micro lens 7 attached on an opposite side of the side the second glass base plate 6 , on which the common electrode 5 is attached.
The micro-lens 7 transmits light entering a BM(Black Matrix), a signal line or a scan line (, which are non-modulated areas) toward the pixel electrodes and increase effective aperture ratio.
FIG. 2 illustrates a detailed cross-sectional view of the pixel electrode of FIG. 1. A gate electrode 9 of the TFT 2 is connected to the scan line of the LCD panel, a source electrode 8 is connected to the signal line of the LCD panel, and a drain electrode 10 is connected to the pixel electrode 5 of the LCD panel.
An operation method of the LCD panel on which the micro lens is attached will be described as follows.
In case of a selection period of time:
If voltage of the gate electrode 9 connected to the scan line is larger than that of the source electrode 8 connected to the signal line, a connection resistance of a channel formed between the drain electrode 10 and the source electrode 8 becomes small. Therefore, voltage of the source electrode 8 connected to the signal line is formed between the pixel electrode 3 and the LC layer 4 .
In case of a non-selection period of time:
If voltage of the gate electrode 9 connected to the scan line is smaller than that of the source electrode 8 connected to the signal line, the connection resistance of a channel formed between the drain electrode 10 and the source electrode 8 becomes larger, and thereby the drain electrode 10 and the source
electrode 8 are electrically isolated. Therefore, the LC layer 4 keeps electric charge accumulated during the selection period of time.
If root means square (rms) voltage, which is applied to the LC layer 4 formed between the pixel electrode 3 and the common electrode 5 , is controlled when linearly polarized light emitted from a polarizer (not shown) mounted on the outside of the micro lens 7 passes the LC layer 4 through the micro lens 7 , the polarized state of the light is changed. The LCD pixel brightness is changed by the changed light selectively passing the analyzer mounted to the outside of the first glass base plate 1 of the LCID panel, and thereby the pixel brightness change as data information.
Meanwhile, the LCD projector according to the prior arts, according to LC mode, uses a 90° TN mode in case of a transmission type, a parallel oriented ECB (Electric Controlled Birefringence) mode in case of a reflection type, or a TN mode having a twist angle less than 90°.
Recently, the LCD panel used in the LCD projector shows resolution of 0.7 inch XGA level and may show resolution of 0.5 inch XGA level in the future.
However, the conventional LCD, on which the micro lens is attached, and the LCD projector using it has still several problems that the brightness change in each gray level is large and the transmittance rate change due to alignment error is large, and thereby the video quality is deteriorated and the production yield is low. The problems will be described in more detail, taking examples as follows.
FIG. 3 illustrates a graph showing a relative transmittance change in each gray level of the LCD panel according to the cell gap of the prior art.
As shown in FIG. 3 , G 0 indicates the reference, so the transmittance change is zero when the thickness is 4.0 μm, G 1 indicates the relative transmittance change when the cell gap is 4.4 μm, and G 2 indicates the relative transmittance change when the cell gap is 3.6 μm. Therefore, because the cell relative transmittance change differs about 40% or more according to the cell gap, the brightness change in each gray level is still large.
Therefore, even though the conventional LCD panel, on which the micro-lens is attached, places the focus on the pixel electrode, the brightness change in each gray level is large and the transmittance rate change due to the alignment error is large, thereby deteriorating the video quality and lowering the production yield.
Meanwhile, the LCD projector using the conventional LCD panel, on which the micro lens is attached, also has the above problems that the brightness change in each gray level is large, the transmittance rate change due to the alignment error is large, thereby deteriorating the video quality and lowering the production yield.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to an LCD panel of large cell gap tolerance and an LCD projector using it that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide an LCD panel of large cell gap tolerance and an LCD projector using it, which can minimize a transmittance rate change in each gray level by compensating the thickness of the LCD panel, to improve the video quality and the production yield.
Another object of the present invention is to provide an LCD panel of large cell gap tolerance and an LCD projector using it, which can minimize a transmittance rate change due to brightness and alignment errors in each gray level by compensating the thickness of the LCD panel, to improve the video quality and the production yield.
A further object of the present invention is to provide an LCD panel of large cell gap tolerance and an LCD projector using it, which minimize a transmittance rate change due to brightness and alignment errors in each gray level by placing focus of a micro lens on a central symmetric line of a slit pattern or a floating electrode and compensating the thickness of the LCD panel, to increase the video quality and the production yield.
A still further object of the present invention is to provide an LCD panel of large cell gap tolerance and an LCD projector using it, which can minimize a transmittance rate change due to a cell gap change and an alignment error using a side electric field property according to the cell gap change.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, an LCD (Liquid Crystal Display) panel having large cell gap tolerance includes: an LC (Liquid Crystal) having properties changed by input voltage, the LC changing a transmittance rate change of light incident from the outside; electrodes for applying voltage to the LC; base plates on which the electrodes are formed, each base plate having an LC layer located at prescribed intervals to inject the LC between the electrodes; a slit pattern or a floating electrode formed inside each electrode, changing voltage applied to the LC and compensating a cell gap change; and a micro-lens attached on one side of one of the base plates, the micro lens gathering lights, which are incident from the outside, on a central symmetric line of the slit pattern or the floating electrode.
In another aspect of the present invention, to achieve these objects and other advantages and in accordance with the purpose of the invention, an LCD projector includes: dichromatic filters for dividing light output form a light source into red, green and blue colors; LCD panels for modulating the lights by minimizing a transmittance rate change of the lights output from the dichromatic filters by compensating a value that multiplies a anisotropic refractive index(Δn) of LC and d(cell gap) in relation to a cell gap deviation in a gray level condition; and a projection lens for gathering and magnifying the lights output from the LCD panels.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings;
FIG. 1 illustrates a cross-sectional view of a conventional LCD panel on which a microlens is attached;
FIG. 2 illustrates a detailed cross-sectional view of a pixel electrode of FIG. 1 ;
FIG. 3 illustrates a graph showing a relative transmittance change in each gray level of the conventional LCD panel according to the cell gap;
FIG. 4 illustrates a cross-sectional view of an LCID panel, on which a micro-lens is attached, according to a first preferred embodiment of the present invention;
FIG. 5 illustrates a detailed cross-sectional view of a pixel electrode of FIG. 4 ;
FIG. 6 illustrates a view showing a structure of an equivalent circuit of a slit pattern of FIG. 4 ;
FIG. 7 illustrates a graph showing a relative transmittance change in each gray level according to the cell gap of the LCD panel, on which the micro-lens is attached, according to of the present invention;
FIG. 8 illustrates a view showing a relative transmittance change due to alignment error of the micro-lens;
FIG. 9 illustrates a cross-sectional view of an LCD panel using a micro-lens according to a second preferred embodiment of the present invention;
FIG. 10 illustrates a detailed cross-sectional view of a pixel electrode including a floating electrode of FIG. 9 ; and
FIG. 11 illustrates a view showing a structure of an LCD projector of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
FIG. 4 illustrates a cross-sectional view of an LCD panel, on which a micro-lens is attached, according to a first preferred embodiment of the present invention.
As shown in FIG. 4 , the LCD_(Liquid Crystal Display) panel, on which the micro-lens is attached, includes a first glass base plate 11 , TFTs 12 , pixel electrodes 14 and slit patterns 15 , which are formed on the first glass base plate 11 , a second glass base plate 18 formed in a predetermined interval from the first glass base plate 1 , a common electrode 17 directing the TFTs 12 and the pixel electrodes 14 which is formed on the second glass base plate 18 , an LC(Liquid Crystal) layer 16 filled with LC between the pixel electrodes 14 and the common electrode 17 , and the micro-lens 19 attached on an second glass base plate 18 . Here, the micro-lens 19 is positioned opposite side of the common electrode 17 with reference to the second glass base plate 18 is.
FIG. 5 illustrates a detailed cross-sectional view of the pixel electrode of FIG. 4 .
A gate electrode 21 of the TFT 12 is connected to a scan line of the LCD panel, a source electrode 20 is connected to a signal line of the LCD panel, and a drain electrode 22 is connected to the pixel electrode 14 of the LCD panel. Furthermore, the slit pattern 15 formed in the pixel electrode 14 is designed in such a manner that a cross-sectional center of a light spot 23 passing the micro-lens 19 is located at the center of the slit pattern 15 , i.e., a point where an X-axis symmetric line and a Y axis symmetric line of the slit pattern meet with each other. Here, a central symmetric line of the slit pattern 15 is a symmetric line, which divides the slit pattern 15 into two in a longitudinal direction.
An operation method of the LCID panel according to the present invention will be described as follows.
First, referring to the drawings, when voltage is applied to the LC layer, the relationship between an electric field induced to the silt pattern 15 and a voltage 5 distribution will be described as follows.
FIG. 6 illustrates a view showing a structure of an equivalent circuit of the slit pattern of FIG. 4 .
As shown in FIG. 6 , V1 and V3 indicate voltage formed on the pixel electrodes, and V2 indicates voltage formed on the common electrode. At this time, 10 assuming that there is a microelectrode at a part A in the slit pattern, C 1 , C 2 and C 3 indicate capacitances formed among the pixel electrodes, the common electrode and the microelectrode.
Therefore, induction voltage_(V(A)) induced to the microelectrode(A) of the slit pattern is obtained through the following equation(1):
V ( A )= C 1 V 1 +C 2 V 2 +C 3 V 3 +. . . /C 1 +C 2 + C 3 +. . . (1)
In the relationship between the voltage distribution_(V1, V3; V1=V3) induced to the microelectrode of the part A and the voltage distribution of the pixel electrodes, if the voltage distribution_(V1, V3; V1=V3) induced to the microelectrode of the part A is different from the voltage distribution of the pixel electrodes, the horizontal electric field of voltage corresponding to a difference between the voltage distribution(V1, V3; V1=V3) induced to the microelectrode of the part A and the voltage distribution of the pixel electrodes is applied between the microelectrode of the part A and the pixel electrode.
In the relationship between the cell gap change and the induction voltage distribution, the V(A) moves toward the voltage distribution of the common electrode because the capacitance_(C 2 ) between the microelectrode and the common electrode is increased if the cell gap is reduced, and the V(A) moves toward the voltage distribution of the pixel electrode because the capacitance_(C 2 ) is lowered if the cell gap is increased. That is, if dielectric anisotropic(A C) of LC is positive and a lateral electric field and a vertical electric field are applied at the same time, liquid crystal molecules increase a strength oriented horizontally if the lateral electric field becomes strong, but increase a strength oriented vertically if the lateral electric field becomes weak.
In the relationship between the cell gap change and LC anisotropic refractive index (Δn), LC anisotropic refractive index (Δn)is increased because the horizontal electric field is increased if the cell gap_(d) is reduced, but reduced because the vertical electric field is increased if the cell gap is increased.
Therefore, the cell transmittance is proportional to a value that multiplies anisotropic refractive index (A n) of LC and the cell gap_(d). If one of anisotropic refractive index (A n) of LC and the cell gap_(d) is increased, the other is reduced because anisotropic refractive index (A n) of LC and the cell gap_(d) are acted in opposite directions to each other. Therefore, the transmittance rate change of the LCD panel according to the cell gap change is reduced because the value that multiplies anisotropic refractive index (A n) of LC and the cell gap_(d) is changed small.
FIG. 7 illustrates a graph showing a relative transmittance change in each gray level according to the cell gap of the LCD panel, on which the micro lens is attached, according to the present invention. G 10 is a graph showing the transmittance rate change in case that a reference cell gap is 4.011 m, G 11 is a graph showing the transmittance rate change in case that the cell gap is 4.4 Fun, and G 12 is a graph showing the transmittance rate change in case that the cell gap is 3.6 μm.
The following table 1 shows the maximum transmittance rate when the cell gap is changed ±10% in case that a diameter of light spot gathered on a symmetric central line of the slit pattern through the micro-lens is 4μ like the width of the slit pattern, and the width of the pixel electrode is 4 μm.
TABLE 1
Graylevel
32
64
96
128
160
192
224
256
Maximum
16.4
4.2
8.2
14.1
15.5
17.8
15.4
3.1
Brightness
change (%)
As shown in the drawing, the width of the transmittance rate change according to the cell gap deviation of the LCD panel, on which the micro lens is attached, of the present invention is narrower in each gray level than that of the conventional LCD panel of FIG. 3 . That is, the LCID panel, on which the micro-lens is attached, according to the present invention is reduced in the alignment error and minimized in the light transmittance rate change.
FIG. 8 illustrates a view showing a relative transmittance change due to alignment error of the micro lens in a gray level 96 of FIG. 7 . The graph shows the relative transmittance rate that the transmittance rate within the range of light spot radius of 2 μm is integrated every point of 0.25 μm from the central symmetric line of the slit pattern.
For example, assuming that at a point x away from the central symmetric line and an integrated value of the transmittance rate of the light point radius of 2 μm from x is I(x), the integrated value of the transmittance rate of radius of 2 μm from the point 1 μm away from the x is I(x+1), and thereby the relative 5 transmittance rate(R(x)) is obtained by the following equation (2).
R ( x )= I ( X+ 1)/ I ( X ) X 100 (2)
Therefore, the relative transmittance rate change due to the alignment error is smallest when light passing the micro lens is incident on the central symmetric line of the slit pattern. That is, because an effect of the slit pattern is not shown when the light passing the micro lens is separated from the slit pattern, the micro lens is designed in such a manner that the micro lens places the focus on the central symmetric line of the slit pattern.
Meanwhile, the slit pattern is designed in such a manner that the width of the slit pattern is smaller than the cell gap because the operation voltage is increased and the light and dark contrast ratio is lowered if the width is increased. For example, if the cell gap is about 4 μm, the operation voltage is lowered and the light and dark contrast ratio is increased only when the width of the slit pattern is 4 μm. Therefore, to make the light, which passed the micro-lens, satisfy the above conditions and pass the slit pattern, the light must be located within 2 μm from the central symmetric line.
FIG. 9 illustrates a cross-sectional view of an LCD panel using a micro-lens according to a second preferred embodiment of the present invention.
As shown in FIG. 9 , the LCD panel, on which the micro lens is attached, includes a first glass base plate 11 , TFTs 12 and pixel electrodes 14 , which are formed on the first glass base plate 11 , floating electrodes 15 - 1 formed inside the pixel electrodes 14 , a second glass base plate 18 formed in a predetermined interval from the first glass base plate 11 , a common electrode 17 directing the TFTs 12 and the pixel electrodes 14 , which is formed on the second glass base plate 18 , an LC layer 16 filled with LC between the pixel electrode 14 and the common electrode 17 , and a micro-lens 19 attached on an opposite side of the side of the second glass base plate 18 . Here, the micro-lens 19 is positioned opposite side of the common electrode 17 with reference to the second glass base plate 18 .
FIG. 10 illustrates a detailed cross-sectional view of the pixel electrode including the floating electrode of FIG. 9 .
A gate electrode 21 of the TFT 12 is connected to a scan line of the LCD panel, a source electrode 20 is connected to a signal line of the LCD panel, and a drain electrode 22 is connected to the pixel electrode 14 of the LCD panel. Furthermore, the floating electrode 15 -I formed in the pixel electrode 14 is designed in such a manner that a cross-sectional center of a light spot 23 passing the micro-lens 19 is located at the center of the floating electrode 15 - 1 , i.e., a point where an X axis symmetric line and a Y axis symmetric line of the floating electrode 15 - 1 meet with each other. If the floating electrode 15 - 1 is designed to satisfy the above conditions, the transmittance rate change due to the alignment error is minimized like the slit pattern 15 of the first embodiment.
Meanwhile, because of the structure of the pixel electrode and the micro-lens, if the focus of the micro lens is not placed on the point where the symmetric lines of the X axis and the Y axis meet with each other, the focus is placed on one point of the central symmetric line.
In the LCD panel, in which the floating electrode 15 - 1 is formed inside the pixel electrode, voltage induced to the floating electrode is induced like the above equation 1 relative to the LCD panel, on which the slit pattern is formed, of the first embodiment. That is, because the floating electrode serves as the microelectrode (A) of the slit pattern of the first embodiment, the capacitance formed between the surrounding electrodes is equal to that formed between the microelectrode and the surrounding electrodes in an equivalent circuit.
Therefore, in case that there is the floating electrode, because voltage induced to the floating electrode is moved toward voltage of the common electrode if the cell gap is reduced, the horizontal electric field is increased, and thereby the cell refraction anisotropy is increased. To the contrary, because voltage induced to the floating electrode is moved toward voltage of the pixel electrode if the cell gap is increased, the anisotropic refractive index (A n) of LC is reduced.
The cell brightness is a function of a value that multiplies anisotropic refractive index (A n) of LC and the cell gap_(d). Here, because the cell refraction anisotropy_(Δn) and the cell gap(d) act in opposite directions to each other, the LCD panel including the floating electrodes formed on the pixel electrodes operates like the LCD panel having the slit pattern of the first embodiment. That is, the transmittance rate of the LCD panel including the floating electrodes is insensible to the cell gap change.
Therefore, the LCD panel, on which the micro lens is attached, according to the present invention can reduce the alignment error generated when the micro-lens is attached. Furthermore, the LCD panel according to the present invention can minimize the transmittance rate change by designing in such a manner that the focus of the micro lens is placed on the symmetric point of the slit pattern or the floating electrode. Thereby, the LCD panel can have improved color uniformity, color purity and color reproducibility.
Till now, the LCD panel according to the present invention is described in relation to the embodiments having the slit pattern and the floating electrode formed on the first glass base plate, but the slit pattern and the floating electrode may be formed on the common electrode. At this time, in case that the slit patterns or the floating electrodes are formed in the pixel electrodes, they are simultaneously formed when the pixel electrodes are formed. However, in case that the slit patterns or the floating electrodes are formed on the common electrode, a step of exposing the common electrode is added.
The LCD panel constructed as the above may be utilized as an LCD element of an LCD projector requiring high brightness and quality like conference data or HDTVs.
FIG. 11 illustrates a view showing a structure of the LCD projector of the present invention. The LCID projector includes a light source 40 generating and outputting white light, diachromatic filters or diachromatic mirrors 41 r , 41 b - 1 , 41 b - 2 and 41 g receiving the white light and dividing the white light into red, green and blue lights LCD panels 42 R, 42 G and 42 B for modulating (i.e., controlling the transmittance rate) and outputting the red, green and blue lights, refraction mirrors 43 1 and 43 - 2 for regulating a optical path of the lights, and a projection lens 44 receiving and magnifying the lights passing the LCD panels 42 R, 42 G and 42 B and outputting the magnified lights to a screen 45 .
Here, as described above, the LCD panels 42 R, 42 G and 42 B place the focus of the micro-lens on the center of the slit patterns or the floating electrodes formed on the pixel electrodes.
Therefore, the LCD projector according to the present invention can have excellent color uniformity, color purity and color reproducibility displayed on the screen.
The forgoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teachings can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art.
|
A LCD panel having the large cell gap tolerance includes: an LC (Liquid Crystal) having properties changed by input voltage and changing a transmittance rate change of light incident from the outside; electrodes for applying voltage to the LC; base plates on which the electrodes are formed, each base plate having an LC layer located at prescribed intervals to inject the LC between the electrodes; a split pattern or a floating electrode formed inside each electrode, changing voltage applied to the LC and compensating a cell gap change; and a micro-lens attached on one side of one of the base plates and gathering lights, which are incident from the outside, on a central symmetric line of the slit pattern or the floating electrode. The LCD panel of large cell gap tolerance and the LCD projector using it include LCD panels having large LCD cell gap tolerance.
| 6
|
BACKGROUND OF THE INVENTION
This invention relates to eyeglass holders and, more particularly, to improved eyeglass temple receiving and holding fixtures used on eyeglass holders.
With the ever increasing use of eyeglasses, there has been a commensurate increase in the use of eyeglass holders for holding the glasses on the head of the wearer or for retaining the glasses suspended from the neck of the user of the eyeglasses.
A typical eyeglass holder is comprised of a flexible, elongated strap which may or may not be elastic and which, at both its ends, mounts eyeglass temple receiving and holding fixtures. In some cases, the fixtures are made adjustable so as to receive and hold temples of varying sizes. In some instances, the fixtures are formed separately from the strap, while in others, they are an integral part thereof, most often when the entire holder is a molded product.
Many of the molded products in use today are undesirable in that when placed on glasses, the end of the fixture receiving the temple tends to poke into the head of the wearer. Similarly, many of the eyeglass holders using fixtures separate from the strap are undesirable in that they may be difficult to manufacture and/or they do not firmly grip the temple of the eyeglass.
SUMMARY OF THE INVENTION
It is the principal object of the invention to provide a new and improved eyeglass holder. More specifically, it is an object of the invention to provide a new and improved eyeglass temple-receiving and holding fixture for use with eyeglass holders.
An exemplary embodiment of the invention achieves the foregoing object in an eyeglass holder having an elongated flexible band terminating in opposed ends, each having eyeglass temple-receiving and holding fixtures thereon. According to the invention, there is utilized an improved fixture which comprises a unitary, elastomeric, molded part having a disc-like portion and an integral tail-like projection extending therefrom. An elongated slot is disposed in the projection.
In a highly preferred embodiment, the projection is considerably thicker than the disc-like portion and the slot extends along the majority of the length of the projection with the end of the slot nearest the disc-like portion being spaced therefrom.
A highly preferred embodiment of the invention also contemplates that the sides of the projection adjacent the disc-like portion taper inwardly from about the edge of the disc-like portion to the thickness of the disc-like portion at a point well short of the center thereof.
Preferably, the slot is substantially coplanar with the disc-like portion and, in a highly preferred embodiment, the fixture is symmetrical about the longitudinal axis of the projection so that it may be used on either end of the strap with equal facility and without concern for proper orientation thereon during assembly.
Other objects and advantages will become apparent from the following specification taken in connection with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a pair of eyeglasses having assembled thereto an eyeglass holder made according to the invention;
FIG. 2 is an elevational view of a fixture made according to the invention;
FIG. 3 is a plan view of the fixture;
FIG. 4 is an enlarged view of the fixture similar to FIG. 2, but illustrating the application of a securing means applied to the fixture along with an adjusting device; and
FIG. 5 is a view of the fixture similar to FIG. 3 but with the components illustrated in FIG. 4 assembled thereto.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of an eyeglass holder made according to the invention is illustrated in FIG. 1 in connection with a pair of eyeglasses, generally designated 10, having temples 12. The eyeglass holder consists of an elongated, flexible band or strap 14 which may be elastic if intended to be used only for retaining the glasses on the head of the wearer. Conventional means, including a buckle 16, are utilized for adjusting the length of the band 14.
The ends 18 of the strap or band 14 mount eyeglass temple receiving and holding fixtures 20. Preferably, at each end 18 there is provided a female snap connector of conventional construction for use in securing the fixtures 20 thereto.
Referring to FIGS. 2 and 3, each of the fixtures 20 is defined by a disc-like portion 22 which, as illustrated, is circular, and an integral, tail-like projection 24 extending therefrom. The fixtures 20 preferably are molded out of any suitable elastomer. The projection 24 has elongated slot 26 therein for receipt of one of the temples 12. It is to be observed that the slot 26 is closed ended and the end 28 nearest the disc-like portion 22 terminates at a location spaced from the disc-like portion 22. In a typical instance, the spacing will be on the order of 1/8 inch.
As best seen in FIG. 3, the sides 30 of the projection taper inwardly as at 32 from about the edge of the disc-like portion 22 to a point well short of the center 34 of the disc-like portion 22. FIG. 3 also illustrates that the slot 26 is coplanar with the disc-like portion and projection 24 is considerably thicker than the disc-like portion 22. It will also be seen that the fixture 22 is symmetrical about the longitudinal axis of the projection 24 so that the same part can be used as the fixture on either end of the strap 14 without regard as to whether the right or left temple 12 of the eyeglass is to be held thereby.
A small wire band 34 is applied to the projection 24 and is sized so as to substantially close the slot 26 at its location on the projection 24. By adjusting the position of the band 34, the effective length of the slot 26 may be varied to thereby adjust its size so as to provide tight gripping for any of a wide variety of differing size temples l2.
As seen in FIGS. 4 and 5, a male snap connector 36 of conventional construction has been secured to one side of the disc-like portion 22 by means of a conventional, penetrating locking ring 38. Thus, the fixture 20 may be easily assembled to the female snap connector on the strap 14.
Of considerable consequence to the present invention is the fact that the end 28 of the slot 26 terminates well short of the disc-like portion 22 and the presence of the blended or tapered sides 32 of the projection to the disc-like portion 22 in the manner mentioned previously. It has been determined by the applicant that such a construction is ideally suited for withstanding the localized stresses present at the interface of the projection 24 and the disc-like portion 22 which have prevented successful use of fixtures such as that of the present invention due to premature failure caused by such stresses.
The end of the projection 24 is generously rounded as at 40 (FIG. 4) and 42 (FIG. 5) to allow easy assembly of the band 34 to the projection 24 and to provide a structure free of corners which might poke into the head of the wearer or otherwise cause discomfort.
From the foregoing, it will be appreciated that an eyeglass holder made according to the invention is simply and economically manufactured and will reliably hold glasses having temples of a wide variety of sizes. It will also be appreciated that when the fixture 20 is secured to the band 14 such that the plane of the disc-like portion 22, and thus the slot 26, is essentially coplanar with the plane of the band 14 if straightened, there will be no tendency of the end of the projection 24 to poke into the head of the wearer.
An eyeglass holder made according to the present invention possesses substantial other advantages over similar holders using bent plastic tubing in forming the fasteners. In such prior art holders, the tubing is bent in half and then inserted in a machine which places the male snap fastener on the tubing to form a closed ended loop. The bend in the tubing generates a constant stretch or strain which occasionally fails due to the continuous nature of the stress thus imposed at the bend. The molded fastener of the present invention is totally lacking in molecular stress points which could crack or fail if stored or used over long periods of time.
Moreover, in holders using tubing-type fasteners, since the tubing is normally extruded, the molecular structure is less dense than that present in the molded fastener of the present invention. Thus, the fastener of the present invention is considerably stronger and less subject to distortion or tearing.
The configuration of a fastener made according to the invention lends itself to automatic assembly techniques, minimizing labor costs since the uniformity of its configuration lends itself to exact guide placement.
|
An eyeglass holder having an elongated, flexible band terminated in opposed ends each having eyeglass receiving and holding fixtures, the fixtures comprising unitary elastomeric molded parts having disc-like portions and integral tail-like projections extending therefrom, the projections being considerably thicker than the disc-like portions and having elongated, temple-receiving, closed ended slots extending along the majority of the length of the projections, the end of the slot nearest the disc-like portions being spaced therefrom.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to direct current discharge lamps and, more particularly, to improvements in a direct current discharge lamp for use in an optical instrument and to an improved light source using such lamp as attached to a reflector.
2. Description of the Related Art
Discharge lamps such as extra-high pressure mercury lamps and metal halide lamps are widely used in optical instruments such as liquid crystal projectors, OHPs and motion picture projectors and in general lightings. Such discharge lamps are highly advantageous in that their energy efficiency is three to five times higher than that of incandescent lamps such as halogen lamps, which emit light by heating filament, and their life time is five to ten times longer than that of such incandescent lamps.
Recently, demands have arisen from users, particularly from users of optical instruments that discharge lamps be further improved in life time, energy efficiency (specifically, to achieve a higher screen brightness per electric power applied to lamps) and evenness of screen brightness.
Intensive study and development have been made to improve discharge lamps for use in optical instruments so as to satisfy such demands; for example, enabling lamps to use direct current in order to enhance their emission efficiency in optical instruments, shortening the spacing between opposite electrodes to shorten the arc length or increasing the pressure in the lamps thereby improving the luminance of arc, and improving the reflecting efficiency of a reflector based on an improved arc luminance.
FIG. 4 shows a conventional discharge lamp (B). This conventional lamp (B) involves the following problems: (1) anode 12 b , which is heated to a higher temperature than cathode 12 a in DC lighting, is subjected to severe damage and loss, resulting in a substantial luminous flux attenuation from the initial period of use, hence in an unsatisfactory life time (refer to FIG. 5 ); (2) seal-cut portion 27 of bulb 21 a interfere with the light path to cause a 10 to 20% loss in lighting efficiency (refer to Table 1); (3) the seal-cut portion 27 is reflected on a screen as shadow causing uneven screen brightness (refer to Table 2); and like problems.
To solve the problems (2) and (3) of the above problems, study has made to develop tipless lamps which are fabricated without using any sealing tube so as to avoid formation of any seal-cut portion as indicated at 27 . Such tipless lamps are now being realized for a lower wattage.
Such tipless technique, however, involves not a few problems remaining unsolved. The first one is unfeasibility of obtaining lamps of a higher wattage due to process limitations. Specifically, a higher wattage lamp requires the use of a glass tube having a thicker wall and a larger diameter and this makes it difficult to achieve tipless sealing. The second one is incapability of preventing malfunction of a lamp due to impurities produced in the lamp. Specifically, in the manufacturing process of even a lower wattage lamp, certain amounts of impurities are produced from a glass tube used. The amounts of impurities grow larger as the wattage of a lamp grow higher because such a higher wattage lamps employs a larger glass tube. Larger amounts of impurities remaining in the lamp cause malfunction of the lamps. The third one is costly manufacture, which leads to expensive optical instruments such as a projector. Moreover, the problem (1) is left unsolved.
It is, therefore, an object of the present invention to provide a direct current discharge lamp having a prolonged life time.
Another object of the present invention is to provide a direct current discharge lamp enjoying an improved energy efficiency.
Yet another object of the present invention is to provide a direct current discharge lamp providing improved evenness in screen brightness.
Further object of the present invention is to provide a direct current discharge lamp of a higher wattage and to enable the manufacturing cost of a direct current discharge lamp to be reduced.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a direct current discharge lamp comprising a bulb portion containing therein an anode and a cathode, a first seal portion outwardly extending from the bulb portion on the anode side, a second seal portion outwardly extending from the bulb portion on the cathode side, a pair of feeder elements respectively inserted through the first and second seal portions for feeding electricity to the anode and cathode, and a extended tube portion interconnecting the bulb portion and the first seal portion.
With a conventional direct current discharge lamp, when the lamp is turned on, arc is produced between the anode and the cathode and electrons are emitted from the cathode toward the anode. This heats the anode to a high temperature with the result that the anode material is evaporated and scattered within the bulb portion to cause darkening of the bulb portion.
With the direct current discharge lamp of the above construction according to the present invention, in contrast, the provision of the extended tube portion which serves to extend the space adjacent the based portion of the anode allows the heat of the anode to dissipate easily. This suppresses the evaporation of the anode material from the anode, hence the darkening of the bulb portion. As a result, luminous flux attenuation is mitigated to prolong the lamp life time.
Preferably, the anode is extended from the bulb portion into the extended tube portion. This feature enables the anode to be lengthened relative to a conventional one. Such a lengthened anode has an increased heat capacity and allows easier heat dissipation thereby suppressing excessive heating of the anode. This advantage results in the lamp enjoying a further prolonged life time.
In a preferred embodiment the extended tube portion is formed with a seal-cut portion. Usually such a seal-cut portion is formed on the bulb portion as a trace of introducing filler substances (gases or the like) into the bulb portion and hence interferes with light passing therethrough. However, the advantageous feature according to the present invention that the seal-cut portion is located on the extended tube portion allows light from the luminous spot appearing adjacent the leading end of the cathode and from a region immediately next to the luminous spot to advance outwardly of the lamp without interference of the seal-cut portion. Thus, a screen when illuminated by such lamp is free of any shadow attributable to the seal-cut portion, resulting in a more even screen brightness.
The present invention also provides a light source comprising a reflector and a direct current discharge lamp, the lamp comprising a bulb portion containing therein an anode and a cathode, a first seal portion outwardly extending from the bulb portion on the anode side, a second seal portion outwardly extending from the bulb portion on the cathode side, a pair of feeder elements respectively inserted through the first and second seal portions for feeding electricity to the anode and cathode, and an extended tube portion interconnecting the bulb portion and the first seal portion and formed with a seal-cut portion, the first seal portion of the lamp being inserted into a central mounting hole of the reflector.
With this construction, the seal-cut portion is located adjacent the central mounting hole of the reflector, and even if light passing through the seal-cut portion is reflected by the reflector, such light does not pass through a liquid crystal panel or aperture of an optical instrument which restricts light adapted to illuminate the screen. Thus, any shadow caused by the seal-cut portion is not formed on the screen.
The foregoing and other objects, features and attendant advantages of the present invention will become apparent from the following detailed description of the preferred embodiments of the invention when read in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view showing a direct current discharge lamp according to a first embodiment of the present invention;
FIG. 2 is a sectional view showing a direct current discharge lamp according to a second embodiment of the present invention;
FIG. 3 is an explanatory sectional view showing a light source in which the direct current discharge lamp according to the second embodiment is mounted to a reflector and turned on;
FIG. 4 is a sectional view showing a conventional direct current discharge lamp; and
FIG. 5 is a graphic representation comparing the luminous flux attenuation rate per time of the lamp according to the present invention with that of a conventional lamp.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with reference to the drawings.
Referring to FIG. 1 showing a representative DC discharge lamp (A 1 ) according to a first embodiment of the present invention, the lamp (A 1 ) includes a lamp envelope 1 formed of quartz glass and comprising a spherical bulb portion 1 a , a rectangular seal portion 4 outwardly extending from one side of the bulb portion 1 a , an extended tube portion 6 outwardly extending from the opposite side of the bulb portion 1 a , and another seal portion 5 extending outwardly from the extended tube portion 6 . The bulb portion 1 a may be shaped otherwise, for example, like a rugby ball or elongated ellipse in section.
A seal-cut portion 7 formed on the bulb portion 1 a is a vestige of a thin tube 7 a shown in phantom, the thin tube 7 a having been in communication with the bulb portion 1 a so as to feed filler substances (gases) therethrough into the bulb portion 1 a and then sealed by heat cutting.
The extended tube portion 6 is a straight tube having an outer diameter smaller than the largest outer diameter of the bulb portion 1 a and an inner diameter larger than the outer diameter of anode 2 b . Each of the seal portions 4 and 5 is shaped rectangular by a known pinch sealing process and airtightly contains a feeder element 3 extending therethrough from the corresponding electrode (anode 2 b or cathode 2 a ).
The feeder element 3 comprises an inner lead pin 3 a joined or welded with the corresponding electrode 2 a or 2 b , an outer lead pin 3 c outwardly extending from the corresponding seal portion 4 or 5 , and a sealing foil 3 b of molybdenum embedded in the seal portion 4 or 5 and welded with the inner and outer lead pins 3 a and 3 c at opposite ends thereof.
In the present invention, the cathode 2 a typically comprises a thin tungsten pin which serves also as the inner lead pin 3 a , and a thick portion 14 comprising a tungsten coil or sleeve attached to the inner end of the thin tungsten pin, while the anode 2 b typically comprises a thick tungsten pin having a larger diameter than the cathode 2 a which is shaped into a truncated corn. Such features are employed because direct current is used.
The electrodes 2 a and 2 b face opposite each other with a predetermined spacing therebetween at a substantially central location in the bulb portion 1 a . The spacing between the electrodes is 1.5 to 2 mm in the embodiment, typically 0.5 to 3 mm, but not limited thereto.
The characteristic feature of the present invention which is highly advantageous over the prior art consists in that the provision of the extended tube portion 6 enables the anode 2 b to be lengthened extending from the substantially central location in the bulb portion 1 a into the extended tube portion 6 since the extended tube portion 6 has an inner diameter larger than the outer diameter of the anode 2 b and hence accommodates base portion 2 c of the anode 2 b with a sufficient spacing therebetween. This allows the anode 2 b to have a greater heat capacity than the conventional one and the space within the extended tube portion 6 to be used for heat dissipation from the anode 2 b . It is, of course, possible to use an anode having the same length as the conventional one and to utilize the extended tube portion 6 only as a heat dissipation space extending behind the anode.
Predetermined amounts of filler substances such as mercury, argon gas, other required filler gases and metal halides are encapsulated in the bulb portion 1 a through the thin tube 7 a which is sealed and cut by heating the base portion thereof after the completion of introduction of the filler substances. The seal-cut portion 7 is the vestige of sealing and cutting of the thin tube 7 a.
When the direct current discharge lamp (A 1 ) thus constructed is turned on, arc is produced between the cathode 2 a and the anode 2 b and electrons are emitted from the cathode 2 a toward the anode 2 b thereby heating the anode 2 b . The additional space provided around the base portion of the anode 2 b by the extended tube portion 6 enables the anode 2 b to dissipate heat easily. As a result, evaporation and scattering of the anode forming material is suppressed and, hence, darkening of the bulb portion 1 a is suppressed. This mitigates the luminous flux attenuation of the lamp, resulting in the lamp enjoying a prolonged life time.
Though not shown, it is possible to shorten the anode 2 b to have the same length as the conventional one and extend the inner lead pin 3 a so as to pass through the extended tube portion 6 . This construction also allows easy heat dissipation by virtue of the extended space provided by the extended tube portion 2 b and hence suppresses the loss of the anode forming material.
Referring to FIG. 2 showing a direct current discharge lamp (A 2 ) according to a second embodiment of the present invention, features different from those of the first embodiment are described in detail and the description of common features is omitted.
In the second embodiment seal-cut portion 7 is formed on extended tube portion 6 unlike the first embodiment. The second embodiment provides the following advantages in addition to those provided by the first embodiment.
That is, since the seal-cut portion 7 is located on the extended tube portion 6 , light from luminous spot 11 appearing adjacent the cathode 2 a and from a region immediately next to the luminous spot 11 is outwardly emitted through the bulb portion 1 a without interference of the seal-cut portion 7 . Thus, the lamp (A 2 ) according to the second embodiment does not cause a shadow attributed to the seal-cut portion 7 on a screen, thereby ensuring an improved evenness in screen brightness.
The lamp (A 2 ) thus constructed can advantageously used as a light source incorporated in an optical instrument as well as for general lighting. In such optical instrument the lamp (A 2 ) is usually attached to a reflector 8 . In this case the seal-cut portion 7 located on the extended tube portion 6 , which would be responsible for a decreased evenness in screen brightness and for a shadow if it is located on the bulb portion 1 a as in the lamp (A 1 ), does not cause any decrease in screen brightness such as a decreased evenness in luminance and a shadow. Thus, the lamp (A 2 ) is capable of improving the evenness in screen brightness and eliminating shadow on the screen.
Specifically, when direct current is applied to the lamp (A 2 ), arc 12 comprising luminous spot 11 appearing adjacent the cathode 12 and a light-emitting portion 13 surrounding the luminous spot 11 is produced between the electrodes 2 a and 2 b . In attaching the lamp (A 2 ) to reflector 8 the seal portion 5 on the anode side is inserted into tubular portion 8 a of the reflector 8 so that the luminous spot 11 coincides with the focus of the reflector 8 , and then fixed thereto with an adhesive or a metal fixture.
In a certain type of optical instrument the lamp (A 2 ) attached to the reflector 8 as a light source is located behind an LCD panel. A portion of light from the lamp (A 2 ) passes through liquid crystal portion 9 of the LCD panel or an aperture to form an image on the screen 10 , while other portions of light which do not pass through the liquid crystal portion 9 or the aperture do not reach the screen 10 .
With a conventional direct current discharge lamp (B) having a seal-cut portion on a bulb portion as shown in FIG. 4, light passing through the seal-cut portion 27 on the bulb portion 21 a reaches the screen through the liquid crystal portion 9 or the aperture to cause a shadow on the screen 10 .
With the lamp (A 2 ) of the present invention, in contrast, light passing through the bulb portion 1 a and the liquid crystal portion ( 9 ) or the aperture is entirely free of distortion and hence never causes any shadow on the screen.
EXAMPLE 1
The life time of lamp (A) according to the present invention was compared with that of the conventional lamp (B). The results are shown in FIG. 5 in which the ordinate represents luminous flux attenuation (%), the abscissa represents time; curve (A) represents the luminous flux attenuation of the lamp (A 2 ) according to the present invention; and curve (B) represents the luminous flux attenuation of the conventional lamp (B).
As can be seen from FIG. 5, the luminous flux of the conventional lamp (B) sharply dropped in the initial lighting period and then gently dropped, while the luminous flux of the lamp (A) did not sharply dropped in the initial lighting period but gently dropped throughout the test period. From this test it is found that the lamp (A) of the present invention had a greatly improved lift time as compared to the conventional lamp (B).
EXAMPLE 2
Five test samples (AI to AV) of lamp (A 2 ) shown in FIG. 2 were prepared in which predetermined amounts of mercury, a metal halide or a mercury halide, argon gas and other inert gases were encapsulated and the spacing between the electrodes was 1.5 mm. Similarly, five test samples (BI to BV) of conventional lamp (B) were prepared under the same conditions as above.
These test samples were DC-operated with use of a 250W ballast to compare the screen brightness of the lamp (A 2 ) of the present invention to that of the conventional lamp (B). The results are shown in Table 1.
TABLE 1
SCREEN BRIGHTNESS
Working distance
Aperture DIA
Total luminous
(mm)
(mm)
flux (lm)
BI
48
8
4410
BII
48
8
4550
BIII
48
8
4320
BIV
48
8
4250
BV
48
8
4520
Average
4410
AI
48
8
5200
AII
48
8
5150
AIII
48
8
5300
AIV
48
8
5500
AV
48
8
5400
Average
5410
As seen from Table 1, lamp (A 2 ) having a seal-cut portion 7 on the extended tube portion 6 showed a remarkable increase in total luminous flux and hence in screen brightness.
It is to be noted that the working distance as used in Table 1 was a distance (L) from the opening of reflector 8 to aperture 9 .
In turn, these test samples were tested for the extent of luminance unevenness and the percentage of luminance unevenness with use of a 40-inch screen. The percentage of luminance unevenness was obtained from the formula: x/y×100 where x is the lowest illuminance of an observable luminance unevenness and y is the highest illuminance of the observable luminance. The results are shown in Table 2.
TABLE 2
LUMINANCE UNEVENNESS TEST
Extent of
Luminance
Visual
luminance
unevenness
observability
unevenness (mm)
(%)
BI
observable
70
75
BII
ditto
70
70
BIII
ditto
50
80
BIV
ditto
70
70
BV
ditto
80
60
Average
68
71
AI
unobservable
0
0
AII
ditto
0
0
AIII
ditto
0
0
AIV
ditto
0
0
AV
ditto
0
0
Average
0
0
As can be seen from Table 2, the lamp (A 2 ) of the present invention did not cause any observable shadow (luminous unevenness) and exhibited excellent performance in terms of the extent of luminance unevenness and of the percentage of luminance unevenness.
While only certain presently preferred embodiments of the present invention have been described in detail, as will be apparent for those skilled in the art, certain changes and modifications can be made in embodiment without departing from the spirit and scope of the invention as defined by the following claims.
|
A direct current discharge lamp includes: a bulb portion 1 a containing therein an anode 2 b and a cathode 2 a ; a first seal portion 5 outwardly extending from the bulb portion 1 a on the anode side; a second seal portion 4 outwardly extending from the bulb portion 1 a on the cathode side; a pair of feeder elements 3 respectively inserted through the first and second seal portions 5 and 4 for feeding electricity to the anode 2 b and cathode 2 a ; and an extended tube portion 6 interconnecting the bulb portion 1 a and the first seal portion 5.
| 7
|
INTRODUCTION
[0001] 1. Field of the Invention
[0002] The invention relates to processing of messages such as SMS messages.
[0003] 2. Prior Art Discussion
[0004] Control of SMS messages being sent and/or received allows operators to apply additional services to them. These services can have different ways of impacting the message, such as:
no impact, e.g. creating a message copy message modification, e.g. inserting an advertisement into the message or forwarding a message and inserting a forwarding indication message blocking, e.g. content control (keyword filtering)
[0008] A feature in 3GPP 23.040 allows mobile handsets to divide a long text message into multiple segments, and pass each segment as an individual SMS message into the mobile network. Only the receiving mobile handset is expected to collect all segments, and present them as a single message to the mobile recipient.
[0009] Within the operator's mobile network, this handling of multiple segments as an individual message can conflict with the goal of controlling the complete message in order to apply a service.
[0010] Currently SMS routers are used in practice to off-load SMSCs or to intercept SMS messages to allow for the creation of additional services. Due to the nature of SMS standardization, these SMS routers are not able to transparently handle concatenated messages when service needs to be applied. All elements of the concatenated message are first retrieved and stored temporarily to be able to apply the appropriate service(s) on the complete message.
[0011] As a result, billing information and delivery reports are no longer correctly reflected to the originating handset or SMSC. No way to properly handle concatenated messages in a transparent manner was defined in standardization, and as a result even a newer standard like the IP-SM-GW now explicitly describes the non-transparent handling (TS23.204 section 6.9).
[0012] Main problems with this non-transparency include:
Billing between operators is based on the actual delivery outcome. By introducing non-transparency, the billing for the originating operator is no longer based on the actual delivery of the MT-FSM message. Moreover applying a non-transparent MT delivery behaviour breaks legislation for some European countries that requires that billing is applied for SMS throughout service when the message is actually delivered. In many countries there are legal requirements that require a reliable indication (SMS notification) to the originator whether the SMS was actually delivered. Non-transparent behaviour breaks the possibility to commit to this legal requirement.
[0015] Due to non-transparency, it will either be very difficult (requiring changes to the operator inter-billing environments) or even not be possible (violation of the law) for operators to introduce advanced services in the MT path.
[0016] In a conventional mobile network the basic message flow of a CM is shown in FIG. 1 (success) and FIG. 2 (temporary delivery failure for first segment).
[0017] It should be noted that:
for each segment, the submission leg and delivery leg are independent (as Service Centre takes care of store+forward), in the message submission leg, the submitting handset only starts sending a next segment once the acknowledgement of the Service Centre for the previous segment has been received, and in the message delivery leg, the Service Centre will only attempt a delivery for a next segment, once the previous segment is reported as successfully delivered.
[0021] The timing as depicted in this flow is one of many variations. In principle, the timing of the delivery flows from the service center to handset B is totally de-coupled from the timing of the submission flow by handset A, with as the only constraint that the delivery of a segment to handset B cannot start before the Service Center has received it from the handset A.
[0022] There are no constraints in standardization that all segments go to the same Service Centre. For example, if handset A is moving and the Service Centres are bound to a specific region, it can occur that segment 1 is submitted to Service Center 1 and Segment 2/3 to Service Center 2 due to the handset crossing a geographical boundary and reconnecting to Service Center 2.
[0023] Due to the acknowledged nature of the protocol, it is unlikely that SMS segments will be submitted out of sequence into the network. The handset will only send a next segment after the previous segment was acknowledged successfully.
[0024] In addition, delivery may not be directly possible. In such a case, it can occur that the delivery of the first segment already fails, and the Servcie Center uses its retry schedule to deliver to the B handset (note: this scenario also shows how the de-coupling of submission and delivery as the Handset A will continue submitting regardless of the delivery attempts of the Service Center).
[0025] Though in theory segments could arrive out of sequence, in practice this does not often occur. In practice, in any SMSC the messages are ordered by B-party number to ensure in-sequence delivery of messages and multi-level routing or dedicated service center addresses are used to ensure that submitted messages to the same B party from various locations in the network are always sent to the same SMSC, thus ensuring that in practice all segments will be delivered in sequence as they are sent from the same SMSC.
[0026] When an SMS router is put in the operator's network to control MO and MT message streams, the concatenated messages need to be stored before any service(s) can be applied to the full content of the message. This behavior is intrusive for the original message stream and causes billing problems for messages that require service(s). FIG. 3 is a depiction of the current functionality for MO concatenated messages that require service.
[0027] In the call flow diagram of FIG. 3 it is shown that all MO elements of the MO concatenated message are first being acknowledged (and stored) by the SMS router then the service is applied (i.e. archiving of the message), and then the original message is handed over towards the operators service centre for storage and MT delivery.
[0028] For MT FIG. 4 depict the current implementation. The MT flow is slightly more complicated: whereas in the MO flow the SMS router resides in the same network as the Service Center, in the MT flow often the SMS router is located in another network than the Service Center.
[0029] The invention addresses the problem of non-transparency in processing of concatenated messages.
SUMMARY OF THE INVENTION
[0030] According to the invention, there is provided a message router comprising a message controller with service logic functions, and a state database, wherein the controller is adapted to:
receive and process message segments, maintain state of single and concatenated messages, and to apply services to said messages.
[0034] In one embodiment, the router further comprises a routing and discrimination engine adapted to access a selected state database among an associated database and distributed state databases.
[0035] In one embodiment, the message controller is adapted to operate in a transparent-relay mode in which a message is relayed to a network element and the response from the network element is returned directly to an originator.
[0036] In one embodiment, the relayed message is a MAP message or its equivalent.
[0037] In one embodiment, the relaying is performed using SCCP relaying.
[0038] In one embodiment, the controller is adapted to operate in a transparent-proxy mode in which the controller generates a fresh message and sends it to a network element and receives the response from the network element, and in turn returns a response to the originator.
[0039] In one embodiment, the message is a MAP message or its equivalent.
[0040] In one embodiment, the network element is a service centre or a switching centre.
[0041] In one embodiment, in the transparent relay mode the controller is adapted to perform the steps of:
receiving a segment of a concatenated message, and determining that a particular service needs to be applied on the originator of the message, making a copy of this segment and placing this in the state database, relaying the original message to its original destination, and the response from this destination is directly routed towards the original originator of the message, receiving a subsequent segment and determining that this is a concatenated message and determining what service need to be applied, a subscriber service database indicating that an archive service needs to be applied and copying the message into the state database, and the original messages is directly handed over towards the original destination, and repeating these operation if another subsequent segment is received, and checking that all elements have arrived in a temporary message storage in the state database, and reassembling the full message context.
[0050] In one embodiment, the state database is selected based on the TP-OA, TP-DA and a concatenated short message reference number, which combination uniquely identifies a concatenated message from the originator device.
[0051] In one embodiment, the controller is adapted to use a distributed state database to operate when a subsequent segment arrives at the same SMS router instance or another SMS router instance.
[0052] In one embodiment, the controller is adapted to modify the message header to indicate that an additional segment will be part of the message.
[0053] In one embodiment, the service is an archive service.
[0054] In one embodiment, the service is modification of the content of the MO message, for example, introduction of an auto-signature into the message, or changing of the TP-OA to an alias.
[0055] In one embodiment, upon receipt of the first segment, the controller is adapted to store characteristics of the message in the state database and the auto-signature modification planned on the message.
[0056] In one embodiment, for a last segment, the controller is adapted to create a new segment containing the last of the contents concatenated with the start of the modified content, such as the auto-signature, and the controller is adapted to emit a new PDU towards the network element with this content and wait for the response of the network element.
[0057] In one embodiment, if the acknowledge of the network element is positive, the controller is adapted to change contents of a previously received segment to indicate that the current segment is the last and will add a tail of the auto-signature to the contents.
[0058] In one embodiment, the router controller further comprises a discriminator function to check with the state database whether processing of this message is in progress, and wherein the state database is adapted to indicates which service is in progress.
[0059] In one embodiment, for an intermediate segment a message reference is used that was not used by the device in the previous segments and a request for a status report is switched off, thus ensuring that status reports are only generated for the segments for which the originating device requested a status report and that the message reference still matches with the device-generated message reference, thus uniquely identifying a message submit operation.
[0060] In one embodiment, when operating in the proxy mode, the response is known to the router and the controller is adapted to act upon it according to the determined service.
[0061] In one embodiment, the controller is adapted to archive messages that were accepted by a service centre instead of submitted by a user device, based on knowledge as to whether the service centre accepted the message.
[0062] In one embodiment, the service is adding of content in the message.
[0063] In one embodiment, the router is adapted to perform the steps of:
receiving a message segment, determining from a service database what service needs to be applied, in this case addition of content for the recipient of the message, reserving an entry in the state database for this message, storing the content and the original message, modifying the original segment count to indicate the increased size to the receiving user device, creating text of the segment and sending it to the user device, and if this is a subsequent segment the response is used to determine whether to sent the original segment with adapted text) as well and if not it is directly returned as a negative response to the originating service centre, receiving subsequent segments from the service centre and determining from the state database that that text modification is in progress and using the text segment and content stored in the database to create a next text segment to be sent to the user device, and delivering this segment to the user device, and returning the response form the user device to the service centre.
[0072] In one embodiment, the router is adapted to generate additional segments in the message when the additional content is being inserted, or only at the end.
[0073] In one embodiment, by retaining this state, if the message cannot be delivered to the user device or the response towards the service centre is lost, in the case of a retry the same modification can be re-applied towards the same segment.
[0074] In one embodiment, the controller is adapted to deliver the message segments to ensure that delivery reports generated by the originating service centre are still correct, even though the concatenated message is diverted to another user device and content indicating the diversion is pre-pended to the message.
[0075] In one embodiment, if the service database indicates that a diversion service needs to be applied on the recipient of the message from B to C the controller is adapted to create a new segment containing the diversion text, making use of the fact that the new segment does not have to be full but can contain only the necessary character, and the fact that this diversion is in progress is stored in the state database.
[0076] In one embodiment, the controller is adapted to perform content control in which:
at a first received message segment, an additional segment is inserted in a maximum segment count and this segment is used to cater for partial matches of forbidden content, for each segment, the content is searched for ‘trigger’ keywords or phrases and if no phrase match is found the segment is passed as it is. if a match is found, the appropriate content control action is taken such as do not deliver, or modify the text, if a partial match is found at the end of a segment, the beginning of the segment is sent out, and the tail of the segment is stored in the state database, when the next segment arrives, the partial match and the contents of the new segment are searched for violations, this procedure continues until all segments have been passed through the router, and by reserving any extra segment it is possible to not send out potential matches at the end of the text and instead, this text is retained until the next segment arrives and only then checked again when the full context is known.
[0083] In one embodiment, the controller is adapted to handle out of sequence segments.
[0084] In one embodiment, the controller is adapted to add any modifications only to the head of the message, as only the first segment contains information on the nature of the pay-load of a message.
[0085] In another aspect, the invention provides a computer program product comprising a computer usable medium having a computer readable program code embodied therein, said program code being adapted to be executed to:
receive and process message segments, maintain state of single and concatenated messages, and apply services to said messages.
[0089] In another aspect, the invention provides a method of operation of a message router comprising a message controller with service logic functions, and a state database, the method comprising the steps of:
receiving and processing message segments, maintaining state of single and concatenated messages, and applying services to said messages.
[0093] The invention also provides other method aspects as set out above in the various embodiments
DETAILED DESCRIPTION OF THE INVENTION
[0094] The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only with reference to the accompanying drawings in which:—
[0095] FIGS. 1 to 4 are message flows of the prior art as outlined above;
[0096] FIG. 5 is a diagram illustrating architecture of an SMS router of the invention;
[0097] FIG. 6 is a sequence diagram for MO transparent-relay concatenated message flow;
[0098] FIG. 7 is a sequence diagram showing a flow with the introduction of an auto-signature;
[0099] FIG. 8 is a sequence diagram showing MO transparent-proxy concatenated message flow in another embodiment;
[0100] FIG. 9 shows MT transparent-proxy concatenated message flow; and
[0101] FIG. 10 shows desired MT transparent-relay concatenated message flow.
GLOSSARY OF TERMS AND THEIR DEFINITIONS
[0102]
[0000]
Acronym
Meaning
Explanation
MO
Mobile Originated
SMS message from a mobile to an
SMSC
MT
Mobile Terminated
SMS messages from an SMSC to a
mobile
CM
Concatenated Message
SMS messages consisting of multiple
SMS
3GPP
3rd Generation
Standard for G3 network
Partnership Project
TP-DA
TP-Destination
Destination Address in an 23.040
Address
SMS PDU
TP-OA
TP-Originator
Originator Address in an 23.040
Address
SMS PDU
TP-MR
TP-Message Reference
Message Reference number in an
23.040 SMS PDU
UD
User Data
The User Data (pay-load) of a 3GPP
TS23.040 SMS message PDU.
UDH
User Data Header
First bytes of the user data field
(Message Text Field) that provides
information on for example segmen-
tation and other information on the
properties of the User Data
SMS
Component capable of handling the
router
SMS protocol without the store &
forward capability that is standar-
dized as part of an Service Center.
Trans-
A transparency mode where the SMS
parent-
router relays the MAP message using
relay
SCCP relaying to the Service
Center/MSC and the response from
the Service Center/MSC is returned
directly towards the originator of
the request bypassing the router.
Trans-
A transparency mode where the SMS
parent-
router emits a new MAP message to
proxy
the Service Center/MSC, the
response from the Service Center/
MSC is returned towards the router
and the router then returns the
response to the original request
to the originator.
[0103] The invention achieves handling of the SMS messages transparently towards the network, while at the same time allowing services on the message as a whole.
[0104] An SMS router of the invention has conventional hardware components, and additional functionality illustrated in FIG. 5 , including:
a state database, maintaining state of (single) and concatenated SMS messages being sent through the network, service logic, allowing for the application of services on single and concatenated SMS messages and with an interface for serviced traffic (e.g., message copies), a routing and discrimination engine, allowing for the selection of a specific state database in a distributed implementation of the invention, SMS interface, providing the 29.002 MAP interface and the 23.040 SMS encoding, a controller, responsible for the finite state machine/flow through the various components, and an (external) service database, indicating which services to apply to which subscriber.
[0111] In order to become less intrusive for the original message flow it is proposed with this invention to handle concatenated messages and apply their service(s) in the following way. The call flows discriminate on two different types of handling for MO (Scenario 1A & 1B) and MT (Scenario 2A & 2B) concatenated messages:
Transparent-relay (see Glossary) Transparent-proxy (see Glossary)
Use case of Invention 1A & 1B (Mobile Originated)
[0114] FIG. 6 : MO Transparent-Relay Concatenated Message flow on the invention (Invention model 1A), FIG. 8 MO Transparent-proxy Concatenated Message flow on the invention (Invention model 1B) describe the desired implementation and handling for these two types (Transparent-relay and Transparent-proxy) of concatenated messages where service(s) needs to be applied in the MO leg of the SMS message (i.e. an archive service).
The SMS router receives segment 1 of 3 (where the UDH indicates to the invention that this is a concatenated message). The router triggers to determine what service needs to be applied. The service database indicates that an archive service needs to be applied on the originator of the message. (Not depicted) The SMS router makes a copy of this segment message and places this in the state database. The state database is selected by the router/discriminator based on the TP-OA, TP-DA and the ‘Concatenated short message reference number’ (the first octet of the concatenation IEI field). This combination uniquely identifies a concatenated message from the Handset A (note TP-MR cannot be used as it is incremented for each segment). The router will now SCCP relay the original message to its original destination (Local SMSC). The response from this destination is directly routed towards the original originator of the message. The router receives segment 2 of 3. UDH indicates that this is a concatenated message and triggers the subscriber service database to understand what service(s) need to be applied. (Not depicted) The subscriber service database again indicates that an archive service needs to be applied and the invention will copy the message into the appropriate state database using the procedure described above. After that the original messages is directly handed over towards the original destination (Local SMSC). Note the second segment can arrive at the same SMS router instance or another SMS router instance, this is why the router/discriminator together with the distributed state database is of importance. The router receives segment 3 of 3. UDH indicates that this is a concatenated message and triggers the subscriber service database to understand what service(s) need to be applied. (Not depicted) The subscriber service database indicates that an archive service needs to be applied and the invention will copy the message into the appropriate state database using the procedure described above for reassembly. After that the original messages is directly handed over towards the original destination (Local SMSC) The router controller will see that all elements have arrived in the temporary message storage in the state database (Based on the UDH information) and will now start to reassemble the full message context. This can now be included in the service traffic interface towards an external system to apply the archive service.
[0123] This procedure will copy any attempt to submit a concatenated message by the handset regardless of whether the service center accepts it. In practice, this may not always be desirable for a copy service, and in that case the next flow may be more appropriate.
[0124] An alternative function for which the above flow can be used are modifications to the content of the MO message, for example, the introduction of an auto-signature into the message, the changing of the TP-OA to an alias. The changing of the TP-OA to an alias is trivial as it consists of changing an existing field only and does not result in changes to the segmentation.
[0125] Handling of error situations: if the SMSC does not respond with an accept of the message but with a temporary error, the handset A will retry the sending of each not accepted segment. The SMS router detects this as the combination of TP-OA, TP-DA and ‘Concatenated short message reference number’ is already present in the database, thus ensuring that a copy of any submission attempt is created only once.
[0126] As an example, the introduction of an auto-signature (which combines the generation of an additional message segment in proxy mode with the submission of the original segments in relay mode) is given in FIG. 7 .
[0127] Referring to FIG. 7 :
The router receives segment 1 of 3 (where the UDH indicates to the invention that this is a concatenated message) the invention triggers the service database to determine what service needs to be applied. The service database indicates that an auto-signature service needs to be applied on the originator of the message. The router will now store the characteristics of the message in the state database and the auto-signature modification planned on the message (extending it with a number of characters). The state database in a specific instance (in the case of a distributed implementation) is selected by the router/discriminator based on the TP-OA, TP-DA and the ‘Concatenated short message reference number’ (the first octet of the concatenation IEI field). This combination uniquely identifies a concatenated message from the Handset A (note TP-MR cannot be used as it is incremented for each segment). The router will now modify the UDH in the message to indicate that an additional segment will be part of the message (i.e., segment 1 of 4) and SCCP relay the original message to its original destination (Local SMSC). The response from this destination is directly routed towards the original originator of the message. It is always necessary to reserve space for the additional segment as it is known at segment 1 what the total length of the message is (i.e., whether the last segment has sufficient room available for the auto-signature or not). The router receives segment 2 of 3. UDH indicates that this is a concatenated message. The controller uses the Router/Discriminator to check with the state database whether processing of this message is in progress. The state database indicates that processing is in progress, in this case an auto-signature is being applied. The controller will change the UDH of this message to indicate that it is segment 2 of 4 and SCCP relay the resulting PDU to the Service Center. The router receives segment 3 of 3. UDH indicates that this is a concatenated message. The controller uses the Router/Discriminator to check with the state database whether processing of this message is in progress. The state database indicates that processing is in progress, in this case an auto-signature is being applied. As this is the last segment, the controller will create a new segment containing the last of the contents concatenated with the start of the auto-signature that still fits in the segment, with as its segment indication segment 3 of 4. The controller emits a new PDU towards the Service Centre with this content and waits for the response of the Service Centre. If the acknowledge of the Service Centre is positive, the controller with change the contents of the previously received segment to indicate segment 4 of 4 and will add the tail of the auto-signature to the contents. It will then SCCP relay the resulting PDU to the Service Centre. The Service Centre acknowledges this final PDU to the handset.
[0137] As a result of this way of operating, the content of the message was successfully changed while minimizing the total number of SS7 PDUs needed through the use of SCCP relaying. Care must be taken that in the intermediate segment a TP-MR is used that is not used by the handset in the previous segments and that a request for a status report is switched off. This ensures that status reports are only generated for the segments for which the originating handset requested a status report and that the TP-MR still matches with the handset generated TP-MR thus uniquely identifying the SMS-SUBMIT.
[0138] Error situations are handled correctly as the state is retained for the validity period of the message, thus ensuring that if a segment is re-submitted the same modifications are applied to the segment again.
[0139] When operating in proxy mode, the response is known to the SMS router as well and it can act upon it. Proxy mode is also mandatory if the MAP versions between handset A and the message router of the invention and between the message router of the invention and Service Center are not the same.
The router receives segment 1 of 3 (where the UDH indicates to the invention that this is a concatenated message) invention triggers to determine what service needs to be applied. The service database indicates that an archive service needs to be applied on the originator of the message. (Not depicted) The router will now make a copy of this segment and places this in the state database. The state database in a specific invention instance (in the case of a distributed implementation) is selected by the router/discriminator based on the TP-OA, TP-DA and the ‘Concatenated short message reference number’ (the first octet of the concatenation MI field). This combination uniquely identifies a concatenated message from the Handset A (note TP-MR cannot be used as it is different for each segment). The router will now proxy the original message to its original destination (Local SMSC). The response from this destination is returned by the invention towards the original originator of the message. The router receives segment 2 of 3. UDH indicates that this is a concatenated message and triggers the subscriber service database to understand what service(s) need to be applied. (Not depicted) The subscriber service database again indicates that an archive service needs to be applied and the invention will copy the message into the appropriate state database using the procedure described above. After that the response is returned by the invention to the original originator. Note the second segment can arrive at the same invention instance or another invention instance, this is why the router/discriminator together with the distributed state database is of importance. The router receives segment 3 of 3. UDH indicates that this is a concatenated message and triggers the subscriber service database to understand what service(s) need to be applied. (Not depicted) The subscriber service database indicates that an archive service needs to be applied and the invention will copy the message into the appropriate state database using the procedure described above for reassembly. After that the original message is proxied over towards the original destination (Local SMSC) and the response of the SMSC is returned by the invention to the originating handset. The router controller will see that all elements have arrived in the temporary message storage in the state database (based on the UDH information) and will now start to reassemble the full message context. This can now be included in the service traffic interface towards an external system to apply the archive service.
[0148] The proxy case is especially of interest for archiving all messages that were accepted by the Service Centre instead of submitted by the handset, as in this case the invention has knowledge whether the Service Centre accepted the message.
[0000] Use case of Invention 2A & 2B (Mobile Terminated) In the call flow diagrams FIG. 9 : MT Transparent-proxy concatenated Message flow on the invention (Invention model 2A), FIG. 10 : Desired MT Transparent-relay Concatenated Message flow on the invention (Invention model 2B) the desired implementation for handling concatenated MT messages where service(s) need to be applied is depicted and described in each figure.
[0149] An example is an MT-advertising service which inserts an additional text (before, after or in the middle of the message) when delivering to the B-handset (the flow shows somewhere in the middle of the first segment, but in principle it can be in any location).
The router receives segment 1 of 3 (UDH indicates to the invention that this is a concatenated message) The invention consults the service database to determine what service needs to be applied. The service trigger response indicates that an advertising service needs to be applied on the recipient of the message. Based on this, it will reserve an entry in the state database for this message, store the advertisement text and the original message. The router will modify the original segment count to indicate the increased size to the receiving handset. The text of the segment is created (by appropriately mixing the advertisement text and the original text) and sent to the handset. If this is the extra segment, the response is used to send also determine whether to sent the original segment (with adapted text) as well. If not, it is directly returned as a negative response to the originating Service Centre which will go in retry mode. The router receives segment 2 of 3 from the service centre. UDH indicates that this is a concatenated message and looks up the state database to determine which service is pending. The state database indicates that that text modification is in progress and will use the text segment and advertisement text stored in the database to create the next text segment to be sent to the handset, including the increased segment count in the UDH. This segment is delivered to Handset B. The response of Handset B is returned to the Service Center. The router receives segment 3 of 3. UDH indicates that this is a concatenated message and looks up the state database to determine which service is pending. The state database indicates that that text modification is in progress and will use the text segment and advertisement text stored in the database to create the next text segment to be sent to the handset, including the increased segment count in the UDH. This segment is delivered to Handset B. As this is the ‘extra’ segment, the fact that it is sent out is stored in the state database. The original segment 3 of 3 is modified to 4 of 4 and the left-over text of segment 3 is inserted in it and delivered to the handset. The response of Handset B is returned to the Service Centre, finalizing this transfer.
[0157] Though in the flow, the advertisement segment is shown at the start of the message, in principle it can be inserted in any location in the message (at the front, in the middle, at the back). To allow for that, the state database stores the advertisement text, the character location at which the advertisement text needs to be inserted and the ‘left-over’ text of the original segment which was replaced by the advertisement text.
[0158] Additional segments can be generated in the middle of the message at the moment the advertisement text is being inserted, or only at the end as indicated in the MO flow.
[0159] By retaining this state, if the message cannot be delivered to the handset or the response towards the service centre is lost, in the case of a retry the same modification can be re-applied towards the same segment.
[0160] In case the advertisement was not applied yet, and a retry occurs after significant time, the advertisement text can be refreshed by only reserving the amount of data to be inserted at the initial segment and requesting the advertisement text only when it is really needed, ensuring that advertisements can be tailored to time of day and subscriber location.
MT Transparent Relay—Diversion Case
[0161] In this case, transparent relay is used for the delivery of the actual message segments. This ensures that the delivery reports (which are generated by the originating SMSC) are still correct, even though the concatenated message is diverted to another user and a text indicating the diversion (e.g., ‘Divert from <B>:’) is pre-pended to the actual message text.
The router receives segment 1 of 3 (UDH indicates to the invention that this is a concatenated message). The invention looks up the service database to determine what service needs to be applied. The service database indicates that a diversion service needs to be applied on the recipient of the message from B to C. The SRI to determine whether the C handset is in coverage is not shown in the flow for clarity. The router will now create a new segment containing the diversion text, making use of the fact that the new segment does not have to be full but can contain only the necessary characters. The UDH is set to indicate that this is segment 1 of 4. The fact that this diversion is in progress is stored in the state database. The router delivers the segment to the handset and updates the state database to indicate it was delivered successfully. The router will now SCCP relay the original message to the MSC for delivery to its diverted destination handset C, updating the UDH to indicate segment 2 of 4. The response from this destination is directly relayed towards the original originator as it does not contain information identifying that the response came from C instead of from B. The router receives segment 2 of 3. UDH indicates that this is a concatenated message and triggers the state database to understand what service(s) is in progress. The state database indicates that a diversion service needs to be applied and that the extra segment and the initial segment were already delivered to the handset. The invention will modify the UDH to indicate 3 of 4 and SCCP relay the message to the MSC for delivery to handset C. The MSC returns the response directly to the originating SMSC. The router receives segment 3 of 3. UDH indicates that this is a concatenated message and triggers the state database to understand what service(s) is in progress. The state database indicates that a diversion service needs to be applied and that the extra segment and the initial segment were already delivered to the handset. The invention will modify the UDH to indicate 4 of 4 and SCCP relay the message to the MSC for delivery to handset C. The MSC returns the response directly to the originating SMSC.
[0170] In the diversion case, the insertion of the Diversion information in the SMS is not always this trivial:
If a UDH is present containing more information, this UDH needs to be part of the first segment still and the diversion indicator appended. The second segment then is shortened to contain only the concatenation indicator in the UDH and the original segment text. If the UDH contains EMS formatting information, the offsets for the formatting need to be changed to take the additional inserted text into account. If the diversion indicator is not in the GSM7 character set but in UCS2 and the original SMS is in GSM7, a significantly larger number of delivery SMS messages needs to be generated. The original content is converted to UCS. An additional segment is first sent for delivery containing the initial text of the SMS and then the tail of the content in the segment is relayed using SCCP relaying. This ensures consistency of billing information and delivery reports with the actually delivered end user segments.
Content Control
[0174] In the content control case, the same procedure can be applied with an additional constraint that the messages must be in sequence. The procedure is described below:
At the first segment, an additional segment is inserted in the maximum segment count. This segment is used to cater for partial matches of forbidden content. For each segment, the content is searched for ‘trigger’ keywords or phrases. Only partial matches can be made as a word may be ‘broken’ as part of the total content. No phrase match was found at all, the segment is passed as is. If a match was found, the appropriate content control action is taken (do not deliver, modify the text etc.). If a partial match was found at the end of a segment, the beginning of the segment (+the final text of the previous segment if any) is sent out. The tail of the segment (the partial match) is stored in the state database. When the next segment arrives, the partial match and the contents of the new segment are search for violations. This procedure continues until all segments have been passed through the system.
[0182] By reserving the extra segment(s) it is possible to not send out potential matches at the end of the text. Instead, this text is retained until the next segment arrives and only then checked again when the full context is known. By this procedure, full content control is possible while still acting transparently.
Out of Sequence Segments
[0183] Though in practice, all segments will be sent in sequence as they will come from the same originating SMSC and will be ordered by TP-MR or time stamp, this is a good practice across all operators that is not pre-scribed in the standard.
[0184] However, also in the case of non in-sequence messages it is still possible to provide part of the functionality. The main restriction in that case is that any modifications must be made to the head of the message, as only the first segment contains information on the nature of the pay-load of a message (the full UDH).
[0185] The procedure when dealing with out of sequence messages is as follows:
When the first out-of-sequence segment is seen, an entry is allocated in the database and the service logic is checked to determine whether a service needs to be applied. The maximum number of segments added by this service is determined (dependent on the size of the text/forwarding information to be added to the SMS). This information is stored in the state database. The max sequence count and the sequence number of the SMS are increased by the number of additional segments to be inserted. Any subsequent segment which is not the first segment is treated in the same manner. When the first segment is received, the UDH is inspected. Dependent on the contents of the UDH (which text or binary SMS, which character set), the modifications are defined:
In case of a binary SMS, no modification is possible so the original segment is split over the still available segments which are sent out in sequence (the newly generated segments in proxy mode, the original in relay or proxy mode but returning the actual delivery result to the originating SMSC). In case of a text SMS or EMS, taking the encoding into account a segment with the original UDH, but modified for the additional information is pre-pended (number of segments, in EMS also the character offsets for certain formatting). The new text is added after that in the appropriate character set encoding for as many segments as needed for the additional text. The original first segment text contents (and optionally additional text) are sent out and the result of this delivery is used to return to the originating SMSC.
[0194] By using this procedure, all text and EMS messages can still be modified (or transparently passed through if the conclusion is that they cannot be modified anymore), even if messages are not delivered in sequence. The main restriction is that any modifications to the text must be in the same character encoding as the original SMS message.
[0195] The invention is not limited to the embodiments described but may be varied in construction and detail.
|
A message router comprises a message controller with service logic functions, and a state database. It receives and processes message segments, maintains state of single and concatenated messages, and applies services to the messages. A routing and discrimination engine accesses a selected state database among an associated database and distributed state databases. The controller operates in a transparent-relay mode in which a message is relayed to a network element and the response from the network element is returned directly to an originator. The relaying may be performed using SCCP relaying. The controller can operate in a transparent-proxy mode in which it generates a fresh message and sends it to a network element and receives the response from the network element, and in turn returns a response to the originator.
| 7
|
This application is a continuation-in-part of application Ser. No. 227,810, filed Jan. 27, 1981, now abandoned, which was a continuation of application Ser. No. 57,399, filed July 13, 1979, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dental products and processes and, more particularly, to the fabrication of precision dental models, dental tools, dental appliances, dental attachments, and dental prosthetic devices.
2. Prior Art
A major purpose of the dental profession is to replace or correct damaged or deformed tooth structure or condition by fabricating and installing dental constructs such as dental appliances, e.g., artificial denture plates, bridges, and orthodontic brackets, attachments therefore, and prosthetic devices, e.g., inlays, onlays, partial or full dentures, and crowns. All such products ideally (1) should be inert in the oral environment, (2) should resist the forces of mastication, (3) should be capable of assuming physiologically compatible anatomical configuration, and (4) should exhibit aesthetic qualities similar to those of natural teeth. Dental tools are not required to meet the last three criteria but must exhibit good strength as well as inertness to oral environments.
Present dental constructs are customarily composed of metal alloys, porcelain, amalgam, or acrylic polymers and combinations thereof, which do not completely meet the foregoing ideal requirements. Metal alloys and amalgam are undesirable in locations where aesthetics is a major consideration because they sharply differ from teeth in optical characteristics. Porcelain and acrylic polymers are either too brittle or too weak to resist masticatory forces in many locations. Composite structures, as in the case of an alloy substructure for strength and a porcelain superstructure for appearance, are extremely technique sensitive and are too bulky in many situations. In other words, prior dental constructs have been at best a compromise among the four ideal requirements.
SUMMARY OF THE INVENTION
The present invention is based upon the discovery that dental constructs exhibiting visual appearances similar to those of tooth enamel, having expansion coefficients and thermal conductivities approximating those of tooth enamel, and demonstrating mechanical strengths at least as great as those of composite tooth structures can be readily fabricated from glass-ceramic materials. Such materials are also useful in the fabrication of dental tools.
Glass-ceramics had their genesis in U.S. Pat. No. 2,920,971 and their production comprehends three fundamental steps. First, a glass-forming batch of a predetermined composition is melted. Second, that melt is simultaneously cooled to a temperature at least below the transformation range thereof and shaped into a glass body of a desired configuration. Third, that glass shape is subjected to a particular heat treatment to cause the in situ development and growth of crystals therewithin such that the glass is converted into a predominantly and, frequently, essentially totally crystalline article.
The transformation range is defined as that temperature at which a liquid melt is deemed to have been transformed into an amorphous solid, that temperature typically being considered as lying in the vicinity of the annealing point of a glass. If desired, the glass melt can be cooled all the way to room temperature to permit visual inspection thereof for glass quality. However, in the interests of production speed and energy economy, the commercial manufacture of glass-ceramics commonly involves cooling the initial melt to only slightly below the transformation range and then proceeding with the crystallization heat treatment. The crystallization heat treatment commonly follows a two-step practice; viz, the glass body is first heated to a temperature in or somewhat above the transformation range and maintained thereat for a sufficient length of time to cause the development of nuclei and to initiate crystallization, and, thereafter, the nucleated body is heated to a higher temperature, which may approach or, most often, will exceed the softening point of the glass, and held at the temperature for a sufficient length of time to effect the growth of crystals on the nuclei. These two steps have been termed nucleation and crystallization, respectively.
Because a glass-ceramic is derived through the controlled crystallization of a glass, all the many forming methods known to the glass technologist can be utilized in achieving a desired product shape. But, because of the highly crystalline microstructure inherent in glass-ceramics, the physical properties exhibited thereby will be more closely akin to those of the crystal phases present therein than to those of the parent glass body. As a corollary to that factor, the physical properties demonstrated by whatever residual glass is included in a glass-ceramic body will be quite distinct from those of the precursor glass, since the components of the crystal phase will have been removed therefrom. Finally, inasmuch as the glass-ceramic body results from the in situ crystallization of a glass, it will exhibit the same geometry as the parent glass body and be free from voids and non-porous.
Reference is hereby made to that patent for further information relating to the production, microstructure, and physical properties of glass-ceramic articles.
In the broadcast terms, the method of the instant invention contemplates four basic elements. First, a glass-forming batch of a desired composition is melted. Second, the melt is cast into a mold or otherwise shaped, as by compression molding, centrifugal casting, or injection molding, to form a glass body having an intermediate configuration with at least one selected surface of particular conformation. Third, the glass body will be heat treated in a particular manner to crystallize it in situ and thereby convert it into a glass-ceramic body of corresponding intermediate shape. Fourth, selected surfaces of the glass-ceramic body will be machined or otherwise formed into a dental tool or construct of final shape.
The glass-ceramic compositions operable as dental constructs are limited only by the constraints that they: (a) be inert in the oral environment; (b) be sufficiently strong to resist the forces of mastication, i.e., exhibit a tensile strength as defined in terms of modulus of rupture greater than 8000 psi; (c) be capable of assuming physiologically compatible anatomical configuration; (d) have coefficients of thermal expansion and thermal conductivities approximating those of tooth structure; and (e) will preferably exhibit a visual appearance similar to that of tooth structure. This latter is not absolutely mandatory since an outer layer, e.g., porcelain, can be applied thereto. However, such practice adds expense and involves careful matching of the properties of the porcelain and substrate material. The material for dental tools must be inert in the oral environment, possess a modulus of rupture greater than 8000 psi, and be capable of ready shaping.
As was noted above, U.S. Pat. No. 2,920,971 provides the basic disclosure in the field of glass-ceramics and numerous exemplary compositions are set forth therein. However, as has been alluded to above, the final configuration of dental constructs and dental tools is customarily achieved through machining of the body material. This capability of being machined or otherwise mechanically shaped with relative ease, utilizing conventional steel tools, is particularly demonstrated in glass-ceramics wherein a mica constitutes the predominant crystal phase. Numerous glass-ceramics containing synthetic fluormica crystals have been disclosed in the prior art.
Mica-containing glass-ceramics demonstrate a relatively unique property which renders them particularly desirable in applications such as dental tools and constructs. Thus, such bodies manifest deviations from brittle behavior which permit them to withstand point impact with limited fracture propagation. For example, those bodies can be indented in a point hardness test procedure where conventional porcelains are fractured. This capability of mica-containing glass-ceramics is due to the fact that the crystal phase can flow plastically to some extent through translational gliding along the basal or cleavage plane.
U.S. Pat. No. 3,689,293 is explicitly directed to glass-ceramic bodies demonstrating excellent machinability accompanied with good mechanical strength and impact resistance. Those glass-ceramics contain fluorophlogopite solid solution as the predominant crystal phase and have an overall composition consisting essentially, by weight on the oxide basis, of about 25-60% SiO 2 , 15-35% R 2 O 3 , wherein R 2 O 3 consists of 3-15% B 2 O 3 and 5-25% Al 2 O 3 , 2-20% R 2 O, wherein R 2 O consists of 0-15% Na 2 O, 0-15% K 2 O, 0-15% Rb 2 O, and 0-20% Cs 2 O, 6-25% MgO+Li 2 O consisting of 4-25% MgO and 0-7% Li 2 O, and 4-20% F. The precursor glass bodies are converted to glass-ceramics via heat treatment at temperatures between about 750°-1100° C. The preferred heat treatment consists of nucleating at about 750°-850° C. followed by crystallization at about 850°-1100° C. Such products can be very readily shaped into dental constructs and dental tools.
However, whereas not as readily machinable as the materials prepared from U.S. Pat. No. 3,689,293, the most preferred compositions for use as dental constructs and dental tools are those disclosed in U.S. Pat. No. 3,732,087. These latter compositions not only demonstrate somewhat superior chemical durability and mechanical strength, e.g., modulus of rupture values up to 30,000 psi, but also exhibit two other very important features--one cosmetic and the other of practical significance. First, the crystallized products closely approximate the translucency-opacity characteristics of natural teeth. Second, the materials display wearing properties quite similar to those of natural teeth, i.e., the hardness and abrasion resistance are very comparable such that the glass-ceramic product wears at about the same rate as natural teeth. This latter faculty makes for long term comfort and efficient mastication.
The glass-ceramic materials of U.S. Pat. No. 3,732,087 demonstrate good machinability and contain tetrasilicic mica as the predominant crystal phase. The base compositions therefor consist essentially, by weight on the oxide basis as calculated from the batch, of about 45-70% SiO 2 , 8-20% MgO, 8-15% MgF 2 , 5-35% R 2 O+RO, wherein R 2 O ranges from about 5-25% and consists of at least one oxide selected in the indicated proportion from the group of 0-20% K 2 O, 0-23% Rb 2 O, and 0-25% Cs 2 O, and wherein RO ranges from about 0-20% and consists of at least one oxide selected from the group of SrO, BaO, and CdO. As optional ingredients, up to 10% Sb 2 O 5 and/or up to 5% of conventional glass colorants may be present. The parent glass bodies are crystallized in situ to glass-ceramics by nucleating at 650°-850° C. followed by crystallization at about 800°-1200° C. As observed therein, a period of about 0.25-10 hours is generally sufficient to induce nucleation and about 1-100 hours will customarily be utilized in the crystallization step to insure a high proportion of crystals in the product. Finally, compositions consisting essentially of about 55-65% SiO 2 , 12-20% MgO, 9-13% MgF 2 , 7-18% K 2 O, and 0.5-8% As 2 O 5 are preferred for their machinability character.
Nevertheless, whereas machinability is a vital characteristic necessary for utility in the production of dental constructs and tools, three other factors must also be evaluated regarding the suitability of glass-ceramic compositions for dental application; viz, visual appearance, chemical durability, and the capability of being processed via traditional dental laboratory techniques. The first two were alluded to briefly above.
In working with the inventive materials, the quality of visual appearance has been assessed in terms of translucency, since the property can be quantified and is the key optical attribute for a dental material. Other characteristics such as color and vitality are also important, of course, but, if the translucency of a material does not fall within a given range, the body will not function aesthetically.
Chemical durability is of critical significance since a dental construct must endure a warm and wet environment over a pH regime normally varying between about 6-8, with occasional excursions outside that range. An accelerated procedure for determining the long term durability of the inventive materials was developed.
Two vital factors require consideration when judging a material candidate for processing in a dental laboratory. The most important characteristic is the sag evidenced by the material, that is, the capability to maintain body geometry during a heat treatment cycle. Although dental constructs are prepared in an investment which helps in holding shape and dimensions, a minimum degree of stiffness is required. The second significant process variable is the amount of contraction experienced by the material resulting from densification as the precursor glass is converted to a glass-ceramic. This value is customarily expressed as percent linear contraction and is calculated from density data.
Based upon those criteria, compositions operable to provide the most ideal combination of translucency, chemical durability, and processibility, as well as high strength and machinability, consist essentially, expressed in terms of weight percent on the oxide basis, of
______________________________________ K.sub.2 O 10-18 MgO 14-19 SiO.sub.2 55-65 Al.sub.2 O.sub.3 0-2 ZrO.sub.2 0-7 F 4-9______________________________________
wherein BaO and/or SrO may optionally be substituted for up to 50% of the K 2 O on the molar basis.
To insure the highest chemical durability and resistance to staining from foods, the preferred compositions will contain 1-9% Al 2 O 3 +ZrO 2 with the most preferred materials containing at least 0.5% Al 2 O 3 and/or at least 2% ZrO 2 . Conventional glass colorants may optionally be included in customary amounts and, although significantly increasing the cost of the inventive materials, a substantial proportion of the K 2 O content may optionally be replaced on the molar basis with Rb 2 O and/or Cs 2 O. The inventive glasses are generally sufficiently fluid that no fining agent is necessary. If such an agent should be required, however, As 2 O 3 and/or Sb 2 O 3 will not be utilized to forestall any possible toxic effects.
The use of glass-ceramic materials for fabricating dental crowns and inlays was suggested by W. T. MacCulloch in "Advances in Dental Ceramics," British Dental Journal, Apr. 16, 1968, pages 361-5. The author noted the use of a metal phosphate as a nucleating agent and formed a tooth from a glass-ceramic composition within the Li 2 O-ZnO-SiO 2 system. MacCulloch also observed that, through the use of silver as the nucleating agent, the parent glass became photosensitive such that, through differential exposure of the glass with ultraviolet radiation, differences in crystallization can be achieved, thereby simulating the polychromatic effect of natural teeth. The only composition data provided comprised the single reference to Li 2 O-ZnO-SiO 2 glass-ceramics with no details as to amounts of each component.
U.S. Pat. No. 4,189,325 describes the use of glass-ceramic materials in dental restorations. The compositions therefor consist essentially, expressed in terms of mole percent on the oxide basis, of about 25-33% Li 2 O, 1-10% CaO, 0.5-0.5% Al 2 O 3 , and 52-73.5% SiO 2 to which are added 0.003-0.01% by weight platinum and 0.2-2% by weight Nb 2 O 5 as nucleating agents. No data regarding the identity of the crystallization developed are provided, but the compositions thereof self-evidently preclude the formation of fluormica crystals which give rise to the machinability characteristics exhibited by the glass-ceramics forming the basis of the present invention.
Brief Description of the Drawings
For a fuller understanding of the nature and objects of the present invention, reference is made to the following detailed description, which is to be taken in connection with the accompanying drawings, wherein:
FIG. 1 illustrates producing an investment mold in accordance with the present invention;
FIG. 2 illustrates forming a parent glass casting in accordance with the present invention;
FIG. 3 illustrates heat treating the casting to form a glass-ceramic component in accordance with the present invention; and
FIG. 4 illustrates machining the glass-ceramic component to provide a final dental construct.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Generally, with reference to the drawings, the process of the present invention comprises the following steps. First, an impression 10 is formed conventionally by pressing a soft dental impression composition (e.g., silicon rubber, wax, mercaptan rubber, and the like) against prepared dental surfaces of specified configuration and solidifying the resulting shape. Next, this is filled with dental stone (e.g. plaster of Paris) to form a master model 12. Next, a wax (or the like) pattern 20 of the dental construct, characterized by a sprue 14 and a pattern body 16, is prepared in association with the master model. In this case, the prepared dental surfaces are presented by the prepared facets of a tooth to be restored and the specified configuration is shown as involving the reentrant, but not undercut, inward facets 21 of a restoration having an anatomical outward surface 22. Next, wax pattern 20 is imbedded in a refractory investment slurry 24, which is permitted to solidify. Next, the investment is heated to remove the wax from the resulting mold cavity 26. The investment slurry material typically is a phosphate-bonded or silicate-bonded inert cementitious clay or other silicate. A batch of a predetermined composition or a preferred glass shape is heated to a temperature of from about 1325° to 1500° C. in a refractory crucible, composed for example of platinum, alumina, silica, mullite, or zirconia. The resultant melt is injected into the mold, which normally will have been heated to a temperature of from 700° to 950° C. to forestall cracking or breakage thereof from thermal shock, under a back air pressure of, for example, from about 8 to 50 psig. A vacuum may be applied in conjunction with the back air pressure to assist in insuring complete filling or, if desired, sufficient vacuum may be applied alone to suck the melt into the mold. In general, the vacuum will range between about 0.2 to 1.0 bar. Also, as can be appreciated, mechanical means, such as a piston, injection molding, or centrifugal casting can be utilized to fill the mold cavity. Centrifugal forces ranging about 1-15 psig have been found very satisfactory for this purpose.
Under these circumstances, the contraction rate of the mold cavity during cooling will closely match the contraction rate of the melt so that little or no compression is exerted by the mold on the casting. Initially, the elevated temperature of the melt does not affect the temperature of the mold because the mass of the melt is relatively small. Next, the mold and its contents are allowed to cool to room temperature and a clear parent glass casting 28, certain of its surfaces 30 being of the original specified configuration, is removed from the mold. The transparency permits the casting to be readily inspected visually for any flaws. As shown, the parent glass casting 28 generally is in the shape of a cap having, in addition to dome-shaped surface 32, a residual sprue 34 and button 35, which have resulted from the aforementioned casting steps. Then parent glass casting 28, conveniently touching only sprue 34, is heat treated at a temperature and for a time sufficient to cause in situ crystallization thereof such that the casting is converted from a glass to a predominantly crystalline body. Then, certain surfaces of this dental component are machined, employing conventional dental drills and mills to produce the finely desired shape. As shown, glass-ceramic component 36 is ground at 38 to sever sprue 34 and to provide a polished, anatomically-shaped surface. Thereafter, the outer surface of the component is optionally polished to provide a smooth and glossy appearance. Also, if desired, the dental component is optionally colored and/or glazed to conform the appearance of the component to that of tooth structure with which it is to be associated.
In the tetrasilicic fluorine micas which crystallize from the starting glasses to form the preferred glass-ceramic materials, the X, Y and Z positions are believed to be filled in the following manner: X position K; Y position Mg; and Z position Si. These micas, which normally have the postulated formula KMg 2 .5 Si 4 O 10 F 2 , are described as tetrasilicic because they do not display Al- or B-for-Si substitutions in the Z 2 O 5 hexagonal sheets of the mica layer as do the fluorophlogopites (KMg 3 AlSi 3 O 10 F 2 ) or (KMg 3 BSi 3 O 10 F 2 ), such as comprise the predominant crystal phases in the products of U.S. Pat. No. 3,689,293. Those crystals have been termed trisilicic fluormicas.
In general, the dental laboratory will not melt the batch materials to produce the precursor glass since very high temperatures and stirring are utilized to insure a homogeneous body. Rather, the dental laboratory will commonly purchase the precursor glass from a glass manufacturer in some convenient form, e.g., buttons, marbles, or other small shapes. This glass preform can then be remelted in the laboratory and will be poured into a mold at a temperature above its liquidus or otherwise shaped to form a glass body having at least one surface of a particular conformation. Heat treatment is effected after the melt has been cooled below its transformation range and is continued until nuclei are first formed throughout the glass followed by the growth of fluormica crystals on those nuclei.
The resulting glass-ceramic compositions are such that they are typically characterized by a white or off-white color, unless colorants have been deliberately added to the batch. The intermediate glass component has a characteristic clear or somewhat hazy vitreous structure. The final glass-ceramic product consists essentially of tetrasilicic fluormica crystals homogeneously dispersed within a residual glassy matrix, the crystals constituting the predominant proportion of the body. In general, the higher the proportion of crystals, the more desirable the product.
The foregoing process contemplates the production of a variety of dental tools and constructs of the foregoing compositions. The dental constructs considered here are deemed to fall under the four general categories of dental models, dental appliances, dental attachments, and prosthetic devices. Typically, the inlays are of the type that have inward walls or facets of a tooth and outward walls or facets that are in continuity with the external contour of the tooth. Customarily, as described above with reference to FIGS. 1 to 4, the caps or crowns are of the type that fit over and cover the prepared crown form or root canal post of a tooth stump, having lower inward walls or facets that conform to prepared outer walls or facets of the tooth stump and upper outward walls or facets that are in continuity with the external contour of the tooth. Commonly, the prostheses are of the type that replace dental and/or related structures in the oral cavity, for example, false teeth, dentures and components thereof.
Example
With reference to the drawings, the illustrated process of the present invention comprises the following steps for producing a dental restoration. A wax pattern is formed conventionally and, as shown at 20, is mounted on the upper end of sprue 14. The lower end of the sprue is attached to a cylindrical casting form 40 by a soft wax bond 42. Wax bond 42 is manipulated to provide continuously smooth joints. Wax pattern 20 is painted with polar surfactant solution, e.g., either aqueous or alcohol, to minimize tackiness and is blown dry with an air stream. Wax pattern 20 is surrounded by a metal casting ring 44, which has an asbestos or other thermal insulating liner 46. An investment slurry 48 is prepared by mixing a refractory such as silica flour and an aqueous liquid such as water-ethyl silicate solution. The investment slurry is first painted onto the wax pattern and then is poured into the casting ring so as to cover the pattern completely, but to a height of no more than about one-half inch (1.25 centimeters) above the wax pattern. The investment slurry is allowed to set for approximately forty-five minutes to form a green investment mold. To cure this green investment mold, it is placed into a cold furnace, heated to approximately 650° C. (1200° F.) in a one hour period of gradually increasing temperature, and is maintained within the temperature range of approximately 650°-950° C. for a one hour period of steady temperature.
The cured investment mold is thereafter removed from the casting form and casting ring and inverted to provide precision cavity 26 which communicates with a dished upper mouth 50 through a port 52, the wax and the plastic tube having been burned out during the curing period. Into this cavity through a suitable port is poured the melt of, for example, a tetrasilicic fluormica composition, which has been heated in a suitable crucible to a temperature providing adequate fluidity. The melt is forced through depression 50 and port 52 into cavity 26 by a backup air pressure 54 of approximately 8 pounds per square inch (0.56 kg/cm 2 , which is maintained until the melt has solidified to a glass.
After the casting is cooled to room temperature, the bulk of the investment material is removed mechanically from the glass casting and residual adhering fragments are removed by application of an investment solvent liquid and by ultrasonic energy. Then the parent glass casting (after visual inspection for possible casting flaws) is mounted by button 34, and unsupported other than by the sprue and button, in a furnace. The temperature within the furnace is raised slowly at about 200° C./hour to about 1050°-1150° C., maintained thereat for about 4 hours, and thereafter cooled. Finally, sprue 34 and button 35 are removed by grinding and the surfaces of the cap are ground to finally adjusted shape.
It will be appreciated that, if desired, the parent glass casting can be heat treated while within the investment mold to effect crystallization thereof. This practice has the advantages of speeding production and fuel economy. Thus, rather than cooling the glass to room temperature and then reheating, the glass need only be cooled to below the transformation range thereof and thereafter reheated to the nucleation and crystallization temperature ranges. The investment material will then be removed mechanically from the crystallized casting. However, it is apparent that this practice does not permit inspection of the casting for flaws in the glass casting prior to crystallization. Moveover, at the elevated temperatures required in heat treating, the investment material is prone to sinter into a solid mass, rendering difficult removal from the casting.
As has been emphasized above, the three characteristics which materials designed for use in dental constructs must demonstrate are a particular visual appearance, as delineated in terms of translucency, excellent chemical durabilty within a pH range of about 6-8, and processibility, as measured in terms of thermal deformation or sag during the heat treatment cycle and the degree of contraction resulting from densification during conversion of the precursor glass body to a glass-ceramic.
Table I records a group of glass compositions, expressed in terms of parts by weight on the oxide basis, which illustrate the criticality of composition control to achieve the necessary balance of forming and physical properties to be suitable for the production of dental constructs and tools. It will be observed that the sum of the individual components totals somewhat over 100. This circumstance is the result of the oxygen correction required to compensate for stating the fluoride content separately. However, because this sum is not far removed from 100, for all practical purposes the individual values can be deemed to represent weight percent. The actual batch ingredients may comprise any materials, either oxides or other compounds, which, when melted together, are converted into the desired oxides in the proper proportions. The fluoride was incorporated into the batch as MgF 2 , although it will be appreciated that other compounds can be utilized as a source thereof.
The batch ingredients were compounded, ballmilled together to secure a homogeneous mixture, deposited into platinum crucibles, lids placed upon the crucibles, and the crucibles introduced into a furnace operating at 1450° C. After a dwell period of four hours within the furnace, the melts were poured into glass slabs having the approximate dimensions of 8"×4"×0.5" (20×10×1.3 cm) and the slabs immediately transferred to an annealer set at a temperature of 500° C. The temperature of the annealer was raised to 620° C. and the slabs were annealed for about 0.5-0.75 hour. A visual description of the annealed glasses is reported in Table I.
TABLE I__________________________________________________________________________1 2 3 4 5 6 7 8 9__________________________________________________________________________K.sub.2 O 13.7 9.0 20.0 9.0 20.0 13.7 13.7 13.7 18.0MgO 17.2 17.2 17.2 21.9 10.9 17.2 17.2 17.2 17.2Al.sub.2 O.sub.3 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5SiO.sub.2 60.7 65.4 54.4 60.7 60.7 60.0 58.7 57.7 56.4ZrO.sub.2 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0F 5.6 5.6 5.6 5.6 5.6 4.88 7.0 8.0 5.6Total 102.7 102.7 102.7 102.7 102.7 101.28 102.1 102.1 102.7Visual Clear Clear, Slight Clear Clear Clear Hazy Cracked ClearDescription Slight haze patches edges, surface center crystal crystallized__________________________________________________________________________
Al 2 O 3 and ZrO 2 are advantageously included in the above exemplary compositions to improve the chemical durability and stain resistance thereof. Accordingly, to preserve the beneficial effect of Al 2 O 3 +ZrO 2 , but not to modify the forming and physical properties of the base glass, those additions were held constant.
In order to secure crystals of adequate size, i.e., >0.5 microns, in a highly crystalline body to insure the demanded high strength and translucency within a practical length of time, i.e., about 1-8 hours, the precursor glass will be exposed to temperatures between about 1050°-1150° C. and, preferably, in the vicinity of 1075°-1100° C. To eliminate any effect upon the physical characteristics of the exemplary compositions which modifications in heat treatment might exert, small pieces i.e., 3×3 cm, of each of the glasses in Table I were subjected to the following heat treatment in an electrically-fired furnace to develop tetrasilicic fluormica crystallization in situ:
Heat at 200° C./hour to 800° C.
No hold
Heat at 100° C./hour to 1075° C.
Hold for six hours
Cool furnace rate to room temperature (˜3° C./minute)
Table II recites a qualitative assessment of the thermal deformation experienced by glass during this crystallization process along with a visual description of the outward appearance of each. Finally, an estimate of the grain size and extent of the crystallization, as obtained via a visual examination of fracture surfaces, is also recorded therein.
TABLE II__________________________________________________________________________ 1 2 3 4 5 6 7 8 9__________________________________________________________________________Form Held shape Held shape Completely Held shape Completely Partially Held shape Held Highly deformed deformed deformed deformedAppearance Very Opaque -- Opaque -- Very Very Very Very translucent translucent translucent translucent translucentSurface Smooth, Fine-grained, Coarse, Fine-grained, Coarse, Smooth, Smooth, Smooth, Smooth,Fracture silky smooth sugary smooth sugary, silky silky silky silky, few some glass spherulites__________________________________________________________________________
Translucency is determined via reflectance measurements conducted by means of a laboratory exposure/photometer system utilizing both a white and a black background. The more highly translucent the material, the greater will be the spread between the white and black backed readings. Translucency T is defined as: ##EQU1## wherein Y W represents the luminous reflectance with a white background and Y B designated the luminous reflectance with a black background.
Table III reports levels of translucency measured on the glass-ceramic bodies of Table II. A preferred value of translucency has been deemed to range between about 0.50-0.70. Below 0.4 is definitely too opaque and above 0.8 too transparent.
An accelerated test for evaluating the chemical durability of the glass-ceramic bodies was developed wherein the amount of K 2 O extracted after exposure for four hours to water at 95° C. The test sample is a square having the dimensions of 5.1×2.5×0.3 cm which is polished on all sides. The square is immersed into 100 ml of water and the K 2 O extracted is expressed in terms of micrograms/cm 2 of surface area. To be considered acceptable, the level of K 2 O extracted will not exceed 10 micrograms/cm 2 . Table III lists K 2 O values extracted for the glass-ceramics of Table II.
To evaluate the thermal deformation (sag) experienced by the glass-ceramic material during heat treatment, a bar having dimensions of 4.4×0.64×0.32 cm is cut from annealed glass and the surfaces subjected to a fine grind. The bar is centered across a 1.9 cm span with the 0.64 cm side down. The sag is measured in terms of mm as the movement of the bottom surface from its initial position. Values evidenced by several of the examples of Table II are recorded in Table III. A maximum sag of 8 mm is deemed acceptable.
The extent of densification undergone during the conversion of the parent glass to the glass-ceramic state is defined in terms of percent linear contraction and is calculated from density data. The density of the precursor glass and the density of the glass-ceramic, expressed in terms of grams/cm 3 , and the calculated linear contractions are provided in Table III. To be tolerable, the linear contraction will not exceed 2%.
Finally, coefficients of thermal expansion, measured over the ranges of 25°-300° C. and 25°-500° C., exhibited by several of the glass-ceramics of Table II are recited in Table III in terms of ×10 -7 /°C.
TABLE III__________________________________________________________________________ 1 2 3 4 5 6 7 8 9__________________________________________________________________________Translucency 0.630 0.139 Melted 0.010 Melted 0.647 0.603 0.525 0.677Durability 1.2 0.6 Devit 2.4 Melted 0.6 3.5 4.7 15.0Sag 4.4 0.33 Devit 0.127 Melted 5.3 2.36 1.14 MeltedGlass Density 2.565 2.572 2.590 2.613 2.514 2.571 2.641 2.707 2.584Glass-Ceramic Density 2.679 2.686 -- 1.806 -- 2.667 2.728 2.847 2.682Linear Contraction 1.4 1.4 -- 2.3 -- 1.2 1.1 0.5 1.2Coef. Exp. 25°-300° C. 70.1 62.0 -- 78.7 -- 73.7 74.8 73.1 87.1Coef. Exp. 25°-500° C. 74.3 66.4 -- 82.4 -- 76.3 77.0 76.6 89.8__________________________________________________________________________
The criticality of composition control, becomes immediately evident from an examination of Tables I-III. Thus, Examples 3 and 5 either melted and/or devitrified. Examples 2 and 4 are too opaque and Example 9 failed the durability and sag tests. Yet, those Examples were prepared from compositions closely approaching those of Examples 1 and 6-8. Example 1 is deemed to represent the most ideal combination of processing and physical properties.
Since certain changes may be made in the foregoing disclosure without departing from the objects hereof, it is intended that all matter described in the foregoing specification and shown in the accompanying drawings be interpreted in an illustrative and not in a limiting sense. Hence, as has been stated above, other forming techniques such as compression molding, centrifugal casting, and injection molding can be successfully employed.
|
Precision dental tools, models, appliances, prostheses, and attachments are produced by providing a glass body of selected conformation, and then heat treating the glass body to yield a glass-ceramic component of superior characteristics wherein tetrasilicic fluormica constitutes the predominant crystal phase.
| 0
|
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates primarily to a dispensing apparatus for the dispensing deodorant cream emulsions, antiperspirants and the like, and more particularly, to a novel dispensing apparatus having a dispensing tube assembly encased in an outer housing that minimizes post-dispensing of the product.
2. Description of the Related Art
Prior art deodorant dispensers often dispense the deodorant product by the displacement of a piston elevator advancing upward in response to rotation of a hand-wheel. The consequent pressurization of the deodorant product causes residual pressure to be exerted and thereby cause undesirable weeping of the product.
Efforts to address this problem has led to the development of product dispensers that allow seepage of the deodorant product from between the junction of the base and the sidewalls of the dispenser. In these systems, vent holes that are provided for the depressurization beneath the elevator piston causes the product to leak or exude from the dispensing package onto the surface where the dispenser is stored.
U.S. Pat. No. 5,000,356 discloses a dispensing package designed to relieve the residual pressure on a cream product and also dispense the product in incremental doses. The piston elevator axially advances and retracts as a feed screw is rotated. A plurality of internal cams cause reciprocal motion of the piston elevator. During the advancement of the piston elevator, the product is dispensed and during retraction, the residual pressure is relieved.
None of the prior art dispensing systems accomplishes the objects of the present invention of having an internal dispensing assembly encased in an outer housing that minimizes post-dispensing of the product.
SUMMARY OF THE INVENTION
The present invention relates to a novel dispensing-package that finds use in dispensing cosmetic creams, lotions and deodorants. This novel designed dispenser provides a product tube situated within an outer housing. Rotation of the product tube dispenses the product in controlled dosage increments while minimizing unwanted weeping of the product.
In typical use, the user manually rotates a propeller, which then causes axial displacement of a piston elevator. The upward advancement of the piston elevator causes the deodorant product to be dispensed through orifices in an application surface where it is subsequently applied to the axillae of the user. The present invention provides means for reciprocal motion of the piston elevator in order to relieve the residual pressure exerted on the product and thereby control undesirable post-dispensing. The present invention also provides means for uniform dispensing of the product by audible and/or tactile sensations.
In accordance with one aspect of the present invention, a dispensing apparatus is provided which comprises a hollow housing having a central longitudinal axis and a container wall; an application cap secured to the container wall at the top of the housing, the application cap having an application surface having a central opening therein and a downwardly extending flange located about the central opening; a hollow product tube having a bottom wall and an open top end, the product tube being received within the housing and being spaced from the container wall, the product tube being disposed about the longitudinal axis and being adapted to contain an associated product; a rotatable threaded spindle disposed along the longitudinal axis, a first end of the spindle being received in a spindle well located in the bottom wall of the product tube; a piston elevator being mounted onto the spindle for axial movement within the product tube; rotational prevention means for preventing rotation of the piston elevator about the spindle; rotatable drive means for rotation of the threaded spindle, the drive means being fixedly secured to a second end of the spindle, the drive means comprising a rotatable propeller and a hollow product head having an upper surface and an open lower end, the product head being affixed to the propeller and rotatable therewith, the open lower end of the product head communicating with the open top end of the product tube and the upper surface of the product head being received within the flange of the application cap; directing means for directing the associated product from the product tube to the application surface, the directing means comprising a plurality of orifices in the upper surface of said product head; and, association means for maintaining a predetermined association between the housing, the product tube and the drive means.
According to another aspect of the invention, the dispensing apparatus further comprises means for reciprocating the product head within the flange of the application cap. The reciprocating means may comprise a cam located at a bottom of the flange; a cam follower being rotatable with the product head and contacting the cam; and, a flexible strip extending between the product head and the propeller, the flexible strip being able to displace axially in response to movement of the cam follower along the cam.
According to another aspect of the invention, the bottom wall of the product tube is integrally molded with the housing.
According to another aspect of the invention, the product tube, the container wall and the base are a single integrally molded member.
According to another aspect of the invention, the bottom wall of the product tube includes a plurality of vent holes therein.
According to another aspect of the invention, the dispensing apparatus includes means for dispensing a uniform dose of said associated product.
One advantage of the present invention is that the deodorant dispenser has very few parts to substantially reduce the manufacturing and assembly costs.
Another advantage of the present invention is the provision of a concealed product tube within a dispenser housing. This arrangement provides for much neater application of product and storage of the dispensing package.
Still other benefits and advantages of the invention will become apparent to those skilled in the art to which it pertains upon a reading and understanding of the following detailed specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a dispensing apparatus according to the present invention;
FIG. 2 is a line perspective view of a preferred embodiment of the dispensing apparatus having the applicator cap removed and showing the internal structure;
FIG. 3 is a sectional view of one embodiment of the present invention taken along line 3 — 3 of FIG. 1;
FIG. 4A is a fragmentary perspective view of a preferred embodiment showing an advanced position of the product head;
FIG. 4B is a fragmentary perspective view similar to FIG. 4A showing a retracted position of the product head;
FIG. 5A is a graphical depiction showing the product dosage dispensed vs. rotation of the propeller;
FIG. 5B is a graphical depiction showing the axial displacement of the piston elevator as a function of the propeller rotation;
FIG. 6 is a break-away line perspective plan view of a preferred embodiment of the deodorant dispenser;
FIG. 7 is a fragmentary perspective view detailing one embodiment of the spindle and spindle head;
FIG. 8 is a sectional view of one embodiment of the product head showing the spindle well;
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, a preferred embodiment of the present is illustrated wherein a deodorant or other product is enclosed in a dispensing apparatus 10 . The apparatus 10 comprises a housing 24 that is made of a suitable material, such as molded polypropylene. The dispensing apparatus 10 further includes a removable cap 80 which allows selective access to an application surface (not shown in this view). Cap 80 performs the conventional functions of protecting the product from contaminants and retaining the product within the dispensing apparatus 10 when not in use. The product is dispensed through rotation of a propeller 60 having a partially exposed region 70 for access by the user through the housing 24 . In the embodiment shown in the Figure, the exposed region 70 is located near the bottom of the dispensing apparatus 10 . However, the dispensing apparatus 10 may incorporate other designs modifying the location of access to the propeller 60 without departing from the scope of the invention. For example, it is within the scope of the present invention to provide access to the propeller 60 near the junction of the dispenser housing 24 and application cap 26 . Propeller 60 may be accessed anywhere along its length by providing a cut-out in the dispenser housing 24 . The length of the propeller 60 may be adjusted accordingly. The dispenser housing 24 provides a fixed element for the user to hold while propeller 60 is rotated.
A more detailed view of the preferred embodiment is shown in FIG. 2 . In the preferred embodiment, housing 24 conceals nearly all of the propeller 60 which rotates within housing 24 as will be described in greater detail below. Propeller 60 includes an axially disposed hollow cylindrical region 100 which extends from the base 70 . The base 70 may be ribbed, flared or otherwise adapted to be easily grasped by a user. A hollow product tube 16 is concealed within the hollow cylindrical region 100 , and holds the product to be dispensed. In a preferred embodiment of the invention, rotation of propeller 60 allows for the convenient dispensing of a desired dose of product. One or more audible clicks may be heard, and tactile feedback may be felt.
The dispensing apparatus 10 further includes an application cap 26 located at the top of the dispenser housing 24 . This application cap 26 preferably snaps onto the top of the dispenser housing 24 by engagement with protrusions 91 . The application cap 26 includes an upper application surface 28 having a centrally located opening 30 therein. A downwardly extending flange 32 follows the contour of the opening 30 . The preferred opening 30 is circular and the application cap 26 is ovate and its application surface is ovate. In a preferred embodiment of the invention, the bottom surface of the flange 32 forms a cam 55 that is useful to provide reciprocal motion of the product head 120 as will be explained in further detail below. The invention may be successfully practiced, however, without provision of a cam 55 . The removable cap 80 , not shown in this view, covers the application cap 26 when it is in place as is well known in the art.
The dispensing apparatus 10 further includes a product head 120 which is adapted to be received within the flange 32 . Product head 120 includes a plurality of dispensing orifices 122 located within an upper surface 124 . The orifices may be of any arbitrary shape, such as round or square, but preferably elliptical. It is further within the scope of the present invention to provide downwardly extending flanges (not shown) at the orifices 122 to assist in directing the product toward the application surface 28 while the product is being dispensed.
In the preferred embodiment, the base of the product head 26 is surrounded by a collar 140 which comprises one or more cam followers 144 . The collar 140 is affixed to one or more flexible strips 150 which are secured at the outer ends to the upper end of cylindrical region 100 of propeller 60 . As shown in FIG. 4A and 4B, the flexible strips 150 support the product head 120 for reciprocal movement relative to propeller 60 . When application cap 26 is snapped in place over the dispenser housing 24 , the product head 120 is received within flange 32 . In this embodiment, rotation of the propeller 60 causes the cam follower(s) 144 to ride along cam 55 . The product head 120 is axially displaced upwardly or downwardly with respect to the application surface 28 by the movement of the flexible strip(s) 150 . During dispensing of the product, the product head 120 is axially displaced upwardly until the upper surface 124 is generally flush with application surface 28 . It should be noted that the product head 120 is rotating along with propeller 60 . In a preferred embodiment, the residual pressure on the product may be relieved by reciprocation of the product head 120 by the action of the cam follower 144 against cam 55 . The depth of the cam 55 , the height of the cam follower 144 , the properties of the flexible strip 150 , or the height of the product tube 16 may be adjusted in order to achieve the desired axial displacement of the product head 120 in accordance with the properties of the dispensed product. It is within the scope of the present invention to allow the cam follower 144 to remain stationary while the cam is rotated by interchanging the locations. In the preferred embodiment, the cam 55 includes sawteeth 33 which are angled so as to allow rotation of the product head 120 in only one direction. Tactile feedback is provided to the user as the propeller 60 is rotated due to the rotation of product head 120 which causes cam follower(s) 144 to ride along cam 55 . The sawteeth 33 engage the cam follower(s) 144 and then disengage upon rotation of the product head. A predetermined amount of product is dispensed in relation to each click or tactile feedback signal and thereby a user may determine a correct dosage of product.
In another embodiment of the invention, the cam 55 /cam follower 144 arrangement is eliminated. However, rotation of the propeller 60 still causes rotation of the product head 120 in order to dispense the product. This embodiment does not provide for the reciprocal motion of the product head 120 and therefore does not allow relief of the residual pressure on the product.
With reference to FIG. 3, a preferred arrangement of dispenser housing 24 , propeller 60 , product tube 16 , application cap 26 and removable cap 80 is shown. Located within product tube 16 is a piston elevator 22 which is mounted onto a threaded spindle 18 for axial displacement within product tube 16 . Spindle 18 is affixed at an upper end to the product head 120 . As the propeller 60 is rotated, product head 120 rotates as does spindle 18 . The rotation of spindle 18 causes upward axial displacement of the piston elevator 22 . It is an important aspect of the present invention that piston elevator 22 be prevented from rotating within the product tube 16 as it advances axially. Because the end of the spindle 18 is fixedly secured to product head 120 , if reciprocal motion of the product head is provided for, as in the preferred embodiment, spindle 18 will likewise reciprocate. Piston elevator 22 therefore also reciprocates with the reciprocation of the product head 120 . It is this slight downward movement of the piston elevator 22 that relieves the residual pressure within the product tube 16 to minimize undesirable oozing of the product. Spindle well 19 is provided in the bottom wall 57 of the product tube 16 . Spindle well 19 receives one end of spindle 18 and allows slight axial displacement of the spindle 18 while maintaining its longitudinal positioning.
The product tube 16 encompasses a first cross-sectional shape that allows the axial displacement of piston elevator 22 while substantially preventing any rotation of piston elevator 22 . The product tube interior may be ovate, octagonal, or the like. The exterior is round for simplicity, this feature is shown only in FIG. 7 . The cross-sectional shape of the interior of the product tube 16 cooperates with the cross-sectional shape of the piston elevator 22 to effectively provide means to prevent rotation of the piston elevator 22 within the product tube 16 . In the preferred embodiment, the products tube is octagonal in cross-sectional shape, while the piston elevator 22 is round or ovate. The piston elevator has resilient peripheral edges. As shown in FIG. 3, the piston elevator 22 has minimal surface area contact with the interior of product tube 16 along the top and bottom edges only of piston elevator 22 . These edges provide contact bands 23 which also serve to seal the product in the product tube 16 . The piston elevator 22 has a frictional fit within product tube 16 which allows upward and downward axial movement of the piston elevator with a predetermined frictional resistance. A similar frictional fit exists between the product head 120 and the product tube 16 . The top of the product tube 16 is flared or flanged, as best shown in FIG. 7, so that there is minimal contact between the product tube 16 and the interior of the product head 120 . The product head 120 may rotate about product tube 16 and be axially displaced relative thereto, while a seal is maintained between the product head 120 and the product tube 16 . The edge around orifice 121 of the product tube 16 acts as a cleaning blade and product back flow is prevented.
With respect to FIGS. 4A and 4B, the reciprocal nature of the product head 120 is illustrated. Initial counterclockwise rotation of the propeller 60 causes movement of the cam follower 144 along cam 55 and upward axial displacement of the product head 120 until upper surface 124 is generally flush with application surface 28 (FIG. 4 A). Further counterclockwise rotation of the propeller 60 causes movement of the cam follower downward, which causes the flexible strip 150 to bend downwardly. The accompanying axial reciprocation of the product head 120 causes a slight retreat of the piston elevator 22 .
FIG. 5A depicts graphically the product dosage dispensed as a function of the rotation of propeller 60 .
FIG. 5B depicts graphically the displacement of the piston elevator 22 as a function of rotation of propeller 60 . In the preferred embodiment, the piston elevator 22 axially advances, then slightly retracts, with each rotation of the propeller 60 . This movement of the piston elevator allows even dispensing of the product with each cycle of rotation of the propeller 60 .
With reference to FIGS. 6, 7 and 8 , the final assembly of the members of the present invention will be discussed. Product head 120 includes a centrally located spindle well 40 . At the bottom of the spindle well 40 are a plurality of protrusions 41 which interact with the rudders 39 found at the upper end of the threaded spindle 18 . Upon assembly of the dispensing apparatus 10 , the upper end of the spindle 18 is snapped into spindle well 40 . As product head 120 rotates, the protrusions 41 act upon rudders 39 to cause rotation of the spindle 18 . A preferred embodiment of the spindle 18 and product head 120 has been described, but other configurations that accomplish the same purposes are within the scope of the present invention.
As shown further, the product tube 16 has a plurality of vent holes 43 in the closed bottom wall 57 in order to alleviate pressurization when inserting the piston elevator 22 and spindle 18 axially downward through the product tube 16 . These vent holes 43 permit the entrapped air to be displaced while equalizing the internal air pressure in the interior of the product tube 16 , when positioning the piston elevator 22 . In addition, these vent holes 43 prevent the formation of a vacuum under the piston elevator 22 as it moved upwardly, thereby alleviating drawing the product around the piston into the spatial vacuum.
In one embodiment, the housing 24 includes a base 154 that is snap fitted onto the container wall by engagement of prongs 156 in openings 160 . In another preferred embodiment, the base 154 is integrally molded with the container wall. Also, in a preferred embodiment, the container wall, base 154 , and product tube 16 are all integrally molded, as shown in the embodiment illustrated in FIG. 3 . Therefore, the bottom wall 57 of the product tube 16 also functions as the base 154 of the housing 24 .
One preferred method of assembling the dispenser apparatus 10 includes positioning the product tube 16 onto base 154 , if these are separate components. Also, the housing 24 may be properly positioned now, or after the product tube is filled. The piston elevator 22 is then positioned in the bottom of product tube 16 . As stated above, the vent holes 43 prevent air from being trapped beneath the piston elevator 22 . The product tube 16 may then be filled with appropriate product. The spindle 18 may be inserted into the product tube 16 , and rotated to engage the piston elevator 22 and inserting the end of the spindle 18 into spindle well 19 . The propeller 60 /product head 120 assembly is then fixedly secured to the top of spindle 18 by engagement of the top of the spindle 18 into spindle well 40 . It is also possible to position the housing 24 after the propeller 60 /product head 120 assembly is positioned. The application cap 26 is then securely fastened to housing 24 . The assembly of the dispensing apparatus 10 is simplified if the housing 24 , base 154 , and product tube 16 are integrally molded. It also within the scope of this invention that the spindle 18 , piston elevator 22 are preassembled and installed within the product tube 16 prior to filling of tube 16 .
Cylindrical region 100 and propeller 60 rotatably relate to a single thread at the base of housing 24 and maintain association to the product tube base 154 , which forms a bottom closure.
While the invention has been described in connection with specific embodiments and applications, no intention to restrict the invention to the examples shown is contemplated. It will be apparent to those skilled in the art that the above methods may incorporated changes and modifications without departing from the general scope of the invention. It is intended to include all such modifications and alterations in so far as they come within the scope of the appended claims or the equivalents thereof.
|
An apparatus for dispensing cream products such as deodorants and the like from a concealed product tube. A rotatable propeller drives a threaded spindle having a piston elevator mounted thereon. As the spindle rotates, the piston elevator rides upward, pushing the product toward an application surface.
| 0
|
BACKGROUND OF THE INVENTION
This invention relates to a guard for the valve, gauge and regulator of a cylinder of compressed gas. Such cylinders of compressed gas are in their body very resistant to damage but in the area of the connection of the valve and gauge to the body of the cylinder they are vulnerable to damage. Thus if impacted in this area by a fall or by a moving body, the valve or gauge and also the regulator which is positioned in this area can become damaged allowing gas to escape from the cylinder. This is dangerous firstly because the gas can itself be explosive and secondly because the gas can be under such high pressure that its escape can propel the cylinder in the opposite direction to the escape. Both of these dangers can of course have catastrophic results.
A number of proposals have been made for providing protective guards for the valve area of cylinders of this type. Most of these guards, however, completely surround the valve area and must be opened or removed before access to the valve can be obtained. Such an arrangement is acceptable in theory but in practice the guard in the working enviroment is often left off or left open thus rendering it totally ineffective.
Other proposals have been made for simple bars or rings surrounding the valve area but these are unacceptable in that they do not provide sufficient protection against the most dangerous situations where the valve, gauge and regulator fall against an elongate or pointed object where the whole of the impact is taken on the valve area.
SUMMARY OF THE INVENTION
It is one object of the present invention therefore to provide an improved guard for a cylinder of compressed gas which provides access to the valve area without removing the guard and yet provides effective protection against impact on the valve.
The invention therefore provides according to a first aspect a guard for a cylinder for compressed gas having a valve, gauge and regulator at one end, the guard comprising a sleeve member having a cylindrical position for surrounding the majority of the peripheral extent of the cylinder leaving an opening extending axially of the cylindrical portion and two spaced flanges on respective sides of the opening and extending axially of the cylindrical portion and outwardly therefrom, and means for clamping the cylindrical portion around the end of the cylinder such that a portion of the sleeve member extends axially beyond the end of the cylinder to surround and protect the valve, gauge and regulator.
In accordance with a second aspect of the invention there is provided the combination of a cylinder for compressed gas having a valve, gauge and regulator at one end and a guard attached to said one end of the cylinder for surrounding and protecting the valve, gauge and regulator the guard comprising a sleeve member having a cylindrical portion for surrounding the majority of the peripheral extent of the cylinder leaving an opening extending axially of the cylinder and two spaced flanges on respective sides of the opening and extending axially of the cylinder and outwardly therefrom, and means for clamping the cylindrical portion around the end of the cylinder such that a portion of the sleeve member extends axially beyond the end of the cylinder.
The invention has the advantage, firstly, therefore that the cylindrical portion of the sleeve member substantially completely surrounds the valve area extending axially from the end of the cylinder but leaves a space between the flanges for access to the valve without the guard being removed or in anyway tampered with. The flanges which extend outwardly from the cylindrical portion protect the space through which access is achieved and preferably extend the full length of the cylindrical portion to provide protection along the full length.
According to a further advantage of the invention, the end of the sleeve member remote from the cylinder can be open so as to provide further access and in addition a further opening in one side of the cylindrical portion can be provided which acts as a handle and also as further access to the valve area without significantly reducing the protection provided by the sleeve member.
In accordance with a yet further advantage of the invention the valve and cylindrical portion can be formed contiguously from a bent sheet of galvanized mild steel so that the flanges lie directly on either side of the space and define the space. Spacer bars extending across between the flanges can reinforce the spacing of the flanges and provide yet further protection for the space between the flanges.
In accordance with a yet further feature of the invention, the clamping means can be obtained simply by clamping together the flanges at the end of the sleeve member adjacent the cylinder so that the cylindrical portion is clamped around the cylinder by drawing the flanges together.
With the foregoing in view, and other advantages as will become apparent to those skilled in the art to which this invention relates as this specification proceeds, the invention is herein described by reference to the accompanying drawings forming a part hereof, which includes a description of the best mode known to the applicant and of the preferred typical embodiment of the principles of the present invention, in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a first embodiment of a guard for use with a large diameter cylinder.
FIG. 2 is a cross sectional view along the lines 2--2 of FIG. 1 showing the guard attached to a cylinder.
FIG. 3 is an isometric view similar to that of FIG. 1 showing a second embodiment for use with smaller diameter cylinders.
FIG. 4 is a cross sectional view along the lines 4--4 of FIG. 3 showing the guard attached to a cylinder.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
The guard of FIG. 1 comprises basically a sleeve formed from a single sheet of galvanized mild steel bent to form a part cylindrical portion 10 with two flanges bent out from the ends of the cylindrical portion 10 and indicated at 11 and 12 respectively. The flanges 11, 12 are spaced by a distance of the order of 3 1/2 inches and which is greater than the width of a hand so as to provide access through the space between the two flanges to the interior of the cylindrical portion.
The sleeve as a whole is cut and shaped so the cylindrical portion 10 approximates in diameter to the diameter of the intended cylinder shown in FIG. 2 and indicated at 13. The flanges can be drawn together by nut and bolt couplings 14, 15 which are arranged such that the bolt 141, 151 passes through both flanges for receiving nuts 142, 152 which can be screwed onto the bolt to draw the flanges 11 and 12 together. The nut 142 can comprise a simple hex nut but the nut 152 is most preferably a wing nut so that the spacing of the flanges at the bottom adjacent the cylinder can be readily adjusted to draw the flanges together and thus reduce the diameter of the cylindrical portion 10 so as to clamp the cylindrical portion around the top of the cylinder. The nut and bolt arrangement 15, therefore, acts as a clamping device and firmly grasps the upper section of the cylinder.
For use with cylinders of a slightly smaller diameter than the diameter of the cylindrical portion 10 particularly in cases where the regulator extends outwardly beyond the cylindrical extent of the cylinder, a plurality of nuts and bolts 16 is provided each being arranged to pass through a respective hole in the cylindrical portion and engage the outer surface of the cylinder. Two of the nuts are arranged adjacent one flange and two adjacent the other flange so that by adjusting the position of the nut on the bolt the extent of the bolt projecting towards the cylinder can be adjusted so as to clamp the top of the cylinder between the cylindrical portion remote from the flanges and the bolt 16 under pressure caused by drawing the flanges together by the bolt 15.
A pair of openings 17 is provided in the cylindrical portion adjacent the top thereof and extending around the periphery over an angular extent of the order of 90°. The upper side of the openings is straight and both lie in the same horizontal plane. Both of the upper sides carry a hand grip section 18 which is provided by a folded strip of resilient material wrapped around the edge so as to provide a smooth surface by which a user can grasp the guard for the purpose of lifting the guard and cylinder for transportation. The openings are both of sufficient extent to receive the hand of the user and in addition extend downwardly a distance sufficient to comfortably receive the fingers of the user and also to provide some access to the interior of the guard. In the embodiment of FIG. 1 the openings 17 are arranged symmetrically of an axis passing through the guard between the flanges 11, 12 and are spaced by a shorter distance at the ends remote from the flanges.
Lying on the axis of symmetry at the front upper edge of the cylindrical portion 10 is a bolt and nut 19 which attaches a chain 20 to the front of the guard. The chain 20 is of relatively heavy-duty construction and provides a length of the order of two to three feet and has a hook on the remote end so the chain can be hooked over a suitable support for the guard and attached cylinder to retain the cylinder in a required position or orientation without the danger of falling. For convenience but not shown in FIG. 1, the chain can be wrapped around the guard between the two openings 17 when not in use.
A second small chain of only a few inches in length is also attached to the guard adjacent this point and this can be used to hang the valve key wrench to prevent it being separated from the cylinder and to retain it in a suitable place for use.
Four hooks 22 are positioned on the flanges facing outwardly and curved toward the cylindrical portion are provided attached to the outer surface of the flanges 11 and 12. These hooks are provided by simple rods threaded at the inner end for attachment by nuts 23 to the flange. The hooks 22 provide a suitable location around which the hose from the cylinder can be wrapped with the handle of the torch secured in a hose clip 24 also attached to the outer face of one of the flanges 11.
A flexible folded edge strip 25 is positioned on the edge of the sleeve member covering the junction between each flange and the cylindrical portion and extending a short distance into the flange and into the cylindrical portion. The edge strip is of a conventional form formed from a metal coated channel-shaped rubber or resilient material which can be secured to the edge of the sleeve by adhesive. The edge strips 25 prevent the hose from being pinched by the edge of the sleeve or from vigorously rubbing on the sleeve in use and thus causing damage or wear to the hose with the consequent danger of escape of the gas.
The arrangement of the valve, regulator and pressure gauge is illustrated in FIG. 2 where it will be noted that the pressure gauge and regulator are accessible through the opening between the flanges 11 and 12 so the pressure can be easily read through the opening without in anyway removing or adjusting the position of the guard. The gauge and regulator are generally indicated at 26. In addition the valve 27 is readily accessible from the open top of the guard so that it can be opened and closed merely by reaching into the open top of the guard. The hose extends from the regulator downwardly and is wrapped under the bar 153 to prevent it being torn from its mount on the regulator.
It will be appreciated therefore that the guard provided by the flanges 11 and 12 on the cylindrical portion 10 provides a complete protection for the valve arrangement at the top of the cylinder 13 with particularly the outwardly extending flanges providing protection for the vulnerable area of the opening in the cylindrical portion 10 through which the access to the pressure gauge and regulator is obtained. In addition the bars or bolts 14, 15 each of which carries a spacer sleeve 143, 153 locate the flanges in the proper position and also provide additional protection for the space between the flanges. Particularly the upper bolt 14 and sleeve 143 protect the area between the open top and the opening between the flanges and prevent an elongate body from entering across the corner between those two openings.
The flanges 11 and 12 provide strength to the upper edge of the cylindrical portion 10 so that it is more resistant to bending inwardly from impact with solid objects.
Turning now to FIGS. 3 and 4, a modified guard arrangement for use with smaller diameter cylinders is shown. Generally it is of similar construction to the previous embodiment in that it comprises a pair of flanges 11 and 12 and a cylindrical portion 10. However in this case the cylindrical portion 10 is of reduced diameter to match the diameter of the intended cylinder and the flanges 11 and 12 are of increased width so as to extend further outwardly from the edge of the cylindrical portion 10 to provide effectively equal protection for the valve, gauge and regulator relative to the embodiment of FIG. 1 despite the reduced diameter of the cylindrical portion 10.
In addition this embodiment is modified in that in place of the two openings 17, a single opening 171 is provided centrally of the cylindrical portion 10 and opposite the space between the flanges 11 and 12. The opening provides a flat horizontal upper edge for receiving a folded edge section 18 of the same construction as that of FIG. 1 so as to provide a hand grip by which the guard and the cylinder can be lifted. A second hand grip can be provided by the upper bolt arrangement 14 of similar construction to that of FIG. 1. The remaining edges of the opening 171 provide a pear-shape that is there is a downwardly extending portion at the center of the opening and this provides access to the valve as shown in FIG. 4 which on the smaller cylinders is arranged on a Y coupling with the valve extending toward the pear-shaped opening and the gauge and regulator extending toward the opening between the flanges 11 and 12. Thus the valve is accessible by the hand of the operative through the opening 171.
The embodiment of FIG. 3 and 4 is further modified in that the chain 20 instead of being connected at one point centrally of the guard is attached at two spaced points either side of the axis of symmetry and is arranged to hang downwardly with a tube of plastic material covering the chain at a central location to enable the chain to be grasped by hand and lifted more comfortably. This modification also allows the cylinder and guard to be suspended from the shoulder of the user for ready transportation to a place of use and to be carried during use.
A further modification is provided in that the hooks 22 instead of being curved include a right angle bend so as to lie substantially parallel to the respective flange 11, 12. This modification is in view of the reduced outward curvature of the cylindrical portion 10 relative to the flanges 11 and 12.
The embodiment is further modified in that the chain 21 instead of being attached to the chain 20 is attached centrally of the guard through a small hole at the bottom of the opening 171. In a final minor modification, the hose clip 24 instead of being attached to a separate bolt and nut coupling is received on the end of the bolt 14 and the bolt 14 is positioned lower on the flanges 11, 12 than in the previous embodiment. The bolt 14 is thus positioned adjacent the gauge and regulator to protect them from damage while they are accessible through the space between the flanges.
In both embodiments the space between the flanges 11, 12 is of the order of the width of the operative's hand to allow access and to allow grasping of the bolts and covering sleeves 14, 143. Such a spacing is of the order of three inches. Thus in the first embodiment the cylindrical portion 10 has a diameter of the order of twice the space between the flanges whereas in the second embodiment the diameter of the cylindrical portion is only slightly greater than the spacing between the flanges since these dimensions are set by different criteria.
Since various modifications can be made in my invention as hereinabove described, and many apparently widely different embodiments of same made within the scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.
|
A guard for attachment to the end of a cylinder of compressed gas comprises a cylindrical portion of diameter approximating the diameter of the intended cylinder and a pair of flanges extending outwardly from the cylindrical portion and contiguous therewith and defining between the flanges a space through which access can be obtained to the interior of the guard for observing and operating upon the valve arrangement of the cylinder. The cylindrical portion is clamped around the cylinder by drawing together the flanges by a pair of bolts extending across the flanges with spaces for defining the minimum space between the flanges. Openings in the cylindrical portion provide handles and access to the interior. The end of the cylindrical portion is open. A chain for supporting the guard and cylinder is attached to the guard and hooks are mounted on the flanges for receiving the hose from the cylinder.
| 8
|
BACKGROUND
The present invention relates to decorative lighting fixtures, and more particularly to garden and other outdoor lighting fixtures, as well as indoor fixtures such as chandeliers, sconces and special purpose decorations such as Christmas tree lights and night lights.
Traditional crystal-light fixture lenses produce rainbow effects by refraction of light as the light passes through various prismaticly shaped portions of the lens. It has also been discovered that rainbow effects can be produced by etching or otherwise forming grating patterns on ordinary glass or plastic. Methods for producing these gratings in the prior art for simulating the effects of prismatic crystal lenses are unfortunately labor intensive in that they require cutting, sandblasting, etc. Also, the visual effects that are produced by such substitutes are significantly poorer than the traditional crystal lens fixtures.
Thus there is a need for decorative lighting fixtures that provide visual effects at least comparable to those produced by prismatic crystal lenses and that can be mass produced at low cost.
SUMMARY
The present invention meets this need by providing a decorative lighting fixture that produces visual effects at least comparable to those produced by prismatic crystal lenses. In one aspect of the invention, the fixture includes a light source; and a translucent grating member having a grating of discontinuities integrally molded thereon for spatially modulating light from the light source, a multiplicity of the discontinuities having a spacing of between approximately 0.5×10 -6 m and approximately 100×10 -6 m. The fixture can further include a translucent lens member that forms an outer envelope portion of the fixture, the grating member being mounted between the light source and the lens member. The grating member can be integrally formed with the lens member. The lens member can be formed from a clear, transparent material.
The fixture can include a pair of the grating members on opposite sides of the light source. The fixture can include a pair of the lens members on opposite sides of the light source, the lens member defining a star-shaped envelope portion of the fixture, the fixture further including a tubular base portion for support by an upper tree extremity.
The fixture can further include a reflector member that is mounted opposite the light source from the grating member and having a concave reflective surface that faces the light source for enhancing light transmission through the grating member. The reflector member can form a quasi-hemispherical rear envelope portion of the fixture. The reflector member can be segmented for directing multiple images of the light source through the grating member. Preferably the reflective surface of the reflector member has a geodesic plurality of reflective portions for producing multiple images of the light source. Accordingly the colored effects that are generated by the fixture are greatly enhanced.
The fixture can further include segmented, partially reflective shell member at least partially enclosing the light source for projecting the light source onto particular locations on the grating surface from a plurality of directions. The shell member can have a polygonal tubular cross section or a star-shaped cross section. Preferably at least some segments of the shell member are located in parallel spaced relation for multiply reflecting the light source therebetween, thereby further compounding a quantity of images of the light source that are projected through the grating surface. The discontinuities can have a depth of from approximately 0.1×10 -6 m to approximately 100×10 -6 m.
In another aspect of the invention, a mold apparatus for molding a translucent grating member includes a large plurality of metallic grating lines corresponding to a diffraction pattern for defining a molded grating surface, a multiplicity of the grating lines having a spacing of between approximately 0.5×10 -6 m and approximately 100×10 -6 m; a metallic substrate member rigidly connecting the grating lines; a cavity member for defining portions of a mold cavity; means for fixedly connecting the substrate to the cavity member with the grating lines facing the mold cavity and defining at least a portion of the mold cavity, whereby the grating surface forms a multiplicity of surface discontinuities on an article molded by the apparatus. The grating lines can have a depth of from approximately 0.1×10 -6 m to approximately 100×10 -6 m.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
FIG. 1 is a decorative lighting fixture according to the present invention;
FIG. 2 is a mold assembly for a light-transmissive grating element of the fixture of FIG. 1;
FIG. 3 is a pictorial elevational diagram of optical tooling for producing a refraction pattern on a photographic plate for the grating of FIG. 2;
FIG. 4 is a detail sectional elevational view showing a portion of the refraction pattern of the photographic plate of FIG. 3;
FIG. 5 is a detail sectional elevational view showing a metal tooling formed on the photographic plate of FIG. 3;
FIG. 6 is a fragmentary sectional elevational view showing an alternative configuration of the fixture of FIG. 1;
FIG. 7 is a fragmentary sectional detail view of a portion of the fixture of FIG. 6;
FIG. 8 is an oblique elevational perspective view showing another alternative configuration of the fixture of FIG. 1;
FIG. 9 is an oblique elevational perspective view showing another alternative configuration of the fixture of FIG. 1;
FIG. 10 is a plan sectional view showing a portion of the fixture of FIG. 9;
FIG. 11 is a plan sectional view as in FIG. 10, showing a further configuration of the fixture of FIG. 1;
FIG. 12 is an oblique elevational perspective of a chandelier fixture incorporating features of the fixture of FIG. 1;
FIG. 13 is an oblique elevational perspective detail view of a portion of the fixture FIG. 12;
FIG. 14 is a perspective view as in FIG. 13, showing another portion of the fixture of FIG. 12;
FIG. 15 is a perspective view as in FIG. 13, showing another portion of the fixture of FIG. 12;
FIG. 16 is a perspective view as in FIG. 13, showing another portion of the fixture of FIG. 12;
FIG. 17 is a perspective view as in FIG. 13, showing another portion of the fixture of FIG. 12;
FIG. 18 is a perspective view as in FIG. 13, showing another portion of the fixture of FIG. 12;
FIG. 19 is a perspective view as in FIG. 13, showing a further portion of the fixture of FIG. 12; and
FIG. 20 is a bottom oblique elevational view of a further alternative configuration of the fixture of FIG. 1.
DESCRIPTION
The present invention is directed to a decorative lighting fixture for producing colorful visual effects similar to effects that are normally produced by prismatic crystal fixtures. With reference to FIG. 1 of the drawings, a fixture 10 has a conventional incandescent lamp 12, a centrally located light-transmissive grating element 14, and a light-transmissive lens 16, the lens 16 defining a front extremity of the fixture 10. In the exemplary configuration of FIG. 1, the fixture 10 is shaped like a spherical Christmas tree ornament, a socket 18 for the lamp 12 being mounted within a quasi-hemispherical rear reflector 20, the reflector 20 defining a convex rear envelope of the fixture 10. Flexible power leads 22 extend from the rear of the socket 18 for connection in a conventional manner to a suitable source of power (not shown) together with other counterparts of the fixture 10. As further shown in FIG. 1, the lens 16 has a hemispherical shell configuration, the grating element 14 being supported at its periphery within an equatorial recess 24 of the lens 16, a front extremity of the reflector 20 also being connected against the grating element 14 and retained by the recess 24.
According to the present invention, the grating element 14 has a grating surface 26, further described below, the grating surface 26 facing the lamp 12 and being directly molded as an integral part of the element 14. The reflector 20 has a reflective surface 28 formed on its inside wall in a conventional manner. Light from the lamp 12, and as augmented by the reflective surface 28, passes through the grating element 14, the light being spatially modulated by the grating surface 26 and being further transmitted through the lens 16 as indicated by the arrows in FIG. 1. Preferably, and as indicated in FIG. 1, the reflective surface 28 forms a geodesic plurality of surface segments 28' for multiply imaging the lamp 12 through the grating surface 26, thereby enhancing the visual effect of the fixture 10. Depending on the pattern of the grating surface 26 and other factors discussed below, colorful and ornamental rainbow or spectrum-like patterns emanate from the fixture 10.
With further reference to FIGS. 2-5, the grating surface 26 is molded from a tooling plate 30 that forms a part of a mold assembly 32 for molding the grating element 14, the mold assembly 32 also having a main cavity member 34, a cover 36, and a backing plate 38. As shown in FIG. 2, the tooling plate 30 is clamped between the cavity member 34 and the backing plate 38 by suitable fasteners 40. The cover 36 is also fastened to the cavity member 34 by counterparts of the fasteners 40. Thus the tooling plate 30, the cavity member 34, and the cover 36 define a mold cavity 42 for forming the grating element 14 by injection molding or by pour molding. It will be understood that the cover 36 is not necessarily required for pour molding.
The tooling plate 30 is formed against a cleaned glass plate 44 or similar member having an optical surface 46. As shown in FIG. 3, a silver-bearing photographically sensitive lotion or emulsion 48 is applied as a thin coating on the optical surface 46. The emulsion 48 is preferably applied at a selected thickness between about 0.1×10 -6 m to approximately 100×10 -6 m. A dual-beam laser 50 is directed downwardly toward the optical surface 46, a defraction mask 52 being interposed between the laser 50 and the glass plate 44 for producing a defraction pattern on the emulsion 48. The laser 50 can be an argon-iron laser having radiation at approximately 457.9 nm. Following exposure, the image of the defraction pattern is developed, leaving a thin, interrupted coating or silver on the optical surface 46. As shown in FIG. 4, the silver is in a pattern of lines 54, the lines 54 having width W, a line depth d, and a spacing S, being separated by a distance D. The spacing S is the sum of the distance D and the width W. It will be understood that the lines 54 are in general curved and intersecting, and the width W and the spacing S are typically non-uniform; yet the pattern of lines 54 is typically locally uniform and parallel. The spacing S can range from approximately 0.5×10 -6 m to approximately 100×10 -6 m, the width W and the distance D being typically half of the spacing S. The line depth d corresponds to the thickness of the emulsion 48.
After the exposed emulsion 48 has been developed and dried, the glass plate 44 is positioned within a suitable vacuum chamber (not shown) and a thin coating of silver is vacuum-deposited onto the emulsion 48 for conductively bridging the silver lines 54. Next, a substrate 56 of a suitable metal such as nickel is electroplated onto the deposited silver as shown in FIG. 5, the backing 54 having a thickness T on the order of 2 mm or 3 mm. Finally, the completed tooling plate 30 is peeled from the glass plate 44 for use in the mold assembly 32. It will be understood that while the mold assembly 32 of FIG. 2 has the tooling plate 30 in its original flat configuration as formed on the glass plate 44, the substrate 56 can be formed cylindrically or otherwise curved for defining a correspondingly curved portion of the mold cavity 42, the cavity portion 34 and the backing plate 38 being similarly curved as required for clampingly supporting the tooling plate 30 in its curved configuration. Thus the grating surface 26 of the element 14 is defined by the silver lines 54 inwardly protruding from the substrate 56 into the mold cavity 42.
The grating element 14 can be injection molded of glass or translucent plastic such as acrylic, polyethylene, polypropylene, and polychloride. In preferred practice of the present invention, the mold cavity 42 is formed with highly reflective or polished surfaces for producing corresponding optical quality molded surfaces. Preferably the molded material is optically clear or slightly colored for a high degree of light transmission.
Thus a method for molding a light fixture lens according to the present invention includes the steps of:
(a) providing a silver-bearing photographic emulsion on an optical surface;
(b) imaging a diffraction pattern on the emulsion;
(c) developing the emulsion for forming a large plurality of metal lines on the optical surface, a multiplicity of the metal lines having a spacing of between approximately 0.5×10 -6 m and approximately 100×10 -6 m;
(d) plating a metal substrate onto the metal lines opposite the optical surface, the substrate connecting the lines in spaced relation to the optical surface;
(e) peeling the substrate, together with the metal lines, from the optical surface;
(f) fastening the substrate to a cavity member, the substrate together with the metal lines defining a portion of a mold cavity, the mold cavity extending within the cavity member;
(g) feeding a moldable material into the mold cavity;
(h) solidifying the material for forming the light fixture lens, the metal lines defining a multiplicity of surface discontinuities on a grating surface of the lens; and and
(i) removing the completed lens from the cavity.
The step of plating the substrate can be performed at a substrate spacing from the optical surface of from approximately 0.1×10 -6 m to approximately 100×10 -6 m.
With further reference to FIGS. 6 and 7, an alternative configuration of the fixture 10 has an array of the lamps 12 supportively and electrically connected on a bulkhead member 58 between a pair of star-shaped counterparts of the lens 16, designated grating-lens 60. Each of the grating-lenses 60 has a counterpart of the grating surface 26 directly molded therein and facing the bulbs 12 for producing the rainbow colored effects. A depending tubular base portion 61 of the fixture 10 extends from one or both of the grating-lenses 60 for support of the fixture 10 as a Christmas tree top ornament. The colored effects are made more complex and attractive by virtue of multiple illuminating through the various portions of the grating surface 26 from the array of lamps 12.
With further reference to FIG. 8, another configuration of the fixture 10 has a pair of conductive plug prongs 62 extending from a base member 64 for supporting and powering the fixture 10 from a conventional electrical power outlet (not shown). A counterpart of the lamp 12 extends upwardly within an upstanding counterpart of the grating-lens 60, designated 60'. The lamp 12 is activated in response to a conventional ambient light sensor 66 that is mounted to the base member 64 for operation of the fixture 10 as a safety night light fixture. As further shown in FIG. 8, the grating-lens 60 can be formed of a plurality of lens segments 68, the lens segments 68 forming planar segments that are joined at corner edges of the grating-lens 60'.
With further reference to FIGS. 9 and 10, the fixture 10 can be provided with a mounting post 70, the post 70 being pointed at the bottom for anchoring into the ground. The lamp 12 and its socket 18 are fastened to a bottom housing member 72 of the fixture 10, a suitable power cord 74 being connected to the socket 18 for powering the lamp 12. A plurality of planar counterparts of the grating-lens 60 are arranged in a polygonal array about the lamp 12, being supportively clamped at top and bottom edges thereof between a top housing member 76 and the bottom housing member 72 in any conventional manner. As shown in the drawings, the perimeter edges of the grating-lenses 60 are preferably beveled (by molding) for enhancing the rainbow colored effects resulting from light transmission through the grating surfaces 26.
In further accordance with the present invention, the fixture 10 of FIGS. 9 and 10 preferably includes a translucent reflector member 78 having a partially reflective surface 80 for further enhancing the visual effects by providing multiple images of the lamp 12 at at least some portions of the grating surfaces 26. For this purpose the reflector member 78 has a segmented shell configuration, forming a square prismatic enclosure of the lamp 12 and having apexes 82 proximate midpoints of the grating-lenses 60 in the exemplary configuration of FIG. 9. Thus a pair of images of the lamp 12 are formed at the grating surface 26 as indicated by the arrows in FIG. 9.
With further reference to FIG. 11, a further variation of the fixture 10 has a cylindrically molded counterpart of the grating-lens 60 located concentrically with the lamp 12. A star-shaped counterpart of the translucent reflector member 78 surrounds the lamp 12 for forming multiple images of the lamp 12 at the grating surface 26 as indicated by the arrows in FIG. 11. The grating-lens 60 in the configuration of FIG. 11 is molded in the mold assembly 32 wherein the tooling plate 30 and the backing plate 38 are formed cylindrically and having at least a slight taper for facilitating extraction of the grating-lens 60 following molding.
With further reference to FIGS. 12-19, another alternative configuration of the fixture 10, designated chandelier fixture 10', includes a column frame 84 for suspending from a ceiling, a plurality of the lamps 12 being supported in a spaced array from the frame 84, and a plurality of counterparts of the grating-lens 60, designated pendant grating-lenses or pendants 86, the pendants 86 being supported by respective projecting wire portions 88 of the frame 84 for producing the colored effects when light from the lamps 12 is transmitted therethrough. Exemplary configurations of the grating-lenses 86 include a triangularly prismatic pendant 86a, shown in FIG. 13; a tri-polar pendant 86b, shown in FIG. 14; and a dual-triangular pendant 86c, shown in FIG. 15. As shown in FIG. 13, the pendant 86a has at its upper extremity a tab member 90 that is formed with a horizontally oriented support passage 92 therein for receiving a corresponding one of the wire portions 88, a forwardly facing side of the pendant 86a being formed with rearwardly beveled side faces 94a on opposite sides of a vertical apex 96, and rearwardly beveled end faces 94b that extend above and below upper and lower extremities of the apex 96. A counterpart of the grating surface 26 forms a vertically planar back face 98 that extends behind the full width and height of the front faces 94.
As shown in FIG. 14, the tri-polar pendant 86b has trough-shaped concavely cylindrical counterparts of the side faces 94a and the back face 98 that extend between convex vertical rib extremities 100 of the pendant 86b. The grating surface 26 is thus substantially cylindrically concave. As used herein, the term "cylindrical" means having a surface generated by a straight line that moves parallel to a fixed line. The dual-triangular pendant 86c of FIG. 15 has planar counterparts of the side faces 94a sloping rearwardly from a spaced pair of the vertical apexes 96 for forming a pair of triangularly prismatic portions 102, the grating surface 26 being formed on a counterpart of the back face 98 that extends behind both of the prismatic portions 102.
Another variant of the grating-lens 86, designated panel pendant 86d and shown in FIG. 16, has a rectangular front face 104 formed in parallel spaced relation to a corresponding counterpart of the back face 98, perimeter portions of the faces 98 and 100 being beveled from a perimeter apex 106. As shown in FIGS. 13-16, the grating surface 26 is formed on the back face 98 of each of the pendants 86a, 86b, 86c, and 86d. The panel pendant 86d, being symmetrical front to rear, can have the grating surface 26 formed on its front or rear faces, the surface 26 preferably extending to the perimeter apex 106.
The chandelier fixture 10', in the exemplary configuration of FIG. 12, also includes further variants of the grating-lens 86, designated bipyramid pendant 86e, also shown in FIG. 17; teardrop pendant 86f, also shown in FIG. 18; and an octoid pendant 86g, shown in FIG. 19. As shown in FIGS. 17-19, each of the pendants 86e, 86f, and 86g is assembled from front and rear body portions 108 and 110 that are joined at a medial plane 112 by a suitable adhesive (not shown), the grating surface 26 lying in the medial plane 112, being formed in one of the body portions 108 or 110. The formation of the grating surface 26 across the full face area of the pendants 86 is thus facilitated by locating the grating surface 26 in the medial plane 112 of the pendants 86 having complex or multifaceted shaped. Preferably the material of the pendants 86 has a high refractive index for further enhancing the colored rainbow effects. It will be understood that the chandelier fixture 10' can include a plurality of the pendants 86 that are selected from any collection of pendants configured as the pendants 86a-86g of FIGS. 13-19. Thus it is contemplated that many of only one configuration of the pendants 86 can be included in the chandelier fixture 10'.
With further reference to FIG. 20, yet another configuration of the fixture 10, designated ceiling fixture 114, has a bowl-shaped counterpart of the grating-lens 60 supported within a bezel member 116, the bezel member 116 being configured for mounting to a plane wall or ceiling surface in a conventional manner. As shown in FIG. 20, the grating-lens 60 of the fixture 114 is formed as shallow conical shell having a rounded apex portion 118, the grating surface 26 being formed as an inside surface of the grating-lens 60.
A potential problem in molding the grating element 14 and the grating-lens 60 is the possibility of damage to the grating surface 26 resulting from differential contraction of the solidified molding relative to the lines 54 of the tooling plate 30. It is contemplated that the mold assembly 32 is cooled by conventional means such as liquid passages (not shown) in the mold assembly 32 through which a suitable coolant is circulated. Preferably, the flow rate of the coolant and the temperature thereof are maintained at levels promoting enhanced cooling of the mold assembly 32 for limiting expansion of the tooling plate 30. Also, the molded part is preferably extracted from the mold assembly 32 as quickly as practicable following molding for limiting contraction of the molded part.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. The fixture 10 can have one or a pair of the grating-lenses 60 formed in a conical or bowl-shaped configuration. Also, the grating surface 26 can be molded directly in a glass envelope member of the bulb 12. The partially reflective surface of the reflector member 78 can be formed on the outwardly facing surface rather than the inwardly facing surface as described above. Further, the reflective surface 28 of the rear reflector 20 can be made partially reflective for lighting from the rear of the fixture 10, and a pair to the grating elements 14 can be mounted on opposite sides of the lamp 12. The fixture 10 of FIGS. 6 and 7 can include counterparts of the partially reflective shell member between the bulkhead member 58, and the bulkhead member can also be made fully or partially reflective for generating multiple images of the lamps 12. The frame 84 can be adapted for wall mounting by configuring the pendants 86 in one or more semicircular array portions. Moreover, the grating surface 26 can be formed by permanent deformation of a formable material by the tooling plate 30. In particular, the tooling plate 30 can be formed as a cylindrical segment or as a complete cylinder, the lines 54 being impressed into the grating element 14 or the grating-lens 60 and forming corresponding discontinuities of the grating surface 26 as the tooling plate 30 is rolled. For this operation, the material to be formed by the tooling plate 30 is maintained at an appropriate intermediate temperature for facilitating plastic flow between the lines 54. Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions contained herein.
|
A lighting fixture includes a grating of discontinuities that is integrally molded in a translucent member for spatially modulating light from a light source of the fixture. A translucent lens forms an outer envelope portion of the fixture, the grating being mounted between the light source and the lens. A reflector mounted opposite the light source from the grating enhances light transmission through the grating. A semi-reflective shell member in front of the light source, used alone or in combination with a geodesicly segmented reflector opposite the light source, greatly enhances the visual effects of the fixture by projecting multiple images of the light source through the grating. A mold for molding the grating includes a large plurality of metallic grating lines corresponding to a diffraction pattern for defining the grating surface; a metallic substrate rigidly connecting the grating lines; a cavity member for defining portions of a mold cavity, the substrate being connected to the cavity member with the grating lines facing the cavity and defining at least a portion of the cavity, whereby the grating surface forms a multiplicity of surface discontinuities on a molded article.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to a multiple-needle tufting machine, and more particularly to a cut pile looper apparatus for a narrow gauge tufting machine.
Conventional hook bars for multiple-needle tufting machines are long bars extending transversely of the machine below the needles and the base fabric. A conventional cut pile hook bar has uniformly spaced slots in its front face for receiving the loopers which cooperate with the needles to form loops in the yarns carried by the needles. For a narrow gauge multiple-needle tufting machine, the slots in the front face of the hook bar must be formed close together. The closeness of the spacing of the rear looper slots is limited by the thinness of the walls between the slots.
One solution to spacing the looper slots close together for narrow gauge tufting machines is disclosed in the prior U.S. Pat. No. 3,635,177, issued to Larry P. Gable et al for "NARROW GAUGE HOOK BAR FOR TUFTING MACHINE" on Jan. 18, 1972. The Gable patent discloses a hook bar having uniformly spaced, but staggered, looper slots formed alternately in the front and rear faces of the hook bar. Thus, the staggered front and rear slots receive two transverse rows of staggered hooks or loopers for cooperation with corresponding staggered needles. However, the hook bar disclosed in the Gable patent was primarily designed for a looper apparatus for forming narrow gauge loop pile.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide in a narrow gauge, multiple-needle tufting machine an improved hook bar having alternately staggered front and rear looper slots for receiving cut pile loopers or hooks.
In order to provide a cut pile looper apparatus designed to cooperate with staggered needles for very narrow gauges, in the order of 1/16 inch gauge, the hooks or loopers must be made of relatively thin material, yet must have bills of sufficient length projecting from the body portions of the loopers supported in the hook bar to cross and cooperate with the corresponding staggered needles.
Accordingly, it is one feature of this invention to form in the top portion of the hook bar a plurality of transversely spaced longitudinal top slots. Each of the top slots is in longitudinal alignment with and intercepts a rear slot. Thus, the body portion of a rear slot fits longitudinally within a corresponding top slot, so that the opposing walls of the top slot rigidly hold the thin body portion in a reinforced position in the hook bar to minimize flexing and vibration of the rear looper during its rapid reciprocation and cooperation with its corresponding needle for forming loops. The fitting of the body portion of the rear looper within a top slot also provides rigid support for the looper as it continually cooperates with its corresponding knife for cutting the yarns to form cut pile tufts.
In a preferred form of the invention, top slots are also provided in alignment with and intercepting each of the front slots to firmly support and hold the body portions of the front loopers, even though the front loopers are closer to their corresponding needles than the rear loopers are to their corresponding needles.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary, sectional elevation taken longitudinally through a portion of a narrow-gauge, staggered-needle tufting machine incorporating a cut pile looper apparatus made in accordance with this invention, and disclosing the needles and loopers in operative loop-forming position;
FIG. 2 is a fragmentary, front elevation of the looper apparatus, taken along the line 2--2 of FIG. 1; and
FIG. 3 is a fragmentary, top plan view of the looper apparatus, taken along the line 3--3 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in more detail, FIG. 1 discloses a transverse needle bar 10 in a conventional multiple-needle tufting machine supporting a first row of uniformly spaced front needles 11 and a second row of uniformly spaced rear needles 12 offset preferably midway between the front needles 11, to provide a uniform, narrow gauge staggered needle tufting machine. The needle bar is vertically reciprocated by conventional means, not shown, to cause the front and rear needles 11 and 12 to move between an upper position above the base fabric 13 to a lower position penetrating the base fabric 13 so that the needles will carry yarns, such as yarn 14, through the base fabric 13 to form loops of tufting therein. The base fabric 13 is supported upon a needle plate 15 for movement, by means not shown, in the direction of the arrow of FIG. 1, that is longitudinally from front-to-rear through the machine.
The looper apparatus 18 which cooperates with the needles 11 and 12 includes a transverse hook bar 20 fixed upon a transverse hook bar plate 21, which is in turn supported upon a plurality of rocker arms 22 journaled on a rock shaft, not shown, and driven by conventional means connected at link pins 23.
The hook bar 20 has a front face 24, a rear face 25 and a top surface or face 26.
Formed in the front face 24 are a plurality of uniformly spaced vertical front slots 28. The thickness of the front slots 28 is substantially the same as the thickness of the portion of the corresponding front looper 30 to be received therein.
In a similar manner, a plurality of uniformly spaced rear slots 32 are formed through the rear face 25 of the hook bar 20. However, the rear vertical slots 32 are evenly staggered with respect to the front slots 28, as best disclosed in FIG. 3. Each rear slot 42 is of a width substantially the same as the thickness of the portion of a rear looper 34 to be received therein.
Each of the rear slots 32 is in alignment with and intercepts a first top slot 35 which is straight and extends longitudinally the full breadth of the hook bar 20 and through the front face 24 of the hook bar 20.
In like manner, a second set of top slots 36 extend straight and longitudinally through the top wall 26 and the front face 24 of the hook bar 20. Each top slot 36 is in alignment with and intercepts each of the front slots 28.
In a preferred form of the invention, each of the top slots 35 and 36 is separated by a substantially rigid supporting wall 37.
Each of the rear loopers 34 is of a substantially uniform, relatively thin steel material and includes a body portion 39 adapted to be received in the first top slot 35 substantially snugly. A shank portion 40 depending from the body portion 39 is also snugly received within a rear slot 32 and held in the rear slot 32 by means of the set screws 41. Projecting longitudinally forward from the body portion 39 is a relative short bill 42 adapted to cooperate with a rear needle 12.
In a similar manner, the body portion 43 of each looper 30 is also of uniformly thin material adapted to be received in a top slot 36. A shank portion 44 depends from the body portion 43 for reception within a front slot 28, and the shank portion 44 is held in the front slot 28 by a front set screw 45. Projecting longitudinally forward from the body portion 43 is the long bill 46 adapted to cooperate with a corresponding front needle 11 for forming a loop of yarn.
In a preferred form of the invention, each body portion 39 and 43 form transversely aligned throat portions 47 and 48, each of which is adapted to cooperate with one of a plurality of transversely aligned conventional tufting knives 50.
It will be noted in FIG. 1 that the rear portion of the body portion 43 projects behind the shank portion 44 so that it is snugly received within its own top slot or groove 36.
Thus, with each body portion 39 and 43 of each corresponding looper 34 and 30 snugly received throughout a substantial portion of its length within a corresponding top slot 35 and 36, the thin loopers 34 and 30 required for the extremely narrow gauge of the needles 11 and 12 are adequately reinforced and supported for their continuous and rapid reciprocation. Vibration and wear of the thin reciprocating loopers cooperating with the respective needles 11 and 12 and in cutting cooperation with the respective knives 50, are minimized.
It will be apparent from the drawings that the knives 50 must also be thin and of lesser thickness than the corresponding divider walls 37 between the adjacent top slots 35 and 36.
It is also within the scope of the invention to reverse the lengths of the bills 42 and 46 and reverse the stagger of the corresponding needles. Thus, the front bill 46 would be the short bill and the rear bill 42 would be the long bill.
The rear extension of the body portion 43 of the front looper 30 preferably rests solidly in the bottom of the slot 36 to gauge the height setting of the looper 30. Likewise, the lower edge of the body portion 39 rests solidly in the bottom of the top slots 35 to gauge the height of the rear looper 34.
|
A narrow gauge, cut pile looper apparatus for a multiple-needle tufting machine, preferably having staggered needles, comprising a transverse hook bar having staggered front and rear slots in the front and rear faces of the hook bar and longitudinal top slots, a top slot being in alignment with each of the corresponding front slots and rear slots, for receiving a corresponding front or rear looper.
| 3
|
BACKGROUND OF THE INVENTION
The present Invention relates in general to shading devices, and in particular to a sun shading device of the type used to shade the corners of rectangular, vinyl-lined, in-ground swimming pools.
The damaging effects of the sun's ultraviolet light upon the corner areas of vinyl-lined swimming pools can be a costly consequence for the backyard swimming pool owner. Constant exposure of the vinyl pool liner to the sun's ultraviolet light causes the liner to deteriorate over a period of time, for example, five to ten years, above the water level of the pool. As the vinyl liner deteriorates, it loses its elasticity and dry rots, thusly becoming susceptible to tearing from the stress of the weight of the water pulling at the liner, specifically at the corners of the pool.
Once the vinyl liner begins to tear in the upper corners of said pool, the only repair remedy currently available to the swimming pool owner is to patch the torn liner with a vinyl covering affixed in place with glue. This has proven to be at best a temporary repair to the aforementioned liner.
Eventually, the constant and unyielding weight of the water exceeds the mending ability of the aforecited repair process, and yields to further tearing and repatching.
Eventually, the aforementioned pool liner becomes irreparable and replacement of the swimming pool liner is necessitated.
SUMMARY OF THE INVENTION
To prevent and/or limit the aforementioned damaging effects of the sun upon vinyl-lined swimming pools, I have achieved the present invention.
Accordingly, the principal object of the present invention is to provide a device for use on swimming pools with vinyl liners to shade a significant portion of the pool's corners from the sun, thereby protecting said liner from sun damage in the area of the pool corners.
It also is an object of the present invention to provide such a device which is of simple, inexpensive construction.
Another object is to provide such a device which, in use, will provide a multipurpose insulating mat that overlays the swimming pool deck surface to place items commonly used around pools such as, but not limited to, plant containers, drinking glasses, ashtrays, and the like.
The foregoing objects can be accomplished by providing a shading device formed into a keyhole-like shape, which when placed on the swimming pool deck at the corners, would overhang the corner and extend down to the water level, thereby shading the vinyl liner behind said shading device.
The upper portion of the shading device, the circular portion of the keyhole shape, would remain on the deck surface providing an insulation mat for plant containers and other previously, described items.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the most preferred embodiment of the present invention.
FIG. 2 is a front perspective of the central portion of the device of FIG. 1.
FIG. 3 is a side perspective of the upper portion of such device.
DETAILED DESCRIPTION
As shown in the drawings, the preferred sun shade device in accordance with the present invention is comprised of a flat mat with front and back surfaces, an upper end portion 2 and a lower end portion 3, which preferably is constructed of a resilient and flexible material. As best seen in FIG. 1, the preferred sun shade device is of a generally keyhole-like shape.
The upper end portion 2 of the sun shade device is of a generally circular shape forming a flat rotary plane.
For illustrative purposes, the sun shade device is bisected by score line 8 at the base of said upper end portion 2.
The lower portion 3 of the sun shade device includes opposite side tabs 4 and 5 respectively, the top edges of which are adjacent to said upper end portion 2 and are curved so as to produce opposite concave edges 6 and 7 respectively. The top edges 6 and 7 of side tabs 4 and 5 are formed as outwardly sloping down from the bisecting score line 8 to a nadir at which point said edges 6 and 7 sharply angle downward forming opposite, parallel vertical sides 9 and 10 respectively. Sides 9 and 10 are connected by a linear edge 11 which is opposite the upper most edge of upper end portion 2 and is parallel to bisecting score line 8. Edge 11 forms the bottom of lower end portion 3 of the device.
When the sun shade device is to be used the upper end portion 2 will rest flatly on the deck surface 12 of an inground, vinly-lined, rectangular swimming pool 1 adjacent to the corner of said swimming pool 1 as shown in FIGS. 2 and 3.
The force of gravity secures said upper portion 2 in place, said upper portion 2 providing a counterbalance means for supporting said lower portion 3.
The flat mat-like rotary plane surface formed by said upper portion 2 can thusly be optionally used as an insulation mat for placement of plant containers and other swimming pool accessories.
The lower end portion 3 of said device will drape down and over the swimming pool edge 13 at the corner of said swimming pool 1 forming a generally right angle with upper end portion 2 at bisecting score line 8.
It will be noted as clearly illustrated in FIGS. 2 and 3 that the lower end portion 3 of the sun shade device effectively covers and protects a significant portion of the swimming pool corner, thereby, shading said corner from the damaging effects of the sun.
|
A swimming pool corner sun shade device for use on in-ground, vinyl-lined rectangular swimming pools in the shape of a flat generally keyhole-like shaped mat.
| 4
|
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(a) to Chinese Patent Application No. 2005100202199, filed on Jan. 21, 2005.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to novel peptide compounds, and methods of making and using the peptides for the treatment of fungal infections, e.g., Candida albicans, Cryptococcus neoformans, Aspergillus flavus, Magnaporthe grisea and Fusarium moniforme.
2. Related Art
Fungus is opportunistic pathogens in humans. Fungus typically does not infect healthy tissues, yet once tissue defense mechanisms have been compromised, they can readily infect the tissue. One typical model of this opportunistic fungal infection is candidiasis, which is caused by Candida albicans.
Candida albicans occurs as normal flora in the oral cavity, genitalia, large intestine, and skin of approximately 20% of humans. The risk of infection increases in children and pregnant women; people who use certain antibiotics or have nutritional and organic disease or immunodeficiency (e.g., AIDS) or trauma; and people with invasive devices, e.g., pacemakers. Candida albicans and its close relatives account for nearly 80% of nosocomial fungal infections and 30% of deaths from nosocomial infections in general.
Historically, opportunistic fungal infections in hospitalized patients were rather unusual. Textbooks from the past described these agents as common contaminants with weak pathogenic potential, and infections were considered extreme deviation form the normal. Older ideas concerning these so-called harmless contaminants are now challenged because in those days immunodeficient and debilitated patients had died from their afflictions long before fungal infection took place. However, currently, with the advent of innovative surgeries, drugs, and other therapies that maintain such patients for expected periods, the survival rates of patients have significantly increased and the number of compromised patients has thus increased. One clinical dilemma that cannot be completely eliminated, even with rigorous disinfections, is the exposure of such patients to potential fungal pathogens from even normal flora. Fungal infections in such high-risk patients progress rapidly and are difficult to diagnose and treat. In one study, fungi caused approximately 40% of the deaths from clinically acquired infections. Up to 5% of all nosocomial opportunistic fungi cause infections.
Fungi also present special problems in chemotherapy. A majority of chemotherapeutic drugs used in treating bacterial infection are generally ineffective in combating fungal infection. Moreover, the similarity between fungal and human cells often means drug toxic to fungal cells are capable of harming human cells. A few drugs with special antifungal properties have been developed for treatment of systemic and superficial fungal infections. For example, macrolide polyenes represented by amphotericin B, have a structure that mimics some cell membrane lipids. Amphotericin B which is isolated from a species of streptomycin is by far the most versatile and effective of all antifungal drugs. The azoles are broad-spectrum antifungal drugs with a complex ringed structure. As one of the most effective azole drugs, fluconazole, is used in patients with AIDS-related mycoses.
Magnaporthe grisea is the pathogen of a devastating fungal disease of rice plants known as rice blast. The fungus can also cause a similar disease in over 50 grasses, including economically important crops such as barley, wheat, and millet. Fusarium is another important genus of fungal pathogens, responsible for devastating diseases such as cereal scab.
SUMMARY OF THE INVENTION
The present invention is directed to novel peptides comprising a fungi specific targeting agent, e.g., a pathogenic fungal peptide pheromone, and channel-forming colicin or a channel-forming fragment thereof (also referred to herein as “domain”). Peptides comprising a pheromone as the fungi specific targeting agent, and a colicin domain, are referred to herein as “pheromonicin peptides”.
The molecular structure of the formed peptides may have the C-terminus of colicin or a channel-forming domain linked with the N-terminus of a fungi specific targeting agent, e.g., a fungal pheromone, or the N-terminus of colicin may be linked with the C-terminus of a fungi specific targeting agent e.g., a fungal pheromone. The fungal pheromone can be from a pathogenic fungus, e.g., Candidas . The molecular weight of the peptide may vary, e.g., from about 26,000 to about 70,000 daltons.
The peptides of the present invention may be formed by a variety of methods. One method of forming a peptide of the present invention is by inserting a nucleic acid molecule encoding a fungal pheromone into a selected position of a nucleic acid molecule encoding a colicin, or a channel forming domain thereof, then transfecting the mutant plasmid into a host cell, e.g., E. coli , to produce the peptide. In an alternative embodiment, portions of the peptide may be made separately, e.g., synthetically, or by recombinant means, and later linked by known methods.
In one embodiment, the peptides of the present invention are useful in treating infections of Candidas or Aspergillus or Magnaporthes or Fusarium . Exemplary infections are those created by Candida albicans, Candida tropicalis, Candida parapsilokis, Candida krusei, Candida dubliniensis, Cryptococcus neoformans, A. fumigatus, A. flavus, A. niger, Magnaporthe grisea and Fusarium moniforme.
The invention further provides nucleic acid molecules that encode the peptides of the invention. The invention also provides vectors comprising the nucleic acid molecules, e.g., expression vectors. The invention also provides cells, e.g., host cells, comprising the vectors of the invention.
Host cells, including bacterial cells such as E. coli , insect cells, yeast or mammalian cells (such as Chinese hamster ovary cells (CHO) or COS cells), can be used to produce the peptides of the invention. Other suitable host cells are known to those skilled in the art. The invention thus provides methods for producing the peptides of the invention comprising the steps of culturing the host cells of the invention and isolating the peptides of the invention therefrom.
In another embodiment, the invention provides a method for preparing a peptide which inhibits growth of a fungus comprising: (i) inserting a nucleic acid molecule encoding colicin, or a channel forming domain thereof, into a selected position of a nucleic acid molecule encoding a fungal targeting agent, e.g., a pheromone; (ii) transfecting the mutant plasmid into a host cell, e.g., an E. coli cell; and (iii) allowing said host cell to produce said peptide. In further embodiments, the peptide may be purified from the cells.
In another embodiment, the invention provides a method for preparing a fusion peptide comprising: (i) incorporating a nucleic acid molecule encoding the peptide chain of colicin Ia with a nucleic acid molecule encoding a fungal pheromone such as Candida albicans α-mating pheromone; (ii) introducing said nucleic acid molecule encoding the peptide chain of colicin Ia incorporated with said fungal pheromone a following the C-terminus of the colicin Ia to form a nucleic acid molecule that encodes a 639 residue peptide.
In another embodiment, the invention provides a method for preparing a fusion peptide comprising: (i) incorporating a nucleic acid molecule encoding a peptide chain of colicin Ia with a nucleic acid molecule encoding a fungal pheromone such as Candida albicans α-mating pheromone; (ii) introducing said nucleic acid molecule before the N-terminus of said colicin Ia to form a nucleic acid molecule that encodes a 639 residue peptide.
In one embodiment, the invention provides a method of treating a subject having a fungal infection comprising: administering to a subject a therapeutically effective amount of a fusion peptide of the present invention, e.g., a peptide comprising a colicin Ia with a fungal targeting agent, e.g., a pheromone. Said subject may have a Candidas or Aspergillus or Magnaporthe or Fusarium infection. Specifically, Candidas or Aspergillus or Magnaporthe or Fusarium may be selected from the group consisting of Candida albicans, Candida tropicalis, Candida parapsilokis, Candida krusei, Candida dubliniensis, Cryptococcus neoformans, A. fumigatus, A. flavus, A. niger, Magnaporthe grisea and Fusarium moniforme . The peptides of the instant invention can also be used to treat clinical fugal infections and other fungal infections in crops.
The peptides of the invention can be incorporated into pharmaceutical compositions suitable for administration to a subject. In a preferred embodiment, the pharmaceutical composition comprises a peptide of the invention comprising the C. albicans α-pheromone and a pharmaceutically acceptable carrier.
The term, “pharmaceutically acceptable carrier” includes any and all solvents, dispersion media, coatings, antibacterial and antifungal agents, isotonic and absorption delaying agents, and the like that are physiologically compatible. Preferably, the carrier is suitable for intravenous, intramuscular, subcutaneous or parenteral administration (e.g., by injection). Depending on the route of administration, the active compound may be coated in a material to protect the compound from the action of acids and other natural conditions, which may inactivate the compound.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts the structure of a recombinant plasmid that contains the gene of colicin Ia with the gene of Candida albicans α-mating pheromone inserted following the C-terminus of colicin Ia in the plasmid pET-15b to form a plasmid referred to herein as pCHCCA1.
FIG. 2 schematically depicts the structure of a recombinant plasmid that contains the gene of colicin Ia with the gene of Candida albicans α-mating pheromone inserted following the N-terminus of colicin Ia in the plasmid pET-15b to form the plasmid referred to herein as pCHCCA2.
FIG. 3 depicts a growth inhibition assay wherein ATCC 10231 C. albicans cells were grown in M-H solid medium and exposed to (A) borate stock solution as control, (B) 50 μl amphotericin B (1 μg/ml), (C) 50 μl fluconazole (3 μg/ml), (D) 50 μl pheromonicin-SA (Ph-SA)(50 μg/ml), the fusion peptide against Staphylococcus aureus and (E) 50 μl pheromonicin-CA1 (Ph-CA1)(50 μg/ml), the peptide produced by the pCHCCA1 plasmid.
FIG. 4 depicts the inhibition effects of Ph-CA against the growth of ATCC 10231 C. albicans cells in M-H liquid medium. The amount of sedimentary fungal filaments at the bottom of flasks indicated the inhibition effects of treatment agents. (A) Control, (B) fluconazole, (C) amphotericin B, (D) Ph-SA, (E) Ph-CA2 produced by pCHCCA2 plasmid and (F) Ph-CA1.
FIG. 5 depicts the inhibition effects of Ph-CA against the growth of C. albicans cells in liquid medium. The amount of spores and filaments of ATCC 10231 C. albicans cells indicated the inhibition effects. (A) Control, (B) fluconazole, (C) amphotericin B, (D) Ph-SA, (E) Ph-CA2 (F) Ph-CA1. X400.
FIG. 6 depicts the fluorescent imaging of ATCC 10231 C. albicans cells treated by Ph-CA1 and stained with 50 nM FITC/600 nM propidium iodide. (A) Control, cells were stained by FITC as green, (B) cells became red after 24 hrs Ph-CA1 treatment (10 μg/ml). X400.
FIG. 7 depicts a growth inhibition assay wherein Huaxi 30168 Cryptococcus neoformans cells were grown in M-H solid medium and exposed to (A) and (B) 100 μl amphotericin B (2 μg and 0.5 μg/ml respectively), (C) and (D) 100 μl Ph-CA1 (50 μg and 25 μg/ml respectively).
FIG. 8 depicts a growth inhibition assay wherein Huaxi 30255 Aspergillus flavus cells were grown in PDA solid medium and exposed to (A), (B) and (C) 100 μl tricyclazole (5 mg, 0.5 mg, and 0.05 mg/ml respectively), (D) 100 μl Ph-CA1 (50 μg/ml).
FIG. 9 depicts a growth inhibition assay wherein ACCC 30320 Magnaporthe grisea cells were grown in PDA solid medium and exposed to (A) 100 μl amphotericin B (0.5 μg/ml), (B) 100 μl tricyclazole (0.5 mg/ml), (C) and (D) 100 μl Ph-CA1 (25 μg and 50 μg/ml respectively).
FIG. 10 depicts a growth inhibition assay wherein ACCC 30133 Fusarium moniforme cells were grown in PDA solid medium and exposed to (A) control, (B) 100 μl amphotericin B (0.5 μg/ml), (C) Ph-CA1 100 μl Ph-CA1 (50 μg/ml) and (D) 100 μl tricyclazole (0.5 mg/ml).
FIG. 11 depicts in vivo activity of Ph-CA1 against systemic candidiasis. The C. albicans infected mice were untreated or treated by intraperitoneal amphotericin B or Ph-CA1.
FIG. 12 depicts in vivo activity of Ph-CA1 against systemic candidiasis. The C. albicans infected mice were untreated or treated by intravenous amphotericin B or Ph-CA1.
FIG. 13 depicts the microscopic view of visceral organs of mice treated with Ph-CA1 30 days. (A) liver, (B) kidney and (C) spleen stained with hematoxylin and eosin. 100×.
DETAILED DESCRIPTION
The antifungal peptides of the present invention comprise a fungi specific targeting agent e.g., a fungal pheromone, and one or more channel-forming colicins or channel-forming domains thereof. The molecular structure is generally either the C-terminus of a colicin or channel-forming domain thereof, linked with the N-terminus of the fungal specific targeting agent, or the N-terminus of the colicin or channel forming domain thereof, linked with the C-terminus of a fungal specific targeting agent. Although full-length colicin may be used in the methods and compositions of the invention, in some embodiments, only a channel-forming domain is used. In a preferred embodiment, the colicin channel-forming domain consists essentially of amino acids 451-626 of colicin Ia.
Colicins are protein toxins produced by strains of E. coli . They are generally classified into groups corresponding to the outer membrane receptor on sensitive E. coli cells to which they bind, with colicins that bind to the BtuB protein, the high affinity receptor for vitamin B12, being known as the E group. E-type colicins are about 60 kDa proteins that have three functional domains each implicated in one of the three stages of cell killing. The C-terminal domain carries the cytotoxic activity, the central domain carries the receptor-binding activity, and the N-terminal domain mediates translocation of the cytotoxic domain across the outer membrane. Three cytotoxic activities are found amongst E-type colicins: (i) a pore-forming ion channel that depolarizes the inner membrane (colicin E1); (ii) an H—N—H endonuclease activity that degrades chromosomal DNA (colicins E2, E7, E8 and E9); and (iii) ribonuclease activities (colicin E3, E4, E5 and E6). Colicin-producing bacteria are resistant against the action of their own colicin through possession of a small immunity protein that inactivates the cytotoxic domain. After binding to E. coli cell surface receptors, E-type colicins are translocated to their site of action by a tol dependent translocation system.
The peptides of the present invention maybe prepared by inserting a nucleic acid molecule encoding a fungal pheromone into the selected position of a nucleic acid molecule encoding a colicin, or a channel forming fragment thereof. The resulting transfected mutant plasmid may then inserted into a host cell, e.g., E. coli , to produce the peptide. Colicin Ia has the nucleic acid sequence set forth in SEQ ID NO: 1. Candida albicans α-mating pheromone has the nucleic acid sequence set forth in SEQ ID NO:2 and the amino acid sequence set forth in SEQ ID NO:3.
The peptides of the invention may be used to treat subjects having a fungal infection, e.g., Candidas, Cryptococcus, Aspergillus, Magnaporthes or Fusariums . Exemplary fungal infections are oral thrush, oesophageal thrush (Oesophagitis), cutaneous (skin) candidiasis, vaginal yeast infection or candida vaginitis, balanitis, and systemic candidiasis. The peptides of the invention may also be used to treat devastating fungal infections in crops.
EXAMPLES
Example 1
A fusion peptide that has been identified as pheromonicin-CA1(Ph-CA1) was created incorporating a peptide chain of colicin Ia with a Candida albicans α-mating pheromone, wherein the pheromone was c-terminal to the colicin Ia to produce a polynucleotide having the nucleic acid sequence of SEQ ID NO:4 which encodes a polypeptide having the amino acid sequence of SEQ ID NO:5.
Example 2
A second fusion peptide denominated as pheromonicin-CA2 (Ph-CA2) was created by incorporating a peptide chain of colicin Ia with a Candida albicans α-mating pheromone, wherein the pheromone is n-terminal to the colicin Ia, to produce a polynucleotide having nucleic acid sequence of SEQ ID NO:6 which encodes a polypeptide having the amino acid sequence of SEQ ID NO:7.
Results
Ph-CA1 had definite antifungal effect on Candida albicans (ATCC 10231) in vitro and in vivo. In contrast, Ph-CA2 almost had no effect. One in vitro cell growth inhibition assay was performed with M-H or PDA solid mediums. About 5 μl Cells (10 8 CFU/ml) of Candida albicans (ATCC 10231), Cryptococcus neoformans (Huaxi 30168 strain, clinical isolated strain by West China Hospital, Sichuan University), Aspergillus flavus (Huaxi 30255 strain), Magnaporthe grisea (ACCC 30320 strain, Species Conservation Center, Chinese Academy of Agriculture Sciences), or Fusarium moniforme (ACCC 30133 strain) were inoculated on the surface of 10 ml M-H or PDA solid mediums contained in disks. Then 50-100 μl amphotericin B (0.5 μg to 2 μg/ml) or fluconazole (3 μg/ml) or tricyclazole (0.05 mg to 5 mg/ml) or Ph-CA1 (25 to 50 μg/ml) either rinsed in a piece of filter paper or contained in a container then being placed on the surface of the medium, and incubated at 35° C. for 2 to 4 days.
As shown in FIG. 3 , only an inhibition-zone surrounds Ph-CA1, while no similar zones were observed with other agents. FIGS. 7 to 10 show that Ph-CA1 had definite antifungal effects against corresponding Cryptococcus neoformans, Aspergillus flavus, Magnaporthe grisea and Fusarium moniforme cells. On a molar basis, such antifungal effects were one hundred to one thousand times greater than that of known antifungal antibiotics.
In vitro cell growth inhibition assays were performed in 100 ml Klett flasks containing 10 ml of M-H medium which were monitored turbimetrically with a BioRad 550 microplate reader at OD595 nm every 60 min. The filament (mycelium) precipitation at the bottom of flask was counted with a digital photo-recorder every 6 hrs. Cells were inoculated to an initial cell density of about 2.5×10 5 CFU/ml and shaken at 200 rpm on an orbital shaker at 35° C. Sedimentary fungal filaments appeared in about 36 hrs growing.
Ph-CA1 and Ph-CA2 were added at the start of the culture. The same amount of borate stock solution (50 mM borate, PH9.0), Ph-SA (pheromonicin constructed by colicin Ia and staphylococcal pheromone AgrD1)(10 μg/ml) and several antibiotics preparations (2 μg/ml amphotericin B, 6 μg/ml fluconazole) were used as controls. All assays were expressed in turbidometric absorbance units measured at 595 nm and pictures of the filament sedimentation at the bottom of the flask were taken.
Fluconazole and Ph-SA had no effect on the growth of C. albicans compared to untreated controls. In contrast, 10 μg/ml Ph-CA1 completely inhibited C. albicans growth, as did 2 μg/ml amphotericin B. 10 μg/ml Ph-CA2 had about 30% of the inhibition effect as the Ph-CA1. Considering the difference in molecular weight between Ph-CA1 (70 kDa) and amphotericin B (about 0.9 kDa), the inhibitory effect of Ph-CA1 against C. albicans was approximately ten times greater, on a molar basis, than that of amphotericin B (see FIG. 4 ). The spores and filaments of 2 μl treated medium were dripped on a slide and observed under microscope. In comparison with control and other treatments, spores were scarcely observed in the amphotericin B and Ph-CA1 (see FIG. 5 ).
FIG. 6 shows that after 24 hrs of incubation with Ph-CA1 (10 μg/ml), cell membrane of most C. albicans cells (stained by FITC as green in the presence of propidium iodide) was damaged thus the propidium iodide entered into the cell to stain cells red.
KungMing mice, half male and half female, weighing 18-22 g were injected intraperitoneally with 0.5 ml of C. albicans (ATCC 10231), 10 8 CFU/ml. One hour after C. albicans injection, mice were injected intraperitoneally with 0.9% saline (A) alone as control (n=10) (C), or with amphotericin B (n=10, 1 μg/gm/day) (B), or with Ph-CA1 (n=10, 5 μg/gm/day) (A) daily for 14 days. The number of surviving animals was determined every 24 hours ( FIG. 11 ).
KungMing mice, half male and half female, weighing 18-22 g were injected intraperitoneally with 0.7 ml of C. albicans (ATCC 10231), 10 8 CFU/ml. One hour after C. albicans injection, mice were injected in the tail vein with 0.9% saline alone as control (n=10) (C), or with amphotericin B (n=10, 1 μg/gm) (B), or with Ph-CA1 (n=10, 5 μg/gm) (A). The mice were then injected intraperitoneally with 0.9% saline alone, or with amphotericin B (n=10, 1 μg/gm), or with Ph-CA1 (n=10, 5 μg/gm) each day. The number of surviving animals was determined every 24 hours ( FIG. 12 ). Considering the difference in molecular weight between Ph-CA1 (70 kDa) and amphotericin B (about 0.9 kDa), the in vivo antifungal activity of Ph-CA1 against systemic candidiasis was at least twenty times greater, on a molar basis, than that of amphotericin B.
KungMing mice (n=10), half male and half female, weighing 18-22 g were injected intraperitoneally with Ph-CA1 (200 μg/mouse/day) for 20 days. The bodyweight of all mice was increased. There was no microscopic evidence of necrosis or inflammation in the livers, kidneys or spleens of mice ( FIG. 13 ).
A 300 m 2 rice field (seed, gangyou 725) with Magnaporthe grisea infection was randomly divided as three zones. The middle 100 m 2 area was treated with water spraying twice as control, the left 100 m 2 area was treated with tricyclazole spraying twice (0.5 mg/ml and 1 mg/ml) and the right 100 m 2 area was treated with Ph-CA1 spraying twice (1 μg/ml and 2 μg/ml) at the tillering stage. The time interval between two sprayings was 7 days. Each 200 leaves were randomly examined in control and treatment areas to determine the protecting efficacy of Ph-CA1. The data are depicted below in Table I.
TABLE I
Grades of impaired leaves
Examining date
0
1
3
5
7
9
Incident rate
Infected index
Protecting efficacy
One day Before Treatment
152
27
14
6
1
24
5.88
After Treatment
89
57
30
7
7
8
55.5
17.38
Seven days Tricyclazole
172
10
12
6
14
4.22
75.83
Ph-CA1
67
12
13
8
16.5
5.05
70.94
Another 300 m 2 rice field (seed, gangyou 725) with Magnaporthe grisea infection was randomly divided as three zones. The middle 100 m 2 area was treated with water spraying once as control, the left 100 m 2 area was treated tricyclazole spraying once (1 mg/ml) and the right 100 m 2 area was treated with Ph-CA1 spraying once (2 μg/ml) at the head stage. About 200 ears were randomly examined in control and treatment areas to determine the protecting efficacy of Ph-CA1. The data are depicted below in Table II.
TABLE II
Grades of impaired ears
0
1
3
5
7
9
Impaired ears rate
Infected index
Damage rate
Control
178
33
22
11
2
2
28.6%
8.33
4.2%
Tricyclazole
184
16
9
2
2
0
13.62%
3.5
1.63%
Ph-CA1
218
19
5
0
0
0
9.92%
1.56
0.53%
In both of the above in vivo protecting assays, the concentration of Ph-CA1 used was approximately 500 times smaller than that of tricyclazole. On a molar basis, the protecting effects of Ph-CA1 were three hundred times greater than that of tricyclazole. With these two factors taken together, the total effects of Ph-CA1 against rice blast disease was approximately 10 4 to 10 5 times greater than that of tricyclazole.
|
The present invention is directed to fusion peptides comprising a fungal targeting agent and a channel-forming domain consisting essentially of amino acids 451-626 of colicin Ia, as well as the polynucleotides encoding the peptides of the invention. The fusion peptides of the peptides of the present invention are particularly useful for the treatment of fungal infections in a wide variety of organisms.
| 0
|
FIELD OF THE DISCLOSURE
[0001] The present disclosure is directed to a dual relief tap, and more specifically, to a relief tap where a segment on the threaded body, likely next to the chamfer of the tap, has a first relief technology, and at least a second segment of the threaded body has a second relief technology to limit overfeed and underfeed effects during tapping.
BACKGROUND OF THE INVENTION
[0002] Threads are used to mate pieces and convert torque into axial force between two objects. The first object, such as a bolt anchored to a piece to be secured, has male threads on its outer surface and is screwed into a second object with mating female threads on the inner surface of an opening. The use of threads as a fastening means is well known. To form threads on the inner surface of the opening, a hole is drilled using a drill bit where female threads are created in a subsequent step. The drill bit, because of its rapid rotational speed, removes chips of matter but leaves the surface of the hole relatively flat. Threads must be added to the surface in a second step using a manual tap as shown in FIG. 1 or any other type of tap.
[0003] Taps are cutting tools used to create threads in solid substances, including but not limited to metal, wood, or plastic, by shaving away thread-like areas on the inner surface of a cylindrical hole. To ease threading forces on the tap, threads are cut during a process that includes screwing in the tap over a handful rotations to remove small layers as shown in the right end of FIG. 7 . Male taps 100 in FIG. 1 (i.e., taps capable of forming female threads inside of holes) are generally sold in the form of a long cylindrical tool body tool with a threaded length and a shank equipped with an end portion for positioning the tap in a torque-creating support.
[0004] A user attaches the tap 100 inside a torque support 36 , places the tap on the hole of a piece, and screws the tap 100 into the hole to create threads. The first rotations of the tap inside the hole are critical. Misalignment, uneven driving forces, or incorrect tap technology may result in the creation of undesired, uneven mating threads.
[0005] Taps often include fluted openings made longitudinally along the thread length. These flutes define land portions between two flutes where chips removed from the surface being threaded are evacuated upwards and out of the hole. FIG. 1 shows a tap 100 placed inside a torque-creating support 36 operated by a user 40 and stabilized in a grip 38 . While a manual support 36 is shown, nonmanual supports are also used interchangeably with the disclosed technology.
[0006] Three types of fluted taps are shown in FIGS. 2-4 , respectively. FIG. 2 is a spiral flute tap where the fluted openings spiral along the length of the threaded body creating lands between the fluted openings of fixed lengths but where the cutting edge at the intersection of each land with the flute is a cutting surface at an attack angle. FIG. 3 illustrates a straight flute tap where the fluted openings are longitudinally aligned with the tap axis. In this type of tap, each thread has a similar cutting edge on the edge of the opening and there is no forward cutting attack angle. FIG. 4 illustrates a gunpoint tap where, in the chamfer area of each land, the width of each thread decreases to create an intermediary configuration between the tap of FIG. 2 and the tap of FIG. 3 . This type of tap benefits from a greater attack angle in the chamfer area for each thread edge and a linear threaded portion past the chamfer.
[0007] FIG. 5 is a close-up view of the cutting edge a variable angle at a cutting edge of a land of a spiral flute tap of FIG. 2 , or a variable angle at a cutting edge of a land in the chamfer area of the gunpoint tap of FIG. 4 . As shown, each thread has a leading flank and a trailing flank where both flanks attack at different angles a surface into which they cut. FIG. 6 shows the opposite configuration of the straight fluted tap of FIG. 3 or the threaded portion of the gunpoint tap of FIG. 4 where the cutting edge is aligned with the fluted openings, resulting in a symmetrical cutting angle.
[0008] When taps enter a drilled hole, the surface where material is intended to be cut is removed in incremental layers as the chamfered threads are rotated in. Without a chamfer, the first thread would need to remove the totality of the material to be cut, would require great torque to operate, and would be subject to dulling of the cutting edge. On the right of FIG. 7 is an animation view of the tip of a tap where a chamfer area enters a drilled hole over six consecutive rotations and creates perfect threads. On the left of FIG. 7 , a normal tapping process creates a normal thread (i.e., a V-shaped thread in the metal). On the right, an overfed thread (i.e., a staircase-shaped thread in the metal) is created when overfeeding of the tap occurs. At each rotation, the tap advances a fraction of a thread forward and cuts into the thread in a step-forward manner. FIG. 8 is a close-up view of an overfed tooth where the overfeed is shown while each subsequent thread in the chamfer area is entered. The tap 100 is illustrated along with the cutting layers of the thread as shown in lines within the thread. FIG. 9 is the same close-up view but of an underfed tooth. Lines 150 show the shape of the teeth produced during the overfeed and underfeed.
[0009] Overfeeding can be caused by a plurality of effects. The main effect stems from the need to reduce frictional forces between the external surface of the threads on the tap as the tap enters the internal surface of the object being threaded. To reduce the friction, flutes are cut into the threads. Also, these flutes serve to evacuate from the chamfer chips of material cut from the surface. To further reduce friction, a portion of each thread in the back of the cutting edge is tapered away from the material surface in what is called a “relief.” A relieved thread is distanced at some point from the inner surface of the hole in which it burrows. The gap created between the thread and the object's inner surface, while beneficial to the tap, loosens the tap to some extent. A loosened tap may move, tilt, change position, and cause overfeed or underfeed.
[0010] To illustrate the relief, FIGS. 10-11 , 13 - 16 , and 18 - 24 use a segment made of a tap with several adjacent threads over a portion of a land between two adjacent flutes. The tap is shown as a solid. The gap created by the relief of each thread, i.e., the distance between the internal surface of the drilled hole and the external surface of the tap, is illustrated using lines over the solid to show the distance from a threaded object's inner surface as it would be if an x-ray were taken of the tap inside the hole. One of ordinary skill in this art will recognize on these figures how reliefs, thread designs, and chamber designs are made without undue experimentation.
[0011] FIG. 10 illustrates a regular eccentric relief 151 where the distance increases regularly from the front to the back of the land along each thread. Another possible form of relief is illustrated in FIG. 11 where some threads are removed altogether 152 from the threaded region on the tap. FIG. 12 shows how the top portion of each thread can be recessed 153 (i.e., a flattened thread) to reduce the contact area between the tap and the material in which the tap is inserted and provide additional relief. As shown in FIG. 12 , threads distant from the chamfer are shown as recessed, but the use of recessed relief in any portion of the threaded area on a tap is contemplated. FIG. 13 shows a land concentric threads 154 , FIG. 14 illustrates an eccentric 155 thread relief, FIG. 15 a con-eccentric thread relief 156 , and FIG. 16 a specially shaped thread relief where portions of the middle thread are shifted away from the contact surface (not illustrated by dashed lined but simply on the solid thread). One of ordinary skill in the art of tap design will understand that while a handful of different types of relief are shown in FIGS. 10-16 , other single relief types are also contemplated.
[0012] Different technologies of relief exist to help reduce frictional forces on the tap, and each technology results directly or indirectly in overfeed or underfeed of the tap. What is needed is a tap with a new type of relief designed to keep the structure of the tap centered and aligned and to prevent any overfeed or underfeed during the creation of threads by the tap.
SUMMARY
[0013] The present disclosure is directed to a dual technology relief tap, and more specifically, to a relief tap where a segment on the threaded portion has a first type of relief and the remainder of the threads have a second type of relief or a concentric thread to limit tilt and loosening and ultimately to prevent overfeed or underfeed. In some embodiments, a neutral, negative, positive, convex, or other type of relief is applied generally to most of the threaded portion with or without concentric threads, and a second type of relief of any type, such as a neutral, a negative, a positive, a convex, or other relief, is applied to some selected threads. In another embodiment, the second type of relief is applied to the first threads after the chamfer or are spaced regularly over the threaded surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The features of the present disclosure are believed to be novel and are set forth with particularity in the appended claims. The disclosure may best be understood by reference to the following description taken in conjunction with the accompanying drawings, where the figures that employ like reference numerals identify like elements.
[0015] FIG. 1 is an illustration of a fluted tap with a torque-creating support in a piece secured to a vice grip.
[0016] FIG. 2 is a side view of a spiral fluted tap.
[0017] FIG. 3 is a side view of a straight fluted tap.
[0018] FIG. 4 is a side view of a gunpoint tap.
[0019] FIG. 5 is an illustration of the cutting edge on a curved land of a fluted tap.
[0020] FIG. 6 is an illustration of the cutting edge on a straight land of a fluted tap.
[0021] FIG. 7 is a dual animated view of the tapping process of a tap without overfeed and with overfeed.
[0022] FIG. 8 is a close-up view of an overfeed thread created in a material along with traces of the different cutting edges.
[0023] FIG. 9 is a close-up view of an underfeed thread created in a material along with traces of the different cutting edges.
[0024] FIG. 10 is an illustration of a regular thread relief on a fluted tap from the prior art.
[0025] FIG. 11 is an illustration of an interrupted thread relief on a fluted tap from the prior art.
[0026] FIG. 12 is an illustration of a spiral fluted tap, a straight fluted tap, and a gunpoint flute tap with recessed threads from the prior art.
[0027] FIG. 13 is an illustration of concentric threads on a fluted tap from the prior art.
[0028] FIG. 14 is an illustration of an eccentric thread relief on a fluted tap from the prior art.
[0029] FIG. 15 is an illustration of a con-eccentric thread relief on a fluted tap from the prior art.
[0030] FIG. 16 is an illustration of a specially shaped thread relief on a fluted tap from the prior art.
[0031] FIG. 17A is a side view used to illustrate schematically the nomenclature of tap cutting tools.
[0032] FIG. 17B is a detailed view of one of the lands located between two flutes of the tap cutting tool of FIG. 17A .
[0033] FIG. 17C is a top view of the tap cutting tool of FIG. 17A as seen from the cut line 17 C- 17 C as shown in FIG. 17A .
[0034] FIG. 17D is a sectional view without shading of the tap cutting tool of FIG. 17A as seen from the cut line 17 D- 17 D as shown in FIG. 17A .
[0035] FIG. 18 is a dual relief tap with an eccentric relief as a first type of relief and a convex relief as a second type of relief according to an embodiment of the present disclosure.
[0036] FIG. 19 is a dual relief tap with an eccentric relief as a first type of relief and concentric threads as a second type of threads according to another embodiment of the present disclosure.
[0037] FIG. 20 is a dual relief tap with an eccentric relief as a first type of relief and a negative relief as a second type of relief according to another embodiment of the present disclosure.
[0038] FIG. 21 is a dual relief tap with an eccentric relief as a first type of relief and a convex relief as a second type of relief according to another embodiment of the present disclosure.
[0039] FIG. 22 is a dual relief tap with an eccentric relief as a first type of relief and a combined negative and concentric relief set as a second type of relief or second type of threads according to another embodiment of the present disclosure.
[0040] FIG. 23 is a dual relief tap with an eccentric relief as a first type of relief and a combined eccentric, negative, and positive relief, and concentric threads at the second type of relief according to another embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0041] The present invention is not limited to the particular details of the device depicted and other modifications and applications may be contemplated. Further changes may be made in the above-described device without departing from the true spirit of the scope of the invention herein involved. It is intended, therefore, that the subject matter in the above depiction should be interpreted as illustrative, not in a limiting sense.
[0042] FIG. 1 illustrates how a tap 100 is operated by a user 40 to cut threads into a hole made in a block of material. The block is held in a vice grip 38 vertically using a torque-creating support 36 , such as a small block with lateral support, movable by rotating two horizontal handles placed on each side of the torque-creating support 36 . A user 40 then applies torque by rotating the handles in the horizontal plane. While a manual torque-creating support 36 is shown, what is contemplated within this disclosure is the use of any type of tap 100 , using any engaging mechanism to rotate the tap, thus activating the cutting edges.
[0043] Describing a tap in general, FIG. 17A illustrates a tap 100 with an overall length 6 that may be separated into a thread length 8 and a shank length 10 having a fixed shank diameter 2 . The ratio of these two lengths is purely illustrative, and it is understood that these lengths may vary according to the model and type of tap 100 . The shank length 10 can also include a driving length 28 where the tap 100 is secured to a torque-creating support. The driving length 28 is also of a geometry as shown in FIG. 17C to allow for the coupling of the tap 100 to any needed torque-creating support. While a square attachment 30 is shown, any attachment is contemplated.
[0044] Flutes 18 as shown in FIG. 17D separate lands 22 created in the threaded length 8 between two consecutive flutes 18 . In one embodiment as shown in FIG. 17D , four flutes 18 are positioned at 90 degrees circumferentially around the thread length 8 . Other taps may have flutes 18 of smaller radii and variable curvature as shown in FIG. 3 and may be placed around a cylindrical tool body or minor diameter 12 of different sizes to create a tap 100 with five or more flutes 18 or three or fewer flutes 18 . Also shown in FIG. 17A is a tap 100 with straight flutes 18 . The use of a helical angle, a spiral, or any other type of flute 18 that is not aligned with the longitudinal axis 4 of the tap 100 is also contemplated.
[0045] Returning to FIG. 17A , the threaded length 8 comprises a series of V-shaped threads, each thread having a thread lead angle 26 corresponding to a pitch or average median thread distance between two consecutive threads. In some embodiments, as shown by dashed lines, the tap 100 includes a point 20 . FIG. 17D is a sectional view without shading of the tap cutting tool of FIG. 17A as seen from cut line 17 D- 17 D as shown in FIG. 17A . This section shows the land width 14 and a section with threads having a minor diameter 156 and a major diameter 155 . FIGS. 17A-17D show that the cylindrical tool body of the tap 100 includes a longitudinal axis 4 rotatable about the longitudinal axis 4 and having successively a shank of shank length 10 and a threaded length 8 with at least a flute 18 for creating at least a land 22 with a front cutting surface 150 with a cutting edge and a heel as shown in FIG. 17B .
[0046] FIGS. 18-25 shows a dual relief tap 200 for cutting a thread into a workpiece. The tap 200 as numbered in FIGS. 2-4 includes a cylindrical tool body 201 having a longitudinal axis 202 rotatable about the longitudinal axis 202 and having successively along the cylindrical tool body a shank 203 , a neck 204 (in some embodiments), a threaded length 205 with a plurality of threads (as shown in FIGS. 18-25 ) with at least a flute 206 for creating at least a land 207 with a front cutting face 208 with a cutting edge 209 , and a chamfer area 210 . These different parts of the tap 200 are shown in the general illustration of a tap in FIG. 2 . A tap without a neck 204 is shown in FIG. 17A , while a tap with a neck 204 is shown in FIGS. 2-4 . Further, the tap 200 shown in FIG. 17A does not include a chamfer 210 , while the taps shown in FIGS. 2-4 include a chamfer 210 . This disclosure is directed to all different tap configurations, with or without a chamfer, a neck, or other secondary features.
[0047] What is disclosed is a tap 200 where each of the plurality of threads has either similar or different geometries, such as, for example, the pitch as shown in FIGS. 18-24 , but where each of the plurality of threads has a compound relief 310 made of least two different reliefs where one portion of the threads 311 has a first type of relief resulting either from a new type of relief or from a different geometry of tooth, and a second portion of the threads 312 has a second type of relief. In turn, the first and second portions 311 , 312 can include only identical threads with identical reliefs, but the first portion 311 can include a first segment of the threaded length 321 with a first portion of the plurality of threads 311 where each of the plurality of threads in the first portion 311 has a first type of relief 331 , and wherein a second segment 322 of the threaded length 205 includes a second portion 312 of the plurality of threads where each of the plurality of threads in the second portion 312 has a second type of relief 332 .
[0048] As illustrative examples of a tap 200 with different portions 311 , 312 , each with different threaded lengths 321 , 322 and different types of relief 331 , 332 , FIG. 18 shows a tap 200 with an eccentric relief as a first type of relief 331 and a convex relief as a second type of relief 332 . FIG. 19 shows a tap 200 with a first eccentric relief 331 and a second relief such as simple concentric threads 332 . FIG. 20 shows a tap 200 a first eccentric relief 331 and a second negative relief 332 . FIG. 21 shows a tap 200 with a first eccentric relief 331 and a second convex relief 332 . FIG. 22 shows a tap 200 with first eccentric relief 331 and a second relief made of combined negative relief threads and concentric threads 332 according to another embodiment of the present disclosure. FIG. 23 is a dual relief technology tap with a first relief as concentric threads 331 and a second relief made of concentric threads and specially shaped relief 332 . FIG. 23 shows a gunpoint tap 200 , and FIG. 24 is a close-up view of the gunpoint tap 200 as shown in FIG. 23 with a dual relief technology with a first eccentric relief 331 and a second combined eccentric, negative, and positive relief, and concentric threads 332 .
[0049] While FIGS. 18-22 and 24 illustrate some of the possible configurations of the first and second reliefs 331 , 332 on the different portions of the threaded length 205 of the tap 200 , taps 200 where the first relief 331 is a an eccentric relief, a flattened thread relief, a removed thread relief, a concentric thread, a con-eccentric relief, a special shape relief, a convex relief, a positive relief, a negative relief, or any combination thereof are contemplated. Also, the second relief 332 may also be any of the eccentric relief, the flattened thread relief, the removed thread relief, concentric threads, the con-eccentric relief, the special shape relief, the convex relief, the positive relief, the negative relief, or any variation thereof. One of ordinary skill in the art will recognize that while a list of known relief types is given, any type of relief is also contemplated.
[0050] In another embodiment, the first segment 331 and second segment 332 are of the length of the threaded length 205 . In another embodiment, the first segment 331 is substantially longer than the second segment 332 . For example, the second segment 332 as shown in most of FIGS. 18-22 and 24 is one or two threads in length. In one embodiment, the second segment 332 is one to five threads in length, in a further embodiment, the second segment 332 is made of one to three threads, and in yet another embodiment, the second segment 332 is made of two threads in length.
[0051] Further, the second segment 332 may be either in or adjacent to the chamfer area as part of several threads immediately between the first segment 331 and second segment 332 . While configurations of threads are described where two different segments and thread reliefs are shown, the use of other segments, thread reliefs, and portions are contemplated, such as, for example, a third segment of the threaded length with a third portion of the plurality of threads, and wherein the threads from the third portion have a second type of relief, a third type of relief, etc. The principle of this disclosure centers around, at a minimum, the use of selected threads having different relief technologies to alter the side effects resulting from the use of threads with a first technology in a threaded area of a tap. These teachings are consistent with the use of more than one corrective thread; the use of two or more corrective threads along the threaded area is also contemplated. Further, the second portion 312 may be located between the first portion 311 and the third portion on the threaded length or any other area along the threaded length 205 .
[0052] In another embodiment, a method for reducing the overfeed and/or underfeed of a dual relief tap 200 in a workpiece is also contemplated, the method comprising the steps of placing a shank of a dual relief tap 200 in a support 36 and turning the tap 200 into a workpiece along the longitudinal axis 202 . In another embodiment, the method may include a further step of inserting a second segment 322 into the workpiece and inserting at least a portion of the first segment 321 into the workpiece.
[0053] It is understood that the preceding is merely a detailed description of some examples and embodiments of the present invention and that numerous alterations to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention but to provide sufficient disclosure to one of ordinary skill in the art to practice the invention without undue burden.
|
The present disclosure is directed to a dual technology relief tap, and more specifically, to a relief tap where a segment on the threaded portion has a first type of relief and the remainder of the threads have a second type of relief or a concentric thread to limit tilt and loosening and ultimately to prevent overfeed or underfeed. In some embodiments, a neutral, negative, positive, convex, or other type of relief is applied generally to most of the threaded portion with or without concentric threads, and a second type of relief of any type, such as a neutral, a negative, a positive, a convex, or other relief, is applied to some selected threads. In another embodiment, the second type of relief is applied to the first threads after the chamfer or are spaced regularly over the threaded surface.
| 8
|
BACKGROUND OF THE INVENTION
The present invention relates to a method of controlling a wire-cut electric discharge machine to prevent cutting errors which would be produced upon flexing of a wire electrode when a corner is cut during an electric discharge cutting operation, and more particularly to a simple method of controlling a wire-cut electric discharge machine to cut an accurate corner.
Wire-cut electric discharge machines operate on the principle that a voltage is applied across a gap between a wire electrode and a workpiece to generate a spark discharge across the gap for cutting the workpiece with the spark energy. The workpiece can be cut to a desired contour by moving the workpiece with respect to the wire electrode based on cutting command data.
More specifically, as schematically shown in FIG. 1, which shows a known wire-cut electric discharge machine, a wire 1 is reeled out of a reel RL 1 , extends between a lower guide 4 and an upper guide 4, and is wound around a reel RL 2 . A voltage is applied by a contact electrode (not shown) to the wire to generate a discharge between the wire 1 and the workpiece 2 for cutting the workpiece. The workpiece 2 is fastened to a table TB movable by motors MX and MY in the X and Y directions, respectively. Thus, the workpiece 2 can be cut to a desired configuration by moving the table TB in the X and Y directions. The upper guide 4 is attached to a moving mechanism MMC movable by motors MU and MV in the X and Y directions respectively so that the upper guide 4 is movable in the X and Y directions. The moving mechanism, the reels RL 1 and RL 2 and the lower guide 4 are mounted on a column CM.
A numerical control unit NC serves to read the contents of a command tape TP, and has a distributor circuit DS for distributing commands for respective axes and drive circuits SVX, SVY, SVU and SVV for the corresponding axes for energizing the motors MX, MY, MU and MV respectively to move the table TB and the moving mechanism until the workpiece 2 is cut to a desired shape.
FIG. 2 illustrates of a cutting operation of such an electric discharge cutting machine. When the wire electrode 1 moves in and along a slot 3 in a given direction while cutting the workpiece 2 with electric discharge, a pressure is developed between the wire electrode 1 and the workpiece due to the electric discharge and pushes back the wire electrode 1 in the direction of the arrow which is opposite to the direction in which the electrode 1 moves along, as shown in the cross-sectional view of FIG. 3. The wire electrode 1 is therefore backed off or flexes from the position of the wire guides 4. The cutting accuracy is not affected to an appreciable extent by the amount of such flexing as long as the wire electrode 1 cuts the workpiece 2 along a rectilinear slot. However, the amount of flexing causes a serious problem when the wire electrode 1 cuts the workpiece to form a corner. Thus, as shown in FIG. 4, which is a plan view of a cut slot, a slot 3 is composed of a first rectilinear slot L1 and a second rectilinear slot L2 extending perpendicularly to the first rectilinear slot L1, and defining such a combined slot 3 which requires a corner CN to be cut at the junction between the first and second rectilinear slots L1 and L2. To this end, the workpiece 2 and the wire electrode 1 are caused to move relatively in one direction to form the first rectilinear slot L1, and thereafter the direction of such relative movement needs to be changed at a right angle under a cutting command to form the second rectilinear slot L2. The wire electrode 1 however has a tendency to be dragged inwardly of the corner CN due to the flexing of the wire electrode 1 at a position in which the electric discharge takes place, with the result that the contour of the slot 3 as it is cut is distorted considerably inwardly and becomes blunt as shown by the dotted lines, a configuration which is different from a commanded shape (shown by the solid lines).
FIG. 5 is a plan view of an arcuate corner CN' to be formed between the first and second rectilinear slots L1 and L2. In cutting such an arcuate corner CN', the fixing of the wire electrode 1 due to the electric discharge causes the corner CN' to be cut along a path shown by the dotted lines which is duller than a commanded shape as illustrated by the solid lines.
It is known that the cutting errors at such arcuate and angular corners can be reduced by changing the path of cutting, the cutting power supply, the speed of feed, and other factors. However, there are a great many combinations available for such cutting conditions, and the customary practice is complex and impractical as no specific standard is established for controlling the cutting path, the feeding speed, and the cutting power supply voltage.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a simple method of controlling a wire-cut electric discharge machine to improve blunt corner shapes.
Another object of the present invention is to provide a method of controlling a wire-cut electric discharge machine for improving blunt corner shapes and accurately cutting corners simply by changing the feeding speed.
Still another object of the present invention is to provide a method of controlling a wire-cut electric discharge machine to minimize the amount of flexing of the wire electrode at a corner being cut, for an increased cutting accuracy, by changing a commanded feeding speed dependent on radius of curvature data of the corner, corner angle data, and thickness data of the workpiece.
With the present invention, a relative speed of movement between a workpiece and a wire electrode is determined using radius of curvature data of a corner, a corner angle data, and a commanded feeding speed data, which are given as cutting command data for cutting the corner. The workpiece is moved relatively with respect to the wire electrode at such a determined relative speed for electric discharge cutting of the workpiece. The determined relative speed is moderately lower than the commanded feeding speed for reducing the amount of flexing of the wire electrode to accurately cut the corner of the workpiece.
Furthermore, not only the radius of curvature data of the corner, the corner angle data, and the commanded feeding speed data, but also the thickness of the workpiece, are utilized to calculate the relative speed of movement between the workpiece and the wire electrode for moving the workpiece with respect to the wire electrode at such a relative speed as to effect electric discharge cutting of the workpiece. Accordingly, highly accurate electric discharge cutting of the corner can be performed no matter how thick the workpiece may be.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a wire-cut electric discharge machine;
FIG. 2 is a perspective view of the principle on which a workpiece is cut by a wire due to electric discharge;
FIG. 3 is a cross-sectional view of flexing of the wire electrode;
FIGS. 4 and 5 are plan views of problems with a conventional electric discharge cutting process;
FIG. 6 is a block diagram of an arrangement for effecting a method according to the present invention;
FIG. 7 is a diagram showing corner shapes; and
FIG. 8 is a graph of relative speeds between a workpiece and a wire electrode at a corner being cut.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described in more detail with reference to the drawings.
FIG. 6 is a block diagram of an arrangement for effecting a method according to the present invention, FIG. 7 is a diagram of corner shapes, and FIG. 8 is a graph of the relative speeds between a workpiece and a wire electrode at a corner being cut.
Designated in FIG. 6 at 101 is a paper tape in which a cutting program (NC data) is punched, and 102 is a tape reader. The NC program contains numerical data (positional command data and path command data) for determining a desired shape to be cut, M function instruction data, G function instruction data, radius of curvature data of a corner to be cut, corner angle data, and commanded feeding speed data. A numerical control unit 103 comprises a decoder 103a for decoding the NC data read from the paper tape 101 by the tape reader 102, an override arithmetic unit 103b for calculating an amount of override K (%) to override the commanded feeding speed based of the data r on the radius of curvature of the corner, the corner angle data, and various parameters (described later on), a memory 103c for storing the parameters, and a register 104d for storing the commanded feeding speed F O . The numerical control unit 103 also includes a relative speed arithmetic unit 103f for calculating a relative speed of movement F between a workpiece and a wire electrode from the command feeding speed F O , the thickness t of the workpiece, and the amount of override K based on the following equation: ##EQU1## The numerical control unit also generates a train of pulses CP having the relative speed F. When numerical data X and Y is read out of the paper tape 101, a processing unit 103g calculates and supplies increments ΔX and ΔY to pulse distributors in a succeeding stage, and generates an output of 1/√ΔX 2 +ΔY 2 . A frequency divider 103h serves to frequency-divide the pulse train CP having the pulse speed F from the relative speed arithmetic unit 103f into pulses having a frequency of 1/√ΔX 2 +ΔY 2 . The processing unit 103g serves to store in its memory the increments ΔX and ΔY as remaining amounts of movement Xr and Yr for one block, and carries out the arithmetic operations:
Xr-1→Xr and Yr-1→Yr (2)
The processing unit 103g also monitors the remaining amounts of movement each time the pulse distributors generate a single pulse Xp and Yp, internally produces a pulse-distribution completion signal DEN when Xr=0 and Yr=0 to stop generation of the pulse train CP, and enables the tape reader 102 to read a movement command for a next block from the paper tape 101. A control board 104 sets the maximum thickness of the workpiece at "1". Pulse distributors 105X and 105Y are in the form of digital differential analyzers (DDA) respectively of X and Y axes. Although not shown, the pulse distributors. 105X and, 105Y have registers for storing the increments ΔX and ΔY as settings, accumulators, and adders for adding the increments ΔX and ΔY set in the registers to the contents of the accumulators each time the frequency divider 110 generates a pulse CEP. The accumulators in the pulse distributors 105X and 105Y produce overflow pulses which are distributed as the pulses Xp and Yp to servo circuits SVX and SVY for the corresponding axes to drive the X-axis and Y-axis motors MX and MY, respectively, for thereby moving the wire electrode with respect to the workpiece along a commanded cutting path. Speeds F X and F Y of the distributed pulses Xp and Yp are expressed respectively as: ##EQU2## Therefore, the relative speed of movement between the wire electrode and the workpiece is given by √F X 2 +F Y 2 F, which precisely conforms to the relative speed F as it is calculated by the relative speed arithmetic unit 103f.
Operation of the arrangement shown in FIG. 6 will now be described. The thickness t data of the workpiece is supplied as an input through the control board 104 into the register 104e. Then, a start pushbutton (not shown) is depressed to enable the tape reader 102 to read the NC data from the paper tape 101 and feed the same into the numerical control unit 103. The NC data read from the tape 101 is delivered to the decoder 103a in which the data is decoded. The decoder 103a supplies data on the radius of curvature r of a corner and corner angle data θ to the override arithmetic unit 103b, supplies data on a commanded feeding speed F 0 to the register 104d, and supplies numerical data X and Y to the processing unit 103g.
The override arithmetic unit 103b first reads parameters m and n, dependent on the magnitude of the corner angle data θ from the parameter memory 103c. The n and m having the following values: ##EQU3## The values p 1 , q 1 , p 2 and q 2 are experimentally determined and stored in the parameter memory 103c in advance.
The override arithmetic unit 103b effects an arithmetic operation based on the radius of curvature data r of the corner to determine an amount of override K (%), which is then delivered to a next stage. More specifically, the override arithmetic unit 103b carries out the following arithmetic operation if r <S:
K=n·a (4)
or the following arithmetic operation if S <r<m·T: ##EQU4## or the followng arithmetic operation if m·T≦r:
K=100 (6)
to determine the amount of override K (%) and deliver the same to the relative speed arithmetic unit 103f. The values S, T and a are experimentally determined and stored in a register (not shown). Consequently, the amount of override K (%) varies with the radius of curvature r of the corner as indicated by the solid-line curve in FIG. 8. The larger the radius of curvature r of the corner, the more rectilinear the shape of the corner becomes and hence the less blunt the corner shape becomes upon flexing of the wire electrode. Stated otherwise, as the radius of curvature of the corner becomes larger, the bluntness of the corner becomes smaller, and the amount of override K (%) may be increased to cause the relative speed of movement between the workpiece and the wire electrode to approach the commanded feeding speed. As the corner angle θ becomes larger, the K-r characteristic tends to follow the dotted-line curve in FIG. 8, and as the corner angle becomes smaller, the K-r characteristic tends to follow the dot-and-dash-line curve in FIG. 8. This is because the larger the corner angle θ, the more closely the corner shape is assumed and the less blunt the cut shape becomes upon flexing of the wire electrode. Therefore, as the corner angle θ becomes greater, the bluntness of the corner shape is reduced and the amount of the override K (%) can be increased to let the relative speed of movement between the workpiece and the wire electrode approach the commanded feeding speed.
With the amount of override K (%) determined, the relative speed arithmetic unit 103f effects the arithmetic operation of the equation (1) to determine the speed of relative movement F between the workpiece and the wire electrode for generating the pulse train CP of the relative speed F.
Simultaneously with the above process for determining the relative speed F, the processing unit 103g uses the numerical data X and Y to determine increments ΔX and ΔY, and supplies the latter to the pulse distributors 105X and 105Y and at the same time calculates 1/√ΔX 2 +ΔY 2 which is input to the frequency divider 103h. The frequency divider 103h frequency-divides the pulse train CP of the relative speed F supplied from the relative speed arithmetic unit 103f into pulses having a frequency of F/ √ΔX 2 +ΔY 2 which are then fed to adders (not shown) contained in the pulse distributors 105X and 105Y. The pulse distributors 105X and 105Y effect an arithmetic operation for pulse distribution to supply distributed pulses Xp and Yp to the servo circuits SVX and SVY for driving the X-axis and Y-axis motors MX and MY to move the wire electrode with respect to the workpiece. The distributed pulses Xp and Yp are also supplied to the processing unit 103g in which the arithmetic operation of the equation (2) is performed each time the distributed pulses Xp and Yp are delivered. When the remaining amounts of movement become zero, the processing unit 103g internally produces a pulse-distribution completion signal DEN to stop generation of the pulse train CP, and at the same time enables the tape reader 102 to read NC data for a next block to be cut from the paper tape 101. The speeds F X and F Y of the distributed pulses Xp and Yp generated from the pulse distributors 105X and 105Y are given by the equations (3). The combined speed (which is a speed of movement of the table) is expressed by √F X 2 +F Y 2 F which is exactly the same as the relative speed as calculated by the relative speed arithmetic unit 103f.
With the present invention as described above in detail, the degree of bluntness of the shape of a corner cut can be improved to a considerable degree without having to take the workpiece thickness t into consideration. Therefore, there is no need to consider the workpiece thickness t in the arithmetic operation to determine the relative speed of movement. While the equations (4)-(6) are used to find the amount of override K (%), they need not be relied on. Amounts of override dependent on radii r of the curvature of corners and corner angles θ may be stored in the form of tables in memories, and an amount of override K (%) corresponding to the actual radius r of curvature and corner angle θ may be read out of the memories.
Furthermore, various amounts of override which differ with the materials of workpieces and wire electrodes may be stored in the memories, and an appropriate amount of override may be determined according to the materials of a workpiece and a wire electrode as well as the corner angle and the radius of curvature of the corner.
With the present invention as described above, the relative speed of movement of the workpiece and the wire electrode at a corner to be cut is rendered moderately lower than the commanded speed so that the frequency of electric discharges at the corner can be reduced to lower the electric discharge pressure and thereby minimize the amount of flexing of the wire electrode. Since the corner is cut with the wire electrode which flexes to a small degree, the corner can be cut accurately along a commanded cutting path. Even if the same commanded speed is selected for a cutting operation along a straight line and a corner, an appropriate corner cutting speed can automatically be determined.
|
A cutting control method for reducing cutting errors at a corner due to flexing of a wire electrode in a wire-cut electric discharge machine in which a voltage is applied between the wire electrode and a workpiece to cut the latter with electric discharge energy while moving the workpiece relatively to the wire electrode based on cutting command data for cutting the workpiece to a predetermined shape. An amount of override (K) is determined by an override arithmetic unit (103b) using data (r) on the radius of curvature of a corner angle (θ) data which are given as the cutting command data from a paper tape (101). A relative speed (F) is derived by a relative speed arithmetic unit (103f) from the amount of override (K) and a commanded feeding speed (F 0 ). Motors (MX, MY) are rotated by pulse distributors (105X, 105Y) and servo circuits (SVX, SVY), respectively, based on the relative speed (F) which is lower than the commanded feeding speed (F 0 ) to move the workpiece with respect to the wire electrode for electric discharge cutting of the corner.
| 6
|
BACKGROUND OF THE INVENTION
The present invention generally relates to direct memory access controllers, and more particularly to a direct memory access controller which controls a direct memory access between an input/output control unit and a memory or between two memories.
FIG. 1 shows a data processing system which includes an example of a conventional direct memory access controller (hereinafter simply referred to as a DMAC). The data processing system has a DMAC 1, a central processing unit (CPU) 2, an input/output control unit 3, and memories 4 and 5 which are coupled via a system bus 6 which includes an address bus, a data bus and a control bus.
When making a desired data processing on this data processing system, a data transfer is made between the input/output control unit 3 and the memory 4 or 5 or between the memories 4 and 5. In order to improve a data transfer rate of the data transfer, a direct memory access (DMA) transfer is made between the input/output control unit 3 and the memory 4 or 5 or between the memories 4 and 5 by hardware and not through the CPU 2. This DMA transfer is controlled by the DMAC 1 so that the DMA transfer takes place during a time when the CPU 2 does not make access to the system bus 6 or by stopping the operation of the CPU 2. When making the DMA transfer, it is desirable that the DMA transfer can be terminated with an arbitrary timing.
When controlling the data transfer between the input/output control unit 3 and the memory 4 or 5 by the conventional DMAC 1, the data transfer is started responsive to a transfer request signal REQ from the input/output control unit 3 and the data transfer is terminated in a normal termination at an intermediate stage of the data transfer responsive to an interrupt request signal DONE from the input/output control unit 3. The data transfer between the memories 4 and 5 can be started responsive to a trigger signal which is continuously generated within the DMAC 1.
However, the memories 4 and 5 do not have the function of generating the interrupt request signal DONE. For this reason, once the DMAC 1 starts the DMA transfer, there is a problem in that it is impossible to terminate the DMA transfer at an intermediate stage of the data transfer in a normal termination unless an abnormality such as a bus error occurs.
On the other hand, a Japanese Laid-Open Patent Application No. 61-133460 discloses a method of interrupting the DMA transfer at an intermediate stage of the data transfer by a terminate signal which is supplied directly from the input/output control unit to the DMAC via a signal line which is provided exclusively for the terminate signal. In this case, the DMAC stops operating responsive to the terminate signal which is supplied directly to the DMAC and not through the CPU which carries out the main control of the data processing system. For this reason, the CPU may not be aware that the DMAC has stopped operating. As a result, this method introduces problems when it is necessary to make some kind of a decision or discrimination in the CPU before stopping the operation of the DMAC.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a novel and useful DMAC in which the problems described above are eliminated.
Another and more specific object of the present invention is to provide a direct memory access controller adaptable to control a direct memory access transfer in a data processing system which includes at least a central processing unit and a system bus. The controller comprises register means coupled to the system bus for outputting a transfer terminate request signal which instructs a normal termination when the central processing unit is operating and a write operation is carried out with respect to the register means from the central processing unit, and transfer termination means coupled to the register means for stopping so as to accept a new transfer request signal or stopping so as to generate a transfer request signal responsive to the transfer termination request signal in order to make an instructed channel inactive. According to the direct memory access controller of the present invention, it is possible to make a normal termination during a direct memory access transfer regardless of whether or not a memory involved in the direct memory access transfer has a function of generating a normal termination request signal. Further, the normal termination can be made at an arbitrary timing.
Still another object of the present invention is to provide a direct memory access controller adaptable to control a direct memory access transfer in a data processing system which includes at least a central processing unit and mutually independent system buses, where the central processing unit being coupled to one of the mutually independent system buses the direct access controller comprises register means coupled to the mutually independent system buses for outputting a transfer terminate request signal which instructs a normal termination when the central processing unit is operating and a write operation is carried out with respect to the register means from the central processing unit, and transfer termination means coupled to the register means for stopping to accept a new transfer request signal or stopping to generate a transfer request signal responsive to the transfer termination request signal so as to make an instructed channel inactive.
A further object of the present invention is to provide a direct memory access controller adaptable to control a direct memory access transfer in a data processing system which includes at least a central processing unit and a system bus. The controller comprises a request handler for outputting a process request signal and an operation channel number in response to a transfer request signal and for outputting a process request signal instructing a normal termination in response to an interrupt request signal, a microsequencer which stores microprograms for renewing an address and a byte number required for a direct memory access and for generating a control signal based on the process request signal and the operation channel number received from the request handler, a data handler for making access to the system bus in response to the operation channel number received from the request handler and the control signal received from the microsequencer and for generating a read/write signal, and a register which is accessible by the central processing unit through the system bus, the register outputting a transfer terminate request signal which instructs a normal termination when the central processing unit is operating and a predetermined information is written in the register from the central processing unit.
Other objects and features of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a system block diagram showing a data processing system including an example of a conventional DMAC;
FIG. 2 is a system block diagram showing an essential part of a data processing system including a DMAC according to the present invention for explaining an operating principle thereof;
FIG. 3 is a system block diagram showing an embodiment of the DMAC according to the present invention;
FIG. 4 is a system block diagram showing an embodiment of a request handler of the DMAC shown in FIG. 3;
FIG. 5 is a flow chart for explaining the operation of the DMAC shown n FIG. 3; and
FIGS. 6A and 6B are system block diagrams respectively showing data processing systems to which the DMAC according to the present invention may be applied.
DETAILED DESCRIPTION
First, a description will be given of an operating principle of a DMAC according to the present invention by referring to FIG. 2. In FIG. 2, a DMAC 10 is coupled to a CPU 13, and this DMAC 10 includes a register 11 and a transfer termination means 12. The register 11 outputs a transfer terminate request signal which instructs a normal termination of a data transfer when the CPU 13 writes information requesting a termination of the data transfer in the register 11. The transfer termination means 12 stops accepting a new transfer request signal or stops generating a transfer request signal responsive to the transfer terminate request signal, and makes an instructed channel inactive.
Even when a DMA transfer is started, the transfer termination means 12 stops accepting a new transfer request signal or stops generating a transfer request signal when the CPU 13 writes the above described information in the register 11. For this reason, it is possible to terminate the DMA transfer in a normal termination at an intermediate stage of the data transfer regardless of whether or not the DMA transfer involves a memory or the like having no function of generating a normal termination request signal.
FIG. 3 shows an embodiment of the DMAC 10. The DMAC 10 has a request handler 15, a microsequencer 16, and a data handler 17. A system bus 20 has a data bus 20a, an address bus 20b, and a control bus 20c. The DMAC 10 may be applied to a data processing system shown in FIG. 6A, for example. In FIG. 6A, the data processing system includes a CPU 50, memories 51 and 52, an input/output control unit 53 and the DMAC 10 which are coupled via the system bus 20.
The request handler 15 receives transfer request signals REQ0 through REQ3 of channels "0" through "3" from the input/output control unit 53, and outputs a process request signal OPE and an operation channel number CH depending on a predetermined priority. In addition, the request handler 15 receives an interrupt request signal DONE from the input/output control unit 53 if needed, and outputs a process request signal OPE indicative of the interrupt request. Furthermore, as will be described later, the request handler 15 also outputs a process request signal OPE which instructs a normal termination responsive to a terminate request signal CLS received from the data handler 17.
The microsequencer 16 stores microprograms and and renews an address, byte number and the like required for the DMA transfer depending on the process request signal OPE and the operation channel number CH received from the request handler 15. The microsequencer 16 also outputs a control signal CTRL which is supplied to the data handler 17.
The data handler 17 has an internal register 18 which corresponds to the register 11 shown in FIG. 2. The data handler 17 makes access to the data bus 20a and the address bus 20b depending on the operation channel number CH and the control signal CTRL. At the same time, the data handler 17 outputs control signals such as a read/write signal, and these control signals are outputted on the control bus 20c. When an access is made to an internal register such as the register 18 of the data handler 17 by a chip select signal CS which is received from the CPU 50 through the control bus 20c, the data handler 17 makes a data write operation or a data read operation with respect to a selected internal register of the data handler 17. Data from the data bus 20a is written into the selected internal register of the data handler 17 by the data write operation, and a stored data is read out from the selected internal register of the data handler 17 by the data read operation.
The request handler 15 generates the process request signal OPE for terminating the DMA transfer, and FIG. 4 shows an embodiment of the request handler 15. The request handler 15 includes a register part 23, a sample and hold circuit 24, a sampling control circuit 25, an operation priority determination part 26, a process request signal output part 27, a channel priority determination part 28, a channel output part 29, and a clear control circuit 30.
For example, the register part 23 stores a cycle steal mode, a burst mode and a request generation information, and a sampling mode of the sample and hold circuit 24 is set depending on such information stored in the register part 23. The cycle steal mode refers to a mode where a DMA transfer is made using a time interval in which the CPU 50 does not make an access to the system bus 20. The burst mode refers to a mode where a data transfer is made by stopping the CPU 50. In this burst mode, a discrimination is made every time to determine whether or not a next request for DMA transfer exists, and the DMA transfer is made continuously when the next request for DMA transfer exists. Further, the request generation information refers to information which indicates whether an external transfer request is to be received or a transfer request is to be self-generated within the DMAC 10.
The sample and hold circuit 24 samples and holds one of the terminate request signal CLS, the transfer request signal REQ (REQ0 through REQ3) and the interrupt request signal DONE responsive to a sample instruction signal from the sampling control circuit 25, and supplies the sampled and held signal to the operation priority determination part 26.
When signals are received at the same time, the operation priority determination part 26 determines the priorities of the signals according to a predetermined sequence and supplies the priorities to the process request signal output part 27 and the channel priority determination part 28. The priorities are also supplied to the channel output part 29 through the channel priority determination part 28 and is supplied to the microsequencer 16 and the data handler 17 as the operation channel number CH.
The process request signal output part 27 supplies process request signals OREQ and OCODE to the microsequencer 16. These request signals OREQ and OCODE correspond to the process request signal OPE. The following Table shows the relationship of the value of the process request signal OCODE and the content of the process request.
TABLE______________________________________Value of OCODE Content of Process Request______________________________________00 START01 ABORT10 CLOSE11 IRA______________________________________
In the Table, "START" indicates an instruction to start a DMA transfer, "ABORT" indicates an abnormal termination instruction based on an external request which is entered via a signal line other than the system bus 20, "CLOSE" indicates a normal termination instruction at an intermediate stage of the DMA transfer, and "IRA" indicates an instruction when an illegal register access is made. The illegal register access occurs when a write operation is made with respect to an internal register of the DMAC 10 in a state where the DMAC 10 is operating and no rewriting of the internal register should be made.
In FIG. 4, OACK and ACTCLR respectively denote process terminate signals received from the microsequencer 16. The process terminate signal OACK is supplied to the sampling control circuit 25 and the clear control circuit 30, while the process terminate signal ACTCLR is supplied to the clear control circuit 30. The process terminate signals OACK and ACTCLR are respectively entered when terminating the process. However, although the process terminate signal OACK is entered every time each of a plurality of processes terminate during a time in which the channel is active, the process terminate signal ACTCLR is only entered at a time when the processes as a whole terminate. The register part 23 is cleared by an output signal of the clear control circuit 30 when the processes as a whole terminate.
Next, a description will be given of the operation of the embodiment shown in FIG. 3 by referring to a flow chart shown in FIG. 5 and the block system shown in FIG. 4. For the sake of convenience, it is assumed that a DMA transfer is made directly between the two memories 51 and 52 and not via the CPU 50. In this state where the DMA transfer is made, the CPU 50 outputs the chip select signal CS responsive to an external interrupt request. In a step S1, the CPU 50 discriminates whether or not a write operation is made with respect to the register 18 within the data handler 17 for instructing an interrupt request responsive to the chip select signal CS. When the discrimination result in the step S1 becomes YES, the data handler 17 in a step S2 supplies the terminate request signal CLS to the request handler 15 as described before in conjunction with FIG. 3.
Accordingly, in a step S3, the request handler 15 stops accepting the transfer request signal REQ and outputs the process request signal OPE for making a normal termination (interruption) of the process. In other words, the request handler 15 stops the operation of sampling and holding a new transfer request signal REQ in the sample and hold circuit 24 shown in FIG. 4 after the terminate request signal CLS is received, and the process request signal output part 27 outputs the normal termination instruction signal indicated as "CLOSE" in the Table described before responsive to the terminate request signal CLS.
In a step S4, the microsequencer 16 makes the instructed channel inactive. The processes of the steps S3 and S4 are realized by the transfer termination means 12 shown in FIG. 2.
Therefore, even when the data processing system has such a system structure that the memory cannot generate the interrupt request signal during the DMA transfer between two memories, it is possible to make a normal interruption of the DMA transfer as if the interrupt request signal DONE is generated, by making a write operation with respect to the register 18 from the CPU 50.
In the described embodiment, the register 18 is an internal register of the data handler 17. However, it is of course possible to provide the register 18 within the request handler 15, for example. In addition, instead of stopping the acceptance of the new transfer request signal REQ as described above, it is also possible to stop the generation of the transfer request signal REQ within the DMAC 10.
On the other hand, the DMAC 10 is also applicable to a data processing system having two mutually independent system buses as shown in FIG. 6B. In FIG. 6B, those parts which are basically the same as those corresponding parts in FIG. 6A are designated by the same reference numerals, and a description thereof will be omitted. In FIG. 6B, the CPU 50 is coupled to a system bus 20 1 , and the DMAC 10 is coupled to both system buses 20 1 and 20 2 . The memories 51 and 52 and the input/output control unit 53 are coupled to the system bus 20 2 .
Further, the present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
|
A direct memory access controller adaptable to control a direct memory access transfer in a data processing system which includes at least a central processing unit and a system bus, comprises a register coupled to the system bus for outputting a transfer terminate request signal which instructs a normal termination when the central processing unit is operating and a write operation is carried out with respect to the register from the central processing unit, and a transfer termination part coupled to the register for stopping to accept a new transfer request signal or stopping to generate a transfer request signal responsive to the transfer termination request signal so as to make an instructed channel inactive.
| 6
|
PRIORITY CLAIM
[0001] This application is a continuation of U.S. application Ser. No. 10/407,487 filed Apr. 4, 2003, which invention claims priority to U.S. provisional application Ser. No. 60/370,085, filed Apr. 4, 2002.
FIELD OF THE INVENTION
[0002] This invention relates generally to ocean powered desalinization systems.
BACKGROUND OF THE INVENTION
[0003] It has long been recognized that the oceans provide tremendous potential in kinetic energy which can be harvested to generate electricity. Across the globe there are many tidal electric generation systems installed and in full operation. An example of an installed and fully operational tidal electro-generation system is the barrage system installed near St. Malo on the Brittany Coast in France across the La Rance estuary. The St. Malo system is a 240 megawatt system and has been reliably generating electricity for a good number of years. Despite this good record the complete blockage of the La Rance estuary has caused significant environmental effects. The submerged turbine blades have interfered with migration of fish and the overall barrage itself has blocked shipping. Other tidal powered systems include tidal fences and submerged underwater windmills and all have a greater or lesser effect on the environment. The aforementioned power generating systems, though effective, are big and require a complex series of power grids to convey the power off the barrage or tidal fence to an offshore power collection and distribution system.
[0004] Smaller tidal and wave powered electro-generation systems include various wave riding devices which bob up and down and move dynamos that generate electricity. Although these systems are smaller and can be located at remote locations, they nevertheless require electricity to be harvested and a grid to be constructed onto these bobbing devices. The grid in particular is cumbersome and has limited their practical implementation.
[0005] Various locations across the globe in which tidal ranges are ideal for generating electricity are places that also happen to be devoid of water. Such locations are in Africa, the Mideast and Polynesia. As these desert coastal regions are commonly devoid of electricity and drinkable water, various devices have been proposed to meet both the electricity and potable water demands of coastal residents. Such a system is described in U.S. Pat. No. 5,167,786 which generates compressed oxygen and hydrogen gas on a toroidal float which moves up and down with the waves and the tide. This up and down motion drives a DC generator which in turn is arranged to electrolytically produce hydrogen and oxygen gas. The hydrogen and oxygen gas is stored on the toroidal float apparatus and transferred to a reaction chamber to chemically generate electricity. Electricity thus generated is then sent to a DC motor to drive a high pressure pump which forces sea water through a reverse osmosis membrane to remove salt and produce drinkable fresh water. This toroidal gas generation system to generate electricity to drive electric DC motors in order to make drinkable water is a desalinization system which works but it is unnecessarily complex. Where there is a need primarily for fresh water to be generated from a desalinization process especially in remote regions a gas generated gas reactor system is unduly complex and likely to not have the robustness to serve in remote locations. Furthermore, such a system is very costly.
[0006] In many desolate parts of the world that have a good tidal and wave coastline but yet is primarily in an arid region there is a need to have a robust mechanically simple desalinization system powered by the tides and wave action of the seas. Such a system is simplified if it does not have electric generators but instead goes directly to the desalinization process. Such a simplified system uses the potential and kinetic energy of the oceans to directly send saltwater into a desalinization system without the intervening production of electricity inherent in other systems.
[0007] The need for a simplified robust desalinization system powered directly by the oceans to make fresh water and store the fresh water is needed. Such a system must be fairly mobile, assembleable, disassembleable, and transportable to remote coastal locations where potable water is not easily obtained.
SUMMARY OF THE INVENTION
[0008] The instant invention overcomes many of the disadvantages of having a dual electricity generation system and a saltwater desalinization system. A preferred embodiment of the present invention utilizes a barge mounted to a plurality of pistons that reciprocate inside a matching plurality of vessels or cylinders, and utilizes the vertical motion being caused by the action of tidal forces and waves. Each piston is in fluid communication with the ocean as the source of power to perform on board desalinization. The barge is restricted to up and down vertical motions via a plurality of posts or piles secured by embedded positioning into the bedrock of the sea floor to stabilize the barge against ocean-caused lateral displacement. The up and down motion of waves and tidal forces causes the pistons to reciprocate upwards and downwards with its waves and tides. That is, as the tide rises or falls, the pistons rise and fall, generating a two-way pumping action. This pumping action is due to the combined forces of rising tides and falling tides, or the combined forces of rising waves and falling waves. There is no intervening electric generation of power from the use of alternate powered devices. This reciprocating pumping action delivers a pressurized saltwater flow. Using a plumbing and valving system, the pressurized saltwater flow is directed to an on board desalinization system, such as a reverse osmosis (RO) filtration system, that generates and stores fresh water into reservoirs by being powered directly from the reciprocating movement of waves and tides. The on board desalinization system is in fluid communication with each cylinder and reservoir.
[0009] Another preferred embodiment of the present invention does not utilize bedrock embedded piles or posts to keep the barge positioned at a chosen site on the ocean floor, but instead secures the barge's ocean floor location through supports massive enough to resist lateral displacement caused by wave and tidal action. This alternate preferred embodiment is particularly suited for ocean floors having deep sandy beds.
[0010] Yet another preferred embodiment of the present invention uses a single pile or post floating barge or platform that slidably oscillates between vertical limits imposed by wave and tidal action. The single pile is secured to the ocean floor by a support massive enough to resist lateral displacement of ocean flows. The pile or post projects through a platform aperture. Alternatively, the single pile may be embedded in the ocean floor to increase stability against lateral displacement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
[0012] FIG. 1 is a preferred general arrangement of an approximately 50 foot by 100 foot barge which contains the desalinization system. The cylinders are depicted below the water line, and barge positions depicted include a high tide position and a low tide position;
[0013] FIG. 2 is an up view or plan view of the preferred deck arrangement of the barge;
[0014] FIG. 3 is a cutaway view detailing a cutaway view of a preferred reverse osmosis filtration system and storage reservoir arrangement in the approximately 50 foot by 100 foot barge;
[0015] FIG. 4 is a depiction of the preferred machinery arrangement in a cutaway view of the approximately 50 by 100 foot barge;
[0016] FIG. 5 is a depiction of a preferred arrangement of the cylinder and in-flowing and out-flowing check valves;
[0017] FIG. 6 is a schematic of the reverse osmosis purification system and its piping connection with cylinders and storage reservoirs; and
[0018] FIG. 7 is a schematic depiction of a preferred embodiment of the invention with the cylinders located above the water line.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Arrangement of the barge mounted tidal powered desalinization system comprises a series of pistons mounted to the barge which oscillate within cylinders attached to a shaft which is mounted into the bedrock of the ocean bed. To the shaft are attached a plurality of cylinders where each cylinder has a piston and the piston has a rod which is attached to the barge bottom. As the barge moves up or down with tidal or wave action the pistons move up or down within the cylinders. Through appropriate plumbing valves to direct the flow of saltwater in a one-way direction results in the delivery of saltwater into the reverse osmosis membranes.
[0020] The design of the instant invention using the rising and falling of the tides to create a flow of seawater under pressure suitable for feeding existing reverse osmosis desalinization systems. The design consists of a floating vessel attached to one end of a standard type hydraulic cylinder, the other end of the cylinder is connected to the sea floor. As the floating vessel or barge rises and falls with the tides, the cylinder is extended and compressed. This motion pumps the seawater. The pressure and flow rate of seawater depends on cylinder size and the mass of the vessel and the displacement of the vessel which occurs during tidal cycles.
[0021] On the upward stroke of the cycle the buoyant force of the float limits the amount of pressure that can be created. On the downward stroke the weight of the float determines the maximum pressure. The actual work on the down stroke is a function of gravity, not of the tides. The cylinders are sized so that the float is not really floating but is suspended on the cylinders.
[0022] In concert with the up and down motion of the barge in response to tidal flows and wave action, the cylinders are configured to cyclically deliver pressurized saltwater for subsequent desalinization. Simultaneously, the pressurized and delivered saltwater is replaced with incoming charges of salt water that will be subsequently pressurized and delivered for desalinization with the next tidal or wave action. For example, as the tide recedes the buoyant force on the barge decreases and the barge falls, pushing each piston downward into their respective cylinders. During each piston's downward stroke, each cylinder is configured to deliver pressurized saltwater for desalinization, and concurrently, to fill each cylinder with a replacement charge of saltwater. Similarly, as the tide comes in, the buoyant force on the barge increases and the rising barge pulls each piston upward into their respective cylinders. During the piston upward stroke, each cylinder is configured to deliver pressurized saltwater for desalinization, and concurrently, to fill each cylinder with a replacement charge of saltwater.
[0023] Thus, an unbalanced hydraulic cylinder is used as the pumping mechanism. The down stroke acts on the larger surface area of the cylinder. This is done so that the substantial mass of the floating vessel can be used to create pressure and flow. On the upstroke, buoyant forces lift the floating vessel, thereby acting on the smaller surface area portion of the hydraulic cylinder, generating a forward flow of saltwater. As the tide recedes, the floating vessel sinks, generating a down stroke. The down stroke generates a reverse flow of saltwater. The result is a system that is half powered by tidal forces and half powered by gravity. Pumping action can also be used to pump the fresh water exiting the reverse osmosis filters into the water distribution system resulting in the conversion of saltwater into potable water under pressure without any electrical or fuel input.
[0024] The invention is best described by referring to the figures. In FIG. 1 the invention 10 is shown in two positions depending upon the tide position. A barge 12 is located in a high tide position and a low tide position. The Barge 12 moves up and down about along a first post 14 and along with a second post 34 . Attached to the top side of the barge 12 is a first platform 15 which circumscribes the first post 14 and a second platform 42 which circumscribes the second post 34 . The first Post 14 and the second post 34 are mounted into the bedrock of the ocean floor. The first post 14 is supported by a first post guide 30 and the second post 34 is supported by a second post guide 36 . The first and second guides 30 and 36 sit atop the bedrock of the ocean floor. On the first guide 30 is seen a first plurality of cylinders that includes a first cylinder 20 and a second cylinder 32 . On second guide 36 is seen a second plurality of cylinders that includes a first cylinder 38 and a second cylinder 40 . Within each cylinder is a piston seal and a piston rod assembly. Referring to the first cylinder 20 as representative for other cylinders, the other cylinders including, but not limited by, the second cylinder 32 of the first plurality of cylinders and the second cylinders 39 and 40 of the second plurality of cylinders, the piston rod assembly includes a piston seal 22 which is attached to a piston rod 18 . The piston rod 18 is mounted to the first platform 15 by a rod end 16 . Likewise, other piston rods are attached to the other seals within the other cylinders and are similarly attached to the first platform 15 and the second platform 42 . As can be seen in FIG. 1 there are two extreme positions to the barge 12 when it floats at high tide and when the barge 12 floats at low tide. Similarly, the pistons will also occupy two extreme locations, the high tide position and the low tide position, and reciprocate within their respective cylinders. As depicted in FIG. 1 , the piston seal 22 occupies the top position of the first cylinder 20 when the barge 12 is at high tide, then transits down the first cylinder 20 to the low tide position. As the tides and the waves oscillate in their own diurnal cycle, the piston seal 22 migrates between the high tide extreme and the low tide extreme. In so doing, saltwater is pumped by the movement of the barge as a consequence of rising with the tide and falling with gravity, generating a pressurized saltwater flow powered by a suction cycle and a discharge cycle. Using a plumbing and valving system (not shown), the suction and discharge cycles of the double acting cylinders are regulated to produce a steady pressurized flow of saltwater. The plumbing and valving systems include a first plumbing and valving system configured to deliver pressurized water to the on board desalinization system and a second plumbing and valving system configured to deliver incoming saltwater to the cylinders concomitantly as the pressurized saltwater is delivered from the cylinders.
[0025] FIG. 2 shows in more detail the deck arrangement of the barge 12 in a top view. The top of the barge 12 is shown the first post 14 and the second post 34 . The first post 14 is surrounded by the first platform 15 and the second post 34 is shown surrounded by the second platform 42 . Beneath the first platform 15 is the first plurality of cylinders. The first plurality of cylinders includes the first cylinder 20 , the second cylinder 32 , a third cylinder 60 , and a fourth cylinder 62 . Beneath the second platform 42 resides the second plurality of cylinders. The second plurality of cylinder includes the first cylinder 38 , the second cylinder 40 , a third cylinder 64 , and a fourth cylinder 66 .
[0026] FIG. 3 shows a cutaway view of a preferred reverse osmosis filtration system and storage reservoir arrangement in the approximately 50 foot by 100 foot barge. The cutaway view is from the top view of the barge 12 . The cutaway view 104 shows four compartments. The four compartments include a first compartment 110 , a second compartment 120 , a third compartment 130 and a fourth compartment 140 . Each compartment contains a stack of reverse osmosis membranes and a plurality of water storage reservoirs. The first compartment 110 shows a first reverse osmosis stack 112 which is fed by a first plurality of pre-filtration tanks. The first plurality of pre-filtration tanks include a first tank 114 , a second tank 116 , and a third tank 118 . The second compartment 120 has a second reverse osmosis stack 122 which is fed by a second plurality of pre-filtration tanks. The second plurality of pre-filtration tanks includes a first tank 124 , a second tank 126 , and a third tank 128 . The third compartment 130 has a third reverse osmosis membrane stack 132 which is fed by a third plurality of pre-filtration tanks. The third plurality of pre-filtration tanks include a first tank 134 , a second tank 136 , and a third tank 138 . The fourth compartment 140 contains a fourth reverse osmosis stack 142 which is fed by a fourth plurality of pre-filtration tanks. The fourth plurality of pre-filtration tanks includes a first tank 144 , a second tank 146 , and a third tank 148 . Each reverse osmosis stack uses a third plumbing and valving system (not shown) to deliver the generated fresh water to the plurality of water storage reservoirs. Also seen in the cutaway view 104 is a first moon pool 150 delineating the space for the first post 14 and a second moon pool 160 delineating the space for the second post 34 . Each reverse osmosis stack can be loaded with RO membranes configured to meet varying levels of salinity and silt contents in the saltwater.
[0027] FIG. 4 is a side cutaway view of the barge 12 . The first and second platforms 15 and 42 are shown above the first compartment 110 and the second compartment 120 respectively. Within the first compartment 110 is seen the first reverse osmosis stack 112 and the second pre-filtration tanks 116 and 118 of the first plurality of pre-filtration tanks. Similarly, inside the second compartment 120 is seen the second reverse osmosis stack 122 and the first and second pre-filtration tanks 124 and 126 of the second plurality of pre-filtration tanks.
[0028] FIG. 5 is a depiction of a preferred arrangement of the cylinder and in-flowing and out-flowing check valves. FIG. 5 shows the arrangement for the cylinder 20 but is also representative for cylinders 32 , 38 , and 40 of FIG. 1 . Inside the cylinder 20 is a connecting rod seal 204 that makes and maintains sealing contact with the connecting rod 18 . As the connecting rod 18 reciprocates within the cylinder 20 , the piston 22 creates a vacuum on the trailing side of the piston 22 , and simultaneously creates pressure on the leading side of the piston 22 . The vacuum created on the trailing side of piston 22 pumps in saltwater through incoming check valves 208 A or 212 A, depending if the piston 22 is moving downwards, or upwards, respectively. Similarly, the pressure created on the leading side of the piston 22 pressurizes the salt water and delivers to the outgoing check valves 208 B and 212 B, depending if the piston 22 is moving upwards or downwards, respectively.
[0029] FIG. 6 is a schematic of the reverse osmosis purification system its piping connection with cylinders and storage reservoirs. Again, using the cylinder 20 as representative for cylinders 32 , 38 , and 40 of FIG. 1 , ambient pressure saltwater is drawn in through incoming check valve 208 A through a first pipe 216 . Alternatively, ambient pressure saltwater is drawn in through incoming check valve 212 A trough a second pipe 220 . Depending on the position of the connecting rod 18 and the piston 22 , pressurized saltwater is delivered to the outgoing check valves 208 B and 212 B. Pressurized saltwater from outgoing check valve 208 B is delivered by a third pipe 224 to a reverse osmosis filtration system 234 . Similarly, pressurized saltwater from outgoing check valve 212 B is delivered by a fourth pipe 228 to the reverse osmosis filtration system 234 . The reverse osmosis filtration system 234 includes the reverse osmosis stacks 112 , 122 , 132 , and 142 working in concert to produce purified water from saltwater. Saltwater excess not purified by the RO system 234 is discarded through a fifth pipe 238 . Freshwater generated by the RO system 234 is delivered through a sixth pipe 244 to a plurality of storage reservoirs 248 . The plurality of storage reservoirs 248 is representative of the reservoirs 114 , 116 , 118 , 124 , 126 , 128 , 134 , 136 , 138 , 144 , 146 , and 148 .
[0030] FIG. 7 is a schematic depiction of a preferred embodiment of the invention with the cylinders not immersed in the saltwater, but instead located above the water line and located onboard the barge. A portion of the barge 12 illustrating the post 14 is shown in FIG. 7 . The first pipe 216 and the second pipe 220 extend below the water line and each connects with the cylinder 20 that is now located onboard the barge 12 , above the water line. Incoming saltwater is delivered via the first pipe 216 and the second pipe 220 . Pressurized saltwater is delivered to the RO system 234 (not shown) from the cylinder 20 via the third pipe 224 and the fourth pipe 228 .
[0031] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, more than two piles or posts can be used as vertical guides to the barge. More than four piston and cylinder assemblies may be mounted around each pile or post, and may be located in different sections of the barge. The vessels or cylinders may be constructed of metal, corrosion resistant metals, plastics, or plastic-lined metals of sufficient thickness and corrosion resistance to permit pumping action. For the preferred alternate embodiment not utilizing bedrock-embedded piles or posts to stabilize against ocean motion caused lateral displacement of the barge, the pile guides are configured to receive cement or receive heavy object attachments to impart enough weight and mass to resist and stabilize the barge against lateral displacement from ocean motion forces. All embodiments of the present invention may also be used to purify polluted fresh water sources. Piles or posts may be connected to the barge internally through barge apertures or secured along the periphery of the barge with collars. Cylinders may be placed around the piles or internally spaced above or below throughout the cross-sectional area of the barge platform. The invention may be adapted to existing floating structures, such as airport runways and parking lots. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment.
|
A tidal-powered desalinization system is mounted on a barge that oscillates about fixed pier structures, generating a two-way pumping action. The two-way pumping action is changed to a single direction flow of seawater. The sea water is directed into an on-board desalinization system. Fresh water is produced and collected in reservoirs, without an intervening generation of electricity.
| 8
|
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a Divisional of co-pending application Ser. No. 11/509,660, filed on Aug. 25, 2006, the entire contents of which are hereby incorporated by reference and for which priority is claimed under 35 U.S.C. §120. This nonprovisional application also claims priority under 35 U.S.C. §119(a) on Patent Application No. 94146967 filed in Taiwan on Dec. 28, 2005, the entirety of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a fabrication method of a modification nano-array, and in particular to a fabrication method of a modifiable nano-array by embossing.
2. Description of the Related Art
Regular nano-structures having a diameter of about 100 nm has special functions, such as low-reflectivity of insect's ommateum, anti-adhering effect of inset's wing, lotus effect. In present nano-technology, the method of fabricating a polymer substrate with hydrophobic surface, anti-oil surface or low-reflective surface, comprises twice surface treatments, and is complicated and expensive. Using lithography as an example, the process of fabricating a surface with regular nano-structures is difficult and expensive as the nano-structures geometries scale down to 90 nm.
In Acta Physiol Scand, insect's ommateum with high-sensitiveness to light at night has been observed by C. G Bernhard et al (1962). Nano-structures of insect's ommateum having a diameter of less than 250 nm exhibit super-low reflectivity in wide wavelength range of light. Moth Eye Principle has been proposed in Nature (1973) by Clapham and Hutley. In Planta, Lotus effect has been observed by W. barthlott et al. There is a plurality of nano-protrusions having a diameter of less than 50 nm on the surface of lotus to obtain a self-cleaning surface due to small contact area of the nano-protrusions.
Using anodic alumina oxidation (AAO) as a template has been published in Science (2002) by M. Steinhard et al. The anodic alumina oxidation with a plurality of regular nano-holes is used to be a template for forming hollow polymer nano-tubes. In US published application (20030089899), Lieber et al provide nanometer-scale articles, including nanoscale wires which can be selectively doped at various locations and at various levels. In some cases, the articles may be single crystals. The nanoscale wires can be doped, for example, differentially along their length, or radially, and either in terms of identity of dopant, concentration of dopant, or both. In US published applications (2004/0126305), Chen et al provide methods of fabricating one-dimensional composite nano-fiber on a template membrane with porous array by chemical or physical process. The whole procedures are established under a base concept of “secondary template”. First of all, tubular first nano-fibers are grown up in the pores of the template membrane. Next, by using the hollow first nano-fibers as the secondary templates, second nano-fibers are produced therein. Finally, the template membrane is removed to obtain composite nano-fibers. In US published applications (20040013873), Wendorff et al provide porous fibers comprising a polymeric material. The fibers have a diameter of 20 nm to 4000 nm and pores in the form of channels extending at least to the core of said fiber and/or through said fiber. The process for producing the porous fiber comprises electrospinning a 5 to 20% by weight solution of at least one polymer in an organic solvent using an electric field above 10.sup.5 V/m to obtain a fiber having a diameter of 20 nm to 4000 nm and pores in the form of channels extending at least to the core of said fiber and/or through said fiber. The porous fiber may be used as a carrier for a catalyst, as an adsorbent or absorbent or as a biomaterial, may be chemically modified or functionalized or may be used as a template for producing highly porous solids. In above-mentioned patents, the template with a plurality of nano-holes must be removed by etching after the formation of the nano-tubes or nano-fibers in the nano-holes.
In korea Patent (Pat. No.KR20030084279), Woo Lee et al provide a method of fabricating nano-structures by AAO templates with different sizes of nano-holes or by a twice anodic alumina oxidation template. In this fabricating process, polymer dissolved in an organic solvent fills the nano-holes of the AAO template, and removing the organic solvent after the nano-holes is filled with polymer. After consolidation of polymer in the nano-holes, the template must be removed by etching to reveal nano-structures formed by the nano-holes. During the etching process, the nano-structures would be deformed and lose the shape of the nano-hole.
In Germany Patent (Pat. No. DE10154756) Sawitowski Thomas uses an oxide coating as a template to have an embossing process for forming nano-columns. In this fabricating process, the shape of the nano-columns cannot change with different process conditions, and the nano-columns are too weak to demolding without surface treatment.
BRIEF SUMMARY OF THE INVENTION
The invention provides a modification nano-array comprising a plurality of nano-protrusions formed integrally on a substrate. The nano-protrusion has a concave or convex top surface.
The invention further provides a fabricating method of a nano-array. A template with a plurality of nano-holes is provided. A polymer substrate is embossed by the template, and a plurality of nano-protrusions are revealed by demolding. The nano-protrusions can be further coated with a layer of organic or inorganic coating to enhance scratch resistance, toughness and hydrophile/hydrophobicity, and to reduce the reflectivity of the nano-array or increase the affinity of the surface thereof.
A detailed description is given in the following with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 to FIG. 3 are cross-sectional diagrams of embossing process;
FIG. 4 a and FIG. 4 b are cross-sectional diagrams of nano-arrays with organic or inorganic coating thereon of the invention;
FIG. 5 and FIG. 6 are cross-sectional diagrams of nano-arrays formed by embossing process in different conditions;
FIG. 7 a is a cross-sectional diagram of concave head nano-arrays observed by an electron microscope;
FIG. 7 b is a top view of FIG. 7 a;
FIG. 8 a is a tilt diagram of convex head nano-arrays observed by an electron microscope;
FIG. 8 b is a top view of FIG. 8 a;
FIG. 9 a shows the contact angle between a drop of water and a thermoplastic polymer substrate;
FIG. 9 b shows the contact angle between a drop of water and a thermoplastic polymer substrate having a plurality of nano-protrusions thereon formed by embossing process of the invention;
FIG. 10 a shows the gecko's effect of the nano-protrusion of the invention;
FIG. 10 b shows sweat adhering to a surface having a plurality of nano-protrusions;
FIG. 11 shows the reflectivity of visible spectrum;
FIG. 12 a shows the adhesion test result of 100 nm thick Au sputtered on a polymer substrate with and without nano-protrusions; and
FIG. 12 b shows the adhesion test result of 200 nm thick Au sputtered on a polymer substrate with and without nano-protrusions.
DETAILED DESCRIPTION OF INVENTION
The invention provides a controllable embossing process to forming a plurality of nano-protrusions on a thermoplastic polymer substrate instead of melting polymer in an organic solvent, avoiding environmental protection problems and deformed nano-protrusions caused while removing the solvent and demolding.
FIG. 1 to FIG. 3 are cross-sectional diagrams of a embossing process of the invention. As shown in FIG. 1 , an anodic alumina oxidation template (AAO) 101 with a plurality of nano-holes 105 is fabricated by anodizing an aluminum substrate, and further anodizing again to increase the uniformity of the nano-holes for reducing the difference of diameter between each nano-protrusion formed by the anodic alumina oxidation template 101 in sequent process. The diameter of the nano-holes 105 is less than about 200 nm, preferably between about 20 nm and 150 nm.
As shown in FIG. 2 , a polymer substrate 103 is softened by heating. The heating temperature depends on the material of the polymer substrate 103 . The polymer substrate 103 comprises thermoplastic polymer, thermoset polymer or UV curing polymer, preferably thermoplastic polymer such as PMMA (polymethyl Methacrylate), PC (polycarbonate), COC (cyclo-olefin copolymers), PP (polypropylene), PE (polyethylene), PVC (polyvinyl chloride), PET (polyethylene terephthalate) or PI (polymide), or thermoset polymer such as PI (polyimide) or Epoxy. As shown in FIG. 2 , the polymer substrate 103 is extruded by the AAO template 101 . During the extrusion process, the AAO template 101 sinks into the polymer substrate 103 while the polymer substrate 103 is extruded into the nano-holes 105 . After the extrusion process, the polymer substrate 103 is cooled to consolidate, and a surfactant is introduced to separate the polymer substrate 103 and anodic alumina oxidation template 101 . As shown in FIG. 3 , a plurality of nano-protrusions 107 is formed on the polymer substrate 103 . The diameter of the nano-protrusions 107 is between about 20 nm and 150 nm. The height of the nano-protrusions 107 is smaller than about 400 nm. The distance between adjacent nano-protrusions is less than about 50 nm. The aspect ratio of the nano-protrusions 107 is smaller than about 3, preferably smaller than about 2.
Still referring to FIG. 3 , during demolding process, there is no organic solvent remaining on the polymer substrate 103 , thus avoiding environmental protection problem and deformed nano-protrusion caused by organic solvent. The embossing process by using AAO template of the invention costs less than the conventional lithography process per unit process area. The nano-protrusions 107 formed on the shallow portion of the polymer substrate 103 are revealed by demolding through the difference of affinity between the polymer substrate 103 and AAO template 101 instead of removing the template by etching. The top portion of the nano-protrusions 107 can be formed in different shapes by adhesive force on the inner wall of the nano-holes 105 , cohesion of polymer as heating and shrink by consolidation.
FIG. 5 and FIG. 6 show nano-arrays formed by embossing process of the invention at different conditions. Cyclo-olefin polymer (Tg=130° C.) substrate is embossed by an AAO template having a plurality of nano-holes with a diameter of less than about 100 nm, at conditions of 150° C., vacuum less than 1 atm and pressure less than 5 bar, forming a plurality of nano-protrusions 107 a with a convex top surface 108 a as shown in FIG. 5 . In addition, Cyclo-olefin polymer(Tg=130° C.) substrate is embossed by an AAO template having a plurality of nano-holes with a diameter of between about 100 nm and 200 nm, at conditions of 152° C., vacuum more than 1 atm and pressure less than 5 bar, forming a plurality of nano-protrusion 107 b having a concave top surface 108 b . The height of the nano-protrusions 107 a and 107 b are less than 400 nm. The function of the nano-protrusion depends on the shape of the top surface thereof. The nano-protrusions 107 of the invention have high contact angle, hydrophobicity and Van de Waals force due to smaller contact area of the top surface thereof. In addition, the polymer substrate 103 with a plurality of nano-protrusions may be transparent and covered by a coating to reduce the reflectivity in wavelength range of visible light, thus improving the utility rate of light.
A layer of organic or inorganic coating 109 may be further formed conformally on the nano-protrusions 107 to enhance the strength thereof, as shown in FIG. 4 a and FIG. 4 b . The thickness of the organic or inorganic coating 107 is less than about 100 nm preferably. The inorganic coating may be metal such as Zr, Ti, Cu, Ag, Au, Al, Ni, W, Fe or Pt, oxide such as SiO2, TiO2 or ITO, GaAs, InGaAs, polysilicon or amorphous silicon. The organic coating may be polysiloxane, silicon, conductive polymer, OLED (organic light emitting diode), PLED (polymer light emitting diode) or PEDOT (polyethylenethioxythiophene) to enhance the toughness of the nano-protrusions 107 . The organic or inorganic coating can reveal the strength thereof directly on the nano-protrusions 107 , just like a strengthening sugar coating. The organic or inorganic coating has the same shape with the nano-protrusions 107 by conformal formation of coatings on the nano-protrusions.
FIG. 7 a is a cross-sectional diagram of nano-arrays observed by an electron microscope according to an embodiment of the invention. A transparent thermoplastic polymer substrate is embossed by an AAO template having a plurality of nano-holes with a diameter of less than about 100 nm and an adjacent distance of about 20 nm. During embossing process, the transparent thermoplastic polymer substrate is extruded to fills part of the nano-holes. After embossing process, a plurality of nano-protrusions with aspect ratio of about 2 are revealed on the transparent thermoplastic polymer substrate by demolding, as shown in FIG. 7 a . The nano-protrusion has a concave top surface as shown in FIG. 6 . FIG. 7 b is a top view of the nano-protrusions observed by an electron microscope. As shown in FIG. 7 b , the nano-protrusions distribute uniformly.
FIG. 8 a is a cross-sectional diagram of nano-arrays observed by an electron microscope according to another embodiment of the invention. A transparent thermoplastic polymer is embossed by an AAO template having a plurality of nano-holes with a diameter of about 100 nm and an adjacent distance of about 50 nm. After embossing process, a plurality of nano-protrusions with aspect ratio about 3 are revealed on the transparent thermoplastic polymer substrate by demolding, as shown in FIG. 8 a . The nano-protrusion has a convex top surface as shown in FIG. 5 . FIG. 8 b is a top view of the nano-protrusions. As shown in FIG. 8 b , the nano-protrusions distribute uniformly.
FIG. 9 a shows the contact angle between a drop of water and a general thermoplastic polymer substrate. The contact angle therebetween in FIG. 9 a is about 90 degrees. FIG. 9 b shows the contact angle between a drop of water and a thermoplastic polymer substrate having a plurality of nano-protrusions thereon formed by embossing process of the invention. The contact angle therebetween in FIG. 9 b is over 140 degrees. Accordingly, the nano-arrays formed by a template with a plurality of nano-holes exhibit superhydrophobicity as lotus effect.
FIG. 10 a shows the gecko's effect of nano-arrays of the invention. As shown in FIG. 10 a , a drop of water having a volume of less than about 10 μL, are locked on a substrate having a plurality of nano-protrusions thereon. FIG. 10 b shows drops of water adhering to a substrate having a plurality of nano-protrusions thereon.
FIG. 11 shows a transparent substrate comprising region A with nano-protrusions of the invention thereon and region B having no nano-protrusions of the invention. As shown in FIG. 11 , the reflective brightness of light in region A is lower than in region B. The transparent substrate in FIG. 11 may be PC (Polycarbonate) or COC (Cyclo Olefin Copolymers). For PC, region A has a reflectivity of about 2-3 between visible light wavelength of about 400-700 nm. For COC, region A has a reflectivity of about 1-2 between visible light wavelength of about 400-700 nm. The reflectivity of region A for different substrate materials is similar. It is known that the nano-array of the invention can reduce glare and reflection without inducing color-shift.
Experimental study indicates that the nano-protrusions substantially increase the adhesion between a polymer substrate and an overlying coating. FIGS. 12 a and 12 b respectively show the adhesion test results of 100 nm and 200 nm-thick Au coatings on PC polymer substrates. The adhesion test was carried out using crosshatch adhesion test, where a grid of 100 squares was cut into the coated substrate, and a 3M tape was applied over the grid, and then rapidly peeled away. The number of squares remaining on the substrate gives a relative percentage value of adhesion. As shown in FIGS. 12 a and 12 b , regions C with nano-protrusions passed the adhesion test, while regions D without nano-protrusions failed. Note that the nano-protrusions can be used to improve adhesion of any organic or inorganic coatings, such as Si, Au; Cu, or the like. Further, polymer substrates other than the PC substrate (COC substrates, for example) may be used to practice the invention.
Table 1 shows transmission of a thermoplastic polymer substrate having a plurality of nano-protrusions thereon formed by embossing process of the invention. The reflectivity of general transparent thermoplastic polymer substrate, such as plastic, measured by Hazemeter is under 3.5%. As shown in Table 1, nano-protrusions formed by embossing process of the invention can increase the reflectivity of the general transparent polymer substrate to 94%.
TABLE 1
transmission
conventional thermoplastic polymer
92.51
thermoplastic polymer substrate having
94.18
a plurality of nano-protrusions
thermoplastic polymer substrate having
93.65
a plurality of nano-protrusions
Finally, while the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements as would be apparent to those skilled in the art. Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
|
The invention provides a method for fabricating a nano-array comprising the following steps. A template with a plurality of nano-holes is provided. A polymer is embossed by the template to integrally form a plurality of nano-protrusions thereon, and demolding to reveal the nano-protrusions. The nano-protrusion has a concave or convex top surface.
| 1
|
This application claims the benefit of U.S. Provisional Application No. 61/092,778, filed Aug. 29, 2008.
FIELD OF THE INVENTION
The invention relates to the treatment and reuse of water produced from a subterranean petroleum reservoir. More particularly, the invention relates to use of that produced water for operations in a well. Most particularly, the invention relates to use of that produced water for stimulation operations as slickwater, and for stimulation operations with energized fluids.
BACKGROUND
It is costly to clean up oilfield produced water, e.g., water produced from a wellbore along with oil and/or gas or otherwise from or in contact with a subterranean petroleum reservoir, for proper treatment for acceptable environmental disposal. On the other hand, sources of fresh water for oilfield treatment processes such as water flooding, subterranean fracturing, etc., can represent a significant expense. Applicants recognized that there is a potential cost savings to be realized by cost-efficiently treating oilfield produced water on-site and then reusing the treated water, for example, to prepare fracturing or other well treatment fluids. The potential cost reduction is at least two-fold: first, there is less cost to dispose of produced water; second, the net amount of fresh water required to be imported for making treatment fluids is reduced or eliminated.
Many commercial fracturing fluids are aqueous based gels or foams. When the fluids are gelled, a viscoelastic surfactant system or a polymeric gelling agent, such as a soluble polysaccharide, can be used. The thickened or gelled fluid helps keep the proppants within the well treatment fluid. Gelling with polymers can be accomplished or improved by the use of crosslinking agents, or crosslinkers, that promote crosslinking, thereby increasing the viscosity of the fluid. U.S. Pat. No. 5,217,632 to Sharif, for example, discloses a synergy between boron and zirconium compounds used as a crosslinking agent for polysaccharides in the same fluid for better stability in the presence of acids, bases, boiling, high dilution and/or aging.
Following placement of a proppant or gravel pack with the viscosified fluid, the hydraulic conductivity of the fracture and the adjacent formation can be established by reducing the viscosity of the fracturing fluid to a low value so that it may flow naturally from the formation under the influence of formation fluids. Crosslinked gels typically rely on viscosity breakers to initiate and/or accelerate the reduction of viscosity or “break” the gel.
Unfortunately, when oilfield produced water was used “as is” (untreated) to prepare fracturing fluids, applicants found that the viscosity of the fluids thus prepared usually quickly deteriorated in much the same manner as if a viscosity breaker had been prematurely activated in the fluid. Also, when oilfield produced water was used “as is” to prepare slickwater, the applicants found that this fluid shows poor fluid viscosity and/or drag reduction. Through a number of control experiments, applicants identified likely causes of the fluid failure as the degradation of polysaccharide or polysaccharide derivatives by bacteria and/or related enzymes present in the produced water. However, bactericides used at typical, antimicrobially effective concentrations were found to have little or no effect on improving the viscosification of the fluid. There is thus an unfulfilled need in the art for a cost-effective treatment of oilfield produced water so that the water can be used in the preparation of otherwise conventional viscosified fracturing fluids when employing standard gelling agents, or otherwise conventional slickwater fluids showing same enhanced fluid viscosity as it would be using non-produced water.
SUMMARY OF THE INVENTION
We have found that oilfield produced water may contain microorganisms, related enzymes, or both, that can lead to premature fluid viscosity loss when the water is reused in viscosified fluids, e.g., well treatment fluids. Water containing the microorganisms and/or enzymes is pretreated with a metal compound to at least temporarily inactivate the microorganisms and/or enzymes. Thereafter, the treated water is used to prepare a fluid for a well treatment procedure without loss of viscosity, and without loss of conductivity in the case of a fracturing fluid.
One embodiment of the invention provides a method of treating a subterranean formation in a well. The method comprises: providing an aqueous medium comprised at least in part of oilfield produced water; contacting the aqueous medium with a zirconium compound; whereby the fluid viscosity and/or fluid drag reduction ability of the combination of the aqueous medium and zirconium compound is improved compared to the aqueous medium alone; introducing the combination in to the well; and allowing the combination to contact the formation. In an embodiment, the aqueous medium can include oilfield produced water. The fluid viscosity of the combination of the aqueous medium and zirconium compound is increased compared to the aqueous medium alone. The fluid drag reduction ability of the combination of the aqueous medium and zirconium compound is better compared to the fluid drag reduction ability of the aqueous medium alone. In another embodiment, the contact can include admixing the zirconium compound in the aqueous medium at a concentration from 1 to 2000 ppm by weight of the aqueous medium or, in an embodiment, at a concentration from 5 to 500 ppm by weight of the aqueous medium.
In an embodiment, the zirconium compound can include an inorganic zirconium compound. In an embodiment, the inorganic zirconium compound can be selected from the group consisting of zirconium nitrate, zirconyl chloride, zirconium phosphate, zirconium potassium chloride, zirconium potassium fluoride, zirconium potassium sulfate, zirconium pyrophosphate, zirconium sulfate, zirconium tetrachloride, zirconium tetrafluoride, zirconium tetrabromide, zirconium tetraiodide, zirconyl carbonate, zirconyl hydroxynitrate, zirconyl sulfate, and the like, and also including any hydrates thereof and combinations thereof. In another embodiment, the mixing can be within 0 to 120 hours of the contacting. In another embodiment, the aqueous medium can be free of detectable sulfide.
In an embodiment, the zirconium compound can include an organo-zirconium compound. In an embodiment, the organo-zirconium compound can be selected from the group consisting of zirconium acetate, zirconyl acetate, zirconium acetylacetonate, zirconium glycolate, zirconium lactate, zirconium naphthenate, sodium zirconium lactate, triethanolamine zirconium, zirconium propionate, and the like, and also including any hydrates thereof and combinations thereof. In another embodiment, the mixing can be within 0 to 72 hours of the contacting. In another embodiment, the aqueous medium can include detectable sulfide.
In an embodiment, the denaturant (the zirconium compound) can further comprise a bactericide. In another embodiment, the denaturant can include both a bactericide and a zirconium compound. In this embodiment, the mixing can be within 0 to 120 hours of the contacting. In an embodiment, the denaturant can include an inorganic zirconium compound in combination with an organo-zirconium compound, and in another embodiment, a bactericide as well. In these embodiments, the mixing can be within 0 to 120 hours of the contacting.
The method can further comprise the step of: introducing proppant in to the well; whereby the combination of the aqueous medium and zirconium compound allows better transport capability of the proppant in to the formation compared to the aqueous medium alone.
The method can further comprise the step of: energizing the combination of the aqueous medium and the zirconium compound with a gas. The gas can be carbon dioxide, nitrogen, air, or combined.
Another embodiment of the invention provides a method of treating a subterranean formation in a well. The method comprises: providing an aqueous medium comprised at least in part of oilfield produced water; contacting the aqueous medium with a zirconium compound and with a friction-reducing additive; whereby the fluid viscosity and/or fluid drag reduction ability of the combination of the aqueous medium, zirconium compound and friction-reducing additive is improved compared to the aqueous medium and friction-reducing additive alone; introducing the combination in to the well; and allowing the combination to contact the formation. The fluid viscosity of the combination of the aqueous medium, zirconium compound and friction-reducing additive is increased compared to the aqueous medium and friction-reducing additive alone. The fluid drag reduction ability of the combination of the aqueous medium, zirconium compound and friction-reducing additive is better compared to the fluid drag reduction ability of the aqueous medium and friction-reducing additive alone.
In an embodiment, the friction-reducing additive is an anionic, cationic, or nonionic friction-reducing additive, including acrylamide polymers and copolymers. In another embodiment, the friction-reducing additive is polysaccharide including guar and derivatized guar.
The method can further comprise the step of: introducing proppant in to the well; whereby the combination of the aqueous medium, the zirconium compound and friction-reducing additive allows better transport capability of the proppant in to the formation compared to the aqueous medium and friction-reducing additive alone.
The method can further comprise the step of: energizing the combination of the aqueous medium, the zirconium compound and friction reducing additive with a gas. The gas can be carbon dioxide, nitrogen, air, or combined.
Still another embodiment of the invention provides a method of treating a subterranean formation in a well. The method comprises: providing an aqueous medium comprised at least in part of oilfield produced water; contacting the aqueous medium with a zirconium compound and with a gelling additive to form a viscosified fluid; whereby the fluid viscosity and/or fluid drag reduction ability of the viscosified fluid made of combination of the aqueous medium, zirconium compound and gelling additive is improved compared to the aqueous medium and gelling additive alone; introducing the combination in to the well; and allowing the combination to contact the formation. The fluid viscosity of the combination of the aqueous medium, zirconium compound and gelling additive is increased compared to the aqueous medium and gelling additive alone. The fluid drag reduction ability of the combination of the aqueous medium, zirconium compound and gelling additive is better compared to the fluid drag reduction ability of the aqueous medium and gelling additive alone.
In an embodiment, the gelling additive can include a viscoelastic surfactant system. In an embodiment, the gelling additive can include a polysaccharide, which in another embodiment, can be crosslinked. Another embodiment can include injecting the viscosified fluid into a subterranean formation adjacent a well bore. A further embodiment can include breaking the injected fluid and producing fluid from the formation through the well bore. In an embodiment, the viscosified fluid can further include proppant and the injection can form a conductive fracture in the formation held open by the proppant.
The method can further comprise the step of: introducing proppant in to the well; whereby the combination of the aqueous medium, the zirconium compound and gelling additive allows better transport capability of the proppant in to the formation compared to the aqueous medium and gelling additive alone.
The method can further comprise the step of: energizing the combination of the aqueous medium, the zirconium compound and gelling additive with a gas. The gas can be carbon dioxide, nitrogen, air, or combined.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows viscosity profiles at 37.8 deg C. for guar gum in de-ionized water, guar gum in “as is” (untreated) produced water, guar gum in produced water treated with glutaraldehyde, and guar gum in produced water treated with zirconyl chloride, respectively.
FIG. 2 shows viscosity profiles at 65.6 deg C. for guar gum in de-ionized water, guar gum in “as is” produced water, guar gum in produced water treated with glutaraldehyde, and guar gum in produced water treated with zirconyl chloride, respectively.
FIG. 3 shows viscosity profiles at 37.8 deg C. for guar gum and potassium chloride in de-ionized water, and guar gum, potassium chloride, and zirconyl chloride in de-ionized water, respectively.
FIG. 4 shows viscosity profiles at 37.8 deg C. for anionic polyacrylamide in de-ionized water, and for anionic polyacrylamide and zirconyl chloride in de-ionized water, respectively.
FIG. 5 shows a percent drag reduction (% DR) as a function of flow rate (kg/min) at about 20 deg C. for guar gum in tap water, guar gum in “as is” produced water, guar gum in produced water treated with glutaraldehyde, and guar gum in produced water treated with zirconyl chloride, respectively.
FIG. 6 shows viscosity profiles at 88 deg C. of titanate-crosslinked fluids prepared with “as is” (untreated) produced water and produced water treated with zirconyl chloride, respectively.
DETAILED DESCRIPTION
At the outset, it should be noted that in the development of any actual embodiments, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system- and business-related constraints, which can vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
The description and examples are presented solely for the purpose of illustrating the preferred embodiments of the invention and should not be construed as a limitation to the scope and applicability of the invention. While the compositions of the present invention are described herein as comprising certain materials, it should be understood that the composition could optionally comprise two or more chemically different materials. In addition, the composition can also comprise some components other than the ones already cited. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possession of the entire range and all points within the range.
“Oilfield produced water” or simply “produced water” includes water that is produced with oil or gas, produced from petroleum-bearing subterranean strata, or otherwise contaminated with hydrocarbons in conjunction directly or indirectly with the production of subterranean fluids. As further representative examples in addition to production water per se there can also be mentioned flowback water, e.g. from a stimulation or workover treatment, reserve pit water, water circulated out of wellbore, and so on, including any combinations thereof.
The term “aqueous media” refers to any liquid system comprising water, optionally including dissolved solutes or dispersed or aggregated undissolved solids. An “aqueous solution” is a portion of water which includes dissolved solids, but which can further include undissolved solids. Reference to zirconium compounds, denaturants or other materials associated with aqueous media shall be construed to encompass any dispersed, dissolved, chelated, hydrated, ionic, and dissociated forms of the zirconium compounds, denaturants or other materials as they may exist in the aqueous media. For example, zirconium sulfate may form various hydrates and/or partially dissociate into ions in water, and the recitation of the term “zirconium sulfate” in the specification and claims is intended to encompass zirconium sulfate per se as well as any or all of the hydrates, ions, chelates, solutes or various other forms of zirconium sulfate.
Zirconium and hafnium are quite difficult to separate during the refining process due to their similar chemical properties. It is reasonable to speculate that there could be certain amount of hafnium in the zirconium compounds. A “zirconium compound” as used herein refers to the compound of zirconium where the zirconium atoms may be replaced with hafnium atoms to an extent of from 0% to 100%.
An “organic compound” as used herein refers to compounds of, containing or relating to carbon, and especially carbon compounds that are or are potentially active in biological systems.
The presence or absence of detectible sulfides in an aqueous medium such as oilfield produced water can be determined directly by smell or chemical analysis. Many people can smell hydrogen sulfide at concentrations in air at about 0.0047 ppm by volume. The sulfides can originate from the subsurface strata from which the water is produced, or from the action of exogenous sulfate-reducing bacteria if there is sulfate present in the produced water.
The water is pretreated in one embodiment by contact with a zirconium compound having the function to denature or otherwise disable the enzymes and/or bacteria. In one embodiment, the zirconium is used in a form that can be at least slightly soluble in the aqueous medium, and in another embodiment is in a form that is soluble in water. In one embodiment, the water is treated by contact with the zirconium in a solid form, e.g., in a heterogeneous system. In another embodiment, the zirconium is soluble or slightly soluble at the conditions of contact, e.g., temperature, pH, ionic strength, presence of chelates, etc., to result in a homogenous treatment system.
In preferred but not exclusive embodiments, the zirconium can be an inorganic zirconium compound, an organic zirconium compound, or can include both inorganic zirconium and organo-zirconium. In an embodiment, the zirconium compound can be selected from the group consisting of zirconium nitrate, zirconyl chloride, zirconium phosphate, zirconium potassium chloride, zirconium potassium fluoride, zirconium potassium sulfate, zirconium pyrophosphate, zirconium sulfate, zirconium tetrachloride, zirconium tetrafluoride, zirconium tetrabromide, zirconium tetraiodide, zirconyl carbonate, zirconyl hydroxynitrate, zirconyl sulfate, zirconia hydrate, zirconium carbide, zirconium nitride, zirconium hydroxide, zirconium orthosilicate, zirconium tetrahydroxide, zirconium tungstate, and the like, and also including any hydrates thereof and combinations thereof. Inorganic zirconium compounds can be beneficial where quick-acting, long-duration treatment is desired.
In an embodiment, the organo-zirconium compound can be selected from the group consisting of zirconium acetate, zirconyl acetate, zirconium acetylacetonate, zirconium glycolate, zirconium lactate, zirconium naphthenate, triethanolamine zirconium, zirconocene dihalides, and the like, and also including any hydrates thereof and combinations thereof. Sodium or potassium zirconium alpha hydroxyl carboxylates such as lactates, citrates, tartrates, glycolates, maleates, saccharates, gluconates, glycerates, mandelates and the like can also be mentioned. Organo-zirconium compounds can be beneficial where the presence or possible presence of sulfide or similar anions may otherwise precipitate or inactivate inorganic zirconium compounds.
The organo-zirconium compound may also be zirconium complexed with alpha or beta amino acids, phosphonic acids, salts and derivatives thereof. The ratio of metal to ligand in the complex can range from 1:1 to 1:4. Preferably the ratio metal to ligand can range from 1:1 to 1:6. More preferably the ratio metal to ligand can range from 1:1 to 1:4. Those complexes can be used to crosslink the hydratable polymers. The following acids and their salts were found to be useful ligands: alanine, arginine, asparagines, aspartic acid, cysteine, glutamic acid, glutamine, glycine, histidine, isoleucine, leucine, lysine, methyonine, phenyl alanine, praline, serine, threonine, tryptophan, tyrosine, valine, carnitine, ornithine, taurine, citrulline, glutathione, hydroxyproline. The following acids and their salts were found to be suitable ligands: DL-Glutamic acid, L-Glutamic acid, D-Glutamic acid, DL-Aspartic acid, D-Aspartic acid, L-Aspartic acid, beta-alanine, DL-alanine, D-alanine, L-alanine, Phosphonoacetic acid. Zirconium IV was found to be preferred metal to form complexes with various alpha or beta amino acids, phosphonic acids and derivatives thereof.
In one embodiment, the organo-zirconium compound comprises zirconium complexed with a beta-diketone compound and an alkoxy group having a branched alkyl group according to the following formula (1):
wherein R is a branched alkyl group having 4 or 5 carbons; and L1, L2, and L3, are the same or different from each other and are each a beta-diketone compound.
The zirconium compound in an embodiment can also include further a bactericidally effective amount of a bactericide. The bactericide in one embodiment is an organic bactericide that inhibits the growth of bacteria in the aqueous medium, or at least suppresses the expression of enzymes, but may not be effective to denature the enzymes. The bactericide can be beneficial in an embodiment where the metal compound is not effective to kill or prevent the growth of bacteria in the amount employed, or where the metal compound and the bactericide have a synergistic effect in either or both the denaturing of enzymes or the destruction of bacteria. Representative examples of bactericides include glutaraldehyde, tetrakishydroxymethyl phosphonium sulfate, and the like.
The type and amount of zirconium compound used to treat the produced water depends on several factors, such as, but not exclusively limited to, the nature and extent of enzyme/bacteria in the water, the presence of species that might adversely react with the zirconium, and the type of system in which the treated water will be used. For example, zirconium compounds might, if employed in excessive amounts, have a possibly adverse effect on polymer gelation, e.g., a resulting fluid of many small gel domains with low viscosity. If the zirconium has not been allowed to sufficiently interact with the bacteria and/or enzyme, it can interact with, for example, borate crosslinkers. In one embodiment, a zirconium compound is used in an amount from 1 ppm or less up to 2000 ppm or more, by weight of the zirconium compound in the aqueous medium. In an embodiment, the metal compound is zirconium compound if sulfide is or may be present in the system. For example, in embodiments where sulfate-reducing bacteria may be or may become present, the organo-zirconium compound can be employed if the sulfate concentration in the water is more than 200, 400, 800 or 1600 ppm by weight. On the other hand, in another embodiment inorganic zirconium compounds can be used as the sole denaturant where sulfide might be present or formed only in amounts insufficient to inactivate them, for example where sulfate reducing bacteria may be or become present in embodiments where the sulfate concentration is less than 1600, 800, 400 or 200 ppm by weight.
In an embodiment, the mixing of the viscosification system with the treated water can occur after a period of time sufficient to allow the denaturant to inactivate the enzymes and/or bacteria, and before the treatment begins to have diminished effectiveness. If the mixing step occurs too soon, the enzymes may still be sufficiently active to adversely affect the viscosity of the fluid, or the raw denaturant may adversely affect viscosity unless it is allowed to equilibrate or be fully “consumed” by the enzymes and/or bacteria. In embodiments, 0, 0.5, 1 or 2 hours can be a suitable minimum period for the denaturant to effectively treat the produced water, whereas 1, 2, 3, 4 or 5 days can be a suitable maximum period before the enzymatic and/or bacteriological system may be able to use up or overwhelm the denaturant and re-establish to interfere with the viscosification system. In an embodiment employing an inorganic zirconium compound the treatment window can be as little as 0 hour to 3 days or more. In an embodiment employing an organic zirconium compound the treatment window can be as little as 0 hour to 5 days or more. In embodiments employing a combination of an inorganic zirconium compound and an organic zirconium compound, or a combination of an inorganic zirconium compound, an organic zirconium compound, and a bactericide, the treatment window can be as little as 0 hour to 5 days or more.
The treated water can be reused in a well treatment fluid in various conventional applications without deleterious consequences or fluid failure. Embodiments include hydraulic fracturing fluids, slickwater, gravel packs, water conformance control, acid fracturing, waterflood, drilling fluids, wellbore cleanout fluids, fluid loss control fluids, kill fluids, spacers, flushes, pushers, and carriers for materials such as scale, paraffin, and asphaltene inhibitors, and the like. Viscosification systems can include polymers, including crosslinked or un-crosslinked polymers, friction-reduction additive, viscoelastic surfactant systems (VES), fiber viscosification systems, mixed fiber-polymer and fiber-VES systems, slickwater (low viscosity) systems, and so on.
The present invention is discussed herein with specific reference to the embodiment of hydraulic fracturing, but it is also suitable for gravel packing, or for fracturing and gravel packing in one operation (called, for example frac and pack, frac-n-pack, frac-pack, StimPac treatments, or other names), which are also used extensively to stimulate the production of hydrocarbons, water and other fluids from subterranean formations. These operations involve pumping a slurry of “proppant” (natural or synthetic materials that prop open a fracture after it is created) in hydraulic fracturing or “gravel” in gravel packing. In low permeability formations, the goal of hydraulic fracturing is generally to form long, high surface area fractures that greatly increase the magnitude of the pathway of fluid flow from the formation to the wellbore.
In high permeability formations, the goal of a hydraulic fracturing treatment is typically to create a short, wide, highly conductive fracture, in order to bypass near-wellbore damage done in drilling and/or completion, to ensure good fluid communication between the rock and the wellbore and also to increase the surface area available for fluids to flow into the wellbore.
Gravel is also a natural or synthetic material, which may be identical to, or different from, proppant. Gravel packing is used for “sand” control. Sand is the name given to any particulate material from the formation, such as clays, that could be carried into production equipment. Gravel packing is a sand-control method used to prevent production of formation sand, in which, for example a steel screen is placed in the wellbore and the surrounding annulus is packed with prepared gravel of a specific size designed to prevent the passage of formation sand that could foul subterranean or surface equipment and reduce flows. The primary objective of gravel packing is to stabilize the formation while causing minimal impairment to well productivity. Sometimes gravel packing is done without a screen. High permeability formations are frequently poorly consolidated, so that sand control is needed; they may also be damaged, so that fracturing is also needed. Therefore, hydraulic fracturing treatments in which short, wide fractures are wanted are often combined in a single continuous (“frac and pack”) operation with gravel packing. For simplicity, in the following we may refer to any one of hydraulic fracturing, fracturing and gravel packing in one operation (frac and pack), or gravel packing, and mean them all.
The treatment fluid based on the reused water according to an embodiment of the present invention is beneficial in embodiments where the viscosity of the viscosified treatment fluid is at least 3, 50, 100, 150, or 200 cP at 25° C., and especially where the treatment fluid is maintained at elevated temperatures without viscosity failure for 30, 60, 90 or 180 minutes or more. Embodiments of polymer viscosifiers include, for example, polysaccharides such as substituted galactomannans, such as guar gums, high-molecular weight polysaccharides composed of mannose and galactose sugars, or guar derivatives such as hydroxypropyl guar (HPG), carboxymethylhydroxypropyl guar (CMHPG) and carboxymethyl guar (CMG), hydrophobically modified guars, guar-containing compounds, and synthetic polymers. Crosslinking agents based on boron, titanium, zirconium or aluminum complexes are typically used to increase the effective molecular weight of the polymer and make them better suited for use in high-temperature wells.
Other embodiments of effective water-soluble polymers (provided that specific examples chosen are compatible with the denaturants of the invention) include polyvinyl polymers, polymethacrylamides, cellulose ethers, lignosulfonates, and ammonium, alkali metal, and alkaline earth salts thereof. More specific examples of other typical water soluble polymers are acrylic acid-acrylamide copolymers, acrylic acid-methacrylamide copolymers, polyacrylamides, partially hydrolyzed polyacrylamides, partially hydrolyzed polymethacrylamides, polyvinyl alcohol, polyvinyl acetate, polyalkyleneoxides, carboxycelluloses, carboxyalkylhydroxyethyl celluloses, hydroxyethylcellulose, other galactomannans, heteropolysaccharides obtained by the fermentation of starch-derived sugar (e.g., xanthan gum), and ammonium and alkali metal salts thereof.
Cellulose derivatives are also used in an embodiment, such as hydroxyethylcellulose (HEC) or hydroxypropylcellulose (HPC), carboxymethylhydroxyethylcellulose (CMHEC) and carboxymethycellulose (CMC), with or without crosslinkers. Xanthan, diutan, and scleroglucan, three biopolymers, have been shown to have excellent proppant-suspension ability even though they are more expensive than guar derivatives and therefore have been used less frequently unless they can be used at lower concentrations.
Friction reducing polymers can be used in another embodiment for slickwater treatments. More particularly, the friction reducing polymers are anionic friction reducing polymers. Suitable anionic friction reducing polymers should reduce energy losses due to turbulence within the treatment fluid. Those of ordinary skill in the art will appreciate that the anionic friction reducing polymer(s) included in the treatment fluid should have a molecular weight sufficient to provide a desired level of friction reduction. In general, polymers having higher molecular weights may be needed to provide a desirable level of friction reduction. By way of example, the average molecular weight of suitable anionic friction reducing polymers may be at least about 2,500,000, as determined using intrinsic viscosities. In certain exemplary embodiments, the average molecular weight of suitable anionic friction reducing polymers may be in the range of from about 7,500,000 to about 20,000,000. Those of ordinary skill in the art will recognize that anionic friction reducing polymers having molecular weights outside the listed range may still provide some degree of friction reduction.
A wide variety of anionic friction reducing polymers may be suitable for use with the present technique. By way of example, suitable anionic friction reducing polymers may comprise any of a variety of monomeric units, including acrylamide, acrylic acid, 2-acrylamido-2-methylpropane sulfonic acid, N,N-dimethylacrylamide, vinyl sulfonic acid, N-vinyl acetamide, N-vinyl formamide, itaconic acid, methacrylic acid, acrylic acid esters, methacrylic acid esters and combinations thereof.
One example of a suitable anionic friction reducing polymer is a polymer comprising acrylamide and acrylic acid. The acrylamide and acrylic acid may be present in the polymer in any suitable concentration. An example of a suitable polymer may comprise acrylamide in an amount in the range of from about 5% to about 95% and acrylic acid in an amount in the range of from about 5% to about 95%. Another example of a suitable polymer may comprise acrylamide in an amount in the range of from about 60% to about 90% by weight and acrylic acid in an amount in the range of from about 10% to about 40% by weight. Another example of a suitable polymer may comprise acrylamide in an amount in the range of from about 80% to about 90% by weight and acrylic acid in an amount in the range of from about 10% to about 20% by weight. Yet another example of a suitable polymer may comprise acrylamide in an amount of about 85% by weight and acrylic acid in an amount of about 15% by weight. As previously mentioned, one or more additional monomers may be included in the polymer comprising acrylamide and acrylic acid. By way of example, the additional monomer(s) may be present in the anionic friction reducing polymers in an amount up to about 20% by weight of the polymer.
Friction reducing polymers can also include guar, and derivativized guar, such as hydroxylpropyl guar (HPG), carboxymethlyhydroxypropyl guar (CMHPG), and others, cellulose polymers including hydroxyethylcellulose (HEC), carboxymethylhydroxyethyl cellulose (CMHEC), starch and starch derivatives, biopolymers such as xanthan and derivatives of biopolymers, and surfactant based systems such as viscoelastic surfactant fluids.
Linear (not cross-linked) polymer systems can be used in another embodiment, but generally require more polymer for the same level of viscosification.
All crosslinked polymer systems may be used, including for example delayed, optimized for high temperature, optimized for use with sea water, buffered at various pH's, and optimized for low temperature. Any crosslinker may be used, for example boron, titanium, and zirconium. Suitable boron crosslinked polymers systems include by non-limiting example, guar and substituted guars crosslinked with boric acid, sodium tetraborate, and encapsulated borates; borate crosslinkers may be used with buffers and pH control agents such as sodium hydroxide, magnesium oxide, sodium sesquicarbonate, and sodium carbonate, amines (such as hydroxyalkyl amines, anilines, pyridines, pyrimidines, quinolines, and pyrrolidines, and carboxylates such as acetates and oxalates) and with delay agents such as sorbitol, aldehydes, and sodium gluconate. Suitable zirconium crosslinked polymer systems include by non-limiting example, those crosslinked by zirconium lactates (for example sodium zirconium lactate), triethanolamines, 2,2′-iminodiethanol, and with mixtures of these ligands, including when adjusted with bicarbonate. Suitable titanates include by non-limiting example, lactates and triethanolamines, and mixtures, for example delayed with hydroxyacetic acid. Any other chemical additives can be used or included provided that they are tested for compatibility with the fibers and fiber degradation products of the invention (neither the fibers or their degradation products or the chemicals in the fluids interfere with the efficacy of one another or with fluids that might be encountered during the job, like connate water or flushes). For example, some of the standard crosslinkers or polymers as concentrates usually contain materials such as isopropanol, n-propanol, methanol or diesel oil.
As mentioned, viscoelastic surfactant fluid systems (such as cationic, amphoteric, anionic, nonionic, mixed, and zwitterionic viscoelastic surfactant fluid systems, especially betaine zwitterionic viscoelastic surfactant fluid systems or amidoamine oxide surfactant fluid systems) may be also used provided that they are tested for compatibility with the denaturant and denaturant degradation products of the invention. Non-limiting examples include those described in U.S. Pat. Nos. 5,551,516; 5,964,295; 5,979,555; 5,979,557; 6,140,277; 6,258,859 and 6,509,301, all hereby incorporated by reference. The solid acid/pH control agent combination of this invention has been found to be particularly useful when used with several types of zwitterionic surfactants. In general, suitable zwitterionic surfactants have the formula:
RCONH—(CH 2 ) a (CH 2 CH 2 O) m (CH 2 ) b —N + (CH 3 ) 2 —(CH 2 ) a′ (CH 2 CH 2 O) m′ (CH 2 ) b′ COO −
in which R is an alkyl group that contains from about 17 to about 23 carbon atoms which may be branched or straight chained and which may be saturated or unsaturated; a, b, a′, and b′ are each from 0 to 10 and m and m′ are each from 0 to 13; a and b are each 1 or 2 if m is not 0 and (a+b) is from 2 to about 10 if m is 0; a′ and b′ are each 1 or 2 when m′ is not 0 and (a′+b′) is from 1 to about 5 if m is 0; (m+m′) is from 0 to about 14; and CH 2 CH 2 O may also be oriented as OCH 2 CH 2 . Preferred surfactants are betaines.
Two examples of commercially available betaine concentrates are, respectively, BET-O-30 and BET-E-40. The VES surfactant in BET-O-30 is oleylamidopropyl betaine. It is designated BET-O-30 because as obtained from the supplier (Rhodia, Inc. Cranbury, N.J., U.S.A.) it is called Mirataine BET-O-30; it contains an oleyl acid amide group (including a C 17 H 33 alkene tail group) and is supplied as about 30% active surfactant; the remainder is substantially water, sodium chloride, glycerol and propane-1,2-diol. An analogous suitable material, BET-E-40, was used in the experiments described above; one chemical name is erucylamidopropyl betaine. BET surfactants, and others that are suitable, are described in U.S. Pat. No. 6,258,859. Certain co-surfactants may be useful in extending the brine tolerance, to increase the gel strength, and to reduce the shear sensitivity of VES fluids, in particular for BET-O-type surfactants. An example given in U.S. Pat. No. 6,258,859 is sodium dodecylbenzene sulfonate (SDBS). VES's may be used with or without this type of co-surfactant, for example those having a SDBS-like structure having a saturated or unsaturated, branched or straight-chained C 6 to C 16 chain; further examples of this type of co-surfactant are those having a saturated or unsaturated, branched or straight-chained C 8 to C 16 chain. Other suitable examples of this type of co-surfactant, especially for BET-O-30, are certain chelating agents such as trisodium hydroxyethylethylenediamine triacetate.
In another embodiment, suitable fibers can assist in transporting, suspending and placing proppant in hydraulic fracturing and gravel packing and can optionally also degrade to minimize or eliminate the presence of fibers in the proppant pack without releasing degradation products that either a) react with certain multivalent ions present in the fracture water or gravel packing carrier fluid, or formation water to produce materials that hinder fluid flow, or b) decrease the ability of otherwise suitable metal-crosslinked polymers to viscosify the carrier fluid. Systems in which fibers and a fluid viscosified with a suitable metal-crosslinked polymer system or with a VES system are known to the skilled artisan to slurry and transport proppant as a “fiber assisted transport” system, “fiber/polymeric viscosifier” system or an “FPV” system, or “fiber/VES” system. Most commonly the fiber is mixed with a slurry of proppant in crosslinked polymer fluid in the same way and with the same equipment as is used for fibers used for sand control and for prevention of proppant flowback, for example, but not limited to, the method described in U.S. Pat. No. 5,667,012. In fracturing, for proppant transport, suspension, and placement, the fibers are normally used with proppant or gravel laden fluids, not normally with pads, flushes or the like.
Any conventional proppant (gravel) can be used. Such proppants (gravels) can be natural or synthetic (including but not limited to glass beads, ceramic beads, sand, and bauxite), coated, or contain chemicals; more than one can be used sequentially or in mixtures of different sizes or different materials. The proppant may be resin coated, preferably pre-cured resin coated, provided that the resin and any other chemicals that might be released from the coating or come in contact with the other chemicals of the Invention are compatible with them. Proppants and gravels in the same or different wells or treatments can be the same material and/or the same size as one another and the term “proppant” is intended to include gravel in this discussion. In general the proppant used will have an average particle size of from about 0.15 mm to about 2.39 mm (about 8 to about 100 U.S. mesh), more particularly, but not limited to 0.25 to 0.43 mm (40/60 mesh), 0.43 to 0.84 mm (20/40 mesh), 0.84 to 1.19 mm (16/20), 0.84 to 1.68 mm (12/20 mesh) and 0.84 to 2.39 mm (8/20 mesh) sized materials. Normally the proppant will be present in the slurry in a concentration of from about 0.12 to about 0.96 kg/L, preferably from about 0.12 to about 0.72 kg/L, preferably from about 0.12 to about 0.54 kg/L. The viscosified proppant slurry can be designed for either homogeneous or heterogeneous proppant placement in the fracture, as known in the art.
Also optionally, the fracturing fluid can contain materials designed to limit proppant flowback after the fracturing operation is complete by forming a porous pack in the fracture zone. Such materials can be any known in the art, such as fibers, such as glass fibers, available from Schlumberger under the trade name PropNET™ (for example see U.S. Pat. No. 5,501,275). Exemplary proppant flowback inhibitors include fibers or platelets of novoloid or novoloid-type polymers (U.S. Pat. No. 5,782,300). Thus the fracturing system may contain different or mixed fiber types, for example non-degradable or degradable only at a higher temperature, present primarily to aid in preventing proppant flowback. The system may also contain another fiber, such as a polyethylene terephthalate fiber, which is also optimized for assisting in transporting, suspending and placing proppant, but has a higher degradation temperature and would precipitate calcium and magnesium without preventive measures being taken. As has been mentioned, appropriate preventive measures may be taken with other fibers, such as, but not limited to, pumping a pre-pad and/or pumping an acid or a chelating dissolver, adsorbing or absorbing an appropriate chelating agent onto or into the fiber, or incorporating in the fluid precipitation inhibitors or metal scavenger ions that prevent precipitation.
Any additives normally used in such well treatment fluids can be included, again provided that they are compatible with the other components and the desired results of the treatment. Such additives can include, but are not limited to breakers, anti-oxidants, crosslinkers, corrosion inhibitors, delay agents, biocides, buffers, fluid loss additives, pH control agents, solid acids, solid acid precursors, etc. The wellbores treated can be vertical, deviated or horizontal. They can be completed with casing and perforations or open hole.
The pad and fracturing fluid can both be prepared using the zirconium treated produced water according to an embodiment of the invention. A pad and fracturing fluid are viscosified because increased viscosity results in formation of a wider fracture, thus a larger flowpath, and a minimal viscosity is required to transport adequate amounts of proppant; the actual viscosity required depends primarily upon the fluid flow rate and the density of the proppant. In a typical fracturing process, such as hydraulic fracturing with aqueous fluids, the fracture is initiated by first pumping a high viscosity aqueous fluid with good to moderate leak-off properties, and typically no proppant, into the formation. This pad is usually followed by a carrier fluid of similar viscosity carrying an initially low concentration and then a gradually increasing concentration of proppant into the extended fractures. The pad initiates and propagates the fracture but does not need to carry proppant. All the fluids tend to “leak-off” into the formation from the fracture being created. Commonly, by the end of the job the entire volume of the pad will have leaked off into the formation. This leak-off is determined and controlled by the properties of the fluid (and additives it may contain) and the properties of the rock. A certain amount of leak-off greater than the minimal possible may be desirable, for example a) if the intention is to place some fluid in the rock to change the rock properties or to flow back into the fracture during closure, or b) if the intention is deliberately to cause what is called a “tip screen-out”, or “TSO”, a condition in which the proppant forms a bridge at the end of the fracture, stopping the lengthening of the fracture and resulting in a subsequent increase in the fracture width. On the other hand, excessive leak-off is undesirable because it may waste valuable fluid and result in reduced efficiency of the job. Proper leak-off control is therefore critical to job success.
Fluid technologies incorporating a gaseous component or a supercritical fluid to form a foam or energized fluid are commonly used in the stimulation of oil and gas wells. For example, some viscoelastic fluids used as fracturing fluids contain a gas such as air, nitrogen or carbon dioxide to provide an energized fluid or foam. Such fluids are commonly formed by injecting an aqueous solution (“base fluid”) concomitantly with a gas, most commonly nitrogen, carbon dioxide or their mixtures, into the formation. Among other benefits, the dispersion of the gas into the base fluid in the form of bubbles or droplets increases the viscosity of such fluid and impacts positively its performance, particularly its ability to effectively induce hydraulic fracturing of the formation, and also its capacity to carry solids (“proppants”) that are placed within the fractures to create pathways through which oil or gas can be further produced. The presence of the gas also enhances the flowback of the base fluid from the interstices of the formation and of the proppant pack into the wellbore, due to the expansion of such gas once the pressure is reduced at the wellhead at the end of the fracturing operation. Other common uses of foams or energized fluids include wellbore cleanout, gravel packing, acid diversion, fluid loss control, and the like. U.S. Pat. No. 7,494,957 and U.S. Application Publication Nos. US2006/0166837 and US2006/0178276, each of which is incorporated by reference in its entirety, describe that by combining a heteropolysaccharide, concomitantly with a gas, an electrolyte, and a surfactant, an aqueous energized fluid is provided with exceptional rheology properties, particle suspension and particle transport capabilities, as well as gas phase stability, especially at elevated temperatures. As such, aqueous energized fluids may include an aqueous medium, a gas component, a heteropolysaccharide, an electrolyte, and a surfactant. The aqueous medium is usually water or brine. The fluids may also include an organoamino compound.
The viscosity of the fluid in which the gas is dispersed affects the resulting viscosity and stability of the foam. In general, foams are more stable and viscous as the viscosity of the base fluid increases. For this reason, high molecular weight polymers are commonly added to increase the viscosity of the base fluid. Commonly used polymers for fracturing applications are polysaccharides such as cellulose, derivatized cellulose, guar gum, derivatized guar gum, xanthan gum, or synthetic polymers such as polyacrylamides and polyacrylamide copolymers.
Foamed and energized fracturing fluids invariably contain “foamers”, most commonly surfactants or blends of surfactants that facilitate the dispersion of the gas into the base fluid in the form of small bubbles or droplets, and confer stability to the dispersion by retarding the coalescence or recombination of such bubbles or droplets. Foamed and energized fracturing fluids are generally described by their foam quality, i.e. the ratio of gas volume to the foam volume. If the foam quality is between 52% and 95%, the fluid is conventionally called foam, and below 52%, an energized fluid. However, as used herein the term “energized fluid” is defined as any stable mixture of gas and liquid, notwithstanding the foam quality value.
EXAMPLES
A series of experiments were conducted to compare effectiveness of well treatment fluids comprising produced water prepared using treated or “as is” samples.
To illustrate some embodiments according to the invention, analysis was conducted on produced water from Texas oilfields. The water usually had high salt content (about 2-5% or more NaCl) and high hardness (>120 mg/L Ca and Mg ions combined). The water also may have had oil contamination, suspensions, precipitations, and/or hydrogen sulfide smell. The ion species and respective concentrations for the produced water samples are listed in Table 1.
TABLE 1
Ion Concentrations in Produced Water Samples (mg/L).
Produced
water
sample
Na
K
Ca
Mg
Fe
Al
Si
Cl −
CO 3 2−
HCO 3 −
SO 4 2−
PW1
9270
175
1490
152
0
0
4
17371
0
192
<800
PW2
11100
151
1160
445
0
0
25
20738
0
168
<200
Viscosity was measured for three fluids prepared with the produced water PW1: (1) 0.48% guar gum in the “as is” (untreated) produced water, (2) 0.48% guar gum in the produced water treated with 0.005% glutaraldehyde, and (3) 0.48% guar gum in the produced water treated with 0.0072% zirconyl chloride. A control sample with 0.48% guar gum in de-ionized (DI) water was also made. The treating time of glutaraldehyde was about 0 to 5 minutes, and the treating time of zirconyl chloride was about 0 to 10 minutes or more. Glutaraldehyde or zirconyl chloride was added at the same time as or prior to the addition of guar gum. After the guar hydration, the fluids were loaded in a Fann50-type viscometer to measure the viscosity evolution. The viscosity change at room temperature (about 20 deg C.) was very slow, but became more visible at 37.8 deg C. (100 deg F.) or over. FIG. 1 shows the viscosity profiles at 37.8 deg C. for the 4 fluids studied. The control sample prepared with de-ionized water showed a nearly straight viscosity-time curve (after fluid temperature reaching 37.8 deg C.). Both fluids, i.e., the guar gum in the “as is” produced water and the guar gum in the glutaraldehyde-treated produced water, showed declining viscosity curves below the viscosity of the control sample (in de-ionized water). The fluid based upon the zirconyl chloride-treated produced water showed a higher viscosity than the control even after 3 hours. At 1 hour, the viscosity of the fluid based upon the zirconyl chloride-treated produced water was over 70% larger than the viscosity of the fluid based upon the “as is” produced water (or the guar gum in the glutaraldehyde-treated produced water).
FIG. 2 shows the viscosity profiles at 65.6 deg C. (150 deg F.) for the 4 same fluids studied above in FIG. 1 . At this higher temperature of 65.6 deg C., the declining viscosity of the fluid based upon the “as is” (untreated) or glutaraldehyde-treated produced water PW1 was more prominent compared with the control prepared with de-ionized (DI) water. The fluid based upon the zirconyl chloride-treated produced water still performed much better than the control. At 1 hour, the viscosity of the fluid based upon the zirconyl chloride-treated produced water was over 100% larger than the viscosity of the fluid based upon the “as is” produced water (or the guar gum in the glutaraldehyde-treated produced water). One possibility is that the role played by the zirconyl chloride is to denature the enzymes produced by the bacteria in the produced water, thus slowing down the damage to guar gum polymer chains by these enzymes. Other zirconium-containing materials act similarly as zirconyl chloride (data not shown). Also, it is observed that, use of the produced water without zirconyl chloride results in significantly lower fluid viscosity as compared with fluid based upon de-ionized water.
To further better define function of zirconyl chloride, two fluids were prepared: (1) 0.48% guar gum and 2% KCl in de-ionized water, and (2) 0.48% guar gum, 2% KCl, and 0.0072% zirconyl chloride in de-ionized water. FIG. 3 shows the viscosity profiles at 37.8 deg C. for these two fluids. At 1 hour, the viscosity of the guar gum solution with the zirconyl chloride was about 9% higher than the viscosity of the fluid based up water without the zirconyl chloride. The zirconyl chloride might slightly viscosify the fluid, resulting in the 9% increase in viscosity for the guar gum in de-ionized water. Compared with the viscosity difference (over 70% increase) at 1 hour between the guar gum in the zirconyl chloride-treated produced water PW1 and the guar gum in the “as is” (untreated) produced water PW1 (as in FIG. 1 ), this 9% increase in viscosity for the guar in de-ionized water was much less significant. It is, therefore, reasonably likely that the denaturing of the bacteria enzymes by zirconyl chloride was the main reason of viscosity enhancement for the guar in produced water.
FIG. 4 shows the viscosity profiles at 37.8 deg C. for two polyacrylamide fluids (polyacrylamide is also routinely used in slickwater): (1) 0.27% anionic polyacrylamide in de-ionized water, and (2) 0.27% anionic polyacrylamide and 0.0072% zirconyl chloride in de-ionized water. At 1 hour, the viscosity of the solution with the zirconyl chloride was about 9% greater than the viscosity without the zirconyl chloride. As polyacrylamide polymers are generally more resistant to bacteria and bacteria-generated enzymes, the addition of the zirconium compound may still enhance the fluid viscosity if not for protecting the polyacrylamide from the bacteria damage. The additional viscosity may further increase the particle transport capability of the polyacrylamide based fluids.
Friction loop testing of slickwater prepared with treated produced water was carried out at about 20 deg C. A friction loop consisting of a ½″ and a ⅜″ pipe was used for the measurements. The pressure difference (ΔP) across the pipes, the mass flow, and the temperature were recorded. The friction loop was calibrated with (clean) tap water. The % DR (percent drag reduction) is calculated using the following equation:
% DR = Δ Pwater - Δ Pfluid Δ Pwater × 100
Four fluids were tested: (1) 0.12% guar gum in the “as is” (untreated) produced water PW1, (2) 0.12% guar gum in the produced water PW1 treated with 0.005% glutaraldehyde, (3) 0.12% guar gum in the produced water PW1 treated with 0.0072% zirconyl chloride, and (4) 0.12% guar gum in tap water (clean water). The treating time of glutaraldehyde or zirconyl chloride was about 0-10 minutes or more. The hydration time of guar gum was 5 minutes. Right after the guar gum hydration, the fluid was loaded in the friction loop machine. FIG. 5 shows the percent drag reduction (% DR) as a function of the flow rate (kg/min) for the four fluids. The curves mostly overlap with each other, suggesting that the addition of zirconyl chloride did not lower the friction reduction ability of the slickwater. In summary, the examples presented in FIGS. 1 , 2 , and 5 suggest that the slickwater prepared with the zirconyl chloride-treated produced water possesses same friction reduction ability but greatly enhanced fluid viscosity. The enhanced fluid viscosity can be translated into better proppant-carrying ability.
The produced water PW2 was treated with 0.01% zirconyl chloride for about 0-20 minutes or more. The tested fluid contains 0.48% guar gum, 0.16% acetic acid, and 0.16% triethanolamine titanate crosslinker. Other commonly used chemicals in the field, such as biocide, buffering agent, alcohols, high temperature stabilizer, and corrosion inhibitor may also be added. The pH of the fluid thus made was about 4, mimicking the pH of the related fluid energized with CO 2 . The control fluid used the same produced water PW2 but without the zirconyl chloride treatment. The viscosity was tested at 87.8 deg C. (190 deg F.) with a HPHT Fann50-type viscometer, following the API RP 39 schedule, and the results are shown in FIG. 6 . The zirconyl chloride treatment of the produced water significantly enhanced the viscosity and stability of the crosslinked fluid (and the related fluid energized with carbon dioxide or nitrogen or combined) at the working temperature.
The foregoing disclosure and description of the invention is illustrative and explanatory thereof and it can be readily appreciated by those skilled in the art that various changes in the size, shape and materials, as well as in the details of the illustrated construction or combinations of the elements described herein can be made without departing from the spirit of the invention.
|
The invention discloses method of treatment and reuse of oilfield produced water. The method comprises: providing an aqueous medium comprised at least in part of oilfield produced water; contacting the aqueous medium with a zirconium compound; whereby the fluid viscosity and/or fluid drag reduction ability of the combination of the aqueous medium and zirconium compound is improved compared to the aqueous medium alone; introducing the combination in to the well; and allowing the combination to contact the formation. In another embodiment, the aqueous medium is further contacted by a friction-reduction additive. Still in another embodiment, the aqueous medium is further contacted by a gelling additive. Still in another embodiment, the fluid is energized with a gas.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor memory module, and particularly relates to improvements in a refresh control technique for a storage device using a plurality of dynamic semiconductor memories.
2. Description of the Prior Art
Generally, a semiconductor memory module is formed of a semiconductor chip (RAM chip) mounted thereon that includes a plurality of dynamic RAMs (each of which hereinbelow will be referred to as a “DRAM”). More specifically, in a configuration of the semiconductor memory module, signals such as a chip-selecting signal and a refresh command signal are generated and supplied to the individual DRAMs. The chip-selecting signal indicates which one of the DRAMs is selected to operate according to a high-order bit of an address signal supplied from a microprocessor.
The refresh command signal provides refresh timing according to control signals supplied from a microprocessor. The control signals include a chip enable signal CE, a read enable signal RE, a row-address strobe signal RAS, and a column-address strobe signal CAS. Each of the DRAMs has a refresh control function of determining a refresh mode according to the row-address strobe signal RAS and the column-address strobe signal CAS, driving a word line to a selected level and performing a refresh operation.
Ordinarily, a memory cell array in a DRAM chip is divided into a plurality of memory banks, and is configured to drive only a selected part of the memory banks to perform a read/write operation. However, in a refresh operation, all the banks are operated, and the peak current therefore is increased. Thus, a high peak current flows into the DRAM module in the refresh operation, and a Vdd/GND noise (power-supply noise) occurs to cause a malfunction in the module.
FIG. 10 shows a conventional example of an ordinary type of a registered DIMM provided with eight DDR SDRAMs to have a ×8-word-configuration. In the configuration shown in the figure, a register buffer and a PLL circuit for generating a base clock are mounted on the module which is formed of a one-bank configuration.
When an external control signal Ext./S, which is a chip-selecting signal, is input to the module, an internal control signal Int./S is output from the register buffer and is transferred to all the DRAMs. As a result, in response to a command defined by combination of external control signals Ext./RAS, Ext./CAS, and Ext./WE, all the chips SDRAM- 1 to SDRAM- 8 are simultaneously operated according to internal control signals Int./RAS, Int./CAS, and Int./WE.
The circuit configuration of the register buffer mounted on the above-described module is known in the art as shown in FIG. 11 . In the configuration, according to various control signals /RESET, Int.CK, Int./CK, and Vref, input signals Input 0 to 13 are individually delayed via an inverter and a flip-flop circuit (F/F). Thereafter, output signals Output 0 to 13 are generated.
FIG. 12 shows a function table of the output signals in response to H/L levels of the various input signals /RESET, CK, /CK, and Inputs.
FIG. 13 shows operational timings in the conventional configuration shown in FIG. 10 . The operational timings represent timings of operation performed such that a refresh command (Refresh) of /RAS, /CAS, and /WE is input, and thereafter, an activation (Act) command is input. As shown in FIG. 13, at time T 1 , an external refresh command (Ext./RAS, Ext./CAS, and Ext./WE) is received by the register buffer, and at time T 2 after one cycle operation from T 1 , an internal refresh command of Int./RAS, Int./CAS, and Int./WE is simultaneously received by each of the eight DRAMs.
In FIG. 13, a delay time tpd represents a necessary time set by totaling a delay time caused within the register buffer and a wiring delay time caused in the field from the register-buffer output to the SDRAM input. The Act command activates the bank in the DRAM chip. After the external Act command is input at time T 4 , an internal Act command is simultaneously received by the eight SDRAM- 1 to SDRAM- 8 at time T 5 . As shown in the figure, since all the eight DRAMs simultaneously start refresh operations, a great peak current flows to be a problem.
SUMMARY OF THE INVENTION
The present invention is made to solve the above-described problems. Accordingly, an object of the present invention is to provide a semiconductor memory module in which execution timings of a refresh command are differentiated and distributed to inhibit a great peak current from flowing when a plurality of DRAMs simultaneously enter refresh modes. Thus, generation of Vdd/GND noise is inhibited, and stable operation can thereby be implemented.
Another object of the present invention is to provide a novel register buffer used in a semiconductor memory module implementing the above features.
To achieve the above objects, the present invention provides a semiconductor memory module which is provided with a plurality of DRAMs, and when an input command is detected as a refresh command according to external control signals externally input to a register buffer for command-execution, internal control signals for a partial number of the DRAMs preliminarily selected among the plurality of DRAMs are delayed. Thus, the refresh command is executed with a time difference, and the semiconductor memory module prevents the plurality of dynamic semiconductor memories from simultaneously entering refresh modes to cause a great peak current to flow.
According to a first aspect of the present invention, a semiconductor memory module is provided with a plurality of dynamic semiconductor memories, and generates internal control signals as a command to be applied to the plurality of individual dynamic semiconductor memories according to external control signals externally input to thereby execute the command. The semiconductor memory module includes: mode determining means for determining whether or not the command is a refresh command in a refresh mode according to the internal control signals; and delay means for establishing a delay in applying the internal control signals to a partial number of dynamic semiconductor memories preliminarily selected among the plurality of dynamic semiconductor memories. Thus, the refresh command is transferred to the plurality of dynamic semiconductor memories with a time difference according to the delay in the refresh mode.
By this configuration, since the plurality of dynamic semiconductor memories that simultaneously perform refresh operations on the module can be distributed to the plurality of groups, the peak current can be significantly reduced.
According to a second aspect of the present invention, there is provided a register buffer device used in a semiconductor memory module having a plurality of dynamic semiconductor memories mounted thereon, and the register buffer device includes: means for generating internal control signals for executing a command for the plurality of individual dynamic semiconductor memories according to external control signals externally input to the register buffer device. The register buffer device further includes mode determining means for determining whether or not the command is a refresh command in a refresh mode according to the external control signals; and delay means for establishing a delay in the internal control signals to be supplied to a partial number of dynamic semiconductor memories preliminarily selected among the plurality of dynamic semiconductor memories. Thus, the refresh command is transferred to the plurality of dynamic semiconductor memories with a time difference according to the delay in the refresh mode.
According to a third aspect of the present invention, there is provided a register buffer device used in a semiconductor memory module having a plurality of dynamic semiconductor memories mounted thereon. The register buffer device includes control means for performing control operations of: generating internal control signals for executing a command for the plurality of individual dynamic semiconductor memories according to external control signals externally input to the register buffer device; determining whether or not the command is a refresh command in a refresh mode according to the external control signals; and establishing a delay in the internal control signals to be supplied to a partial number of dynamic semiconductor memories preliminarily selected among the plurality of dynamic semiconductor memories. Thus, the refresh command is transferred to the plurality of dynamic semiconductor memories with a time difference according to the delay in the refresh mode.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and features of the present invention will be readily understood from the following detailed description taken in conjunction with preferred embodiments thereof with reference to the accompanying drawings, in which like parts are designated by like reference numerals and in which:
FIG. 1 is a block diagram showing a configuration of a semiconductor memory module according to a first embodiment of the present invention;
FIG. 2 is a timing diagram representing operations of the semiconductor memory module according to the first embodiment of the present invention;
FIG. 3 is a circuit configuration view showing a configuration of a refresh detect circuit according to the first embodiment of the present invention;
FIG. 4 is a timing diagram representing operations of the refresh detect circuit according to the first embodiment of the present invention;
FIG. 5 is a block diagram showing a configuration of a semiconductor memory module according to a second embodiment of the present invention;
FIG. 6 is a circuit configuration view showing a configuration of a register buffer according to a third embodiment of the present invention;
FIG. 7 is a block diagram showing a configuration of a semiconductor memory module according to the third embodiment of the present invention;
FIG. 8 is a block diagram showing a configuration of a semiconductor memory module according to a fourth embodiment;
FIG. 9 is a block diagram showing a configuration of a variable delay circuit according to a fifth embodiment of the present invention;
FIG. 10 is a block diagram showing a configuration of a conventional semiconductor memory module;
FIG. 11 is a circuit configuration view showing a configuration of a conventional register buffer;
FIG. 12 is a function table of output signals responding to various input signals of the conventional register buffer; and
FIG. 13 is a timing diagram representing operations of the conventional semiconductor memory module.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinbelow, referring to FIGS. 1 to 9 , embodiments of the present invention will be described. In the figures, the same reference numerals and symbols are used for common portions, and duplicated descriptions will be omitted.
(First Embodiment)
Hereinbelow, a first embodiment of the present invention will be described with reference to FIGS. 1 to 4 . FIG. 1 shows a circuit configuration of a DRAM module 1 according to a first embodiment, and FIG. 2 shows a timing diagram of the circuit. In the present embodiment, eight SDRAMs SDRAM- 1 to SDRAM- 8 mounted on a module 1 are separated into two groups, i.e., a first group A and a second group B, each group consisting of four pieces of the SDRAMs. Specifically, the first group A (first group SDRAMs-(A)) is comprised of SDRAM- 1 to SDRAM- 4 and the second group B (second group SDRAMs-(B)) is comprised of SDRAM- 5 to SDRAM- 8 . In this configuration, refresh-operation timings in the groups A and B are differentiated from each other. Specifically, the timings are differentiated by providing a time difference corresponding to one cycle of a clock signal (CK or /CK).
In order to provide the time difference in the refresh-operation timing, delay circuits 2 (D), mode switches 3 (SW), and a refresh detection circuit 4 are additionally mounted on the module 1 . Each of four circuit blocks 5 to 8 is formed of the delay circuit 2 and the mode switch 3 (SW) coupled together, and the four circuit blocks 5 to 8 are individually coupled between the output terminals of the internal control signals Int./S, Int./WE, Int./CAS, and Int./RAS of a register buffer 9 and the SDRAM groups (A) and (B). The refresh detection circuit 4 is coupled between the individual output terminals of the register buffer for the internal control signals Int./S, Int./WE, Int./CAS, and Int./RAS and the mode switches 3 (SWs) in the individual circuit blocks 5 to 8 .
In this configuration, the mode switch 3 (SW) operates to switch between a refresh mode (shown by REF=H) and a non-refresh mode (shown by REF=L). When a switch terminal 3 a is selected to enter the refresh mode (REF=“H”), control is performed to cause a difference in delay time for transferring a refresh command to the SDRAMs in the individual groups. More specifically, the refresh command is directly transferred to the first group SDRAMs-(A) without passing through the delay circuits 2 (D). Meanwhile, a delayed refresh command (Int./S′, Int./WE′, Int./CAS′, and Int./RAS′) is transferred to the second group SDRAMs-(B) via the delay circuits 2 (D).
In the figure, in order to set a delay amount D in the delay circuit 2 to substantially correspond to one cycle of the clock CK, the circuit configuration is arranged such that, when the frequency of the base clock CK is 100 MHz, a delay of about 10 ns is obtained. In this case, the configuration can be arranged such that, as shown in the operational timing diagram in FIG. 2, SDRAM- 1 to SDRAM- 4 in the first group SDRAMs-(A) receive a refresh command at the time T 2 , and at time T 3 after one cycle thereof, SDRAM- 5 to SDRAM- 8 of the second group SDRAMs-(B) receive the delayed refresh command.
In the configuration arranged as described above, the SDRAMs simultaneously performing refresh operations on the module can be divided to the two groups, i.e., the first and second groups each consisting of the four SDRAMs. Thereby, the peak current can be significantly reduced in comparison to the conventional configuration in which all the eight SDRAMs simultaneously perform the refresh operations.
When a switch terminal 3 b for setting to the non-refresh mode (REF=“L”) is selected by switching operation of the switch 3 (SW), as in the conventional configuration, the internal control signals Int./S, Int./RAS, Int./CAS, and Int./WE are simultaneously transferred to all the SDRAM- 1 to SDRAM- 8 . That is, the command thereof is simultaneously transferred to all the SDRAM- 1 to SDRAM- 8 . In FIG. 2, a delay time tdp (REF) occurring in an output signal of the refresh detection circuit 4 represents the sum of the operational delay in the register buffer, operational delay in the refresh detection circuit, and wiring delay caused in a field up to the switching device.
FIG. 3 shows an example configuration of the refresh detection circuit 4 . FIG. 4 is an operational timing diagram in a case where an activation command (Act command) is input after a refresh command is input. In the configuration shown in FIG. 3, an output signal REF of the refresh detection circuit is driven to the H level (i.e., refresh mode) only when a chip-selecting signal IS is in an L level and a refresh command defined by the combination of /RAS=L, /CAS=L, and /WE=H is input.
As shown in FIG. 3, a delay device 31 setting a delay amount DO is used, and on/off operation of a MOSFET is controlled using a signal N 1 generated via, for example, an inverter and a NAND gate, and thereby input to a latch circuit is controlled. This configuration prevents that, in FIG. 4, the signals Int./RAS, Int./CAS, and Int./WE change to cause the output signal REF to be in L level before the chip-selecting signal Int./S returns to the H level.
(Second Embodiment)
Hereinbelow, referring to FIGS. 2 to 5 , a DRAM module 1 of a second embodiment according to the present invention will be described. The present embodiment has a feature in that in each of the blocks 5 to 8 shown in FIG. 1 explained in the first embodiment, a second delay devices 51 (delay amount Dl) is provided in addition to the delay circuits 2 . Other configurations are the same as those of the first embodiment.
As shown in FIG. 2, the aforementioned second delay device 51 is added to achieve a preferable condition of tdp (REF)<tdp. Specifically, the condition is that the delay time tdp (REF) occurring in the output signal REF of the refresh detect circuit 4 is less than a value representing the sum of the delay tdp occurring in the signal Int./S. As described above, the delay time tdp (REF) is the sum of the operational delay in the register buffer, the operational delay in the refresh detect circuit 4 , and the wiring delay in the field up to the mode switch 3 (SW).
Meanwhile, the delay tdp represents the sum of the delay caused in the operation within the register buffer and the wiring delay time in the field from the register-buffer output to the SDRAM input. The reason for the above arrangement is that the command signals are transferred to each of the SDRAMs after the mode-setting of the switch device 3 is fixed, and more stable operation can be expected.
For the above reason, the present embodiment further includes the second delay device 51 in each of the circuit blocks 5 to 8 to effectively increase the delay time tdp. However, when the delay amount of the second delay device 51 is excessively large, the time of signal transfer to the SDRAM is excessively increased, causing malfunction. To prevent this, the delay amount (Dl) of the second delay device 51 is set so that tpd is slightly larger than tpd(REF).
(Third Embodiment)
Hereinbelow, a DRAM module of a third embodiment according to the present invention will be described with reference to FIGS. 6 to 7 . A configuration example of the present embodiment is shown in FIG. 6 in which the delay circuits 2 , switches 3 , and refresh detection circuit 4 shown in FIG. 1 explained in the first embodiment are included in a register buffer.
In specific, a register buffer 61 shown in FIG. 6 has a configuration in a manner such that the register buffer having the conventional configuration shown in FIG. 11 is further provided with the refresh detection circuit 4 and four circuit blocks 5 to 8 each including the delay circuit 2 (D) connected to the switch 3 (SW).
The circuit blocks 5 to 8 are coupled to flip-flop circuits (F/F) corresponding to the external control signals Ext./S, Ext./WE, Ext./CAS, and Ext./RAS, respectively. In this configuration, the register buffer 61 per se outputs the internal control signals Int./S, Int./WE, Int./CAS, and Int./RAS and delayed internal control signals Int./S′, Int./WE′, Int./CAS′, and Int./RAS′ individually delayed by the delay circuits 2 thereof.
The refresh detection circuit 4 is coupled between the flip-flop circuits (F/F) and the switch devices 3 (SWs) of the individual circuit blocks 5 to 8 . In the configuration, an output signal REF of the refresh detection circuit 4 is input to the individual switch device 3 which is switched based on the level of REF between the refresh mode (REF=H) and the non-refresh mode (REF=L).
FIG. 7 shows a configuration example of a SDRAM DIMM which is formed by mounting the register buffer 61 on the module. In this configuration, when the signal REF is H level for setting the refresh mode, the non-delayed refresh command (i.e., internal control signals Int./S, Int./WE, Int./CAS, and Int./RAS) issued from the register buffer 61 is directly transferred to the first group SDRAMs-(A). Meanwhile, the delayed refresh command (i.e., Int./S′, Int./WE′, Int./CAS′, and Int./RAS′) issued from the register buffer 61 is transferred to the second group SDRAMs-(B).
By using the register buffer having the above-described configuration, the peak current in the refresh operation can be minimized without increasing the number of components on the DIMM.
(Fourth Embodiment)
Hereinbelow, referring to FIG. 8, a DRAM module according to a fourth embodiment of the present invention will be described. In each of the circuit blocks 5 to 8 shown in FIG. 1 explained in the first embodiment, two pairs of the delay circuit 2 and switch device 3 are included therein. The SDRAMs that perform refresh operations on the module are separated into three or more groups, and the refresh timings are differentiated by providing time differences in executing the refresh operations of the groups.
FIG. 8 shows a configuration example in which SDRAMs that perform the refresh operations on the module are separated into three groups A, B, and C, and a time difference is provided for the refresh timings of the SDRAMs in each of the groups. Each of the circuit blocks 5 to 8 includes first and second delay devices 41 and 42 and first and second switching devices 43 and 44 in pairs. In this configuration, the delay control is implemented such that, when the refresh mode (REF=H level) is selected, a time difference is produced in the timings at which a refresh command is transferred to the SDRAMs in each of the groups.
The time difference between the group A of SDRAM- 1 to SDRAM- 3 and the group B of SDRAM- 4 to SDRAM- 6 is set according to the delay amount of the first delay device 41 , and a one-cycle delayed refresh command (Int./S′, Int./WE′, Int./CAS′, and Int./RAS′) is transferred to the second group SDRAMs-(B).
In addition, the time difference between the group B of SDRAM- 4 to SDRAM- 6 and the group C of SDRAM- 7 and SDRAM- 8 is set according to the delay amount of the second delay device 42 , and a two-cycle delayed refresh command (Int./S″, Int./WE″, Int./CAS″, and Int./RAS″) is transferred to the third group SDRAMs-(C).
According to the above-described configuration, as shown in the figure, the eight SDRAMs that perform refresh operations on the module can be distributed into, for example, three groups individually consisting of three SDRAMs, three SDRAMs, and two SDRAMs. As such, compared to the conventional example in which all the eight SDRAMs simultaneously perform refresh operations, the configuration of the present embodiment enables the peak current to be significantly reduced.
When the non-refresh mode (REF=L level) has been selected, as in the conventional configuration, non-delayed internal control signals Int./S, Int./RAS, Int./CAS, and Int./WE are simultaneously transferred to all the eight SDRAMs. Accordingly, all the eight SDRAMs simultaneously execute the transferred commands.
(Fifth Embodiment)
Referring to FIG. 9, a fifth embodiment of the present invention will be described. In the fifth embodiment, variable delay circuits are used as the delay circuits 2 (or, 41 and 42 ) which are individually set to have the delay amount D in the above-described embodiments 1 to 4.
As shown in FIG. 9, a delay circuit 200 includes a first variable delay circuit 201 provided on a command signal line and a second variable delay circuit 202 provided on a base clock CK line on the DIMM. The first variable delay circuit 201 and the second variable delay circuit 202 have identical configurations. In addition, a PLL circuit is configured of the second variable delay circuit 202 and a phase-comparing circuit 203 .
With the PLL circuit configured as described above, the delay amount D of the delay circuit 200 is furnished with a self-adjusting function that self-adjusts the delay amount to be always kept as that corresponding to one cycle of the frequency at that time according to a frequency variation of the base clock CK.
In specific, the phase-comparing circuit 203 compares and checks the phase difference between the base clock CK and the delay amount output of the second variable delay circuit 202 . According to the comparison result, the second variable delay circuit 202 is controlled. More specifically, the delay amount of the second variable delay circuit 202 is adjusted so that the phases of the base clock CK and the output of the second variable delay circuit 202 are the same (that is, the adjustment makes the phase difference to be zero therebetween). Then, the adjusted delay amount just corresponds to one cycle of the frequency of the base clock CK.
When every time the frequency of the base clock CK varies, the second variable delay circuit 202 is controlled to produce the delay amount corresponding to just one cycle of the frequency at that time. On the other hand, since the first variable delay circuit 201 provided on a command signal line on the DIMM is also configured identical to the second variable delay circuit 202 , the two circuits are controlled by the same output signal of the phase-comparing circuit 203 . Consequently, the delay amount of the first variable delay circuit 201 is also controlled to always correspond to one cycle of the frequency at that time.
By employing the delay circuit 200 configured as described above as the delay circuit 2 (or 41 , 42 ) in each configuration of the embodiments 1 to 4, at the time T 3 in FIG. 2 for example, the configuration enables the prevention of reduction in a timing margin when SDRAM- 5 to SDRAM- 8 of the second group receive the refresh command.
Suppose a case occurs in which the delay amount D greatly differs from the cycle time of the base clock CK. This case represents a phenomenon in which the data of the refresh-command signals Int./S′, Int./RAS′, Int./CAS′, and Int./WE′ to be received by SDRAM- 5 to SDRAM- 8 are not valid, and a malfunction is thereby caused. This phenomenon can be prevented by employing the delay circuit having the self-adjusting function according to the present embodiment.
As described above, the present invention enables the provision of a semiconductor memory module and the register buffer used in the semiconductor memory module in which refresh-command execution timings are differentiated and distributed. This inhibits occurrence of a phenomenon in which a plurality of DRAMs simultaneously enter refresh modes to cause a great peak current to flow to cause a Vdd/GND noise. Thus, the present invention thereby enables a stable operation to be implemented.
Although the present invention has been described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they depart therefrom.
|
In a semiconductor memory module having a plurality of DRAMs, when an input command is detected as a refresh command according to external control signals externally input for command-execution to a register buffer, internal control signals for a partial number of the DRAMs preliminarily selected among the plurality of DRAMs are delayed. Thus, the refresh command is executed with a time difference, and the semiconductor memory module prevents the plurality of dynamic semiconductor memories from simultaneously entering refresh modes to cause a great peak current to flow, and thereby implementing a stable operation.
| 6
|
BACKGROUND OF THE INVENTION
This invention relates to a new composition of matter which is a peroxyester derivative of trimellitic anhydride and an alkyl hydroperoxide having the structural formula ##STR1## wherein R is a primary, secondary or tertiary alkyl group of 1 to 10 carbon atoms in the carbon chain.
Thermal decomposition of peresters has been shown to involve the rupture of the --O--O-- bond, in some cases with simultaneous decarboxylation (P. D. Bartlett et al, J.A.C.S., 80 1398)). Accordingly, the compounds of structural formula I of the perester decompose as shown by Equations 1 and 2. ##STR2##
The radicals II, III and IV in the presence of monomers polymerizable by a radical mechanism can initate the terminate polymerization and thereby become attached to the ends of the polymer chain. This invention accordingly relates particularly to the attachment of the radicals II and IV to the ends of the polymer chain, thus introducing anhydride groups to the chain ends. By increasing the amount of the peroxide up to the level tolerated by the solubility in the particular monomer, polymers carrying various amounts of functional anhydride groups can be obtained. For example, an increase in the amount of the peroxide I will lower the molecular weight while increasing the anhydride content.
The general formula of the resulting polymers can be written as V or VI where M represents the divalent radical and repeating unit of the monomer (styrene, substituted styrene, acrylonitrile, acrylic esters, methacrylic esters, vinyl acetate, vinyl chloride, etc.), n is an integer between 2 and 10,000, and R is a primary, secondary or tertiary alkyl group. ##STR3##
It is understood that, although the bulk of the polymer will be represented by formulae V and VI, molecules of different composition will also be present, i.e., both ends of the molecule can be terminated by the same radical, either II or III or IV. In addition II or III or IV can be missing from the chain ends due to competing initiation and termination reactions.
The polymers prepared by this invention find a wide range of application. The lower molecular weight polymers obtained by using larger quantities of the peroxide I can find application as detergents, rust inhibitors, oil additives (dispersants, rust inhibitors, V.I. improvers). For certain applications, it might be advantageous to hydrolyze the anhydride groups of V or VI by steam. If reacted with a diamine, condensation reaction takes place between the anhydride and amine groups. Application of this reaction can be in binding and gluing surfaces, and in modifying and grafting polymers.
In further detail, specific applications of the compounds of the instant invention lie in functional fluids such as hydraulic oils and in plasticizers.
Oils used as functional fluids must be extremely stable to temperature and pressure but their viscosity index must be low because the equipment must operate as a function of the viscosity index. A fully saturated ester of 500 to 50,000 molecular weight which is not subject to oxidation and does not contain either phosphorus or sulfur and accordingly is not corrosive is highly desirable. Additionally, an ester which is not a polychlorinated compound offers advantages of environmental protection if disposal is required.
Phthalic moiety-containing esters of suitable carbon chain length, i.e., from 500 to 50,000 molecular weight which have no volatility, such as the phthalate esters of this invention are very desirable as permanent plasticizers for polyvinyl chloride resins. Permanence is determined, among other characteristics, by low plasticizer volatility. The compounds of this invention as plasticizers have this property.
SUMMARY OF THE INVENTION
4-Perester derivatives of trimellitic anhydride and polymers derived by use of these derivatives as dual function reagents for polymerization and introduction of the phthalic anhydride moiety.
DETAILED DESCRIPTION OF THE INVENTION
The compositions of this invention are the 4-perester derivatives of trimellitic anhydride and alkyl hydroperoxides wherein the alkyl moiety is selected from primary, secondary and tertiary alkyl moieties of one to 10 carbon atoms in the carbon chain. Accordingly, the alkyl moiety can be methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tertiary butyl, amyl, tert-octyl, tert-nonyl, and n-decyl. The alkyl moieties can be substituted or unsubstituted. Since the reaction site between the trimellitic anhydride molecule and the alkyl hydroperoxide involves only the hydroperoxy moiety of the peroxide, the remainder of the peroxide molecule can be substituted with any substituents that do not interfere with the course of the reaction between the anhydride and with which the hydroperoxide moiety is not unstable or subject to rapid decomposition. Accordingly, other substituents which can be in the hydroperoxide reactant are fluorine, chlorine, and nitro moieties. Typical examples of these hydroperoxides and fluoro-tert-butyl hydroperoxide and 2-nitro-tert-amyl hydroperoxide.
Broadly speaking, the 4-peroxyester derivatives of trimellitic anhydride are prepared by reacting trimellitic anhydride and alkyl hydroperoxides. Alkyl hydroperoxides can be prepared by treating an olefin or an alcohol with hydrogen peroxide in the presence of an acid (usually sulfuric acid). t-Butyl hydroperoxide is prepared by reacting t-butyl alcohol with hydrogen peroxide in the presence of sulfuric acid.
The preparation of peroxyesters is well known as many peroxyester compounds have been prepared in the prior art. General approaches to peroxyesters can be by a Schotten-Baumen procedure at a temperature of 0° C. or lower which employs either aqueous alkali or pyridine as a base and utlizes either an acid anhydride or an acid chloride in the presence of the alkyl hydroperoxide. Another approach uses imidazolides as reactive intermediate. These are prepared from the carboxylic acid and either thionyl or N,N'-carbonyldiimidazole which are reacted with the alkyl hydroperoxide. Other methods of preparing peroxyesters are also well known but general application has been hampered by apparent thermal lability of the products.
In detail, the 4-alkyl trimellitic anhydrides are prepared by esterifying a trimellitic anhydride monoacid halide with an alkyl hydroperoxide, by maintaining the reactant mixture at a temperature low enough to prevent side reactions, in the presence of a tertiary amine and in the presence of a hydrocarbon solvent of sufficient solubility to solubilize the reactants and the tertiary amine wherein the said reactants consist essentially of the monoacid halide of trimellitic anhydride and 4-alkyl hydroperoxide where the alkyl moiety is selected from the group consisting of primary, secondary and tertiary alkyl moieties of one to 10 carbon atoms in the carbon chain. Preferably the alkyl moiety is selected from the group consisting of methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, amyl, tert-octyl, tert-nonyl and n-decyl moieties. Preferably the temperature is maintained below a temperature of about 15° C. although the temperature can be as high as 50° C. Preferred monoacid halide of trimellitic anhydride is the bromide or chloride. Preferred tertiary amine when the alkyl moiety is a tertiary butyl moiety is pyridine because of low solubility of the pyridine salt which results as a reaction product. Preferred solvent in the presence of pyridine, the monoacid chloride of trimellitic anhydride and 4-alkyl hydroperoxide wherein the alkyl moiety is tertiary butyl is benzene. Preferred ratio of tertiary amine to monoacid halide of trimellitic anhydride is mole for mole, 1:1, as the tertiary amine hydrohalide is formed as an end product. Preferably, the solvent is chosen so that the hydrohalide salt is insoluble in the solvent and precipitates.
Purification procedures of peroxyesters are limited by their thermal lability. Vacuum distillation can be used with low molecular weight liquids while the higher molecular weight oils are typically isolated by chromatographic procedures using a non-polar medium. Florisil, an absorbent containing a magnesia-silica gel catalyst, Floridin Company, Pittsburgh, Penna. is often used.
Evidence of the presence of peroxyesters is often by means of infrared spectroscopy. Peroxyesters display a characteristic band in the infrared region at about 1770 cm -1 . The approximate purity of a peroxyester can be indicated by infrared spectroscopy as the major contaminants usually contain carbonyl or hydroxyl groups. The peroxide number which is obtained by titrating liberated iodine of a potassium iodide solution with a standard thiosulfate solution also can indicate degree of purity. The calculated peroxide number of the pure peroxyester compared with peroxide number obtained by titrating the liberated iodine indicates relative purity in the presence of organic substances.
Peroxyesters are well-known as initiators in all major types of polymerization systems, such as bulk, solution, suspension or emulsion polymerizations in that peroxyesters are sources of free radicals. Temperature range in which the peroxyesters decompose largely determine the type of application. Thermal stability, compatibility with monomer systems, ease of activation, and efficiency and type of free radicals produced determine application and range of application. In addition, the peroxyesters of trimellitic anhydride introduce phthalic anhydride moieties into the polymer. Presence of an anhydride group at the end of the polymer chain permits cross-linking by the acyl groups. Lower molecular weight polymers with unreacted acyl groups are surface-active agents and dispersants. Higher molecular weight polymers are useful as oil additives.
Specifically, the 4-tert-butyl pertrimellitate anhydride, wherein R is tert-butyl, was prepared. This compound brought about the polymerization of styrene, methyl methacrylate, and 4-vinyl pyridine with simultaneous introduction of phthalic anhydride moieties.
Embodiments of the present invention can be found in the following examples. These embodiments and examples are presented for purposes of illustration only and are not intended to limit the scope of the invention.
EXAMPLE I
To a stirred, cooled solution of trimellitic anhydride acid chloride (10.6 g) in benzene (100 ml) was added dropwise a solution of anhydrous tert-butyl-hydroperoxide (4.5 g) in benzene (50 ml) and anhydrous pyridine (4.1 ml) at 6° C. After 3/4 hour stirring the white precipitate was filtered off and washed with a little benzene. The combined filtrate and washings were passed through a small Florisil column and eluted with benzene. Removal of solvents in vacuo gave a glassy semi-solid product, 11.6 g. Its IR spectrum in the carbonyl region showed bands at 1867, 1810, 1783, and 1762 cm -1 as a neat syrupy liquid. The NMR spectrum confirmed the presence of the tert-butyl group. Peroxide number, mls of normal sodium thiosulfate solution per one gram of sample was 6.0 milliequivalents per gram; this corresponds to 79% purity. This crude perester decomposed violently if placed into a 130° C. bath but decomposition was hardly observable if it was heated up slowly. For practical applications this perester is most conveniently handled in benzene solution.
In a thermal stability study, 3.0 g crude perester was refluxed in 20 ml benzene for 21/2 hours. On standing at 6° C. for 16 hours the solution deposited slightly impure crystals of trimellitic anhydride (0.75 g; IR evidence). The starting perester was the major and only identifiable component of the benzene solution on the basis of IR spectrum.
EXAMPLE II
Styrene (10.0 g, stabilized with tert-butylcatechol) containing 1.0 g of 79% pure tert-butyl pertrimellitate anhydride (I, R=tert-butyl) was bulk-polymerized in a capped vial under nitrogen for 151/2 hours at 65° C. followed by 106° for 16 hours. A brown, very tough solid resulted. (In a control experiment under identical conditions, but without the peroxide, styrene polymerized thermally to a viscous liquid only.) The peroxide-modified polystyrene did not loose any weight on vacuum drying (0.1 mm) overnight at room temperature. Infrared spectrum in carbon tetrachloride solution indicated the presence of anhydride and ester groups (1864, 1784 and 1738 cm -1 ). The 1738 cm -1 peak is theorized as due to an ester carbonyl as shown in V; it cannot be due to the starting perester I(R=tert. butyl), because under the conditions of the polymerization it must have decomposed (see thermal stability in Example I). A direct comparison of the IR spectra of the starting perester (I, R=tert. butyl) and of the polymer--although not available in the same solvent because of differing solubility--also suggested that the polymer contained the ester group. The modified polystyrene also showed carboxyl peak at 1705 cm -1 that is theorized due to trimellitic anhydride, derived from radical II by hydrogen abstraction.
EXAMPLE III
Styrene (10.0 g) was bulk-polymerized in the presence of 0.35 g of the peroxide I (R=tert. butyl, 79% pure) under the conditions of Example II. A transparent solid polymer with a yellowish tint was obtained. Its IR spectrum in carbon tetrachloride solution showed peaks in the anhydride region at 1868, 1804 and 1785 cm -1 whereas the product of Example II showed only a weak shoulder at 1804 cm -1 . This difference can be attributed to greater contribution of the structure VI to the polymer composition. Also, in the present example, the ester and the acid peaks at 1746 and 1705 cm -1 , respectively, were relatively weak.
EXAMPLE IV
Styrene was bulk-polymerized in nitrogen-purged, capped vials at 80° for 16 hours followed at 105° for 5 hours in the presence of different quantities of 76% pure tert-butyl pertimellitate anhydride (I, R=tert-butyl). The products were analyzed by vacuum thermogravimetry (at 120 mm). The table shows the weight losses at 200° at 5°/min. heating rates.
______________________________________Wt. of 76% pure Wt. loss ofinitiator per 10 g Monomer Polymer at 200° C.______________________________________(g) (%)1.51 9.20.71 5.40.35 3.0______________________________________
These data indicate that with increasing quantity to peroxide increasing quantities of lower molecular weight products were produced in agreement with the expectations.
EXAMPLE V
Methyl methacrylate (10.0 g) containing 1.517 g of 76% pure 4-tert. butyl pertrimellitate anhydride (I, R=tert. butyl) was bulk polymerized in a vial under nitrogen for 151/2 hours at 73°, 5 hrs. at 93°, and slowly heated to 120° C. A transparent, slightly yellowish tough solid polymer was obtained. In a control experiment, methyl methacrylate without the peroxide remained a liquid. Vacuum thermogravimetry on the product showed 7.0% weight loss at 190° C. at 5° C./min. heating rate.
EXAMPLE VI
Methyl methacrylate (10.0 g) was bulk-polymerized in the presence of 0.70 g of the peroxide I (R=tert-butyl, 76% pure) under the conditions of Example V. A transparent, almost colorless, tough glassy solid was obtained. Vacuum thermogravimetry (120 mm) gave 3.6% weight loss at 190° (5°/min. heating rate).
EXAMPLE VII
Stabilized 4-vinylpyridine (10.0 g) was bulk-polymerized in the presence of 1.0 g of 79% pure I (R=tert. butyl) under nitrogen in a capped vial at room temperature for 16 hours, followed at 70° C. for one hour. A brown, brittle, fragile solid was obtained, soluble in pyridine. In a control experiment without the peroxide no observable change occurred with 4-vinyl pyridine. Infrared spectrum in pyridine solution showed only anhydride and acid carbonyl bands and only a shoulder at 1720 cm -1 attributable to ester carbonyl.
|
4-Peroxyester derivatives of trimellitic anhydride and polymers derived by use of these derivatives as dual function reagents for polymerization and introduction of the phthalic anhydride moiety.
| 2
|
BACKGROUND OF THE INVENTION
The invention relates to a method and device for opening a valve, especially a load changing valve of an internal combustion engine.
From German patent 30 24 109 C2 a device, operating without camshaft, for actuating a load changing of an internal combustion engine is known. To the stem of the load changing valve an armature plate is fastened which in the fully open position of the valve contacts the solenoid and in the closed position of the valve contacts another solenoid. The armature plate forms together with the valve and two oppositely acting springs an oscillation system which upon activation of one solenoid is secured in one end position, whereby, upon switching off the solenoid, the armature plate moves toward the other end position and is secured thereat by activation of the other solenoid.
Such electromagnetic actuating devices, operating without camshaft, for the load changing valves of an internal combustion engine have the advantage that the control time can be selected substantially freely so that fuel consumption advantages can be achieved and the exhaust gas quality can be improved. A problem of such actuating devices is that the opening of the valve by pressure within the working chamber or combustion chamber is greatly impaired. For example, an exhaust valve must be opened already in certain operational phases when within the combustion chamber there is still a high working pressure. This high working pressure must be overcome by a spring which crowds the valve in the opening direction so that energy is removed from the oscillating system defined by the springs which energy must be then supplied by the solenoid. The solenoid which secures the valve in the fully open position must therefore be designed relatively large so that catching of the valve is possible. In the alternative, the springs must be so strong that high securing forces and thus large solenoids are required.
It is an object of the invention to provide a method and a device for opening a valve, especially a load changing valve of an internal combustion engine, with which a load changing valve can be opened safely and with minimal energy expenditure even when it must be opened counter to the excess pressure within the working chamber.
SUMMARY OF THE INVENTION
The inventive method is deigned for opening a valve, especially a load changing valve of an internal combustion engine, that separates a flow channel from a working chamber or connects it therewith and is embodied as a plate valve. Upon opening, the valve projects into the working chamber, According to the inventive method, energy is withdrawn from a flow out of the working chamber into a flow channel, resulting from excess pressure within the working chamber upon beginning of the opening stroke of the valve, and this energy is used for supporting the further opening movement of the valve.
The inventive device is designed for opening a valve, especially a load change valve of an internal combustion engine, that separates a flow channel from a working chamber or connects it therewith and is embodied as a plate valve. Upon opening, the valve projects into the working chamber. The inventive device comprises a flow guide element connected to the valve and surrounding the valve at a spacing. The flow guide element projects from the backside of the valve seat ring through the flow channel into a blind bore extending away from the flow channel, whereby the circumferential edge at the valve side of the flow guide element for a small valve opening receives a portion of the initial flow from the working chamber into the flow channel and guides it into the space between the valve and the flow guide element. The circumferential edge of the flow guide element at the blind bore side and the circumferential wall of the blind bore are designed such that at least during a portion of the valve stroke a reduced a flow cross-section is provided between them.
In another embodiment of the inventive device, an auxiliary piston component having a tubular shaft, which surrounds the valve stem and is moveably guided coaxially to the valve stem in the cylinder head, is provided. This auxiliary component comprises an auxiliary piston, which cooperates with its circumferential edge with a cylindrical area of the opening of the flow channel into the working chamber, whereby the inner diameter of the cylindrical area corresponds substantially to the outer diameter of the auxiliary piston. An actuating device moves the auxiliary piston substantially in counter phase to the valve so that the auxiliary piston opens the flow channel for a small opening movement of the valve only partially and only opens it completely upon greater valve opening movement.
Inventively, the flow out of the working chamber into the flow channel, resulting from excess pressure present within the working chamber during the initial opening phase of the valve, is used to extract energy therefrom which energy is used for supporting (enhancing or aiding in) the opening action of the valve. In this manner, the energy required for opening the valve against the excess pressure in the working chamber is reduced.
The invention is not only useful for electromagnetically operated load changing valves of internal combustion engines. They are also useful for conventionally actuated load changing valves because the invention lowers the actuating energy. The invention is also suitable for use with valves of pumps or other control members which must open against an excess pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
The object and advantages of the present invention will appear more clearly from the following specification in conjunction with accompanying drawings, in which:
FIG. 1 shows a cross-section of a portion of a valve mounted within the cylinder head of an internal combustion engine and having a flow guide element; and
FIG. 2 shows a basic schematic of a further embodiment of the inventive device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described in detail with the aid of several specific embodiments utilizing FIGS. 1-4.
FIG. 1 shows a cross-section of a portion of a cylinder head 6 which has an outlet channel or flow channel 8 which extends away from the combustion chamber or the working chamber 10 .
At the opening of the outlet channel 8 into the working chamber 10 a valve seat ring 12 is arranged which cooperates with the valve plate 14 of a valve 16 . The valve stem 18 penetrates the outlet channel 8 and is guided in a guide bushing 20 within the cylinder head 6 . Between the cylinder head 6 and the stem 18 a non-represented valve closing spring is arranged.
The aforementioned arrangement with regard to the design and function is known to a person skilled in the art and is therefore not disclosed in further detail. The actuating device for the valve 16 can be embodied conventionally by a camshaft, push rods, rocker arms etc. or performed hydraulically electromagnetically, or pneumatically.
Inventively, a flow guide element 24 is provided that surrounds the valve 16 such that a flow space is created. The flow guide element 24 , adjacent to the valve seat ring 12 or the backside 14 a of the valve plate 14 , ends in a circumferential edge 26 and, adjacent to the cylinder head 6 , ends in a circumferential edge 28 .
The cylinder head 6 is embodied with a blind bore 30 which extends concentrically to the valve shaft 18 . The circumferential edge 28 of the flow guide element 24 projects into the blind bore 30 .
The depth of the blind bore 30 is such that the circumferential edge 28 of the flow guide element 24 in the closed state of the valve 16 is positioned in the vicinity of the bottom 32 of the blind bore 30 . The outer diameter of the circumferential edge 28 corresponds essentially to the inner diameter of the blind bore 30 or is somewhat smaller so that the circumferential edge 28 cooperates with the inner side of the blind bore in the manner of a gap seal.
The circumferential edge 26 at the valve plate side of the flow guide element 24 is embodied such that it forms with the backside of the valve plate 14 an annular gap 35 which receives, upon opening of the valve 16 , the flow exiting from the working chamber in the manner of an opening of a Pitot tube for measuring the flow pressure. In the represented embodiment the circumferential edge 26 in the closed state of the valve 16 projects into a cylindrical portion 34 of the valve seat ring 12 or the opening of the outlet channel 8 , whereby the inner diameter of the cylindrical area 34 corresponds to the outer diameter of the circumferential edge 26 .
The flow guide element 24 is embodied such that between it and the outer circumference of the valve 16 a flow passage 36 is provided whereby the spacing between the flow guide element 24 and the valve 16 in the most narrow portion of the flow passage is, for example, within a magnitude of 0.5 mm.
The flow guide element 24 can be a shaped sheet metal piece comprised of a highly temperature-resistant sheet metal and can be welded to the valve 16 , for example, by individual spot welds 38 .
The function of the flow guide element 24 is as follows:
It is assumed that the valve 16 is in its closed position and that in the working chamber a pressure P zyl is present which is greater than the pressure in the outlet channel 8 . When the valve 16 is only slightly open, a large portion of the flow-cross section, formed between a conical surface of the valve plate 14 and the conical surface of the valve seat ring 12 , is filled by the annular gap 35 between the circumferential edge 26 and the backside of the valve plate 14 so that the flow resulting from the excess pressure within the working chamber 10 is received by the annular gap 35 and is guided into the flow passage 36 between the flow guide element 24 and the valve 16 . This has the effect that in the blind bore 30 within a short amount of time substantially the same pressure P zyl is present. With a corresponding embodiment of the annular gap 35 in the manner of an inlet opening of a Pitot tube, the annular gap 35 , for further opening of the valve, will receive the entire pressure of the flow and will guide it into the blind bore. A reduced outflow cross-section from the blind bore 30 , when the circumferential edge 28 cooperates advantageously with the inner side of the blind bore 30 in the manner of a gap seal (frictional freedom), is without substantial impact on the pressure conditions within the blind bore 30 .
The pressure increase Δp effects at the valve 16 an additional opening force Δp×F, whereby F is the effective surface, i.e., the surface limited by the circumferential edge 28 minus the cross-sectional surface of the stem 18 . Depending on the diameter of the circumferential edge 28 , an additional force of greater or smaller magnitude can be produced which compensates the excess pressure in the working chamber or maybe even overcompensate this pressure. This additional force becomes active and is maintained as long as in the working chamber a pressure P zyl is present which is greater than the pressure in the outlet channel 8 . In this manner, the flow energy from the working chamber is used for improving the opening action of the valves 16 .
The embodiment can be such that upon further opening of the valve 16 the circumferential edge 26 will increasingly free the outlet cross-section into the outlet channel 8 whereby the circumferential edge 28 first keeps the blind bore 30 closed and, only upon further valve stroke, will exit from the blind bore 30 .
As can be taken from the above, the flow guide element 24 provides a device which reduces the energy required for opening the valve 16 counter to an excess pressure within the working chamber 10 by guiding the excess pressure to the backside of the valve 16 in order to create a force in the opening direction. The flow guide element 24 not only employs static pressure but also employs the flow energy.
FIG. 2 shows schematically a changed embodiment of a device for enhancing the opening movement of the valve which functions primarily by employing static pressure.
The valve 60 operates in the outlet opening of an outlet channel 62 of a combustion chamber or working chamber 64 .
The stem 66 of the valve 60 is guided in a guide bushing 68 which is received in a tubular shaft 70 of an auxiliary piston component 72 . The tubular shaft 70 is guided by a further guide bushing 74 in the cylinder head 76 .
The opening of the outlet channel 62 into the working chamber 64 is embodied with a cylindrical area 78 having an inner diameter which matches substantially the outer diameter of the auxiliary piston 79 which is a part of the auxiliary piston component 72 .
In the shown embodiment, for actuating the valve 60 a crank mechanism with a reciprocating actuating lever 80 is provided that is driven by a non-represented device. The actuating lever 80 engages a crank 82 of a shaft 84 connected to the engine. The shaft 84 has connected thereto a two-arm lever 86 . One arm 88 is connected by lever 90 to the tubular shaft 70 of the auxiliary piston component 72 , and the other arm 92 is connected by a lever 94 to the valve stem 66 .
The arrangement is such that, in the closed state of the valve 60 (lever 86 according to FIG. 2 rotated in the clockwise direction to a substantially horizontal position), the auxiliary piston 79 with its circumferential edge 79 a is moved into this cylindrical area 78 and is positioned in the vicinity of the end of the cylindrical area 78 that is close to the working chamber directly behind the valve 60 .
When the valve 60 is now opened by pivoting of the lever 86 in a counter clockwise direction, the auxiliary piston component 72 is moved counter to the movement of the valve 60 whereby the auxiliary piston 79 remains initially within the cylindrical area 78 and closes the inlet into the outlet channel 62 substantially completely so that the auxiliary piston is loaded with the excess pressure present within the working chamber 64 and is thus forced upwardly and supports the opening movement of the valve 60 via the levers 90 , 86 , and 94 . Only upon further opening of the valve 60 , respectively, pivoting of the lever 86 , the circumferential edge 79 a of the auxiliary piston 79 is released from the cylindrical area 78 so that the flow into the outlet channel 62 is possible.
It is understood that the cylindrical area 78 with respect to its depth and with respect to its design details (transition into a substantially partially conical area) are designed according to desired specifications.
In the device according to FIG. 2, the excess pressure in the working chamber, respectively, its release to the backside of the valve plate at the beginning of the opening stroke of the valve, is used in order to reduce the energy for opening the valve.
The specification incorporates by reference the disclosure of German priority document 198 35 403.7 of Aug. 5, 1998.
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.
|
In a method for opening a valve, which valve separates a flow channel from a working chamber or connects it therewith and which is embodied as a plate valve that projects upon opening into the working chamber, energy is withdrawn from a flow from the working chamber into the flow channel, resulting form the excess pressure within the working chamber upon opening movement of the valve. The withdrawn energy is used for aiding in further opening of the valve.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to an automatic masking device for an original picture holder used in a composer for printing repeatedly original pictures onto a photosensitive material such as a film, a plate, or the like.
An original picture to be held on an original picture holder is usually smaller than the entire effective surface of the original picture holder, and accordingly the part of the original picture holder surrounding the original picture is usually masked off.
FIGS. 1(a), 1(b), 2 and 3 of the drawings show the general layout of a prior art original picture holder. The original picture, which comprises a pattern 2 and register marks 3 around it, is shown in FIG. 1a. This is attached to an original picture holder, and is contact-printed onto a photosensitive material, a cut mask 4 having transparent portions in it being laid on the original picture 1 so as to mask off its periphery. The transparent portions correspond to the pattern 2 and the register marks 3. This cut mask 4 is shown in FIG. 1b.
The manner of doing this is as follows. The original picture 1, as shown in FIGS. 2 and 3, is positioned and attached in a central position on one side of a transparent mounting sheet 5 so that its base surface contacts therewith. The cut mask 4 is attached onto the opposite surface of the transparent mount sheet 5, in a position corresponding to that of the original picture 1, and the assembly thus formed is held onto the contact surface 6a of a transparent plate 6 by a vacuum suction means or the like.
Then, this original picture holder is positioned on the photosensitive material so as to contact the original picture 1 with the photosensitive material, and the pattern of the original picture is printed by light directed onto it through the transparent plate 6 onto the photosensitive material.
In FIGS. 2 and 3, the numeral 7 denotes masking means for masking off an unnecessary register mark 3 when the pattern 2 is printed, which is arranged on the opposite surface of the transparent plate 6 from the contact surface 6a, and is slidably moved.
As the automation of the other parts of the composer has become more and more advanced, along with the surrounding devices which are used with the composer, and automatic exchange of original pictures and printing plates has become possible, a fully automatic composer which might operate for a long time without operator attention has been envisaged. For this, automatic masking would be necessary.
Recently an automatic masking device has been developed, in which the pattern size and so forth of the original picture to be photo-composed are written on a control tape of a NC control machine, a computer, or the like, which automatically controls the actions of the composer for a long time, and the effective exposure surface of the original picture holder is varied by the control tape. However, this form of automatic masking is time-consuming, costly, and unsatisfactory: the information for driving the automatic masking device must be written on the control tape, etc., beforehand. Therefore, a simpler form of automatic masking has been desired.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an automatic masking device for an original picture holder of a composer, free from the aforementioned defects, wherein there is no need to write information for driving the masking device according to the size of the original picture onto any memory means, wherein unwanted portions of the original picture are automatically masked off, and which is operable simply and reliably.
According to the present invention, there is provided, in a composer which comprises an original picture holder which comprises a transparent plate against which an original picture is to be held during use of the composer, an automatic masking device comprising a plurality of opaque masking sheets which are adapted to move inwards along the surface of the transparent plate, drive means for moving these masking sheets, and a plurality of detectors, mounted approximately on the inside edges of at least some of the masking sheets, and which control the drive means.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more clearly understood from the following description of a preferred embodiment, taken in conjuction with the accompanying drawings. It should be understood, however, that the embodiment and the drawings are given only for the purpose of description, and are not intended to be in any way limitative of the present invention, or of the scope of protection desired. In the drawings, like parts are throughout denoted by the same reference numbers.
FIGS. 1(a) and 1(b) are top views of a conventional original picture and of a top mask, respectively;
FIG. 2 is a fragmentary longitudinal cross-section of a conventional original picture holder for printing by using a conventional cut mask;
FIG. 3 is a top view of FIG. 2;
FIG. 4 is a fragmentary top view of an original picture holder including an automatic masking device according to the present invention;
FIG. 5 is an enlarged longitudinal cross-section, taken along the line V--V in FIG. 4; and
FIG. 6 is an enlarged longitudinal cross-section, taken along the line VI--VI in FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 4 and 5, there is shown a transparent plate 10 of an original picture holder according to the present invention, which is square in form, and is made of glass, the lower surface of which forms a contact surface 10a on which an original picture is attached.
This is done by attaching a flexible transparent sheet 12, on which the original picture 11 is attached to the central upper surface, to the contact surface 10a by means of a vacuum suction means, or the like.
This original picture comprises a central patterned portion 11a and a border portion 11b having no pattern.
Four pieces of adhesive tape 13, for register marks, are attached to the border portion 11b, adjacent to the pattern portion 11a, of the original picture 11.
An automatic masking device according to the present invention comprises four masking units 15 arranged on the four sides of the square transparent plate 10. Each of these masking units comprises a roll shaft 17 parallel to the side of the transparent plate, which is supported by a pair of bearings 16, a reversible motor 18 for driving the roll shaft 17, a flexible opaque masking sheet 19 rolled on the roll shaft 17, which is adapted to extend as far as the center of the transparent plate 16, and a detector 20 fixed to the free end of the masking sheet 19.
As may be seen in FIG. 4, each masking sheet 19 may be advanced over the surface of the transparent plate 10 separately and independently, and they overlap one another without substantially disturbing their flat lying position against this surface. Thus, by suitably operating the motors 18, any desired rectangle with sides parallel to the sides of the plate 10 can be left uncovered, the rest of the plate 10 being blanked off or masked.
These masking sheets 19 may be made of rubber sheet, polyethylene glycol terephthalate film sheet, metallic foil, or the like.
The detector 20, as clearly shown in FIG. 6, comprises a housing 21 fixed on the masking sheet 19, a light source 22 arranged in the housing 21, a half-mirror 23, and a photoelectric converter element 24.
The light source 22 is positioned just above the slit 25 formed in the masking sheet 19, and the half mirror 23 is arranged between the light source 22 and the slit 25 so that light which comes upwards through the slit 25 and is reflected by the half mirror 23 may be incident to the photoelectric converter element 24.
Thus light from the light source 22 is projected to the original picture 11 through the half mirror 23 and the slit 25 and, if any is reflected from the original picture 11, i.e. from a non-tranparent portion thereof, it will be reflected by the half mirror 23 onto the photoelectric element 24.
An electric circuit, which is not shown since it is of conventional construction, is arranged to stop the operation of the driving motor 18, when the amount of reflected light is greater than a certain threshold level. This means that the edge of the adhesive tape 13 has passed under the detector.
As an alternative, it would be possible to arrange for the controlling electric circuit to stop the motor 18 when the amount of reflected light changes suddenly by more than a certain rate of change. Each of these control methods has its advantages and drawbacks.
If, therefore, it is arranged that the distance from the free end of each masking sheet 19 to the slit 25 of the detector 20 mounted on that masking sheet is the same as that from the edge of the pattern portion 11a of the original picture 11 to the outer edge of the adhesive tape 13, then when the slit 24 is stopped at the outer edge of the adhesive tape 13 the free end of the masking sheet 19 will also stop at the edge of the pattern portion 11a.
The operation of the device according to the present invention will now be described.
The adhesive tapes 13 are properly attached to the original picture 11, and the original picture is attached to the transparent sheet 12. These are then held to the contact surface 10a of the transparent plate 10 by a vacuum suction means or the like. The masking sheets 19 are rolled back to their starting positions, fully rolled up on their roll shafts 17, by reversely driving the motors 18. Then, each of the motors 18 is driven forwards, under the control of the detector element attached to the masking sheet 19 which is being driven by that motor, so that the masking sheets 19 advance across the surface of the transparent plate 10, each until its free end reaches the edge of the pattern portion 11a of the original picture 11, when it is automatically stopped by its detector. Thus the border portion of the original picture 11 is masked off automatically.
The above description has covered an embodiment of the present invention wherein four rollers and masking sheets which are independently controlled by four detectors are provided. This is the most general form. However, other possibilities also exist.
For example, if it is assumed that the original picture 11 is positioned centrally in the transparent plate 10, then each pair of opposing masking units 15 could be provided with but one driving motor 18, and also with only one detector 20 controlling that driving motor 18, which is mounted on one of the masking sheets 19.
As another alternative, if it is assumed that the original picture 11 is positioned in one corner of the transparent plate 10, then there need be provided only two masking units 15, which regulate the positions of two of the sides, only, of the unmasked rectangle.
As a further modification, it would be quite possible for the adhesive tapes 13 to be omitted, and for the edges of the pattern portion 11a to be detected directly by the detectors 20. Or other marks, not tapes, but for instance crayon marks, might be detected. It would be even possible for the detectors to be not optical, but, for example, magnetosensitive, and for them to detect magnetic tapes or marks made on the original picture.
As a yet further possibility, several detectors could be provided at different places on one or more of the masking sheets, and used alternatively, or even in combination, so as to be able to stop the masking sheets in different alternative places, for example in order to print a register mark on the photosensitive material.
Although the present invention has been shown and described with reference to several preferred embodiments thereof, it should be understood that various changes of the form and content thereof can be made by one skilled in the art without departing from the scope of the invention, which is not intended to be limited by any of the details of the embodiments used for illustration, or of the drawings, but, along with the monopoly granted, is intended to be defined solely by the accompanying claims.
|
An automatic masking device for use in a composer, wherein an original picture is held against a transparent plate, which comprises a plurality of opaque maskingsheets which are adapted to move inwards along the surface of the transparent plate from its edges, driven by drive means which is controlled by detectors which are mounted on the inside edges of at least some of the masking sheets.
| 6
|
[0001] I claim priority to U.S. Provisional Patent Application Ser. No. 60/383,570, filed May 28, 2002, and hereby incorporate said application by reference herein in its entirety.
FIELD OF INVENTION
[0002] This invention relates to a composition of botulinum based pharmaceuticals used for therapeutic and cosmetic treatment. This invention offers an improvement on the prior art by eliminating the potential of blood-borne contamination with botulinum based pharmaceuticals.
BACKGROUND OF THE INVENTION
[0003] Human serum albumin (“HSA”) is used to stabilize botulinum toxin at high dilutions. This albumin is a human blood product-derived agent from pooled plasma collections. As the molecular weight of the material is low (69,000), filtration generally allows for excellent filtration sterilization, however, prions (non-nucleic acid dependent infectious agents) have become an increasing concern for both federal regulators and the general public. Most physicians and patients do not even know that there are human blood products within BOTOX-™, the market leading botulinum toxin product. Prion dependent diseases include Creutzfeld-Jacob disease, Kuru, fatal familial insomnia, and Gertmann-Straussler-Scheinker disease. Although the incidences of these diseases are rare (one in 1,000,000), it has been estimated that one in 10,000 are infected with prions at the time of death. Prion diseases generally cause spongiforma encephalopathies of the brain with serious attendant neurologic symptoms prior to death. Humans are thought to acquire prions in two ways: (1) infection from medical procedures such as surgery, biologic agents, and tissue transplants, and (2) genetically. The impact that these observations have made is to try to limit human blood products in biologic agents.
[0004] Recently, recombinant albumin (RECOMBUMIN-™) has become available via Delta Biotechnology LTD, (Nottingham, UK-Aventis-Behring LLC) via high yield yeast expression system, offering a synthetic alternative to human serum albumin and an important differential point. In clinical studies including 500 patients, there have been comparable immunity and allergic reactions to native HSA, although larger study figures may be available at this time.
[0005] HSA has been employed as a stabilizer in botulinum toxin since its introduction into clinical studies in 1981 (see Schantz E., Johnson E. Therapy with Botulinum Toxin, Mercel Dekker, New York, 1994). The purpose of the albumin protein in high concentration relative to the botulinum neurotoxin is to maintain structural and biologic integrity of the toxin during and after the dilution steps in manufacturing pharmaceutically acceptable doses. The albumin appears to bind (via non-covalent molecular interaction) with the neurotoxin, preventing adherence of toxin molecules to the glass containers and protecting the tertiary structures on the protein molecule from disruption when diluted in aqueous solution.
[0006] Botulinum toxin has been stabilized by a number of proteins, hence there are multiple opportunities to remove the human serum albumin from the formulation. Such proteins include, but are not limited to, animal based gelatins, ovalbumin, lysozyme, bovine and porcine albumins. HSA has been the preferred stabilizer primarily because of its low immungenicity. Anaphylastic or analphylactoid reaction, although possible, are low with use of human albumin compared to other protein stabilizers such as gelatins, which have reactivity rates as high as 0.5-1%. The reactivity rate of albumin has been estimated at less than 0.1%, although generalized urticaria syndrome has rarely been observed with human albumin, in a frequency similar to a common blood transfusion reaction. As gelatins have been associated with much higher local and generalized allergic reactions, these categories of proteins are not suitable excipients. Because of the need for repeated injections required to treat many clinical indications and uses, any stabilizing excipient in a botulinum toxin product must have a low immunoreactivity rate.
[0007] Infectious risks of HSA include hepatitis and other infectious agents, which have been eliminated for decades by pasteurization of pooled blood serum. As donor lots typically may come from as many as 50,000 individuals, rigorous standards of processing are necessary. As pasteurization does not eliminate prions, however such measures fo not eliminate the risk of transmission of prions by human blood products, such as HAS. Prion based disease transmission has been demonstrated by transfusing infected donor blood among animal species. In humans, possible transmission has been reported after corneal transplantation and other tissue transplantation procedures. It has been suggested that the disease can be genetically transmitted. The major public risks to prion-based diseases relate specifically to the inability to sterilize animal and human based products from the infectious agent. Conventional gas and heat sterilization have not been reliable, nor have filtration techniques such as those used to prepare botulinum toxin based pharmaceuticals.
[0008] Diseases identified to be caused by prions include Creutzfeld-Jacob disease, Kuru, fatal familial insomnia, and Gertmann-Straussler-Scheinker disease. Creutzfeld Jacob disease and its veterinary correlate (“mad cow disease”) is an encephalopathy which progressively impairs neurologic function causing seizures, dementia, somnolence, and death over a period of months to several years. Incubation periods may be as long as ten years so immediate analysis and elimination of sources of contamination may not be possible. Such a public health risk demands a strict approach to elimination of possible sources and opportunity for transmission. Recently, a blood donor to the albumin pool was reported retrospectively to have contracted Creutzfeld Jacob disease after having contributed to the albumin pool. Fortunately, no one appears to have contracted prion-based diseases to date from the use of human serum albumin within pharmaceuticals or when used as a plasma expander.
[0009] The incidence of prion based disease is rare (1:1,000,000) although it has been estimated that 1:10,000 autopsy analyzed human brains indicate infection at time of death. The pathology is described as a subacute spongiform change, which can be seen on microscopic examination of the neocortex. Even at a incidence of 1 per million, the chance that at least one blood donor contributing to the albumin pool over a twenty year period will be infected is high even with strict standards of screening. To date there are no validated tests to assess a blood donor for the syndrome. Many patients treated with botulinum based pharmaceuticals will need repeated injections over a twenty to thirty year period and so run a repeated risk of exposure.
[0010] In recent years, blood collecting centers have been mandated by regulatory agencies to screen for foreign travel exposure to areas where prion-related diseases have been reported, such as Great Britain, and such donors are excluded from the donor source for pharmaceutical grade albumin (see Reuters News Agency-1999 releases). Despite major worldwide effort to prevent international and intercontinental cross contamination, mad cow disease has recently been reported in Canada in May, 2003. The mode of transmission whether genetic or via contamination needs to be determined.
[0011] In recent years, there has been increasing consumption of botulinum toxin for cosmetic use as compared to its original medicinal indications, such as blepharospasm, spasmodic torticollis spasticity and other involuntary movement disorders. Because of the more casual use of this agent for cosmetic purposes, concerns arose over inadvertent exposure of large numbers of patients to human blood products via albumin. In past publications (Borodic GE Botulinum toxin issues and applications, Current Opinions in Otolaryngology, 1998 Dec. 5; 352(9143):1832), the disadvantages of human blood products within the vials of botulinum toxin were cited, especially relative to its use as a cosmetic agent. Physicians have not been routinely advising patients of the presence of human blood products although the major manufacturer of one form of botulinum toxin (BOTOX-™) has listed the risk of possible prion contamination on its package insert.
SUMMARY OF THE INVENTION
[0012] This invention relates to a composition of botulinum based pharmaceuticals used for therapeutic and cosmetic treatment. This invention offers an improvement on the prior art by eliminating the potential of blood-borne contamination with botulinum based pharmaceuticals. Recombinant serum albumin is taught for use in the place of human serum albumin as a stabilizing or enhancing agent.
[0013] In one aspect, the invention features a pharmaceutical composition comprising a botulinum neurotoxin formulated with a recombinant serum albumin. In another aspect, the invention features a pharmaceutical composition comprising a botulinum cytotoxin formulated with a recombinant serum albumin.
DESCRIPTION OF THE INVENTION
[0014] Given the more casual use of botulinum toxins for cosmetic use, the possible presence of prion-based disease in low incidence in the population and the use of large pooled quantities of human serum albumin from thousands of blood donors, it would be useful to replace the HSA with a nonhuman or bovine sourced albumin.
Botulinum Toxin Manufacturing Specifications:
[0015] Botulinum toxin is prepared from various strains of Clostridia botulinum by fermentation and separation of the protein from spent cultures. Such separation techniques initially involve acid precipitation done in multiple steps causing removal of exogenous proteins and other particulate matter, according to the methods outlined by Schantz and Johnson. Final separation is further accomplished with chromatographic methods yielding a high specific toxicity. The biologic activity of botulinum toxin is generally measured by an LD 50 bioassay, using a 20-30 gram Swiss Webster mouse. Specific toxicity is measured using LD 50 units over nanograms of botulinum neurotoxin or cytotoxin protein. It is appreciated that certain immunotypes of non-A botulinum toxin have not been crystallized by the Schantz precipitation techniques and for such immunotypes the method of separation is limited to chromatographic techniques.
[0016] The strain of Clostridia botulinum may produce any immunotype. Generally a given strain produces usually one immunotype A-G. Certain strains produce exclusively cytotoxin (non-neurotoxin) and such strains can be a source of pharmaceutically active agents. The preferred strain for the production of immunotype A is the Hall strain, which has been previously qualified to produce a highly bioactive toxin (greater than 10 million mouse LD 50 units per milliliter).
[0017] Once full crystallization of botulinum toxin is accomplished, sterilization is conducted using filtration techniques. A dilution with protein-containing solution is done to achieve pharmaceutically active dose forms. To confirm each dose form is retained according to the dilution method, another LD 50 bioactivity assay is performed to maintain quality control. It is critical that the diluent contains a stabilizing protein. The preferred protein is recombinantly-produced human albumin from an recombinant yeast carrier, such as Saccharomyces cervasea or Pichia pastoris . The recombinant serum albumin is inserted into the diluent. For stabilization and shelf life preservation, freeze drying or flash drying may be utilized. Alternatively, pH adjustment can be used to enhance shelf life.
pH and Composition:
[0018] Generally, a pH of 7.4 is desirable in the final composition of the fluid prior to the freeze drying preservation process. This pH results in a more tolerable degree of discomfort to the patient upon injection of the final formulation. Lower pH formulations are associated with a much higher degree of pain upon injection. Lower pH formulations, however, enhance preservation of botulinum toxin and extend shelf life. Recombinant serum albumin may be used either in liquid or freeze dried formulation.
Immunogenicity and Allergic Properties of Recombinant Serum Albumin:
[0019] Early generations of manufactured recombinant serum albumin were limited in utility by the presence of immunogens which cause local inflammation after repeated injections. Botulinum-based pharmaceutical preparations require repeated injections, usually at three to four month intervals. If the recombinant serum albumin contains a critical mass of foreign extraneous yeast proteins, local and systemic inflammation may occur after repeated injections. In test samples, the separation of exogenous proteins was inadequate, hence local and systemic erythema and edema were noted in a significant numbers of test subjects receiving early generations of recombinent albumin. Such preparations were poor choices as a stabilizer, as the stabilizer appeared to cause more drug-induced allergic complications than the active agent. The recombinant serum albumin must be qualified with respect to local allergy at a rate of less than 1% for the preparation to meet a minimally acceptable standard. Any local or systemic allergic response to the recombinant serum albumin would make the use of the botulinum toxin unfeasible, with an adverse risk/benefit ratio for the patient.
Recombinant Serum Albumin Concentration and Botulinum Toxin Based Pharmaceutical Preparations:
[0020] The utility of adjuvant proteins has been appreciated since the inception of botulinum toxin pharmaceutical technology. The importance of concentration however has not been appreciated until recently. The concentration of human albumin does play an important role in the LD 50 unit dosage for botulinum type A toxins. DYSPORT-™ botulinum toxin, for instance, contains one forth the quantity of human serum albumin than BOTOX-™ and such a difference has been associated with a decreased potency relative to the LD 50 unit dosage (Biglalke et al (Exp Neurol 2001 March, 168(1):162-70 Botulinum A toxin: Dysport improvement of biological availability). Such differences relate to pharmacokinetic factors attributable to a direct chemical reaction of the albumin with the botulinum neurotoxin. Non-covalent binding via electrostatic or Van der Waals forces between molecules may contribute to botulinum sequestration necessary for effective binding with botulinum toxin on nerve tissues or possibly other binding sites.
[0021] Recently, higher albumin concentration-containing injection formulations have proven to be more effective than the usual 0.5 mg/vial concentration conventionally used in BOTOX for certain patients, as demonstrated by the following case: NM is a 53 year old woman with a three year history of involuntary blepharospasm causing difficulty driving and maintaining employment. She had been treated with increasing doses of BOTOX-™ containing 0.5 mg albumin/vial in addition to the active neurotoxin complex with associated proteins. She sustained no improvement at doses in excess of 100 units injected into multiple peri-ocular locations. Therapeutic trials with artane and Clonipin failed to produce any therapeutic benefit. An attempt at up to 6000 units of Botulinum toxin type B also failed to produce any benefit. Limited myectomy surgery was performed on both eyelids without substantial lasting benefit. Because of multiple therapeutic failures, a vial of BOTOX-™ was reformulated with concentrated albumin excipient to a concentration 10× that usually employed. The final concentration was 5 mg/vial. Repeat injection at the same dose of neurotoxin which previously failed produced an excellent result lasting at least one month with no side effects or complications.
[0022] A series of six patients, with poor results to BOTOX-™, have been responsive to high albumin concentration botulinum toxin type A. Based on these observations, higher concentration albumin botulinum preparations would be preferable compared to commercially available preparations.
[0023] The observation of the use of higher albumin concentrations with Botulinum type A from BOTOX is contrary to in vitro experimentation for denervation potency in animals using a rat diaphragm model (see Bigalke H, Wohlfarth K., Irmer A., Dengler R. Exp Neurol. 2001 March, 168(1):162-70 Botulinum A toxin: Dysport improvement of biological availability). Wohlfarth could not produce an enhancement of the denervation and pharmacologic potency of BOTOX or other type A toxins using his in vitro animal experiments (International Congress, Hanover Germany, June 2002). His observations implicate an albumin interaction but does not explain the mechanistic importance of the relationship between botulinum toxin and albumin, and how such a relationship can be used to formulate superior pharmaceutical preparations when injected into living tissues subject to blood perfusion.
[0024] Described herein is a method by which larger amounts of albumin (greater than 0.5 milligrams per 100 International Units) can be used to enhance the chemodenervative and potency properties of botulinum toxin by sequestering the neurotoxin and allowing maximum binding with cell surface receptors by preventing the toxin from diffusing away from the injection field. In summary, higher concentrations of recombinant albumin are preferable in the formulation described herein. Following are examples of such a method:
[0000] 1. A 50 year old woman wishing to have effacement of glabellar frown lines and transverse forehead lines, yet wishes no exposure to human blood products is injected with a dose of 10-300 mouse LD 50 units of botulinum toxin into frontalis and glabellar muscles in multiple location. Injections are repeated at three to four month intervals to maintain the desired effects.
2. A 60 year old patient with adult onset spasmodic torticollis not wishing exposure to human blood products with possible attendant risks of prion or other infectious agents wishes to be treated with botulinum immunotype A with no human blood products and higher degrees of stabilizing albumin to prevent diffusion into peripharyngeal musculature with possible attendant dysphagia presents to his physician. The physician injects a botulinum type A toxin with no human blood products and a concentration of recombinant serum albumin exceeding 0.5 mg/cc. using 20-1000 mouse LD 50 units.
3. A 50 year woman with myofascial pain, wishing relief from pain within the posterior cervical region, requests no exposure to human blood products for religious and medical reasons. The physician treats this patient with botulinum type A toxin stabilized with high concentration recombinant serum albumin (greater than 0.5 mg/cc) at a dose of 10-400 mouse LD 50 units. Repeated injections are conducted at various intervals.
4. A 70 year old woman with blepharospasm wishes relief from involuntary blinding eyelid spasms yet requests no exposure to human blood products. This woman is injected with a botulinum toxin preparation stabilized with recombinant serum albumin at a concentration greater than 0.5 mg/cc using between 5-150 mouse LD 50 units.
|
This invention relates to a composition of botulinum based pharmaceuticals used for therapeutic and cosmetic treatment. This invention offers an improvement on the prior art by eliminating the potential of blood-borne contamination with botulinum based pharmaceuticals. Recombinant serum albumin is taught for use in the place of human serum albumin as a stabilizing or enhancing agent.
| 0
|
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to ammunition sabots and particularly to a disintegrating sabot.
"Small caliber" as used herein means 0.50" caliber and below. The state of the art in plastic small caliber sabots has basically remained static since the development of the plastic sabot for hunting ammunition shown in U.S. Pat. No. 3,164,092, issued Jan. 5, 1965, to D. S. Reed et al and assigned to Remington Arms Co., Inc. and which relates to the well-known Remington "Accelerator" hunting cartridge which uses a lead bullet in a polycarbonate sabot.
There is a constant desire to increase the speed, hardness, and density of lightweight subcaliber rifle bullets so that they will penetrate harder and thicker targets. However, it has not been known how to do this in conventional rifles due to the denser bullet materials that are required and the inability of existing sabots such as that taught by the Reed et al patent above to withstand the forces imposed by such launches of subcaliber projectiles having higher sectional density and hardness than the soft lead hunting bullets taught by the Reed et al patent.
The present invention provides a solution to this problem by providing an ammunition sabot which is strong enough to exit a rifled barrel in one piece at peak chamber pressures in excess of 70,000 copper crusher units of pressure (C.U.P.) while carrying a tungsten or tungsten carbide penetrator and then immediately disintegrate so that it doesn't thereafter slow down the projectile or make the projectile inaccurate. In the present invention, this is accomplished by use of a special sabot material and/or a special sabot design.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the attached drawing in which:
FIG. 1 is a cross-sectional view taken along the axis of a preferred sabot and projectile of the invention; and
FIG. 2 is an isometric view of the washer of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A projectile 10 is shown having a major cylindrical rear portion 12 carried with a central recess 14 of a generally cylindrical plastic sabot 16 which has a solid cylindrical rear base portion 18 and a tubular front portion 20. Front portion 20 comprises a plurality of arcuate cylindrical portions 22 connected by weakened portions 24 extending axially on portion 20. Weakened portions 24 are weakened by suitable means such as spaced axial grooves or notches 26 on the inner periphery of central recess 14. Notches 26 run from the front end of sabot 16 part way back on the inner periphery of front portion 20. The outer periphery 28 of sabot 16 is an uninterrupted right cylindrical surface.
Between the floor 30 of recess 14 of sabot 16 and the rear end 32 of projectile 10 is a metallic square washer with rounded corners 34 (also shown in FIG. 2) which extends radially inward and outward of the inner periphery of central recess 14 so as to distribute the accelerational forces during explosive discharge of sabot 16 and projectile 10 together through a rifled gun barrel (not shown) and to prevent rotational slippage between sabot 16 and washer 34 during spin-up of sabot 16 during such discharge. Washer 34 could be of other non-circular symmetrical shapes such as polygonal, (pentagonal, or hexagonal, etc.), oval, or gear-shaped. Washer 34 has rounded corners to reduce stress concentrations at its corners and to allow use of bigger area washers.
Outer periphery of 28 of sabot 16 is of a substantially constant diameter from base 18 up to an axial point 36 which is located forward of the center of gravity 38 of projectile 10 to minimize balloting of projectile 10 during its passage through a rifled gun barrel, as might occur if point 36 was located back of center of gravity 38. A second optional heavy projectile 10a is also shown having a center of gravity 38a, which is also behind point 36.
Sabot 16 is of 7.62 mm caliber and carries a 52 grain tungsten projectile 10 or a 57 grain tungsten projectile 10a. Other calibers of sabot 16 such as 5.56 mm or 0.50 caliber could also be utilized and other sizes, materials, and shapes of projectiles 10 could be utilized, if desired.
The plastic for sabot 16 is of a material that has sufficient tensile strength (at least 12,000 psi when tested under the standard ASTM Test Method D1708), compressive strength (at least 15,000 psi when tested under the standard ASTM Test Method D695), and sufficient shear strength (at least 12,000 psi when tested under standard ASTM Test Method D732) to withstand the shock of explosive discharge from a rifled gun barrel while carrying projectile 10 but having insufficient (less than about 12 ft.-lbs./in. when tested under standard ASTM Test Method D256) Izod impact strength to withstand centrifugal and aerodynamic forces following discharge so that sabot 16 disintegrates immediately (i.e., within a yard) after exiting the barrel muzzle, thus immediately freeing the projectile 10 for unimpeded flight to the target.
One suitable plastic material is "ULTEM 1000", an unreinforced amorphous polyetherimide thermoplastic resin marketed by General Electric Company. Some other plastics believed to be suitable are ULTEM 2200, a 20% glass reinforced polyetherimide resin and LEXAN 3412, a 20% glass reinforced polycarbonate resin, both from General Electric Company and TORLON 4203L engineering resin from Amoco Chemicals Corporation. Other plastics with equivalent mechanical properties could be utilized if the mechanical properties of the plastic are not chemically deteriorated by any exposure to propellants with which it is expected to be utilized.
|
A high velocity ammunition sabot of brittle material which has sufficient strength to withstand the forces of being launched from a rifled gun barrel but which fragments almost immediately upon exit from the barrel due to centrifugal forces. A polyetherimide material is preferred, although materials of equivalent properties could be used.
| 5
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional application of U.S. patent application Ser. No. 10/069,121 filed on Mar. 1, 2002 now U.S. Pat. No. 6,763,854.
BACKGROUND
A. Field
The invention relates to a weaving machine with a system for cutting a filling thread that is held ready for filling insertion from a filling thread already beaten into a woven fabric.
B. Related Art
When weaving, a filling thread inserted into a shed is beaten by a reed against the fabric edge, the so-called fell line. Before the filling thread is inserted into the next shed, it is cut off on the insertion side of the shed. The filling thread awaiting insertion should be cut at a precisely defined time in order to control the length of the next inserted filling and/or the thread tension and to satisfy other conditions.
In a known weaving machine of the above described kind (European patent document 0 284 766 A1), the filling thread is cut by a mechanical cutter which contains a drive that is separate from the main machine drive and that in turn is controlled by a programmable control system.
SUMMARY OF THE INVENTION
The objective of the invention is to design the system of the above kind so that even more precise timing of the cutting can be achieved.
This problem is solved by using a laser as the cutting device.
The invention offers the advantage that such a laser can be actuated very rapidly and that as a result the cutting of the filling can be carried out in a fraction of a second. Moreover such a laser operates without mechanical components that are subject to wear, and consequently a predetermined precise cutting time can be maintained without effect of any wear. The design of the invention provides the further following advantage when the filling is made of a synthetic material, for instance a filament thread or one containing synthetic components. Such synthetic material will be slightly fused when cut so that the fibers of the filament threads of the cut ends are bonded to one another. This feature is especial advantageous in airjet looms. In airjet looms there is a danger that the filling that is kept ready in a main blowing nozzle may fray in the vicinity of its end or may unravel. If this occurs, problems will arise during the subsequent filling insertion because of the increased danger of catching of the fibers on the teeth of the reed. Also, the appearance of fabric edge opposite the insertion side would then be degraded. Therefore the invention provides an advantage with respect to airjet looms. As regards other machinery, for instance gripper looms, the invention also offers substantial advantages, in particular with regard to the accurate determination of the time of cutting.
Cutting systems in the form of lasers are basically known in the textile industry, for instance from the Italian patent 1,140,124, the Dutch patent 175,326 and the Japanese patent document 5 247 835 A. In the state of the art, however cutting systems in the form of lasers are used for fabric-severing or for loop-cutting by the forming of felt cloth.
In a further embodiment of the invention, the cutting laser shall be fitted with an optical system that converts an emitted laser beam into a flat beam.
In order that a low-energy laser shall suffice, its beam normally must be focused onto a comparatively small spot. As regards threads, such a requirement may entail problems because of the practical difficulty of precisely aligning a filling thread to be cut with the focus of the laser. This difficulty is circumvented by transforming the laser beam into a Fat beam. The flat beam may be positioned so that its width direction shall run transversely to that of the thread, and accordingly positioning the thread and/or the laser will not raise problems.
DESCRIPTION OF DRAWINGS
Further features and advantages of the invention will be evident from the description below and from the illustrative embodiment shown in the drawing.
FIG. 1 is a schematic view of an airjet loom fitted with a cutting system of the invention, and
FIG. 2 shows a laser with an optical system converting a laser beam into a flat beam.
DETAILED DESCRIPTION
A fabric 10 is woven from warp threads 11 and filling threads 12 on a weaving machine shown in very schematic form in FIG. 1 . In a manner not shown in detail, the warp threads 11 are periodically raised and lowered by shed-forming elements in order to form sheds into which the fillings 12 may be inserted. Following insertion, the filling thread 12 is beaten by a reed 13 against the fabric edge or fell line. The reed 13 is mounted on a batten profile 14 of the batten beam that pivots to-and-fro. In the embodiment as shown, a main blowing nozzle 15 is mounted on the batten beam profile 14 that accompanies the to-and-fro pivoting motion of the reed 13 . The main blowing nozzle is shown in much simplified form. In practice, preferably two consecutively mounted main blowing nozzles will be used. Relay nozzles are mounted in a distributed manner in a transverse direction across the reed 13 and these relay nozzles are supplied with compressed air to help transport the filling threads within the shed to the opposite side.
By means of a cutting system 16 , the inserted filling thread 12 beaten against the fell line is cut from the filling thread segment 12 ′ remaining within the main blowing nozzle 15 . Thereupon the reed 13 and the main blowing nozzle 15 together with the filling 12 ′ will pivot backward. As soon as a new shed has been opened, a new filling insertion takes place, and this time the filling thread 12 ′ will be inserted. As already stated above, the weaving machine is shown in a very simplified manner. In practice several main blowing nozzles 15 are normally used in an adjoining and superposed manner in order to insert several filling threads of different types and/or colors. A number of main blowing nozzles may be used even when only identical fillings are inserted, for example to increase the operational rate.
The end of the filling 12 ′ currently being kept ready is situated within a moving air stream. The purpose of this air stream is to support the ready filling 12 ′ in such a way that it cannot recoil back out of the main nozzle 15 . While this air stream holding the filling 12 ′ is weaker than that used to insert it, this weaker air stream nevertheless may tend to unravel the end of the ready filling 12 ′, especially if there should be a weaving pause. This phenomenon is especially troubling when the filling threads are filament threads having no or little twist. Such filament threads for example, consist of a plurality of thin individual filaments extending parallel against each other and being fused together at distinct, spaced locations. Such a filament thread may unravel in the vicinity of its end and thus there is a danger that when it is inserted into the shed, it will snag on the reed's teeth. Also, this phenomenon produces an unattractive appearance of the woven fabric at the side of the cloth opposite the insertion side.
To circumvent the above drawbacks, the cutting system 16 is provided with a pulsed laser cutting system. This laser, which is pulsed, may be a solid-state laser or preferably a gas laser and it cuts the filling in a very short time. During cutting, a comparatively large heat is dissipated and melts synthetic threads or synthetic components, whereby the ends of the fibers or filaments may be fused together. Even though the blowing air which continues being expelled from the main blow nozzle 15 causes rapid cooling, the intense heat generated by the laser will nevertheless induce melting. Accordingly the end of the ready filling thread 12 ′ shall remain united.
Moreover, the laser cutting system has the advantage of rapid response time and very quick cutting of the filling thread. As a result, the cutting procedure can be timed very accurately in relation to operating requirements. This feature also is advantageous when applied to other types of weaving machines, for instance, gripper looms. As regards gripper looms, an inserted filling thread may be severed from a ready filling thread only after it has been seized and carried along by the gripper for further insertion. It is important in this respect that the time of cutting be very precisely matched to that time at which the filling thread is clamped onto and carried along by the gripper for its insertion.
The laser cutting beam is tightly focused in order to minimize laser power consumption as much as possible. Illustratively such minimization can be implemented using an optical system including spherical focusing lens elements. On the other hand, point-focusing creates a problem in positioning the laser because the filling thread has a relatively small diameter. Accordingly, an optical system 17 of special lens elements may be used, for example a cylindrical lense. Such optical system 17 converts the laser beam into a flat beam 18 . The flat beam 18 is oriented in such a way that its length direction runs transversely to the longitudinal axis of the filling thread 12 , 12 ′ to be cut.
The laser system 16 offers still another advantage in that the distance between the main blowing nozzle 15 and the reed 13 may be kept comparatively small because the laser cutting beam virtually requires no space. Still another advantage of the system 16 of the invention is the lack of moving parts that are susceptible to wear, and as a result lasting and accurate operation is assured.
|
A weaving machine, in particular an airjet loom, which is fitted with a system ( 16 ) for cutting a filling thread ( 12 ′), which is being held ready for filling insertion, from a filling ( 12 ) already beaten into a fabric ( 10 ), wherein the system ( 16 ) includes a laser.
| 3
|
BACKGROUND OF THE INVENTION
[0001] The present invention relates to floor cleaning machines and in particular to automatic floor cleaning and treating machines which are used for the cleaning of carpets and hard surfaces of large floor areas, such as in hotels, factories, office buildings, shopping centers and the like.
[0002] In general such machines comprise a movable body carrying a brushing means, reservoirs for storing fresh and spent cleaning liquid, means for dosing fresh cleaning liquid onto the floor and a squeegee/vacuum pick-up system for recovering spent cleaning liquid from the floor.
[0003] These machines are normally power-operated comprising a pair of driving wheels for moving the body, a motor for driving the wheels, and steering and speed control members for operating the driving motor. Steering may either be manual or by way of differentiated control of the individual wheel speeds.
[0004] The present invention now in particular relates to a means for controlling speed and/or steering of a floor cleaning machine.
SUMMARY OF THE INVENTION
[0005] According to some embodiments of the invention there is provided a floor cleaning machine comprising a body, a pair of driving wheels for moving the body, an electric motor is coupled to each driving wheel, and a steering assembly for controlling the operation of the driving motors and the direction of motion of the floor cleaning machine. The steering assembly includes a member that is deformable under operator-applied force and also comprises a component which is capable of controlling the current provided to each driving motor as a function of operator-applied deformation of the member.
[0006] One particular embodiment of the present invention is directed toward a steering assembly for a floor cleaning machine having a pair of drive wheels powered by independent motors. The steering assembly includes an elongated frame member and a hand manipulable pivotal member coupled to the frame member. The hand manipulable pivotal member is pivotable about an axis normal to the elongated frame member. A spring extends between the frame member and the hand manipulable pivot member. The spring is positioned and configured to exert a force on the frame member in response to pivotal movement of the hand manipulable pivotal member. A sensor is coupled to the elongated frame member to detect deformation of the frame member due to exerted forces by the spring. A control is coupled to the sensor and the motors of the drive wheels of the cleaning machine. The control receives signals from the sensor and selectively powers each drive wheel motor in response to the signals from the sensor.
[0007] Another embodiment is directed toward a steering assembly for a floor cleaning machine having a pair of drive wheels powered by independent motors. The steering assembly comprises a frame member and a handle bar coupled to the frame member and positioned substantially normal to the frame member. The handle bar has cantilevered ends relative to the frame member, wherein an applied force to the cantilevered ends of the handle bar cause the frame member to deform. A sensor is coupled to the frame member to detect deformation of the frame member due to exerted force on the cantilevered ends of the handle bar. A controller is coupled to the sensor and the motors of the drive wheels of the cleaning machine. The controller receives signals from the sensor and selectively powers each drive wheel motor in response to the signals from the sensor.
[0008] Another embodiment is directed toward a steering and speed control assembly of a floor cleaning machine. The steering and speed control assembly comprises a frame member having a hand manipulable speed control device and a hand manipulable pivotal steering control member coupled to the frame member. The hand manipulable pivotal steering control member is pivotable about an axis normal to the frame member. A spring extends between the frame member and the hand manipulable pivotal steering control member. The spring is positioned and configured to exert a force on the frame member in response to pivotal movement of the hand manipulable pivotal steering control member. A sensor is coupled to the frame member to detect deformation of the frame member due to exerted forces by the spring. A controller is coupled to the sensor, the hand manipulable speed control device, and the motors of the drive wheels of the cleaning machine. The controller receives signals from the sensor and selectively powers each drive wheel motor in response to the signals from the sensor. The controller also receives signals from the hand manipulable speed control device and powers both drive wheel motors in response to the signals from the hand manipulable speed control device. In some embodiments, the speed control device is directly coupled to the hand manipulable pivotal steering control member.
[0009] Another embodiment is directed toward a steering and speed control assembly of a floor cleaning machine. The steering and speed control assembly comprises a frame member having a hand manipulable speed control device and a handle bar steering control member coupled to the frame member. The handle bar has cantilevered ends relative to the frame member, wherein an applied force to the cantilevered ends of the handle bar cause the frame member to deform. A sensor is coupled to the frame member to detect deformation of the frame member due to exerted force on the cantilevered ends of the handle bar. A controller is coupled to the sensor and the motors of the drive wheels of the cleaning machine. The controller receives signals from the sensor and selectively powers each drive wheel motor in response to the signals from the sensor. The controller also receives signals from the hand manipulable speed control device and powers both drive wheel motors in response to the signals from the hand manipulable speed control device. In some embodiments, the speed control device is directly coupled to the handle bar steering control member.
[0010] Further aspects of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a floor cleaning machine with a steering assembly embodying aspects of the present invention.
[0012] FIG. 2 is a perspective view of a steering assembly embodying aspects of the present invention.
[0013] FIG. 3 is another perspective view of the steering assembly shown in FIG. 2 , with the steering device rotated relative to FIG. 2 .
[0014] FIG. 4 is a schematic view of the steering assembly illustrated in FIG. 2 , shown in relation to the sensor, controller, and drive wheel motors.
[0015] FIG. 5 is a schematic view of an alternative steering assembly embodying aspects of the present invention.
DETAILED DESCRIPTION
[0016] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limited. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected,” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. Finally, as described in subsequent paragraphs, the specific mechanical configurations illustrated in the drawings are intended to exemplify embodiments of the invention. Accordingly, other alternative mechanical configurations are possible, and fall within the spirit and scope of the present invention.
[0017] Referring now to FIG. 1 , a floor cleaning machine 10 is shown, comprising a housing 11 , an operator control assembly 12 , a scrubbing assembly 13 and a squeegee 14 . The cleaning machine 10 is supported on main drive wheels 16 , 17 and one or more caster wheels 18 . Although it is not illustrated, several items such as a tank, batteries, pumps, motors, and other parts can be housed within the housing 11 .
[0018] Although the invention will be described in connection with a scrubber, it should be clear that the control has application to other types of vehicles that are controlled by an operator walking or riding behind the machine and are propelled by two electric motors, such as battery powered sweepers and the like. Accordingly, the present invention should not be limited to a scrubber.
[0019] As shown in FIG. 1 , an operator control assembly 12 which is positioned toward the rear of the machine and used by the operator to control speed and direction. The operator control assembly includes a steering assembly 20 and speed control lever 22 . Accordingly, speed and direction can be controlled independently with this operator control assembly 12 . Although the speed control lever 22 is not directly coupled to the steering assembly 20 , in some embodiments, the speed control device 22 can be directly coupled to or integrated into the steering assembly 20 . For example, in some embodiments, the speed control device 20 can be integrated into or manipulated by a rotatable hand grip. Under such an alternative configuration, the speed control device 22 can still remain independently controlled.
[0020] As shown in FIGS. 2 and 3 and schematically illustrated in FIG. 4 , the steering assembly 20 includes a hand manipulatable pivotal member or handle bar 24 having hand grips 26 . The pivotal member 24 is pivotally coupled to and supported on a bar or frame member 28 . As illustrated, the pivotal member 24 is positioned on the frame member 28 to rotate about an axis that is substantially normal to the frame member 28 .
[0021] A spring 30 extends between the pivotal member 24 and the frame member 28 . The spring can be a torsion spring, or more specifically, a dual throw coil spring. However, in other embodiments, other types of bias elements can be used. The spring 30 biases the pivotal member to a neutral position, such as the position illustrated in FIG. 2 . The spring 30 generates a force on the frame member 28 in response to the pivotal member 24 being rotated from the neutral position, such as shown in FIG. 4 . This force causes deformation or bending of the frame member 28 . As described below, this deformation is measured and used to steer the floor cleaning machine 10 .
[0022] An alternative embodiment of the steering assembly 20 is shown schematically in FIG. 5 . Unlike the embodiment shown in FIG. 4 , the handle bar 24 of this embodiment is rigidly fixed to the frame member 28 . In other words, the handle bar 24 does not pivot with respect to the frame member 28 . Accordingly, any attempt to steer the floor cleaning machine 10 via the handle bar 24 will directly cause the frame member to bend or deform. Like the previous embodiment, this deformation is then measured and used to steer the floor cleaning machine.
[0023] In both embodiments, a sensor 32 is coupled to the frame member 28 to measure the deformation of the frame member 28 . Many different sensors can be used to measure the deflection, deformation, or amount of bending in the frame member 28 . For example, strain gauges, a Hall-effect sensors, and other deformation sensitive components can be used to measure the deformation. This measurement can then be used to cause the floor cleaning machine to turn a desired amount as described below.
[0024] As schematically illustrated in FIGS. 4 and 5 , a separate drive motor 34 , 35 is coupled to each drive wheel 16 , 17 . As such, each wheel can be driven independently to cause the floor cleaning machine 10 to turn. The drive motors 34 , 35 are controlled in part by the sensor 32 . In general, the deformation-sensitive component or sensor 32 does not necessarily directly control the current of the driving motors, but preferably is coupled to a controller, amplifying circuit, or other components 33 that control the motor current or power based at least partially upon the information received from the sensor 32 .
[0025] In operation, the floor cleaning machine 10 can be placed in motion by manipulating the speed control lever 22 . The direction can be independently controlled via the steering assembly 20 . As illustrated in embodiment shown in FIG. 4 , the pivotal member 24 can be pivoted with respect to the frame member 28 by applying a force to the hand grips 26 . By pivoting the pivotal member 24 , the spring 30 places a force on the frame member 28 , causing the frame member 28 to deform or bend. The sensor 32 measures the deformation of the frame member 28 and relays the measurement to a controller 33 , which then controls the power provided to each drive motor 34 , 35 . For example, in the illustrated embodiment of FIG. 4 , the steering assembly is rotated to cause a left turn. As such, the power to the left motor 34 may be decreased, while the power to the right motor 35 remains the same or is increased.
[0026] Once the pivotal member 24 of FIG. 4 is released, the spring 30 returns the pivotal member 24 to the neutral position. As such, the bending or deforming force is removed from the frame member 28 and the frame member 28 elastically returns to a non-deformed configuration. Accordingly, no deflection will be detected by the sensor and equal power will be provided to each drive wheel motor 34 , 35 .
[0027] The operation of the embodiment shown in FIG. 5 is similar to the operation of the embodiment shown in FIG. 4 , except the handle bar 24 assembly does not pivot with respect to the frame member. Rather, a force applied to the handle bar 24 directly causes deformation of the frame member 28 . The sensor 32 measures the deformation of the frame member 28 and relays the measurement to a controller 33 , which then controls the power provided to each drive motor 34 , 35 .
[0028] Once the force applied to handle bar 24 of FIG. 5 is released, the elastic force of the frame member 28 causes the frame member 28 to elastically return to a non-deformed configuration. Accordingly, no deflection will be detected by the sensor and equal power will be provided to each drive wheel motor 34 , 35 .
[0029] The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention. For example, various alternatives to the certain features and elements of the present invention are described with reference to specific embodiments of the present invention. With the exception of features, elements, and manners of operation that are mutually exclusive of or are inconsistent with each embodiment described above, it should be noted that the alternative features, elements, and manners of operation described with reference to one particular embodiment are applicable to the other embodiments.
[0030] Various features of the invention are set forth in the following claims.
|
A floor cleaning machine having a speed control and steering member which operates under operator-applied deformation thereof. The invention provides improved consumer convenience at steering and/or speed control.
| 0
|
CROSS REFERENCE TO RELATED APPLICATIONS
N/A
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
BACKGROUND OF THE INVENTION
The invention is concerned with liquid oral prebrushing compositions containing sodium benzoate, sodium lauryl sulfate and small but effective amounts of tetrasodium pyrophosphate. These compositions are designed for removal of plaque from teeth before brushing with a dentifrice. Dental plaque is a problem with the teeth of most persons and consists of a microbial film which adheres firmly to dental surfaces. While it often can be removed with some difficulty by surface cleaning, it has a tendency to reform rapidly so continuous treatment is needed.
Plaque is particularly dangerous when formed on the teeth around the gum surface as it leads to gingivitis, periodontal disease and eventually loss of teeth and jawbone.
While many people can obviate most plaque problems by daily brushing and flossing combined with periodic cleaning by a dental hygienist, for some this is not sufficient. Therefore, it is desirable to have an oral composition which can be used on the teeth prior to brushing to soften and loosen the plaque so that it is more easily removed by the physical abrasion of brushing.
U.S. Pat. No. 5,338,538 uses a combination of pyrophosphate and sodium lauryl sulfate in a prebrushing oral formulation for softening and removal of plaque. The compositions of this patent all have a relatively high concentration of pyrophosphate salt and also operate at an alkaline pH, and tend to have a problem with clouding when stored at cooler temperatures.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a liquid oral prebrushing composition designed to loosen and remove accumulated plaque deposits, has a slightly acidic pH of about 5.0 to less than 7.0, and contains sodium benzoate, sodium lauryl sulfate and tetrasodium pyrophosphate. The composition remains clear and uniform without any indication of clouding or precipitation when stored in temperatures of 7° C. to 40° C. for prolonged periods.
DETAILED DESCRIPTION OF THE INVENTION
The invention preferably is a clear solution comprising about 6.0 to about 10.0 wt. % ethyl alcohol, about 5.0 to about 15 wt. % of a selected humectant, preferably glycerin or sorbitol, about 0.02 to about 0.075 wt. % sodium lauryl sulfate, about 0.2 to about 0.85 wt. % sodium benzoate, an acid buffer to pH at about 5.5 to about 6.5, sodium saccharin to the desired sweetness level, selected flavors, a soluble thickener which may be added at 0.001 to 0.10 wt. %, and D.&C. or F.D.&C. dyes, as required. Sodium fluoride can be incorporated at a safe and effective level to make the product also a post-brushing rinse. About 0.01 to about 0.05 wt. % tetrasodium pyrophosphate, with the other detergent salts, i.e., sodium benzoate and sodium lauryl sulfate, are effective in loosening and assisting in removing accumulated oral plaque when the product is rinsed over dental surfaces prior to a vigorous brushing.
The most effective manner of combining the foregoing ingredients to provide a clear, stable product is as follows:
1. All alcohol soluble ingredients; namely the solubilizers, benzoic acid, and flavors are added to and mixed into the ethyl alcohol.
2. A separate slurry is prepared by dissolving the sodium lauryl sulfate in a portion of the batch water, adding the soluble gum thickener and mixing until clear.
When clear and uniform, the selected humectant (glycerin or sorbitol solution) can be added and mixed until uniform.
3. The major portion of the purified water is charged into the manufacturing tank, mixing is started and the balance of the water soluble materials are added, namely, sodium benzoate, tetrasodium pyrophosphate, sodium saccharin, dyes, sodium fluoride, if desired, and the balance of the humectant. This is then mixed until uniform. The alcohol phase is next added and mixed. The gum slurry is added and, after mixing until uniform, the batch is completed with purified water, mixed and sampled for specification testing.
The manner of making variations of this dental rinse invention is illustrated by the following examples:
EXAMPLE 1
The following oral rinse composition was formulated:
A.
Alcohol phase, All figures are given as w/w;
Ethyl Alcohol (190 Proof)
8.675
Flavors
0.103
Solubilizers
0.45
Benzoic acid
0.02
B.
Gum slurry;
Water, purified
5.0
Sodium lauryl sulfate
0.05
Xanthan gum
0.005
The Gum slurry is mixed until completely clear,
1.5-15.0
and a glycerin solution is added. If desired,
sorbitol can be substituted for glycerin
C.
Batch;
Water, purified
65.0
Glycerin/sorbitol
balance
Sodium benzoate
0.20
Tetrasodium pyrophosphate
0.01
Sodium saccharin
0.0035
F.D. & C. dyes
QS
Alcohol solution
all
Gum slurry
all
Water, purified
QS to 100%
The result is a clear solution having a pH of 5.5/6.5
The result is a clear solution having a pH of 5.5/6.5
EXAMPLE II
Oral Rinse:
% w/w
A.
Alcohol phase;
Ethyl Alcohol (190 proof)
6.1814
Flavors
0.1175
Solubilizers
0.1500
Benzoic Acid
0.0190
B.
Water phase:
Water, purified
85.4559
Humectant
7.110
Sodium Benzoate
9.850
Sodium Lauryl Sulfate
0.050
Tetrasodium Pyrophosphate
0.050
Soluble gum thickener
0.0010
Sodium Saccharin
0.0096
F.D. & C. Dyes
QS
C.
Batch
The alcohol phase and the water phase are combined and
the result is a clear product at a pH of 6.5/6.95
The alcohol phase and the water phase are combined and the result is a clear product at a pH of 6.5/6.95
EXAMPLE III
Pre/post brushing dental rinse:
% wt.
Alcohol Phase:
A.
Ethyl Alcohol (190 proof)
6.4837
Flavors
0.1554
Solubilizer
0.845
Alcohol solubilized humectant
7.0253
B.
Water phase:
Water, purified
83.50
Citric Acid
0.1486
Sodium Benzoate
0.8450
Sodium Lauryl Sulfate
0.0498
Sodium Saccharin
0.0097
Sodium Bicarbonate
0.4998
Sodium Fluoride
0.0020
F.D. & C Dyes
QS
Water, purified
QS
C.
Batch
The alcohol phase and the water phase are combined and
the resulting product is clear and has a pH of 6.5/6.95
The alcohol phase and the water phase are combined and the resulting product is clear and has a pH of 6.5/6.95
The low level of pyrophosphate, namely about 0.01% P 2 O 7 −4 reduces the cloudiness of the product at lower temperatures, i.e., 10° C.
The combination of sodium benzoate, P 2 O 7 −4 and sodium lauryl sulfate is an effective active ingredient combination which reduces the amount of active ingredients that are needed, and thus tends to eliminate the cloudiness problem in such compositions, particularly when used at a acidic composition of pH about 6.0 to below 7.0. The tetrasodium pyrophosphate is present in an amount of 0.005 to 0.015 wt. %. The sodium lauryl sulfate is present in an amount of about 0.025 to about 0.065 wt. % and sodium benzoate is present in an amount of about 0.15 to about 0.25wt. %. Adding about 0.01% to about 0.05 wt. % benzoic acid produces a buffered pH system in combination with sodium benzoate to produce a finished product having a pH of about 5.5 to about 6.5, and thus a stable product which remains stable on prolonged storage, even at low temperatures
The prebrushing composition of the invention may include a humectant to give a moist feel to the mouth. Certain humectants can also impart sweetness to the prebrushing composition. The humectant generally is present in an amount ranging from about 5 to about 25 wt. % of the prebrushing composition. Suitable humectants which may be used include edible polyhydric alcohols, such as sorbitol or glycerol.
The prebrushing composition of the invention may, in addition, include ingredients effective to provide flavoring and coloring. The flavorant may be a flavoring oil, such as, oil of peppermint, spearmint, wintergreen, eucalyptus, lemon, and orange, and sweetening agents such as sucrose, lactose, maltose, saccharine, sodium cyclamate, etc. The amount of flavoring or sweetening agent generally ranges from about 0.002% to about 0.3% of the prebrushing composition.
The prebrushing composition is used in a conventional manner by applying a comfortable amount, such as one tablespoon, in the mouth, and rinsing it about the dental surfaces. A reduction of the amount of plaque on dental surfaces is accomplished when the prebrushing composition of the invention is employed in conjunction with a conventional tooth brushing regimen.
In view of the above, it will be seen that the several objects and advantages of the present invention have been achieved and other advantageous results have been obtained.
As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shall be interpreted as illustrative and not in a limiting sense.
|
A liquid oral composition for loosening and removing accumulated plaque deposits on dental surfaces which has a slightly acidic pH of about 5.0 to less than 7.0 and is stable when stored at 7°-40° C. for prolonged periods. The composition contains 0.15-0.25 wt. % sodium benzoate, 0.025-0.65 wt. % sodium lauryl sulfate and 0.005-0.015 wt. % tetrasodium pyrophosphate as active ingredients.
| 0
|
FIELD OF THE INVENTION
The lamp cooling system inserts into a standard socket and receives a lamp bulb. The lamp cooling system has a fan and cooling fins therein for cooling the lamp and electronics.
BACKGROUND OF THE INVENTION
Lamps generate heat and, in some cases, the heat limits lamp life. In other cases, the generated heat prevents utilization of a lamp of the required luminosity because overheating of the system occurs. Thus, the installation of lamp bulbs is often limited by the cooling capacity of the environment. In many cases, additional cooling is required in order to permit the utilization of a lamp of the desired luminosity.
SUMMARY OF THE INVENTION
In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a lamp cooling system wherein the system includes a housing which has a lamp socket therein and which can be installed in a lighting system. The lamp is inserted into the lamp socket, and the housing contains fins to dissipate heat from the lamp socket and contains a motor-driven fan to move air over the lamp and fins. The housing may contain electronics for powering the fan motor and/or the lamp.
It is thus a purpose and advantage of this invention to provide a lamp cooling system which permits the installation of a high-power lamp bulb in a socket location which would not otherwise permit it due to lack of adequate cooling.
It is another purpose and advantage of this invention to provide a lamp cooling system wherein high-power lamps can be employed to permit illumination at a higher level than would be permitted if ordinary cooling were to be relied upon.
It is another purpose and advantage of this invention to provide lamp cooling systems one of which can utilize a standard screw-in bulb base, while another one permits the insertion of a lamp having a plug-in base, both of which systems have forced cooling of the lamps.
It is another purpose and advantage of this invention to provide lamp cooling systems which can be employed in an ordinary retrofit by screwing it into a standard threaded socket, and yet permit a lamp of higher luminosity because its base is force-cooled.
Other purposes and advantages of this invention will become apparent from a study of the following portion of the specification, the claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view of the first preferred embodiment of the lamp cooling system of this invention which utilizes a lamp bulb with a screw base.
FIG. 2 is a substantially center line section therethrough.
FIG. 3 is a side-elevational view of a second preferred embodiment of a lamp cooling system in accordance with this invention which utilizes a plug-in lamp.
FIG. 4 is a substantially center line section therethrough.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first preferred embodiment of the lamp cooling system of this invention is generally indicated at 10 in FIGS. 1 and 2. The system comprises a housing 12 which carries a threaded plug 14 on its lower end. The threaded plug 14 is of standard dimensions to screw into a bulb socket. It has a metal threaded sheath 16 and a separate insulated nose 16 to make contact at the two electrical potentials in the socket.
Housing 12 is generally cylindrical and tubular. It has a series of ventilation openings 20 adjacent the plug 14. Interiorly of the housing, the housing is provided with a series of steps 22, 24 and 26. These steps are successively of larger diameter in the upward direction away from the plug 14 to permit assembly. The second step 24 carries fan support board 28. Motor 30 is mounted in the center of the fan support board. Fan blades 32 are supported by the motor, are wrapped around the motor, and rotate with the motor. Shroud 34 surrounds blades to increase air delivery efficiency. Fan support board 28 is provided with air flow holes 36 to permit the fan to blow air, preferably downward, toward the threaded plug 14.
It is contemplated that the threaded plug be screwed into a socket which is supplied with 120 volt AC electric power. It is difficult to manufacture a motor 30 sufficiently small for such an application when it is to be powered by 120 volt AC. Accordingly, the motor 30 is of lower voltage and may be a direct current motor. Therefore, motor power supply 38 is provided. The power supply may be a transformer plus a diode bridge plus a condenser to provide a 12 volt DC output for the fan motor. Then the motor power supply is mounted on power supply board 40, which rests upon step 22. Holes 42 around the power supply permit air flow downward through the housing. The fan support board 28 and power supply board 40 may be dielectric and are secured in place by a convenient means such as molded-in resilient stops above the boards or by adhesive attachment. The output of the power supply 38 is connected to fan motor 30.
The top step 28 supports heat sink platform 44. The heat sink platform also has holes 46 therethrough to permit downward flow of air. The heat sink platform carries a socket 48 into which screws lamp bulb 50, in conventional manner. The lamp bulb has a standard threaded plug the same size as plug 14. The socket is firmly mounted on the heat sink plate 44 so that heat is conducted from the plug of the lamp bulb to the socket 40 and thence to the heat sink platform 44. The heat sink platform is made of metal such as aluminum and carries metal fins 52 which extend upward from the platform, as seen in FIG. 2. In addition, surrounding the socket 48, metal fingers 54 extend upward. These fingers are resilient and engage to the collar 56 on the bulb envelope. Quite often, the standard PAR light bulbs have such a collar thereon. When no such collar is present, the fingers 56 can engage on the neck of the bulb envelope above the base. Fingers 58 are also mounted on the heat sink.
Electrical connections from the threaded plug 14 directly connect to the socket 48 so that, when the plug is energized, the socket is energized. In addition, the motor power supply 38 is also energized from that source. As a result, when a lamp bulb is screwed into the socket 48 and the plug 14 is screwed into a source of electric power suitable for the lamp bulb, the system is energized. The lamp bulb is illuminated and the motor is energized. Air is drawn past the lamp bulb, across the fins 52 and through the holes 46 in the heat sink platform 44. The energized fan blades then blow the air across the motor power supply 38 and out through the vent openings 20 in the bottom of the housing. In this way, the lamp bulb runs cooler and, thus, has a longer life. Alternatively, a larger lamp bulb can be installed and still operate within reasonable life design parameters. The system 10 is thus suitable for utilization of standard lamp bulbs, including lamp bulbs with built-in reflectors.
The lamp cooling system 60, shown in FIGS. 3 and 4, is similar to the lamp cooling system 10. However, it is configured to permit the utilization of a lamp bulb which does not incorporate its own reflector. Instead, the reflector is mounted on the housing. Housing 62 is formed in upper and lower housing portions 64 and 66 for purposes of assembly. The two housing portions are joined at a sleeve joint where the upper housing portion enters around the outside of tube 68 and engages against the stop face 70 adjacent tube 68. The lower end of the housing has a standard threaded plug 72 thereon for threaded engagement in a standard socket and electrical engagement therein. Shoulder 74 is formed interiorly of the lower housing portion 66, and printed wiring board 76 engages thereagainst. The printed wiring board carries suitable circuitry and discrete components for providing the conversion necessary for output voltage, frequency and current. The circuitry mounted on printed wiring board 76 is generally indicated at 78 and may include a transformer or other type of converter oscillator to generate a low voltage AC high current, together with rectifiers preferably arranged in a bridge circuit and condensers to smooth the output of the rectifiers to supply the necessary DC voltage for the fan.
Mounted against tube 68 is fan support board 80. Fan motor 82 is mounted on the fan support board, and fan blades 84 are mounted around the fan. Fan shroud 86 surrounds the fan blades and is mounted on the fan support board 80 to enhance fan efficiency. Openings 88 in the fan support board, openings 90 in printed wiring board 76, and openings 92 in the lower housing portion permit air to be driven by the fan downward over the electronics and power converter on the board 76.
Heat sink baseplate 94 has openings 96 therein and has fins 98 thereon. The heat sink baseplate and its fins are preferably made in one piece of low thermal resistance metal such as aluminum or are connected with low thermal resistance therebetween so that heat is readily transferred. The configuration of the fins is generally radial from the upright center line of the baseplate so that the fan draws air downward across the fins, as indicated by the arrows in FIG. 4. It should be noted that the fins 98 extend upward along a portion of the bulb length, but not as far as the filament in the top of the bulb. A portion of the fins extends up into the lower portion of the lamp cover around the lamp bulb.
Lamp bulb socket 100 is directly mounted on a heat sink post 102, which forms an integral part of or is directly attached to the heat sink baseplate. The radial fins are preferably also attached to the heat sink post below socket 100.
In the present preferred embodiment, the lamp bulb 104 mounted in the socket 100 is a halogen lamp. Such halogen lamps require 12 volts AC, and this is also supplied from the power converter 78. Appropriate connections are made from the power converter to the lamp socket 100 and, when rectified, to the fan motor.
Collar 106 is screw-threaded onto the top of housing 62 on screw threads 108. The collar has ventilation openings 110 therein to permit a continuous air opening through the housing, including past the fins, through the fan and support boards and out of the housing. Collar 106 carries lamp cover 112, which has a front substantially transparent lens 114 and a reflector surface 116 around the lamp bulb 104. The reflector surface 116 is preferably configured so that the lamp bulb is at a focus so that substantially parallel light rays are delivered toward the lens 114. While a parabolic reflector together with a forward lens is shown as the preferred embodiment, the configuration of the lamp cover 112 can be as desired. For example, it may be globular or may have a decorative configuration. Furthermore, the lamp cover can be frosted, partly frosted, or partly reflectorized depending upon the application and the manner in which illumination is desired. The configuration of the lamp cooling system permits a halogen lamp to be force-cooled and powered in an ordinary socket.
This invention has been described in its presently contemplated best embodiments, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.
|
Lamp cooler housing contains a lamp socket and a heat sink in association with an internal lamp socket. The heat sink carries fins thereon. A motor-driven fan in the housing moves air across the internal lamp socket and fins for their cooling. Electronics may be mounted in the housing for powering the fan motor and/or the lamp. The moving air also passes across these electronics for the cooling thereof.
| 5
|
RELATED APPLICATIONS
The present patent application claims priority from provisional application Ser. No. 60/479,141, filed Jun. 16, 2003, which is incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
With the advent of indwelling wire sensors has come the danger to the patient of having a cylindrical wire sensor fatigue from the flexure caused by bodily movement and break off inside the body. Under such circumstances a wire sensor can move through tissue relatively quickly and in an unpredictable manner, potentially posing a threat to the delicate internal organs.
Unfortunately, the typical metal used for such a wire sensor is platinum, which is electrochemically active and generally very useful in sensing applications. Platinum, however, is a weak metal that is easily broken with only a little flexure. Moreover, the electrochemical nature of platinum surfaces is only imperfectly understood. Efforts to make sensors from very thin platinum wires that are stranded together, thereby providing greater flex resistance, have encountered negative effects on the biochemical reactivity of the more complex platinum surface.
Also, platinum is very expensive costing on the order of $25–$30 per gram. For a multiple use sensing assembly incorporating a multiplicity of single use sensing elements, this may be a considerable expense. Also, for sensing elements that double as skin piercing lancets, greater strength is needed than may be available from a small diameter platinum wire. Even for sensors that are to be worn for a few days, the cost of the platinum portion of the sensor can place a strain on the overall budget for a production run of sensors.
SUMMARY
In a first separate aspect, the present invention is a sensor adapted to, at least in part, be inserted into a mammalian body. The sensor comprises a core of a structurally robust material and a plated portion, comprising an electrochemically active metal plated onto at least a portion of the core.
In a second separate aspect, the present invention is a method for the continuous monitoring of an analyte within a mammalian body. The method includes inserting at least a portion of a sensor into the mammalian body, continuously monitoring any electric current produced by at least a portion of the sensor. The sensor, in turn, includes a core of structurally robust material and a plated portion, comprising an electrochemically active metal plated onto at least a portion of the core.
In a third separate aspect, the present invention is a method of producing a sensor that is adapted to, at least in part, be inserted into a mammalian body and dwell within the mammalian body for at least an hour. The method comprises applying a layer of an electrochemically active metal onto at least a portion of a core made of a structurally robust material.
The foregoing and other objectives, features and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cross-sectional view of a sensing element according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 , sensing element 12 includes a bimetallic wire 20 that, when a voltage is placed on wire 20 relative to a reference electrode, in conjunction with a membrane system 22 reacts to the presence of glucose and oxygen (in some preferred embodiments, glucose only) by creating a current. Wire 20 is coated with a protective layer 23 , made of durable, non-toxic material such as polyimide, except for where coated by membrane system 22 . In production, protective layer 23 is dip-coated onto wire 20 and then removed, preferably with an excimer or ND:YAG laser in the area in which membrane system 22 is to be applied. In other preferred embodiments there is no protective layer 23 and the entire wire 20 is coated with membrane assembly 22 .
Wire 20 may have a diameter on the order of 227 microns and has a wire core 24 of structurally robust material such as stainless steel or tantalum that is 226 microns thick and an electrochemically active layer 26 , such as platinum, that is less than a micron thick. In an alternative preferred embodiment, wire 20 is 177 microns in diameter, core 24 is 157 microns in diameter and is made of tantalum and layer 26 is 10 microns thick and is a platinum foil that has been joined to core 24 .
To expand somewhat on the specific construction, wire core 24 may be of any structurally robust material, such as tantalum, stainless steel or nitinol, which is an alloy of nickel and titanium. Tantalum and nitinol, although both fairly expensive, are desirable because they are both naturally flexible. This is of particular importance if sensing element 12 is to be inserted in a patient and worn for a period of days. In addition, core 24 could be made of polymeric material or a glass fiber. Electrochemically active layer 26 may be made of one of the noble metals, such as platinum, palladium, gold or a combination of any of the aforesaid with iridium. In a set of preferred embodiments, other noble metals are used in layer 26 .
A number of strategies are possible for making plated core or wire 20 . In one method, a tube of platinum is prepared and molten stainless steel, tantalum or nitinol is poured inside of it, to form a filled tube. The filled tube is then drawn through progressively smaller apertures, until its diameter reaches the desired thickness. This produces a filled tube that typically is far longer than is necessary, but is available to be cut to whatever length is desired. Another issue with drawn filled tubes is that it is difficult to reduce the thickness of the layer of platinum to less than 20 microns. This increases the expense because it forces the use of a greater than otherwise necessary amount of platinum.
Another method starts with a robust metal wire that is then electroplated with platinum or another noble metal, such as palladium. In this method the robust metal wire is typically negatively charged to form a cathode. A plating solution bath is positively charged to form an anode. Typically the first step is to plate the stainless steel with an intermediate layer that bonds well to both stainless steel and platinum. Typically this layer is gold, although it has been found to be advantageous to plate a first intermediate layer of nickel, plate gold over this layer of nickel and finally plate the gold with platinum. The plating solution may be either acid or alkaline.
In one preferred method, a core of nitinol was used. In this method gold is plated over the nitinol. As nitinol oxidizes very rapidly, hydrofluoric acid is included in the gold bath to strip away any oxidation that may have formed on the nitinol.
In yet another preferred method, a core of robust metal is circumferentially clad in noble metal foil. Although with this method a 1 micron cladding cannot be achieved, cladding in the neighborhood of 5 to 15 microns is possible. One advantage of a thicker cladding is that it is harder for pinholes to extend all the way through.
Another possibility is coating by way of plasma vapor deposition, in which a metallic vapor is created and coats the core 24 . First a wire of structurally robust material 24 , such as tantalum, is passivated, meaning that a thin layer of oxide is created on the exterior of the wire. Then platinum is vaporized in a plasma environment, and deposition of layer 26 on the tantalum wire results. Using this technique a robust coating 26 of platinum (or another electrochemically active metal) can be created on an underlying tantalum (or other structurally robust metal) core. Moreover, the layer 26 of platinum is electrically isolated from the structurally sound material 24 by a layer of oxide, which is nonconducting. Accordingly, if there is a pinhole in the platinum 26 , there will nevertheless be no electrical contact between the body fluid and the underlying core 24 of structurally sound material. If body fluid were to contact core 24 , unpredictable electrical activity could result, potentially corrupting the measurement. In a similar manner, an electrochemically active metal may be deposited on a continuous wire of structurally sound metal, designed to host many sensing sites.
Also, sputtering, in which free metallic charged particles are created, may be used to perform the coating or cladding step. Both plasma vapor deposition and sputtering are well known in the art.
In yet another preferred method of producing a thin platinum coating over stainless steel, a strike, or extremely thin (<5 microns) coating of gold is first electroplated onto the stainless steel core. Then, platinum is electroplated in a bath having a current density on the order of 40 amperes/ft 2 or less. It is important to electroplate with a comparatively low current density, causing a slow buildup of platinum, in order to prevent uneven growth of the platinum layer.
The membrane system 22 must perform a number of functions. First, it must provide an enzyme that reacts with glucose and oxygen (or glucose only in some preferred embodiments) to form an electrolyte. A reactive layer 30 of glucose oxidase, glutaraldehyde and albumin, which produces hydrogen peroxide when contacted by glucose and oxygen, performs this function. Other enzymes may be used for this process and fall within the scope of this invention.
Second, because glucose is far more prevalent in the blood and other body fluids than oxygen, system 22 must include a membrane placed over the reactive layer 30 to permit a greater permeation of oxygen than glucose, so that the glucose concentration measurement is not limited by the oxygen concentration in the immediately surrounding tissue. This function is performed by a permselective hard block/soft block copolymer layer 32 . This layer is of the type described in U.S. Pat. Nos. 5,428,123; 5,589,563 and 5,756,632, which are hereby incorporated by reference as if fully set forth herein. Layer 32 is preferably less than 10 microns thick, to permit rapid permeation by glucose and oxygen.
Third, membrane system 22 must prevent interferents, such as acetaminophen, from corrupting the measurement by causing current flow unrelated to the presence of glucose. This function is performed by an inner interferent reducing layer 34 of a compound such as sulfonated polyether sulfone, 3-amino-phenol, or polypyrrole, which quickly permits the permeation of the hydrogen peroxide, which causes the current flow indicative of the concentration of glucose. Persons skilled in the relevant arts will readily recognize that quick permeation is highly desirable in a briefly indwelling sensor so that a measurement may be quickly obtained.
To produce sensing element 12 , first the interferent reducing layer 34 of 3-amino-phenol is solution-coated or electro polymerized onto the surface of platinum plating 26 . Layer 34 may be from a few nanometers to 2 microns thick, to permit rapid permeation by H 2 O 2 ions, thereby reacting very quickly to glucose concentration. Over this the reactive layer 30 of glucose oxidase is dip-coated or electrodeposited. Glutaraldehyde is deposited on the glucose oxidase to immobilize the glucose oxidase. The sensor is dip coated in the soft block/hard block copolymer 32 . In the finished product, the surface of the sensing region 22 is slightly depressed relative the remainder of the surface of sensing element 12 . In one embodiment, the glucose oxidase 30 is applied before layer 34 , which is electrodeposited through layer 30 . A voltage is placed between contacts 72 at the beginning of the measurement process. When electrical current flows between contacts 72 , this indicates that body fluid has completely wet membrane system 22 and serves as a signal to place a voltage on conductor 24 .
In one preferred embodiment, a layer of absorbent metal is included over membrane system 22 . In use, sensing element 12 may be either inserted into the body for a number of days and may provide a multiplicity of glucose measurements or may be used as a single use sensing element. When used for a single use, sensing element 12 may be part of a multiple sensing element assembly. The measurement of glucose concentration may occur when sensing element 12 is briefly indwelling, for example, indwelling for less than 3 minutes, or may occur after it has been withdrawn, with body fluid retained on sensing element 12 being tested. A single use element 12 is typically optimized to provide a fast readout, whereas a sensing element that dwells within the body for days is typically optimized for accuracy over time and to satisfy the greater safety challenge posed by an indwelling device.
The terms and expressions which have been employed in the foregoing specification are used as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
|
A sensing element adapted to, at least in part, be inserted into a mammalian body. The sensing element is made up of a core of a structurally robust metal and a plated portion made of an electrochemically active metal conjoined to at least a portion of the core. This sensing element may be used as part of a method for the continuous or intermittent monitoring of an analyte within a mammalian body. The method includes inserting at least a portion of the sensing element into the mammalian body and measuring any electric current produced by at least of portion of the sensor.
| 0
|
BACKGROUND
1. Technical Field
The present disclosure relates to vacuum technologies and, in particular, to a vacuum device and a method for packaging the same.
2. Description of the Related Art
Some vacuum devices, such as flat panel displays (FPD), are packaged vacuum devices that are used in connection with computers, television sets, camcorder viewfinders, and other electronic devices. Referring to FIG. 6 , according to the prior art, a typical packaging method of the vacuum device is shown. The packaging method includes the following steps. A pre-packaged container 100 having an exhaust through hole 102 defined thereon is provided. An exhaust pipe 110 is provided and one end of the exhaust pipe 110 is inserted into and fixed in the through hole 102 via low-melting glass powder 108 , and another end of the exhaust pipe 110 is exposed outside the pre-packaged container 100 . A cup-shaped connector 104 and a vacuum pump 106 that connects to the cup-shaped connector 104 is provided. The cup-shaped connector 104 is configured for form a seal between the exhaust pipe 110 and the vacuum pump 106 so as to pump from the pre-packaged container 100 to create a vacuum chamber therein via the vacuum pump 106 . A condensing-light sealing device 112 is provided and is used for heating and softening the exhaust pipe 110 so as to seal one end of the exhaust pipe 110 . One end of the exhaust pipe 110 is sealed to obtain a container under vacuum.
The container under vacuum includes the container 100 and the exhaust pipe 110 whose one end is sealed. Alternatively, it can be understood that the pre-packaged container 100 may be directly placed into a vacuum room 114 as shown in FIG. 7 . After the vacuum room 114 is pumped to create vacuum therein via the vacuum pump 106 , a vacuum also is created in the pre-packaged container 100 at the same time. After that, the exposed end of the exhaust pipe 110 can be sealed via the condensing-light sealing device 112 .
However, the exhaust pipe 110 needs to be disposed in the through hole 102 of the container 100 in the above method during packaging the container 100 . Therefore, when finishing the package of the container 100 , a tail of the exhaust pipe 110 may be retained outside of the container 100 , which is disadvantageous in regards of safety and reliability. Furthermore, for expediently sealing the end of the exhaust pipe 110 , the exhaust pipe 110 should have a small diameter, for example, less than 5 mm, which results in expending a lot of time exhausting air from the pre-packaged container 100 . Therefore, the structure of the container 100 becomes complicated and the manufacture cost will be increased.
What is needed, therefore, is a packaging method for a vacuum device, which can overcome the above-described shortcomings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present vacuum device and a method for packaging the same are described in detail hereinafter, by way of example and description of an exemplary embodiment thereof and with references to the accompanying drawings, in which:
FIG. 1 is a schematic, cross-sectional view of a vacuum device according to an exemplary embodiment;
FIG. 2 is a flowchart of a packaging method for the vacuum device of FIG. 1 ;
FIG. 3 is a flowchart of a method for exhausting the air in the low-melting glass powder;
FIG. 4 is a schematic, cross-sectional view of the vacuum device of FIG. 1 connected to a vacuum pump;
FIG. 5 is a flowchart of a method for pumping the container to create a vacuum therein;
FIG. 6 is a typical vacuum device that is connected with a vacuum pump via a cup-shaped connecter;
FIG. 7 is another typical vacuum device that is placed into a vacuum room.
DETAILED DESCRIPTION
A detailed explanation of a vacuum device and a method for packaging the same according to an exemplary embodiment will now be made with references to the drawings attached hereto.
Referring to FIG. 1 , a vacuum device 30 according to an exemplary embodiment is shown. The vacuum device 30 includes a container 300 having an exhaust through hole 302 defined therein, a sealing cover 308 configured for covering the exhaust through hole 302 , a connecting material 304 and a getter 310 . The getter 310 is disposed on the sealing cover 308 toward the inside of the container 300 .
The container 300 includes a housing 312 . The exhaust through hole 302 can be defined in any one sidewall of the housing 312 . The housing 312 may be made a material selected from a group consisting of glass, metal and other material that can be adhered utilizing low-melting glass power. It should be further noted that the vacuum device 30 is an element of a flat panel display, and the housing 312 includes a rear plate, a front plate and spacers disposed between the rear plate and the front plate (not labeled). Some electron elements (not shown) are contained in the housing 312 . In the present embodiment, the housing 312 is comprised of glass. The exhaust through hole 302 can be any opening that is appropriate to the volume of the housing 312 . In the present embodiment, the exhaust through hole 302 has a circular shape and has a diameter of about 2 mm to about 10 mm. However, it is understood too large of a diameter of the exhaust through hole 302 may result in poor reliability.
The sealing cover 308 may have a plate shape and a greater area than that of the exhaust through hole 302 for fully covering the exhaust through hole 302 . The sealing cover 308 may be made of glass or metal and have a greater melting point than that of the connecting material 304 . In the present embodiment, the sealing cover 308 is made of glass that has a melting point higher than 600° C.
The connecting material 304 may be a layer of low-melting glass powder which is placed along the periphery of the sealing cover 308 manually or via screen-printing method. The connecting material 304 is interposed between the container 300 and the sealing cover 308 so as to adhere the housing 312 with the sealing cover 308 . The connecting material 304 may have some air in therein. During packaging, the connecting material 304 is heated for a predetermined period of time to remove the air therein before mounting the sealing cover 308 .
The getter 310 may be mounted on one side of the sealing cover 308 on which the low-melting glass power is located and is configured for absorbing the residual gas in the packaged container 300 after sealing. The getter material generally includes two types: evaporable, and non-evaporable. The evaporable-type getter is mainly made from barium (Ba), magnesium (Ma), strontium (Sr), calcium (Ca), such as barium-aluminum-nickel getter or nitrogen-doped getter. The non-evaporable-type getter is mainly made from titanium (Ti), zirconium (Zr), hafnium (Hf), thorium (Th), vanadium (V), aluminum (al), iron (Fe), or any of their alloys. In the present embodiment, the getter 310 is non-evaporable-type getter made of zirconium, vanadium and iron. Since the getter 310 is directly formed on the sealing cover 308 , a separate space for containing getter materials is not needed in the device, which will simplify the structure of the vacuum device 300 and further decrease the manufacturing costs.
Referring to FIG. 2 , a packaging method according to the exemplary embodiment is shown. The packaging method includes:
step S 101 : providing: the pre-packaged container 300 , having the exhaust through hole 302 defined thereon, and the sealing cover 308 , and a layer of the connecting material 304 located on the periphery of the sealing cover 308 ;
step S 102 : spacing the sealing cover 308 from the exhaust through hole 302 ;
step S 103 : placing the pre-packaged container 300 under vacuum;
step S 104 : melting the connecting material 304 ;
step S 105 : covering the exhaust through hole 302 with the sealing cover; and
steps 106 : cooling down the melted connecting material 304 for providing a seal between the container 300 and the sealing cover 308 .
In step S 101 , in some embodiments, the connecting material 304 is firstly mixed with an adhesive to form a slurry. Then, the slurry is coated on the sealing cover 308 manually or via screen-printing method. In one embodiment, the connecting material 304 has a thickness of less than 1 mm.
In step S 102 , the connecting material 304 firstly need to be heated so as to remove the air in the connecting material 304 . Referring to FIG. 3 , the method for removing the air in the connecting material 304 including:
step S 201 : placing the sealing cover 308 having the connecting material 304 into a vacuum chamber;
step S 202 : heating and melting the connecting material 304 for a predetermined period of time to exhaust the air therein.
In step S 202 , the connecting material 304 can be heated by electrically heated wire, infrared light or laser. In the present embodiment, the connecting material 304 is heated via electrically heating or irradiation of the infrared light for about 30 minutes to about 60 minutes so as to exhaust all of gas included therein. Then, the getter 310 can be adhered on the cover with the connecting materials. In the present embodiment, the connecting materials is the low melting point frit.
For spacing from the exhaust through hole 302 , at least three rod-shaped supporting elements 306 may be arranged on the periphery of the exhaust through hole 302 . The rod-shaped supporting elements 306 are configured for supporting the sealing cover 308 to form at least one gap between the sealing cover 308 and the housing 312 for efficiently allowing air in the housing 312 to escape. In one embodiment, the supporting elements 306 are also made of low-melting glass and have a height larger than 2 mm. Understandably, other methods can be employed for spacing the exhaust through hole 302 with the sealing cover 308 . The sealing cover 308 , for example, can be held by an element of some kind (not shown).
In step S 103 , the pre-packaged container 300 can be pumped via a cup-shaped connector or in a vacuum room. In the present embodiment, referring to FIG. 4 , the container 300 is placed into the vacuum room 314 . When the vacuum room 314 is pumped to a predetermined vacuum-degree, the pre-packaged container 300 may have a same vacuum-degree with the vacuum room. Referring to FIGS. 5-6 , in some embodiments, the method for pumping the pre-packaged container 300 to create vacuum therein includes:
step S 301 : providing a vacuum room 314 connected to a vacuum pump 316 and a heating device 320 mounted on an inner-wall of the vacuum room 314 ;
step S 302 : placing the pre-packaged container 300 and a sealing cover 308 arranged on the exhaust through hole 302 of the pre-packaged container 300 into the vacuum room 314 ;
step S 303 : pumping the vacuum room 314 to a predetermined vacuum-degree;
step S 304 : heating the pre-packaged container 300 by the heating device for further exhausting the gas in the container 300 .
In step S 304 , the heating device 320 can be electrically heating wire, infrared light and/or laser. At the same time, the getter 310 can be activated to absorb gas during heating the pre-packaged container 300 .
In step S 106 , when the heating device 320 stops, the temperature of the connecting material 304 and the supporting spacer 306 may decrease and the connecting material 304 and the supporting spacer 306 may solidify. At the same time, the sealing cover 308 is adhered on the exhaust through hole 302 . Thus, the container 300 is packaged by the sealing cover 308 and vacuum has been created in the container 300 having a predetermined vacuum degree.
Furthermore, an object 322 may be disposed on the top of the sealing cover 308 to provide an external force for the sealing cover 308 . When the connecting material 304 and the supporting elements 306 are melted, it can fully seal the exhaust through hole 302 via the sealing cover 308 .
Since the plate-shaped sealing cover 302 is used for sealing the exhaust through hole 302 of the container 300 , no tail of the exhaust pipe of prior art is retained outside of the container 100 , which is advantageous of safety and reliability. Furthermore, as the exhaust through hole 30 may have a larger diameter, the air in the container 300 can be more quickly removed therefrom. Therefore, the structure of the vacuum device becomes simpler, and the manufacture cost will be decreased.
It is to be understood, however, that even though numerous characteristics and advantages of the present embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
It is also to be understood that above description and the claims drawn to a method may include some indication in reference to certain steps. However, the indication used is only to be viewed for identification purposes and not as a suggestion as to an order for the steps.
|
A method for establishing a vacuum in a container includes the following steps. The container having an exhaust through hole defined therein is provided. A sealing cover including a connecting material located on the periphery of the sealing cover is provided. The sealing cover is spaced from the exhaust through hole for form at least gaps between the sealing cover and the exhaust through hole. A vacuum is established in the container. The connecting material is heated. The sealing cover covers the exhaust through hole and the connecting material is cooled. After that the container is packaged.
| 7
|
RELATED APPLICATION
[0001] This patent application claims priority to U.S. Provisional Application No. 60/710,866 filed Aug. 25, 2005, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to pulsed flash lamp designs for producing high performance and very high power (peak and average) pulsed broadband light, as well as lamps for producing pulsed ultraviolet (PUV) light. Specifically, the present invention relates to lamp designs that reduce lamp degradation and breakage, and provide improved lamp cooling, and electrical-to-optical output efficiency of the desired spectral emission band.
BACKGROUND OF THE INVENTION
[0003] It is known that system designs for high power flash lamps typically include the following components: 1/Lamp envelope or lamp tube made of tubular material with adequate transparency for the desired spectral emission band(s) (e.g., UV-grade quartz for UV radiation), and filled with gas or gases such as xenon, krypton, or other suitable gas(es); 2/Electrodes located in opposite ends of the tube, connected to a source of high voltage and producing an electrical discharge in the gas(es); 3/Surrounding jacket or second tube of suitably transparent material around the circumference of the lamp envelope, providing a volume for circulation of cooling fluid (gas or liquid) between the lamp exterior surfaces and the internal surface of the jacket. Such cooling fluid providing removal of excess heat developed during the lamp operation.
[0004] While there are many known styles and methods for operating pulsed flash lamps, it is most common for high power pulsed lamp operation to encompass some version of the three typical operating modes: an ignition mode, a simmer mode, and a pulse mode. The ignition mode provides initial ionization of gas inside the tube by a special igniter. The simmer (standby) mode is provided by a small current that supports a constant low level of gas ionization inside the tube. The pulse mode is produced by a short, high peak power and high voltage discharge inside the tube, the discharge having a duration between microseconds and milliseconds, and developing pulses with peak power from one to hundreds of megawatts.
[0005] The growing demand by new applications for increased UV processing power has in many instances required much improved flash lamp performance over the capabilities of the generation of PUV lamps prior to this invention. Compared to previous pulsed lamp designs, this new generation of high power and performance pulsed lamps is physically characterized by a much longer length anode-to-cathode spacing (for example, by a factor of three or more), with a subsequent increase in the length, weight, and aspect ratio profile of the lamp. Compared to previous pulsed lamp designs, this new generation of high power and performance pulsed lamps is electrically characterized by pulses with larger currents (peak and/or average magnitude), longer arc lengths (anode-to-cathode spacing), and higher required operating voltages. In order to extend both power and performance capabilities beyond the pre-existing generation of so-called medium-to-high power flash lamps, new methods and designs are required. For example, large-scale water disinfection and remediation is just one application where the older generation of PUV lamps have shown to be lacking, and therefore not considered by industry to be entirely suitable to the task. A new generation of higher power and performance pulsed ultraviolet lamps is both desirable and advantageous. UV light can effectively disinfect across a broad range of targeted pathogens. In sharp contrast with chemical disinfectants such as chlorine, UV light can disinfect without adversely affecting the taste, odor, or safety of the water, and is particularly effective against protozoa, such as Cryptosporidium Parvum. Additionally, pulsed UV systems in particular advantageously can deliver a consistent UV light output efficiency despite any lamp and/or ambient temperature changes, and instant UV power “ON” and “OFF” cycling, instantly variable and precise levels of UV power output throughout the range of zero to 100%. Importantly, PUV can do so with neither the hazardous mercury, nor the explosive potential created by high lamp envelope temperatures and pressures that characterize conventional continuous wave (CW) medium pressure UV lamps. Furthermore, it is known that the CW mercury lamps (among others) have an inherent problem of performance degradation due to thermal gradient induced fouling (minerals attraction) of lamp cooling jackets. Therefore, it is advantageous to create pulsed UV systems with the capability to fulfill the requirements of large-scale UV processing applications.
[0006] It is known by practitioners of the art that the previous generation of PUV lamps, while demonstrating very attractive potential advantages and benefits, have never successfully been deployed on a large scale, and were seemingly relegated to laboratory work and/or relatively low power niche applications. Known problems have included unacceptably short service life, uncompetitive electrical-to-optical output efficiency, inconsistent UV output, and UV spectral and power outputs that are not well-matched to the targeted application. The records show that lamp service lives were limited by one or more combinations of rapidly-declining UV output, excessive lamp aging that degraded and then prematurely prevented operation, and/or catastrophic failure of the lamp envelope material. Electrical-to-UV output efficiencies were within the range of 5% to 9%, which compares unfavorably with the approximate practical range of 17% to 35% typical of CW mercury UV lamps. The UV output of the previous generation of PUV lamps became progressively less consistent (in terms of energy per pulse and spectral characteristics) with eventually unsuccessful attempts to push towards higher output powers.
[0007] The primary reason for these limiting problems is that neither the lamp designs, nor the pulsed power supply designs, are substantively different from the conventional flash lamp technology that has been in use for many decades in relatively lower performance systems. A thorough survey of prior art reveals that there exist no novel departures from standard pulsed lamp designs that enable scaling of the technology into the performance and power levels that today are desirable for certain applications. Indeed, the designs of pulsed lamp systems that fail to meet the more recently extended performance criteria are, in essence, identical to the designs traditionally used in smaller, less demanding, and lower performance systems.
[0008] Practitioners of the art are aware of the long-established body of knowledge concerning the various standard techniques for designing and driving pulsed flash lamps. While these techniques tend to work well within the broad base of established applications for which these designs have been incorporated, it is now known that the simple extension of these standard designs and methods into the more demanding class of very high power PUV lamps has been shown to be insufficient for the task.
[0009] In order to achieve the potential advantages of very high power pulsed UV lamps, it is necessary to create new and unique lamp designs by which this technology is enabled, thereby inventing a whole new generation of higher capability and performance pulsed lamps. The design methods for the older generation of lower performance and power flash lamps are inadequate to the task; this invention provides necessary solutions.
[0010] There are multiple causes for the potentially deleterious stress to which this new generation of high performance pulsed lamps may be subjected, such as compression and tension induced stress, thermal expansion and contraction induced stress, tensile stress resulting from induced deformations, asymmetrical heating and deformation of the envelope resulting in a bending of the lamp envelope, and resonance oscillations.
[0011] For example, a typical characteristic of pulsed flash lamps is that, beginning with the onset of the main current pulse, the discharge consists of a thin cathode sheath (cathode “glow”, negative glow, and so-called “dark spaces”) and a positive column that fills most of the anode-to-cathode space. At the higher lamp pressures, this cathode sheath is less than a micron thick, but has a pressure, applied voltage, and current-independent voltage drop of approximately 150 Volts. Although the sheath-dissipated power is small because of the shallow depth of the sheath, the power dissipated per unit volume is very high, resulting in instantaneously high temperatures and pressures, and the subsequent formation of a strong shock wave. This initial strong shock wave is attenuated within a few millimeters, depositing much of its energy in the region surrounding the electrode, including the lamp envelope. The power of the main pulse that is subsequently deposited into the main column between the anode and cathode rapidly heats the plasma along the length of the bore, thereby creating a cylindrical shock wave that travels to the envelope wall, reflecting and oscillating several times at very high acoustic frequencies (≈100 kHz).
[0012] According to both theoretical calculations of and empirical data from pulsed flash lamp operation, very high power pulses can produce high forces that create compression and tension stresses in lamp materials. In particular, the high power pulses produce gas heating and pressure increase, axial and radial forces, and shock waves through the gas and tube walls. As a result: 1/axial waves propagate through the gas and envelope, completely or partially reflected from tube ends and can produce a set of multiple reflected waves that interfere and create standing waves and stress points in the envelope walls; and 2/radial waves propagate through the gas, envelope walls, cooling fluid and cooling jacket, traversing through boundaries with different material properties, completely or partially reflected back and create standing waves and various stress points in the envelope walls.
[0013] Thermal expansion and contraction induced stress is created due to fast pulse gas heating that produces transient thermal loading upon the inner layer of the lamp envelope. The envelope outer layer is cooled down by outside coolant flow, which results in a temperature gradient through the tube walls and additional pulse tension stress in the envelope outer layer.
[0014] Deformations in the envelope material can result from high peak inner pressures, combined with heating and softening of the envelope inner layer. Fast cooling of the thermally-conductive quartz or glass produces hardening of deformed material and creation of compression stress in inner layers along with tension stress in outer layers of the envelope. This effect is similar to the known method of treatment of artillery cannon barrels (autofrettage) when high internal hydraulic pressure improves the barrel resistance during firing. Very small changes during each short pulse can accumulate and produce sufficient tensile stress in the tube outer layer, tube elongation and bending, which could become an additional source of tensile stress on the bulging side.
[0015] Emanating from the plasma and external lamp wiring, and in some designs also affected by surrounding component layout, high current-induced electromagnetic fields can produce asymmetrical shifting of the plasma filament away from the lamp axis and toward one side of the envelope wall. This can result in asymmetrical heating and deformation of the envelope. Accumulation of deformations and stress after multiple pulses can result in eventual bending of the lamp envelope.
[0016] Lastly, multiple high power pulse sequencing with constantly changing pulse repetition frequencies from single to thousands per second (depending on system design and operating conditions) can create a resonance effect in lamps with natural frequencies in the same range. The move towards the use of dramatically longer length lamps aggravates this situation. Resonance oscillations in a lamp can produce detrimental pulsing tension and compression stresses in lamp components. These and other mechanisms of stress development can accumulate in lamp envelope material(s) and work in combination. It is known that tube-shaped materials (quartz or glass) behave much like other hard and brittle substances; they work very well under compression, but are very sensitive to tension stress. Multiple tension cycles exceeding a critical level of stress can be responsible for a gradual development and emergence of micro-cracks in the material, leading to catastrophic breakage of the lamp. Another effect of stress and micro-cracks accumulation is the degradation of tube transparency (increased absorption of radiation by the envelope walls), and subsequent reduction of lamp electrical-to-optic output efficiency.
[0017] There is therefore a need for a reliable and cost-effective lamp system design and method of manufacture that can prevent lamp breakage and/or premature degradation of desired radiation output.
SUMMARY OF THE INVENTION
[0018] Accordingly, a primary object of the present invention is to provide a reliable and cost-effective lamp design and method of fabrication, thereby preventing lamp breakage due to the forces created by high power electrical pulses.
[0019] A further object of this invention is to provide lamp designs and methods of manufacturing that improve the lamp stability in terms of envelope material degradation and reduction of its optical characteristics.
[0020] These and other objects are achieved in the present invention.
[0021] The present invention overcomes the dilemma caused by accumulation of small deformations in the materials comprising the pulsed flash lamp components, eventually resulting in the development and emergence of micro-cracks, degradation of envelope optical properties and lamp efficiency, and in some cases leading to lamp breakage.
[0022] Accumulation of small deformations in lamp envelope components come as the result of stress produced by multiple high power pulses of high voltage discharge inside the lamp tube.
[0023] These pulses are responsible for: pressure increase inside the tube; heating of tube inner walls; thermal expansion of lamp components; generation of shock waves through the tube working gas; propagation of axial and radial shock waves through the lamp components; resonance oscillation of lamp components; and lamp tube elongation and bending.
[0024] The pulsed flash lamp of the present invention addresses the issues of degradation of strength and transparency of lamp components by providing, for example: better lamp envelope shape, cross-section and material distribution, thereby resulting in greater resistance of the envelope to the combination of forces produced by multiple pulse high power loading; connection points between the tube and envelope that improve lamp rigidity and strength; selective tube/envelope connections and material distribution that focuses on prevention of dangerous tube resonant oscillations; special means to reduce tension load in the tube walls (pressurized cooling fluid, axial and radial preload, etc.,); methods to limit tube axial compression forces in order to prevent bulging (sliding tube holders, etc.,); various methods of shock waves absorption, suppression, and redirection in order to reduce harmful high peak pulse loads upon the relevant lamp components; and various combinations of the afore-mentioned techniques in order to successfully utilize the desirable qualities of certain lamp envelope (tube) materials in situations where the tensile characteristics of those same materials would otherwise be unacceptable for the new generation of high power and performance pulsed lamps.
[0025] The combination of features of the present invention provides a reliable and cost-effective lamp design and method of manufacturing, preventing lamp breakage by forces of high power electrical pulses, and improving the optical transparency and stability of lamp materials.
[0026] There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described further hereinafter.
[0027] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0028] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that equivalent constructions insofar as they do not depart from the spirit and scope of the present invention, are included in the present invention.
[0029] For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter which illustrate preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS AND THE FIGURES
[0030] FIG. 1 illustrates both a high power and performance pulsed ultraviolet flash lamp and a conventional flash lamp.
[0031] FIG. 2 illustrates a means for increased lamp envelope rigidity.
[0032] FIG. 3 illustrates examples of non-round lamp tube shapes.
[0033] FIG. 4 illustrates flash lamp tubes having spiral longitudinal wall depressions.
[0034] FIG. 5 illustrates a means for increased heat exchange.
[0035] FIG. 6 illustrates a double layer lamp tube.
[0036] FIG. 7 illustrates a means for increased lamp tube rigidity.
[0037] FIG. 8 illustrates the use of spiral components for lamp tube support.
[0038] FIG. 9 illustrates a pre-stressed lamp.
[0039] FIG. 10 illustrates axial preload of lamp tube walls.
[0040] FIG. 11 illustrates a means for suppression of shock waves.
[0041] FIG. 12 illustrates a lamp holder with sliding tube.
[0042] FIG. 13 illustrates a means for suppression of resonant waves.
DETAILED DESCRIPTION OF THE INVENTION
[0043] FIG. 1 illustrates an example of the new generation of high power and performance pulsed ultraviolet (PUV) flash lamp 100 , along with an example of the previous generation of lower performance capability flash lamp 120 . The new generation flash lamp 100 comprises a central envelope or tube 102 of material transparent to UV radiation. Such materials are known by those of ordinary skill in the art. In a preferred embodiment, the central envelope comprises UV-grade quartz. The tube volume is filled with a working gas such as known by one of ordinary skill in the art and including but not limited to xenon or krypton.
[0044] Electrode(s) 108 are hermetically inserted in the ends of lamp tube 102 , and are electrically attached by means of lamp connectors 106 to an electrical power source, preferably a high voltage pulsed power source, thereby enabling the production of an electrical discharge in the working gas. The electrode anode-to-cathode distance, or arc length, of perhaps 100 cm or more, is uniquely much longer than that of the previous generation flash lamp 120 ; for a given pulse energy, this length advantageously reduces by a factor of approximately three or more the thermal loading per cm length of lamp tube 102 compared to that of the older generation pulsed lamp 120 .
[0045] Cooling jacket or second tube 104 comprising suitably transparent material is located around the lamp circumference as shown by detailed cross-section A-A, creating annular channel 110 between the lamp and walls of cooling jacket 104 . The cooling fluid is pumped along lamp tube 102 through channel 110 and removes the excess heat developed during lamp 100 operation.
[0046] The previous generation of lower performance capability flash lamp 120 is characterized by a much shorter electrode anode-to-cathode distance, or arc length, typically on the order of 25 cm to 35 cm. For a given pulse energy, this shorter distance between electrodes 124 creates a factor of approximately three or more greater thermal loading per cm length of lamp tube 122 than that of the new generation lamp 100 . Common configurations include cooling fluid inlet 130 through a feed through plate or flange 128 , a cooling fluid circulation volume surrounding lamp tube 122 and enclosed by cooling jacket 126 , cooling fluid outlet 132 through feed through plate or flange 128 , pulsed power source feed through connection 134 to lamp electrode 124 , and ground current return connection 136 from the oppositely situated lamp electrode 124 .
[0047] High power pulses during lamp operation are responsible for gas pressure increase and heating, development of axial and radial forces in tube material, and shock waves through the gas and tube walls. As a result, the accumulation of high peak stresses in the envelope material (quartz or glass) could lead to a degradation of envelope shape, strength, the development of micro-cracks, and premature failure.
[0048] FIGS. 2, 3 , 4 , and 5 illustrate an embodiment of the present invention, wherein the lamp is reinforced by introduction of an improved envelope/tube design, thereby providing better resistance to bending and tensile stress in the envelope material and improved heat transfer and control of cooling fluid flow.
[0049] FIG. 2 illustrates examples of lamp envelope (or tube) designs. For comparison, conventional previous generation (lower power and performance) tube 202 is shown. Unique and advantageous lamp envelope designs include tubes with ribs located on their outer and/or inner surfaces, tubes with depressions located on their outer and/or inner surfaces, and non-round tubes. Tubes with reinforcing ribs and/or depressions can be formed in the shape of annular ring or spiral elements, as illustrated by radial tube 204 . Tubes with reinforcing ribs and/or depressions can also be formed longitudinally along the tube centerline, as illustrated by longitudinal tube 206 . Similarly, longitudinal and radial ribs made by deformation of quartz or glass tube walls can provide an additional improvement in envelope physical strength and a reduction of problems related to bending, stress concentration, and shock waves suppression. Further, such ribs and/or depressions can be discontinuous. In alternative embodiments the tube can instead be comprised of similar constructions that are instead formed as external protrusions instead of internal indentations.
[0050] FIG. 3 further illustrates improved envelope/tube designs, wherein the pulsed flash lamp is made with the envelope cross-section comprised of a non-round shape. Non-round tube cross-sections include but are not limited to elliptical or oval 302 , triangular 304 , rectangular 306 , polyhedron, polyhedron with rounded corners, diamond, and other shapes. Non-round tube cross-sections usually have higher modulus of inertia and can provide better resistance to bending in specific direction. Non-uniform volume of tube in different directions creates some additional tube space, thereby helping to disperse vibration and reduce the harmful effects of shock waves.
[0051] The application of twisted 308 and wave-like 310 components to lamp tubes can improve the tension-induced stress fatigue characteristics of the lamp. Envelopes with constantly changing acoustic-reflecting sides provide good means for suppression and redirection of shock waves propagated through the working gas along the length of the tube.
[0052] FIG. 4 illustrates flash lamp tubes having spiral longitudinal wall depressions. This improvement can simultaneously provide several opportunities for better performance and lifetime. For example, the extra gas volume that is created between tube depressions can serve as pressure absorbing chambers that reduce and redirect shock waves generated by high peak power pulse discharges in the lamp gas. At the same time, the electrical proximity effect of the depressions can advantageously be utilized to optimize the electron density (and therefore, the temperature) of the plasma channel. The electrical field shape is influenced by the size, distance, and shape of the high dielectric envelope material that surrounds the plasma. The depressions can therefore also provide better axial position control of the plasma filament, whereby the inside depression will tend to concentrate the plasma filament toward the lamp centerline, assisting to localize it within the center of the envelope.
[0053] Cross-sectional views in FIG. 4 also illustrate the addition of ground return current bars 402 . Preferably such ground current return bars 402 are a symmetrical array of external metallic conductors, reverse current direction to and coaxial with plasma channel 406 contained within lamp envelope (or tube) 404 . The electromagnetic field produced by the addition of appropriately located ground current return bars (carrying reverse-direction ground current) will act to stabilize lamp plasma 406 into the desired central axis position of tube 404 . By this invention, the multiple parallel conductor ground current return arrangement can provide the advantages of a single, solid coaxial return line (low inductance and EMI shielding), but without the disadvantage of losses produced by such single coaxial return line when utilized with high peak and average power electromagnetic fields. This arrangement interrupts the normally large circumferential current return loop (tangent to the plasma), whereby such circumferential current return loop electrical losses become detrimental in the presence of high current electric fields. Thus such return conductors are constructed as a substantially current-loop-free radial array of parallel conductors located coaxially about the plasma. Furthermore, the radial-positioned array of conductors can be carefully and advantageously placed at locations where their electric field interaction with ambient dielectric components and with the plasma will help shape the plasma. The spatial location, cross-sectional shape, size, proximity to surfaces, and electron current densities of the plasma can all be advantageously optimized for a given application. For example, ground current return conductors can be located at a particular distance form the plasma to optimally locate the plasma along the central axis of the lamp bore. Additionally, ground current return conductors can be located at a particular distance from the plasma in order to optimally achieve a desired plasma current density and/or plasma temperature. As another example, ground current return conductors can be located with respect to intermediary dielectric materials and their associated electric field-shaping characteristics in order to optimally achieve a desired plasma current cross-section shape, size, and/or electron density. Optimization including but not limited to the above cited examples can be readily determined in view of the instant disclosure by one of ordinary skill in the art. Therefore, various combinations of radial parallel coaxial ground return bars can also influence the plasma temperature and subsequent spectral output of the lamp. Alternate embodiments substitute other shapes in place of the conducting bars, such as rods or sheets, with the afore-mentioned additional desirable results made possible by the interacting effects of the plasma and return currents electromagnetic fields in combination with both the shape and proximity of the conductor material and the shape and proximity of the dielectric material (quartz tube).
[0054] FIG. 5 illustrates the use of structural modifications to lamp envelope 502 in a manner that provides improved control of cooling fluid flow, thereby resulting in improved heat transfer from the lamp. Shown is a tangential cross-section view of one end of a pulsed lamp, showing lamp envelope or tube 502 , electrode(s) 504 , and plasma discharge region 506 . Heretofore smooth-walled lamp envelopes disadvantageously maximize the laminar flow of cooling fluids along the external surface of the lamp, so the fluid boundary layer is increased, turbulence decreases, and heat transfer efficiency reduces. This invention eliminates this problem by the use of irregular surface shapes that do not adversely affect the transmission of optical output, yet simultaneously increase the cooling fluid turbulence along the critical surfaces of thermal contact. By so increasing the efficiency and rate of thermal exchange, the average and peak temperatures of the lamp envelope can be lowered, thereby increasing the power and performance capabilities of the pulsed lamp. Judicious choice of location of such elements upon the lamp envelope can be used for improvement of heat transfer through the tube walls and for control of cooling fluid flow through the channel between the lamp envelope and cooling jacket, including the creation of higher turbulence zones at the hottest areas of the lamp. In order to improve coolant turbulence, lamp envelope surfaces and/or tube ribs can be made in the form of discontinuous elements and/or wave-like surface structure, and can be located only where required in order to achieve in those locations the thermal conditions required for any specific high performance pulsed lamp design.
[0055] It is understood that multiple combinations of lamp envelope reinforcement elements can be used with different lamp surface modifications in each of various specific applications.
[0056] FIG. 6 illustrates another embodiment, wherein UV lamp tube 602 is reinforced by introduction of an envelope design with secondary reinforcing sleeve 604 over and/or inside the original envelope. A suitable tight fit between tube 602 and reinforcing sleeve 604 can reduce the level of stress in the tube material and provide a beneficial effect upon the flash lamp lifetime.
[0057] Multi-wall tube(s) of at least two layers of envelope material assembled with preloading, allow control of the stress direction and level (for example, reduced tension in tube inner layer). Further, providing area(s) of contact of the at least two wall adjacent components can achieve an attenuation of radial shock waves, redirecting them back inside the tube, and reducing the stress level on the exterior of the tube. In this manner, certain areas requiring additional support, for example, the region surrounding electrode(s) 606 , may be advantageously strengthened without imposing what might be a detrimental effect upon other less-stressed locations. Various combinations of this method can improve the lamp envelope lifetime.
[0058] Multi-wall tubes can be used partially in areas affected with a higher thermal or mechanical load, such as hot electrode zones or high stressed envelope central area. Thus, such multi-wall tubes can be discontinuous. For example, in one example multi-wall tubes are used near electrode(s) 606 and/or along lamp tube 602 . Use of such multi-wall tubes results in an increased envelope lifetime with less modifications and fewer future problems.
[0059] FIG. 7 illustrates another embodiment of the present invention related to mechanical interactions between lamp tube 702 and surrounding cooling jacket 704 . Creating connection points between lamp tube 702 and cooling jacket 704 allows converting an otherwise loosely-supported lamp (i.e., only at each end, past electrode(s) 706 ) into a better supported design that provides an additional dimension of mechanical structure along with support in the central regions of the lamp.
[0060] This rigid and stable lamp support design is based on multiple variations and combination of flash lamp components and includes different embodiments of cooling jacket 704 with ring-like or longitudinal ribs 708 contacting and supporting the outside surface of lamp tube 702 , the use of non-continuous or continuous exterior ribs 710 upon or integral to lamp tube 702 , and the introduction of independent intermediate spacers 712 between lamp tube 702 and cooling jacket 704 .
[0061] FIG. 8 illustrates various embodiments of flash lamp components based on incorporating either lamp tube 802 , or cooling jacket or second tube 804 , fabricated with spiral ribs that provide mechanical stability to the lamp tube. An integral lamp assembly may therefore be comprised of a ribbed lamp located inside the smooth inside diameter of a cooling jacket, or else a smooth (non-ribbed) lamp 806 exterior located inside ribbed cooling jacket 804 .
[0062] Shown at only one of the two lamp ends is lamp tube 806 and electrode 810 . In an alternate embodiment, both the lamp tube and the cooling jacket may be fabricated with spiral ribs. Furthermore, fabrication of various styles of lamps can be advantageously simplified by assembling at room temperature the lamp and jacket components as a “slip fit” that, upon the lamp achieving the normal elevated temperature of operation, then creates one or more “interference fit” contact points 812 that provide mechanical support for the lamp. Use of components with twisted and or segmented surfaces, whether of longitudinal or radial orientation, creating contact between the tube and jacket, can help with absorption, reflection, and redirection of shock waves, thereby reducing the stress level in the lamp elements. Various combinations of surface patterns may be utilized to increase the turbulence of the cooling fluid, thereby also increasing the efficiency of the heat transfer.
[0063] FIG. 9 illustrates an embodiment providing mechanical support, wherein the reinforcement of lamp tube 902 , shown here with electrode(s) 904 , is accomplished as an integral lamp and cooling jacket assembly by inserting multi-lob spacer(s) 906 connecting the walls of lamp tube 902 and cooling jacket 908 , thereby creating a 3-dimensionally supported mechanical structure of higher strength and rigidity. The location points of connections are chosen in such a manner that reinforcement areas are able to limit tube natural oscillations and resonance, and also in a manner that provides the possibility for axial and radial preloading of the lamp tube material. This advantageously allows the elimination or reduction of tensile stress in lamp envelope (tube) 902 and limits the extent of tube bulging under the axial load.
[0064] Pre-stressed and/or flexible connecting elements (such as spacers) between tube 902 and jacket 908 can provide mechanical stress control and absorption of vibrations caused by shock waves. In one example such flexible connecting element(s) 906 is comprised of any of various suitable materials that are mechanically elastic.
[0065] FIG. 10 illustrates a further embodiment of the present invention, comprising further reduction of deleterious tensile stress in the lamp envelope material by a longitudinal preload of lamp tube walls 1002 during the lamp assembly. Additional compression 1004 force upon tube walls 1002 can prevent development of high-tension stress during multiple pulses of lamp discharge and thereby substantially reduce the chances of micro-crack development in the lamp envelope material. Such compression can be longitudinal compression 1004 , along the length of lamp tube 1002 and as illustrated in this example, as well as radial compression, as previously mentioned. In this example, longitudinal compression 1004 acts to counteract the lamp tube longitudinal expansion 1006 that results from the force of shock waves and transient, thermally-induced post-pulse gas pressure loading upon the respective ends of the lamp, at or near electrode(s) 1008 . Alternatively, compression forces can be transferred from cooling jacket 1010 to the wall of lamp tube 1002 . For example, mechanical connection(s) between cooling jacket 1010 and tube 1002 can mediate axial compression in tube walls.
[0066] A pre-stressed, integrated lamp design can be achieved by using one or more pressure rings 1014 at or near each end of lamp tube 1002 as lamp tube longitudinal compression force 1004 loading members. It is possible by this design to modify the lamp assembly process in a manner that will redistribute the axial forces within the components of lamp tube 1002 and convert some of those forces into longitudinal and/or radial tension stress within cooling jacket 1010 , thereby balancing and reducing the axial compression stress in the walls of lamp tube 1002 .
[0067] Preferably, tube 1002 is centered in cooling jacket 1010 , for example, utilizing a star-like or radial-armed shape as pressure ring 1014 (see for example the shapes illustrated in FIGS. 7 and 9 ) allows cooling fluid circulation in annular gap 1012 surrounding lamp tube 1002 and inside cooling jacket 1010 . Alternative centering means include but are not limited to afore-mentioned examples such as an inner annular ring contacting the lamp tube, with radial arms extending to and contacting the jacket wall; an outer annular ring in contact with the jacket wall, with radial arms extending inward and contacting the lamp tube wall; a central annular ring located midway between the walls of the lamp tube and jacket, with radial arms extending in both directions and contacting the respective walls.
[0068] Yet another embodiment of the present invention comprises reducing the risk of development of excessive tensile stress in tube walls by application of evenly distributed hydraulic pressure along the lamp tube. It is known that higher power pulsed flash lamps typically have channel 1012 between lamp tube 1002 and cooling jacket 1010 whereby cooling fluid is pumped through channel 1012 , removing heat from lamp tube 1002 . By this invention an intentional substantial pressure increase in cooling fluid can result in uniform radial compression of tube walls 1002 , thereby reducing the chances for developing excessive tension stress in the material used for the high performance pulsed lamp tube. In a preferred embodiment, the range of 2 Bar to 7 Bar is beneficial while remaining both achievable and safe to implement.
[0069] FIG. 11 illustrates a further embodiment, comprising a means to limit the deleterious effect of excessive shock waves in the lamp working gas and material comprising the lamp tube walls. Preferably hollow chamber 1124 is created in the general vicinity of electrode head(s) 1104 . For example, in one embodiment turned-down areas on both electrodes 1104 together with the inner wall surface of lamp tube 1102 create small cylindrical hollow chambers 1124 behind electrode head(s) 1104 . These chambers are connected with main tube gas volume 1106 by thin clearances between electrode head(s) 1104 and tube inner surface, and can work as a trap for axial shock waves 1110 propagated through the gas inside the tube. It should be mentioned that the previously described wave-like and twisted tubes and jackets are also able to provide irregular hollows working as multiple traps for shock waves within the gas.
[0070] Additional modifications of electrode and supporting structure, for example, changing the head shape from flat to spherical and introducing special grooves at the back of the head, can promote additional reflection and dissipation of pressure waves in the lamp gas. Alternatively, additional energy dispersing space(s) can be provided through modifications to the surrounding tube.
[0071] FIG. 11 further illustrates flash lamp designs and components responsible for attenuating, redirecting, and diffusing the high energy shock waves (and their harmonics) that propagate through the gases and solid materials of the lamp. Shown is a representation of one end of a pulsed lamp that includes lamp envelope (or tube) 1102 , electrode assembly 1104 , main tube gas volume 1106 , primary high energy shock wave 1108 , small arrows representing secondary dispersed shock wave energy components 1110 within gas-filled cavity 1106 , lamp tube-coupled shock wave energy 1112 within the solid material of lamp tube 1102 , and small arrows representing dispersed shock wave energy 1114 at or near the ends of lamp tube 1102 .
[0072] In an alternative embodiment resulting cavities, for example cavity or chamber 1124 , either include or comprise material having appropriate elastic properties (i.e., similar to some silicone compounds), but need not be limited to only polymers; other material families may also provide compatible characteristics. For example, there are materials exhibiting a compressible structure encompassing voids (similar to a sponge) that are also compatible with the ambient conditions of elevated temperature, high electric stress, high photon flux, and high gas purity.
[0073] Chamfered-out (bevel angled-out) sections 1116 and/or chamfered-in (bevel angled-in) sections 1118 at the ends of lamp tube 1002 are able to redirect and/or dissipate shock waves 1112 propagated through the material of lamp tube 1002 . In another embodiment, filler 1120 located on lamp tube 1002 tube butt-ends 1122 and made of a shock-compensating material with a density that is between that of the lamp envelope material (preferably glass or quartz) and the cooling medium (typically water) can provide additional absorption and attenuation of lamp tube 1002 shock wave 1112 as it couples into filler 1120 .
[0074] Various shock absorbing materials and structures located inside the tube (behind the electrode heads) and outside on tube butt-ends are additional embodiments that can improve flash lamp lifetime and performance.
[0075] Additionally, an increase in the internal diameter of lamp tube 1102 will increase the amount of gas while simultaneously decreasing the tube temperature and effect of shock waves. Importantly, the additional and possibly negative effects that such a change might impose upon the formation and density of the plasma can be entirely mitigated by one or some combination of other teachings and claims of this invention. For example, the afore-mentioned ground current return scheme illustrated in FIG. 4 is one such means whereby the plasma column may be advantageously shaped to achieve the desired conditions.
[0076] All suggestions related to more efficient cooling of lamp electrodes could work in combination with embodiments set forth herein that focus upon reduction of the effect of shock waves and/or envelope reinforcement elements.
[0077] FIG. 12 illustrates an additional embodiment comprising the reduction of excessive longitudinal and axial stress in tube material as a result of repetitive high-energy pulses and lamp tubing thermal expansion. In this embodiment lamp tube holder 1202 located beyond electrode head 1212 at each end of lamp tube 1204 can be constructed with suitable flexible coolant seals in order to provide an opportunity for lamp tube 1204 to slide in longitudinal direction 1206 , thereby reducing possible excessive longitudinal and axial load on the walls of lamp tube 1204 and cooling envelope 1214 . Thus, in this embodiment, lamp tube holders 1202 allow lamp tube 1204 to slide in response to thermal expansion and/or high energy pulses, while also providing a means whereby coolant fluid can be pumped into, throughout, and out of lamp coolant channels 1208 . Radial-armed supporting spacers 1210 located in coolant channels 1208 are constructed so as to provide both axial support to and longitudinal slip for lamp tube 1204 , in addition to passages allowing adequate cooling fluid flow.
[0078] FIG. 13 illustrates the use of the afore-mentioned supporting spacer(s) 1310 located in area(s) of lamp tube 1302 resonant wave anti-node 1312 (maxim amplitudes) in order to limit the natural oscillations of lamp tube 1302 , thereby preventing excessive resonance-induced stress. Supporting spacers 1310 are placed around the circumference of lamp tube 1302 , extending in a radial direction to the inside wall of a cooling jacket, and are positioned as required at appropriate anti-node position(s) 1312 along the length of lamp tube 1302 , thereby mechanically stiffening the lamp. The first mode of vibration resonance wave 1304 , second mode of vibration resonance wave 1306 , and third mode of vibration resonance wave 1308 are illustrated, as are their respective anti-node positions 1312 . In certain more demanding applications, avoiding resonance and possible excessive deflection of tube components can be advantageous and instrumental in the reduction of development of micro-cracks in the lamp tube, thereby preventing premature failure and/or unacceptable pulsed lamp lifetime.
[0079] For the purpose of providing either thermal conductance or the transference of mechanical forces between the lamp tube and cooling jacket, the utilization of connecting and/or compression ring material(s) with intentionally mismatched coefficient of thermal expansion can be advantageous. This method makes use of the differential temperatures between the lamp tube outer surface and the cooling jacket inner surface, and thereby creates a thermal “shrink-fit” with a subsequent intimate physical surface contact between components (lamp tube, rings, and cooling jacket. The amount of compression force upon each can be accurately tailored by the selection of materials and lamp cooling operating parameters. Additionally, a “slip-fit” condition during manufacturing can advantageously become a compressed fit at the more elevated temperature required during lamp system operation.
[0080] Having now described a few embodiments of the invention, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the invention and any equivalent thereto. It can be appreciated that variations to the present invention would be readily apparent to those skilled in the art, and the present invention is intended to include those alternatives. Further, since numerous modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
|
Broadband output high power pulsed flash lamps are useful in many applications, and when specifically optimized, can become an excellent source of ultraviolet (UV) light, which is particularly useful for photo-chemically-induced materials processing applications. Multiple factors involved with the production of high-energy light pulses can in certain cases adversely affect the ultraviolet lamp operation, thereby resulting in the development of micro cracks in lamp envelopes and subsequent limitation in lamp lifetime. Similar factors can be responsible for an increased absorption of UV radiation by lamp components and degradation of lamp efficiency. This invention describes new pulsed flash lamp designs that enable a new generation of high power and performance as required by, for example, many large-scale photo-processing applications. This invention uniquely and advantageously mitigates the development of micro-cracks and failure, and produces dramatically improved electrical efficiency, stability of lamp optical characteristics, and service lifetime.
| 7
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application Ser. No. 10/906,386, filed Feb. 17, 2005, which claims the benefit of U.S. Provisional Application Ser. No. 60/521,073, filed Feb. 17, 2004, each of which is incorporated herein by reference.
GOVERNMENT SUPPORT
[0002] This invention was developed under support from the National Science Foundation under grants OPP-9901076 and OPP-0125152; accordingly the U.S. government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0003] One of the greatest efforts of modern medicine is the control and abatement of cellular proliferative disorders, such as cancers. Considerable research has been conducted searching for new biologically active compounds having useful activity for specific cancers and the organisms which produce these compounds. For example, certain marine soft corals have shown to be a source of biologically active cytotoxins. Also, compounds from sponges have proven effective against lipoxygenase-mediated conditions in humans (See U.S. Pat. No. 6,750,247 to Crews et al.)
[0004] Tunicates have proven to be an important source of bioactive natural products. Among marine natural products that have advanced as cancer treatments the ecteinascidins and didemnins are derived from tunicates, and the eudistomins have potent antiviral activity. As part of an ongoing study of bioactivity among Antarctic marine invertebrates, the inventors had the occasion to study the tunicate Synoicum adareanum.
[0005] S. adareanum is a circumpolar tunicate common in the shallow waters around Anvers island (64° 46′S, 64° 03′W) on the Antarctic Peninsula from 15 to 796 meters depth. S. adareanum colonies consist of large rounded or club-shaped heads with the bottom stalk being wrinkled and leathery and only slightly narrower than the head. S. adareanum colonies can be up to eighteen centimeters high with a diameter of twelve centimeters. S. adareanum colonies may comprise a single head or, up to six heads can arise from a single stalk.
SUMMARY OF INVENTION
[0006] Extracts from S. adareanum , Palmerolide A (1), Palmerolide C, Palmerolide D, and Palmerolide E displayed bioactivity in field-based feeding-deterrent assays, leading the inventors to investigate the chemical nature of the activity. Presented are novel, isolated polyketides, Palmerolide A (1), Palmerolide C, Palmerolide D, and Palmerolide E as the major natural product from extracts of S. adareanum . These polyketides display selective cytotoxicity in the National Cancer Institute (NCI) 60 cell line panel inhibiting, inter alia, melanoma (UACC-64, LC 50 0.018 μM) with three orders of magnitude greater sensitivity relative to other cell lines tested.
[0007] In a general embodiment, the present invention provides a method of treating a subject with cancer, comprising administering to the subject a therapeutically effective amount of at least one isolated compound obtained from extracts of a Synoicum species. In this embodiment, the Synoicum species is S. adareanum and the isolated compound obtained from the Synoicum species is a Palmerolide. The Palmerolide is chosen from the group consisting of Palmerolide A(1), Palmerolide C, Palmerolide D, and Palmerolide E.
[0008] In an alternate embodiment, a composition (or an isomer, racemate or racemic mixture thereof, or a pharmaceutically acceptable salt thereof) is provided comprising an isolated compound of the formula:
[0000]
[0009] In yet another embodiment the present invention provides for a composition (or an isomer, racemate or racemic mixture thereof, or a pharmaceutically acceptable salt thereof) comprising an isolated compound of the formula:
[0000]
[0010] An additional embodiment the present invention provides for a composition (or an isomer, racemate or racemic mixture thereof, or a pharmaceutically acceptable salt thereof) comprising an isolated compound of the formula:
[0000]
[0011] The present invention also provides for a composition (or an isomer, racemate or racemic mixture thereof, or a pharmaceutically acceptable salt thereof) comprising an isolated compound of the formula:
[0000]
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective view of the chemical formula for Palmerolide A.
[0013] FIG. 2 is a chart showing the NMR Data for Palmerolide A.
[0014] FIG. 3 depicts selected ROE correlations relating the relative stereochemistry between C-11 and C-19.
[0015] FIG. 4 is a chart showing the National Cancer Institute (NCI) Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide A.
[0016] FIG. 5 is a continued chart, showing the National Cancer Institute (NCI) Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide A.
[0017] FIG. 6 is a graph showing National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for all cell lines tested for Palmerolide A.
[0018] FIG. 7 is a graph showing National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for Melanoma cell lines tested for Palmerolide A.
[0019] FIG. 8 is a graph showing National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for Colon Cancer cell lines tested for Palmerolide A.
[0020] FIG. 9 is a graph showing National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for Renal Cancer cell lines tested for Palmerolide A.
[0021] FIG. 10 is perspective view of the chemical formula for Palmerolide C.
[0022] FIG. 11 is a chart showing the NMR Data for Palmerolide C.
[0023] FIG. 12 is a chart showing the National Cancer Institute (NCI) Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide C.
[0024] FIG. 13 is a continued chart, showing the National Cancer Institute (NCI) Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide C.
[0025] FIG. 14 is a graph showing National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for all cell lines tested for Palmerolide C.
[0026] FIG. 15 is a perspective view of the chemical formula for Palmerolide D.
[0027] FIG. 16 is a chart showing the NMR Data for Palmerolide D.
[0028] FIG. 17 is a perspective view of the chemical formula for Palmerolide E.
[0029] FIG. 18 is a chart showing the NMR Data for Palmerolide E.
[0030] FIG. 19 is a chart showing the National Cancer Institute (NCI) Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide E.
[0031] FIG. 20 is a continued chart, showing the National Cancer Institute (NCI) Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide E.
[0032] FIG. 21 is a graph showing National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for all cell lines tested for Palmerolide E.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0033] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the invention.
Terms
[0034] Those skilled in the art will recognize that the Palmerolide compounds disclosed herein can exist in several tautomeric forms. All such tautomeric forms are considered as part of this invention.
[0035] “Pharmaceutically acceptable carrier” refers to any carrier, diluent, excipient, wetting agent, buffering agent, suspending agent, lubricating agent, adjuvant, vehicle, delivery system, emulsifier, disintegrant, absorbent, preservative, surfactant, colorant, flavorant, or sweetener, preferably non-toxic, that would be suitable for use in a pharmaceutical composition.
[0036] “Pharmaceutically acceptable equivalent” includes, without limitation, pharmaceutically acceptable salts, hydrates, metabolites, prodrugs and isosteres. Many pharmaceutically acceptable equivalents are expected to have the same or similar in vitro or in vivo activity as the compounds of the invention.
[0037] “Pharmaceutically acceptable salt” refers to a salt of the inventive compounds which possesses the desired pharmacological activity and which is neither biologically nor otherwise undesirable. The salt can be formed with acids that include, without limitation, acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrochloride hydrobromide, hydroiodide, 2-hydroxyethane-sulfonate, lactate, maleate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, oxalate, thiocyanate, tosylate and undecanoate. Examples of a base salt include ammonium salts, alkali metal salts such as sodium and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, salts with organic bases such as dicyclohexylamine salts, N-methyl-D-glucamine, and salts with amino acids such as arginine and lysine. The basic nitrogen-containing groups can be quarternized with agents including lower alkyl halides such as methyl, ethyl, propyl and butyl chlorides, bromides and iodides; dialkyl sulfates such as dimethyl, diethyl, dibutyl and diamyl sulfates; long chain halides such as decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides; and aralkyl halides such as benzyl and phenethyl bromides.
[0038] “Prodrug” refers to a derivative of the inventive compounds that undergoes biotransformation, such as by metabolism, before exhibiting a pharmacological effect.
[0039] The prodrug is formulated with the objective of improved chemical stability, improved patient acceptance and compliance, improved bioavailability, prolonged duration of action, improved organ selectivity, improved formulation (e.g., increased hydrosolubility), and/or decreased side effects (e.g., toxicity). The prodrug can be readily prepared from the inventive compounds using methods known in the art, such as those described by Burger's Medicinal Chemistry and Drug Chemistry, Fifth Ed., Vol. 1, pp. 172-178, 949-982 (1995).
[0040] “Palmerolide,” as used herein, refers to a multi-membered macrocyclic polyketide bearing carbonate and amide functionality. In one embodiment, the Palmerolide is isolated from the tunicate Synoicum adareanum ; collected from the vicinity of Palmer Station on the Antarctic Peninsula.
[0041] “Polyketides,” as used herein, refers to any natural compound containing alternating carbonyl and methylene groups β-polyketones), derived from repeated condensation of acetyl coenzyme A.
[0042] “Macrocycle,” as used herein, refers to a large molecule arranged in a circle with various semi-compounds attached at various points. The point of attachment and the nature of the sub-molecule determines the nature and physiological effect of the compound which contains it.
[0043] “Macrolide,” as used herein, refers to a class of antibiotics characterized by molecules made up of large-ring lactones.
[0044] “Olefin,” as used herein, is synonymous with “alkene” and refers to an acyclic hydrocarbon containing one or more double bonds.
[0045] As used herein, “a clinical response” is the response of a cell proliferative disorder, such as melanoma, colon and renal cancer, to treatment with novel compounds disclosed herein. Criteria for determining a response to therapy are widely accepted and enable comparisons of the efficacy alternative treatments (see Slapak and Kufe, Principles of Cancer Therapy, in Harrisons's Principles of Internal Medicine, 13 th edition, eds. Isselbacher et al., McGraw-Hill, Inc. 1994). A complete response (or complete remission) is the disappearance of all detectable malignant disease. A partial response is an approximately 50 percent decrease in the product of the greatest perpendicular diameters of one or more lesions. There can be no increase in size of any lesion or the appearance of new lesions. Progressive disease means at least an approximately 25 percent increase in the product of the greatest perpendicular diameter of one lesion or tumor or the appearance of new lesions or tumors. The response to treatment is evaluated after the subjects had completed therapy.
Pharmaceutical Compositions
[0046] A “pharmaceutical composition” of the invention is formulated to be compatible with its intended route of administration. Examples of routes of administration include parenteral, intravenous, intradermal, subcutaneous, oral inhalation, transdermal (topical), transmucosal, and rectal administration. Solutions or suspensions used for parenteral, intradermal, or subcutaneous application can include the following components: a sterile diluent such as water for injection, saline solution, fixed oils, polyethylene glycols, glycerine, propylene glycol or other synthetic solvents; antibacterial agents such as benzyl alcohol or methyl parabens; antioxidants such as ascorbic acid or sodium bisulfite; chelating agents such as ethylenediaminetetraacetic acid; buffers such as acetates, citrates or phosphates and agents for the adjustment of tonicity such as sodium chloride or dextrose. pH can be adjusted with acids or bases, such as hydrochloric acid or sodium hydroxide. The parenteral preparation can be enclosed in ampoules, disposable syringes or multiple dose vials made of glass or plastic.
[0047] Pharmaceutical compositions suitable for injectable use include sterile aqueous solutions (where water soluble) or dispersions and sterile powders for the extemporaneous preparation of sterile injectable solutions or dispersion. For intravenous administration, suitable carriers include physiological saline, bacteriostatic water, or phosphate buffered saline (PBS). In all cases, the composition must be sterile and should be fluid to the extent that easy syringability exists. It must be stable under the conditions of manufacture and storage and must be preserved against the contaminating action of microorganisms such as bacteria and fungi. The carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (for example, glycerol, propylene glycol, and liquid polyetheylene glycol, and the like), and suitable mixtures thereof. The proper fluidity can be maintained, for example, by the use of a coating such as lecithin, by the maintenance of the required particle size in the case of dispersion and by the use of surfactants. Prevention of the action of microorganisms can be achieved by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, ascorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars, polyalcohols such as mannitol, sorbitol, sodium chloride in the composition. Prolonged absorption of the injectable compositions can be brought about by including in the composition an agent which delays absorption, for example, aluminum monostearate and gelatin.
[0048] Sterile injectable solutions can be prepared by incorporating the active compound in the required amount in an appropriate solvent with one or a combination of ingredients enumerated above, as required, followed by filtered sterilization. Generally, dispersions are prepared by incorporating the active compound into a sterile vehicle which contains a basic dispersion medium and the required other ingredients from those enumerated above. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and freeze-drying which yields a powder of the active ingredient plus any additional desired ingredient from a previously sterile-filtered solution thereof.
[0049] Oral compositions generally include an inert diluent or an edible carrier. They can be enclosed in gelatin capsules or compressed into tablets. For the purpose of oral therapeutic administration, the active compound can be incorporated with excipients and used in the form of tablets, troches, or capsules. Oral compositions can also be prepared using a fluid carrier for use as a mouthwash, wherein the compound in the fluid carrier is applied orally and swished and expectorated or swallowed. Pharmaceutically compatible binding agents, and/or adjuvant materials can be included as part of the composition. The tablets, pills, capsules, troches and the like can contain any of the following ingredients, or compounds of a similar nature: a binder such as microcrystalline cellulose, gum tragacanth or gelatin; an excipient such as starch or lactose, a disintegrating agent such as alginic acid, Primogel, or corn starch; a lubricant such as magnesium stearate or Sterotes; a glidant such as colloidal silicon dioxide; a sweetening agent such as sucrose or saccharin; or a flavoring agent such as peppermint, methyl salicylate, or orange flavoring. For administration by inhalation, the compounds are delivered in the form of an aerosol spray from pressured container or dispenser which contains a suitable propellant, a gas such as carbon dioxide, or a nebulizer.
[0050] Systemic administration can also be by transmucosal or transdermal means. For transmucosal or transdermal administration, penetrants appropriate to the barrier to be permeated are used in the formulation. Such penetrants are generally known in the art, and include, for example, for transmucosal administration, detergents, bile salts, and fusidic acid derivatives. Transmucosal administration can be accomplished through the use of nasal sprays or suppositories. For transdermal administration, the active compounds are formulated into ointments, salves, gels, or creams as generally known in the art. The compounds can also be prepared in the form of suppositories (for example, with conventional suppository bases such as cocoa butter and other glycerides) or retention enemas for rectal delivery.
[0051] In one embodiment, the active compounds are prepared with carriers that will protect the compound against rapid elimination from the body, such as a controlled release formulation, including implants and microencapsulated delivery systems. Biodegradable, biocompatible polymers can be used, such as ethylene vinyl acetate, polyanhydrides, polyglycolic acid, collagen, polyorthoesters, and polylactic acid. Methods for preparation of such formulations will be apparent to those skilled in the art. The materials can also be obtained commercially from Alza Corporation and Nova Pharmaceuticals, Inc. Liposomal suspensions (including liposomes targeted to infected cells with monoclonal antibodies to viral antigens) can also be used as pharmaceutically acceptable carriers. These can be prepared according to methods known to those skilled in the art.
[0052] A “therapeutically effective amount” is the amount of Palmerolide A, C, D, or E, or any combination thereof necessary to provide a therapeutically effective amount of the corresponding compound in vivo. The amount of the compound must be effective to achieve a response, such as, but not limited to total prevention of (protection against) and to improved survival rate or more rapid recovery, or improvement or elimination of symptoms associated with a cellular proliferative disease or other indicators as are selected as appropriate measures by those skilled in the art. In accordance with the present invention, a suitable single dose size is a dose that is capable of preventing or alleviating (reducing or eliminating) a symptom in a patient when administered one or more times over a suitable time period. One of skill in the art can readily determine appropriate single dose sizes for systemic administration based on the size of a mammal and the route of administration.
Example I
Hollow Fiber Assay for Preliminary In Vivo Testing
[0053] The Biological Testing Branch of the Developmental Therapeutics Program has adopted a preliminary in vivo screening tool for assessing the potential anticancer activity of compounds identified by the large scale in vitro cell screen. This hollow fiber based assay has been in use since June, 1995.
[0054] Each compound is tested against a standard panel of 12 human tumor cell lines including NCI-H23, NCI-H522, MDA-MB-231, MDA-MB-435, SW-620 COLO 205, LOX IMVI, UACC-62, OVCAR-3, OVCAR 5, U251 and SF-295. The cell lines are cultivated in RPMI-1640 containing 10% FBS and 2 mM glutamine. On the day preceding hollow fiber preparation the cells are given a supplementation of fresh medium to maintain log phase growth. For fiber preparation the cells are harvested by standard trypsinization technique and resuspended at the desired cell density (varies by cell line between 2-10×10 6 cells/ml). The cell suspension is flushed into 1 mm I.D. polyvinylidene hollow fibers with a molecular weight exclusion of 500,000 Da. The hollow fibers are heat-sealed at 2 cm intervals and the samples generated from these seals are placed into tissue culture medium and incubated at 37° C. in 5% CO 2 for 24-48 hours prior to implantation. A total of 3 different tumor lines are prepared for each experiment so that each mouse receives 3 intraperitoneal implants (1 of each tumor line) and 3 subcutaneous implants (1 of each tumor line). On the day of implantation, samples of each tumor cell line are quantitated for viable cell mass by a stable endpoint MTT assay so that the time zero (0) cell mass is known. Thus, the cytostatic and cytocidal capacities of the test compound can be assessed. Mice are treated with experimental agents starting on day 3 or 4 following fiber implantation and continuing once daily for a total of 4 doses. Each agent is assessed by intraperitoneal injection at 2 dose levels with 3 mice/dose/experiment. Vehicle controls consist of 6 mice receiving the compound diluent only. The fibers are collected from the mice on the day following the fourth compound treatment and subjected to the stable endpoint MTT assay. The optical density of each sample is determined spectrophotometrically at 540 nm and the mean of each treatment group is calculated. The percent net cell growth in each treatment group is calculated and compared to the percent net cell growth in the vehicle treated controls. Each compound is assessed in a total of 4 experiments (3 cell lines/experiment× 4 experiments=12 cell lines).
[0055] Compounds are selected for further testing (e.g. time/dose exposure studies preliminary pharmacology studies, subcutaneous xenograft efficacy studies) on the basis of several hollow fiber assay criteria. These include: (1) a reduction in net cell growth of 50% or greater in 10 of the 48 possible test combinations (12 cell lines× 2 sites× 2 compound doses); (2) a reduction in net cell growth of 50% or greater in a minimum of 4 of the 24 distant site combinations (intraperitoneal drug/subcutaneous culture); and/or (3) cell kill of 1 or more cell lines in either implant site (reduction in the viable cell mass below the level present at the start of the experiment).
[0056] To simplify evaluation, a point system has been adopted which allows rapid viewing of the activity of a given compound. For this, a value of 2 is assigned for each compound dose which results in a 50% or greater reduction in viable cell mass. The intraperitoneal and subcutaneous samples are scored separately so that criteria (1) and (2) can be evaluated. Compounds with a combined IP+SC score 20 , a SC score 8 or a net cell kill of one or more cell lines can be considered for further studies. The maximum possible score for an agent is 96 (12 cell lines× 2 sites× 2 dose levels× 2 [score]). These criteria were statistically validated by comparing the activity outcomes of >80 randomly selected compounds in the hollow fiber assay and in xenograft testing. This comparison indicated that there was a very low probability of missing a xenograft active compound if the hollow fiber assay were used as the initial in viva screening tool. Because of the design of the hollow fiber assay, the results of individual cell lines are not reported since the statistical power of the assay is based on the impact of a compound against the entire panel of cells. In addition to the hollow fiber results, other factors (e.g. unique structure, mechanism of action, etc.) may result in referral of a compound for further studies without the corn pound meeting these hollow fiber assay criteria.
Example II
Palmerolide Isolation
[0057] S. adareanum was extracted with 1:1 dichloromethane/methanol and the residue resulting from rotary evaporation was partitioned between an equal volume of water and ethyl acetate (EtOAc). Column chromatography of the EtOAc partition fraction using mixtures of hexane, ethyl acetate and methanol resulted in Fractions 4 and 5, which eluted with 2%-5% methanol/ethyl acetate (310 mg) combined. These combined fractions were further separated by gradient elution of 1-10% MeOH/CHCl 3 followed up by purification with HPLC on C-18 (40% I-120/MeCN) afforded Palmerolide A, C, D and E (see Table I below).
[0000]
TABLE I
Example III
[0058] As an illustrative example; Palmerolide A(1) was isolated as a white amorphous solid from the 1:1 methanol/ethyl acetate fraction eluting from silica gel chromatography of the crude (1:1 methanol/dichloromethane) extract. Mass spectrometric analysis provided a molecular formula of C 33 H 48 N 2 O 7 ( FIG. 1 ) (HRFABMS m/z 585.3539, Δ 0.1 mmu for [M + +1]). The C-1 to C-24 carbon backbone of Palmerolide A was unambiguously established based on 1 H- 1 H and 1 H- 13 C connectivity assignments from 2D NMR techniques as described below.
[0059] The C-1 ester carbonyl of Palmerolide A (1) was found to be conjugated to the C-2/C-3 olefin based on observation of cross-correlations in the gHMBC spectrum ( FIG. 2 ) from both H-2 and H-3 to C-1. The olefinic protons were disposed trans based on the large vicinal coupling (J=152 Hz). Three methylene carbons (δ 32.6, 25.7 and 38.5) were observed by both gCOSY and gHMBC to intervene between the C-2/C-3 olefin and a hydroxymethine at δ 3.83 (H-7). A trans-distributed olefin (J=15.5 Hz) could be positioned between the aforementioned hydroxymethine and another at δ 4.15 (H-10). While H-10 showed no gHMBC correlations, H-8, H-9 and H-11 all displayed connectivity by gHMBC to C-10. H-11 could be further extended to C-12/C-13 (C-12 and C-13 are coincident in the 13 C NMR spectrum) by gHMBC and gCOSY, as well as to an ester carbonyl (OCOX) which displayed no further connectivity using these NMR techniques. In the gHMBC spectrum, H-13 coupled into the olefinic region, to C-14 and C-15. The C-14/C-15 trans-olefin (J=14.6 Hz) was shown to be conjugated to a tri-substituted olefin in positions C-16 and C-17 by gHMBC correlations of H-14, H-15, H-18 and H-19, as well as H 3 -27. The C-16/C-17 olefin must be E based on a ROESY spectrum, which demonstrated the proximity ( FIG. 3 ) of H 3 -27 to H-15. A methylene group (C-18, δ 43.9) intervenes between the C-16/C-17 olefin and an oxygen-bearing methine (C-19, δ 75.8), based on gHMBC correlations of H-16 and H 3 -27 to C-18; H-19 and H-20 similarly correlate to C-18. The 20-membered macrocycle was completed based on coupling between H-19 and the C-1 ester carbonyl in the gHMBC spectrum.
[0060] Features of the macrocycle were established by further analysis of 2D NMR data. In addition to the four E olefins described above, three oxygen atoms and one methyl group were pendant on the macrocycle. Hydroxymethine protons at H-7 and H-10 were conclusively assigned based on observation of coupling of the hydroxyl protons in both the gHMBC and gCOSY spectra: in the gHMBC spectrum, the hydroxyl protons correlated to the respective x- and β-carbons, while in the gCOSY spectrum correlations were observed between the hydroxyl protons and their respective hydroxymethines. The third oxygen-bearing carbon (C-11), as described above, correlates with an ester carbonyl (OCOX) at δ 157.3.
[0061] Also pendant on the macrocycle is the C-19 side chain. The H-20 multiplet, correlating to C-19 (gHMBC), was shown by gCOSY to be coupled to a methyl group (C-26, δ 0.90) and the terminus of a conjugated diene system based on H-19 and H-20 gHMBC correlations to olefinic C-21 (δ 130.5). Both the C21/C-22 and the C-23/C-24 olefins were determined to be E, based, in the former case, on a ROESY correlation between H 3 -25 and H-20, and in the latter case the basis of coupling (J=14.2 Hz). Connectivity of the C-23/C-24 olefin could be established based on gHMBC correlations of H-23 to C-21, C-22, C-24 and C-25. C-24 marked the terminus of the contiguous carbon chain and could be shown to bear an —NH group due to gHMBC correlations of an amide proton at δ 9.84 to carbons C-23, C-24 and the amide carbonyl, C-1′ (δ 163.9).
[0062] The isopentenoyl substructure (C-1′ to C-5′) was unusual in displaying 4 J CH coupling in the gHMBC spectrum between the amide carbonyl (C-1′) and both vinyl methyl groups (C-4′ and C-5′). Only one vinyl methyl can be placed within the 3 J CH reach of the typical HMBC experiment optimized for 8 Hz. The 2-methyl-2-butenoyl isomer, wherein protons from one vinyl methyl reside three bonds from the carbonyl and those from the second reside four bonds distant was unlikely on chemical shift grounds, but also because the vinyl methyl groups were mutually correlated in the gHMBC spectrum, FIG. 2 . The substructure was secured as the isopentenoyl group by observation of very small coupling (J=1.0 Hz) of the vinyl proton (H-2′) to both vinyl methyl groups (C-4′ and C-5′), excluding a vicinal relationship (i.e., large J) between the vinyl proton and one vinyl methyl required by the 2-methyl-2-butenoyl isomer.
[0063] The connectivity described above established the full planar structure of Palmerolide A (1) with the exception of a single open valence on the ester carbonyl attached to the macrolide at C-11. Remaining to be accounted from the molecular formula was —NH 2 . That the C-11 functional group was a carbamate is supported by the precedence of that functional group on other polyketides, most notably the anticancer agent discodermolide.
[0064] The stereochemical assignment of Palmerolide A's (1) five asymmetric centers was established by the application of the modified Mosher and Murata methods. (R)- and (S)-MTPA esters's of Palmerolide A demonstrated both C-7 and C-10 to bear the R configuration. Configurational analysis of the C-10/C-11 fragment identified a gauche relationship between H-10 and H-11, based on the small 3 J H-10/H-11 observed between the vicinal protons and the large 3 J CH for both the H-10/C-12 and the H-11/C-9 relationships. Further support for the conformation was found in 2 J C-11/H-10 and 2 J C-10/H-11 , both of which were large and negative, defining the absolute stereochemistry of C-11 as R. Similarly, configurational analysis of the C-19/C-20 system suggested an anti relationship of the respective protons, based on the large 3 J H-19/H-20 , small 3 J C-21/II-19 , 3 J C-26/H-19 and 3 J C-18/H-20 , as well as the large 3 J C-19/H-20 . The relative position of C-18 in this fragment was secured by the observation of ROESY correlations between H 2 -18 and H-20 as well as H 2 -18 and H 3 -26 while no ROESY correlation was observed between H 2 -18 and H-21, requiring the relative configuration 19R*, 20S*.
[0065] The four olefins in the macrocycle constrain the flexibility often found in macrolides, facilitating stereochemical analysis by NOE studies. Further analysis of the ROESY spectrum revealed the macrolide to adopt two largely planar sides of a tear-drop shaped cycle, one side consisting of C-1 through C-6, the other C-11 through C-19, with C-7 through C-10 providing a curvilinear connection. In particular, H-19, H 3 -27, H-15 and H 2 -13 (see FIG. 3 ) are sequentially correlated in the ROESY spectrum, as are H 3 -26, H 2 -18, H-16. H-14 and H-12, defining the periphery of the top and bottom face of the western hemisphere. H-11 correlates only to the top series of protons, a result consistent only with C-19 and C-11 both adopting the R configuration. The absolute stereochemistry of the C-19/C-20 fragment is therefore 19R, 20S.
[0066] Tunicates are not well known as producers of type I polyketides, though the patellazoles and iejimalides are significant, bioactive, representatives. Palmerolide A (1) is unusual in bearing a small macrocycle, with 20 members, compared to 24 in the patellazoles and iejimalides, and a vinyl amide, a feature more commonly associated with cyanophyte-derived macrolides such as tolytoxin. Palmerolide A displays cytotoxicity toward several other melanoma cell lines. FIG. 2 , [M14(LC 50 0.076 μM), SK-MEL-5 (6.8 μM) and LOX IMVI (9.8 μM)] as well as the previously mentioned UACC-62. Besides melanoma, FIG. 3 , one colon cancer cell line (HCC-2998. 6.5 μM), FIG. 4 , and one renal cancer cell line (RXF 393, 6.5 μM), FIG. 5 , Palmerolide A was largely devoid of cytotoxicity (LC 50 >10 μM), representing a selectivity index among tested cell lines of 10 3 for the most sensitive cells. Significantly, Palmerolide A is COMPARE.-negative against the NCI database, suggestive of a previously un-described mechanism of action. Field and laboratory bioassay and chemical studies to address Palmerolide A's potential are ongoing.
[0067] FIGS. 4 and 5 , indicate the National Cancer Institutes Developmental Therapeutics Program In-Vitro Testing Results for Palmerolide A. FIG. 6 shows the National Cancer Institute (NCI) Developmental Therapeutics Program Dose Response Curves for all cell lines tested for Palmerolide A. In comparison, individual results are shown for Melanoma ( FIG. 7 ), Colon Cancer ( FIG. 8 ) and Renal Cancer ( FIG. 9 ).
Example IV
Cytotoxicity of Palmerolide C
[0068] Palmerolide C, shown below and in FIG. 10 , has the chemical formula C 33 H 49 N 2 O 7 (for NMR data see FIG. 11 ). NCI cytotoxicity is shown in FIG. 12 and FIG. 13 . NCI Dose Response Curves for all cell lines are presented in FIG. 14 .
[0000]
Example V
Cytotoxicity of Palmerolide D
[0069] Palmerolide D, shown below and in FIG. 15 , has the chemical formula C 36 H 53 N 2 O 7 . Palmerolide D NMR Data is shown in FIG. 16 .
[0000]
Example VI
Cytotoxicity of Palmerolide
[0070] Palmerolide E, shown below and in FIG. 17 , has the chemical formula C 27 H 39 NO 7 (for NMR data see FIG. 18 ). NCI cytotoxicity is shown in FIG. 19 and FIG. 20 . NCI Dose Response Curves for all cell lines are presented in FIG. 21 .
[0000]
[0071] It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims. In addition, any elements or limitations of any invention or embodiment thereof disclosed herein can be combined with any and/or all other elements or limitations (individually or in any combination) or any other invention or embodiment thereof disclosed herein, and all such combinations are contemplated with the scope of the invention without limitation thereto.
[0072] All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.
|
The present invention concerns compounds derived from tunicates of the species Synoicum adareanum , as well as to pharmaceutical compositions comprising these compounds and methods of use. Extracts from tunicates show selective toxicity against several different cancer cell lines in the NCI 60 cell line panel. These compounds are useful in the effective treatment of cancers, particularly malignant melanomas, colon cancer, and renal cancer cell lines.
| 0
|
RELATED APPLICATIONS
[0001] This patent application claims the benefit under title 35, United States Code, Section 119(e) to the U.S. Provisional Patent Application having serial No. 60/398,625 filed on Jul. 24, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of multimedia compression systems. In particular the present invention discloses methods and systems for specifying variable accuracy inter-picture timing with reduced requirements for processor intensive division operation.
BACKGROUND OF THE INVENTION
[0003] Digital based electronic media formats are finally on the cusp of largely replacing analog electronic media formats. Digital compact discs (CDs) replaced analog vinyl records long ago. Analog magnetic cassette tapes are becoming increasingly rare. Second and third generation digital audio systems such as Mini-discs and MP3 (MPEG Audio—layer 3) are now taking market share from the first generation digital audio format of compact discs.
[0004] The video media formats have been slower to move to digital storage and digital transmission formats than audio media. The reason for this slower digital adoption has been largely due to the massive amounts of digital information required to accurately represent acceptable quality video in digital form and the fast processing capabilities needed to encode compressed video. The massive amounts of digital information needed to accurately represent video require very high-capacity digital storage systems and high-bandwidth transmission systems.
[0005] However, video is now rapidly moving to digital storage and transmission formats. Faster computer processors, high-density storage systems, and new efficient compression and encoding algorithms have finally made digital video transmission and storage practical at consumer price points. The DVD (Digital Versatile Disc), a digital video system, has been one of the fastest selling consumer electronic products in years. DVDs have been rapidly supplanting Video-Cassette Recorders (VCRs) as the pre-recorded video playback system of choice due to their high video quality, very high audio quality, convenience, and extra features. The antiquated analog NTSC (National Television Standards Committee) video transmission system is currently in the process of being replaced with the digital ATSC (Advanced Television Standards Committee) video transmission system.
[0006] Computer systems have been using various different digital video encoding formats for a number of years. Specifically, computer systems have employed different video coder/decoder methods for compressing and encoding or decompressing and decoding digital video, respectively. A video coder/decoder method, in hardware or software implementation, is commonly referred to as a “CODEC”.
[0007] Among the best digital video compression and encoding systems used by computer systems have been the digital video systems backed by the Motion Pictures Expert Group commonly known by the acronym MPEG. The three most well known and highly used digital video formats from MPEG are known simply as MPEG-1, MPEG-2, and MPEG-4. VideoCDs (VCDs) and early consumer-grade digital video editing systems use the early MPEG-1 digital video encoding format. Digital Versatile Discs (DVDs) and the Dish Network brand Direct Broadcast Satellite (DBS) television broadcast system use the higher quality MPEG-2 digital video compression and encoding system. The MPEG-4 encoding system is rapidly being adapted by the latest computer based digital video encoders and associated digital video players.
[0008] The MPEG-2 and MPEG-4 standards compress a series of video frames or video fields and then encode the compressed frames or fields into a digital bitstream. When encoding a video frame or field with the MPEG-2 and MPEG-4 systems, the video frame or field is divided into a rectangular grid of pixelblocks. Each pixelblock is independently compressed and encoded.
[0009] When compressing a video frame or field, the MPEG-4 standard may compress the frame or field into one of three types of compressed frames or fields: Intra-frames (I-frames), Unidirectional Predicted frames (P-frames), or Bi-Directional Predicted frames (B-frames). Intra-frames completely independently encode an independent video frame with no reference to other video frames. P-frames define a video frame with reference to a single previously displayed video frame. B-frames define a video frame with reference to both a video frame displayed before the current frame and a video frame to be displayed after the current frame. Due to their efficient usage of redundant video information, P-frames and B-frames generally provide the best compression.
SUMMARY OF THE INVENTION
[0010] A method and apparatus for performing motion estimation in a video codec is disclosed. Specifically, the present invention discloses a system that quickly calculates estimated motion vectors in a very efficient manner without requiring an excessive number of division operations.
[0011] In one embodiment, a first multiplicand is determined by multiplying a first display time difference between a first video picture and a second video picture by a power of two scale value. This step scales up a numerator for a ratio. Next, the system determines a scaled ratio by dividing that scaled numerator by a second first display time difference between said second video picture and a third video picture. The scaled ratio is then stored to be used later for calculating motion vector estimations. By storing the scaled ratio, all the estimated motion vectors can be calculated quickly with good precision since the scaled ratio saves significant bits and reducing the scale is performed by simple shifts thus eliminating the need for time consuming division operations.
[0012] Other objects, features, and advantages of present invention will be apparent from the company drawings and from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The objects, features, and advantages of the present invention will be apparent to one skilled in the alt, in view of the following detailed description in which:
[0014] [0014]FIG. 1 illustrates a high-level block diagram of one possible digital video encoder system.
[0015] [0015]FIG. 2 illustrates a series of video pictures in the order that the pictures should be displayed wherein the arrows connecting different pictures indicate inter-picture dependency created using motion compensation.
[0016] [0016]FIG. 3 illustrates the video pictures from FIG. 2 listed in a preferred transmission order of pictures wherein the arrows connecting different pictures indicate inter-picture dependency created using motion compensation.
[0017] [0017]FIG. 4 graphically illustrates a series of video pictures wherein the distances between video pictures that reference each other are chosen to be powers of two.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] A method and system for specifying Variable Accuracy Inter-Picture Timing in a multimedia compression and encoding system with reduced requirements for division operations is disclosed. In the following description, for purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present invention. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present invention. For example, the present invention has been described with reference to the MPEG multimedia compression and encoding system. However, the same techniques can easily be applied to other types of compression and encoding systems.
Multimedia Compression and Encoding Overview
[0019] [0019]FIG. 1 illustrates a high-level block diagram of a typical digital video encoder 100 as is well known in the art. The digital video encoder 100 receives an incoming video stream of video frames 105 at the left of the block diagram. The digital video encoder 100 partitions each video frame into a grid of pixelblocks. The pixelblocks are individually compressed. Various different sizes of pixelblocks may be used by different video encoding systems. For example, different pixelblock resolutions include 8×8, 8×4, 16×8, 4×4, etc. Furthermore, pixelblocks are occasionally referred to as ‘macroblocks.’ This document will use the term pixelblock to refer to any block of pixels of any size.
[0020] A Discrete Cosine Transformation (DCT) unit 110 processes each pixelblock in the video frame. The frame may be processed independently (an intra-frame) or with reference to information from other frames received from the motion compensation unit (an inter-frame). Next, a Quantizer (Q) unit 120 quantizes the information from the Discrete Cosine Transformation unit 110 . Finally, the quantized video frame is then encoded with an entropy encoder (H) unit 180 to produce an encoded bitstream. The entropy encoder (H) unit 180 may use a variable length coding (VLC) system.
[0021] Since an inter-frame encoded video frame is defined with reference to other nearby video frames, the digital video encoder 100 needs to create a copy of how each decoded frame will appear within a digital video decoder such that inter-frames may be encoded. Thus, the lower portion of the digital video encoder 100 is actually a digital video decoder system. Specifically, an inverse quantizer (Q −1 ) unit 130 reverses the quantization of the video frame information and an inverse Discrete Cosine Transformation (DCT −1 ) unit 140 reverses the Discrete Cosine Transformation of the video frame information. After all the DCT coefficients are reconstructed from inverse Discrete Cosine Transformation (DCT −1 ) unit 140 , the motion compensation unit will use that information, along with the motion vectors, to reconstruct the encoded video frame. The reconstructed video frame is then used as the reference frame for the motion estimation of the later frames.
[0022] The decoded video frame may then be used to encode inter-frames (P-frames or B-frames) that are defined relative to information in the decoded video frame. Specifically, a motion compensation (MC) unit 150 and a motion estimation (ME) unit 160 are used to determine motion vectors and generate differential values used to encode inter-frames.
[0023] A rate controller 190 receives information from many different components in a digital video encoder 100 and uses the information to allocate a bit budget for each video frame. The rate controller 190 should allocate the bit budget in a manner that will generate the highest quality digital video bit stream that that complies with a specified set of restrictions. Specifically, the rate controller 190 attempts to generate the highest quality compressed video stream without overflowing buffers (exceeding the amount of available memory in a video decoder by sending more information than can be stored) or underflowing buffers (not sending video frames fast enough such that a video decoder runs out of video frames to display).
Digital Video Encoding With Pixelblocks
[0024] In some video signals the time between successive video pictures (frames or fields) may not be constant. (Note: This document will use the term video pictures to generically refer to video frames or video fields.) For example, some video pictures may be dropped because of transmission bandwidth constraints. Furthermore, the video timing may also vary due to camera irregularity or special effects such as slow motion or fast motion. In some video streams, the original video source may simply have non-uniform inter-picture times by design. For example, synthesized video such as computer graphic animations may have non-uniform timing since no arbitrary video timing is imposed by a uniform timing video capture system such as a video camera system. A flexible digital video encoding system should be able to handle non-uniform video picture timing.
[0025] As previously set forth, most digital video encoding systems partition video pictures into a rectangular grid of pixelblocks. Each individual pixelblock in a video picture is independently compressed and encoded. Some video coding standards, e.g., ISO MPEG or ITU H.264, use different types of predicted pixelblocks to encode video pictures. In one scenario, a pixelblock may be one of three types:
[0026] 1. I-pixelblock—An Intra (I) pixelblock uses no information from any other video pictures in its coding (it is completely self-defined);
[0027] 2. P-pixelblock—A unidirectionally predicted (P) pixelblock refers to picture information from one preceding video picture; or
[0028] 3. B-pixelblock—A bidirectional predicted (B) pixelblock uses information from one preceding picture and one future video picture.
[0029] If all the pixelblocks in a video picture are Intra-pixelblocks, then the video picture is an intra-frame. If a video picture only includes unidirectional predicted macro blocks or intra-pixelblocks, then the video picture is known as a P-frame. If the video picture contains any bidirectional predicted pixelblocks, then the video picture is known as a B-frame. For the simplicity, this document will consider the case where all pixelblocks within a given picture are of the same type.
[0030] An example sequence of video pictures to be encoded might be represented as:
[0031] I 1 B 2 B 3 B 4 P 5 B 6 B 7 B 8 B 9 P 10 B 11 P 12 B 13 I 14 . . .
[0032] where the letter (I, P, or B) represents if the video picture is an I-frame, P-frame, or B-frame and the number represents the camera order of the video picture in the sequence of video pictures. The camera order is the order in which a camera recorded the video pictures and thus is also the order in which the video pictures should be displayed (the display order).
[0033] The previous example series of video pictures is graphically illustrated in FIG. 2. Referring to FIG. 2, the arrows indicate that pixelblocks from a stored picture (I-frame or P-frame in this case) are used in the motion compensated prediction of other pictures.
[0034] In the scenario of FIG. 2, no information from other pictures is used in the encoding of the intra-frame video picture I 1 . Video picture P 5 is a P-frame that uses video information from previous video picture I 1 in its coding such that an arrow is drawn from video picture I 1 to video picture P 5 . Video picture B 2 , video picture B 3 , video picture B 4 all use information from both video picture I 1 and video picture P 5 in their coding Such that arrows are drawn from video picture I 1 and video picture P 5 to video picture B 2 , video picture B 3 , and video picture B 4 . As stated above the inter-picture times are, in general, not the same.
[0035] Since B-pictures use information from future pictures (pictures that will be displayed later), the transmission order is usually different than the display order. Specifically, video pictures that are needed to construct other video pictures should be transmitted first. For the above sequence, the transmission order might be:
[0036] I 1 P 5 B 2 B 3 B 4 P 10 B 6 B 7 B 8 B 9 P 12 B 11 I 14 B 13 . . .
[0037] [0037]FIG. 3 graphically illustrates the preceding transmission order of the video pictures from FIG. 2. Again, the arrows in the figure indicate that pixelblocks from a stored video picture (I or P in this case) are used in the motion compensated prediction of other video pictures.
[0038] Referring to FIG. 3, the system first transmits I-frame I 1 which does not depend on any other frame. Next, the system transmits P-frame video picture P 5 that depends upon video picture I 1 . Next, the system transmits B-frame video picture B 2 after video picture P 5 even though video picture B 2 will be displayed before video picture P 5 . The reason for this is that when it comes time to decode video picture B 2 , the decoder will have already received and stored the information in video pictures I 1 and P 5 necessary to decode video picture B 2 . Similarly, video pictures I 1 and P 5 are ready to be used to decode subsequent video picture B 3 and video picture B 4 . The receiver/decoder reorders the video picture sequence for proper display. In this operation I and P pictures are often referred to as stored pictures.
[0039] The coding of the P-frame pictures typically utilizes Motion Compensation, wherein a Motion Vector is computed for each pixelblock in the picture. Using the computed motion vector, a prediction pixelblock (P-pixelblock) can be formed by translation of pixels in the aforementioned previous picture. The difference between the actual pixelblock in the P-frame picture and the prediction pixelblock is then coded for transmission.
[0040] P-Pictures
[0041] The coding of P-Pictures typically utilize Motion Compensation (MC), wherein a Motion Vector (MV) pointing to a location in a previous picture is computed for each pixelblock in the current picture. Using the motion vector, a prediction pixelblock can be formed by translation of pixels in the aforementioned previous picture. The difference between the actual pixelblock in the P-Picture and the prediction pixelblock is then coded for transmission.
[0042] Each motion vector may also be transmitted via predictive coding. For example, a motion vector prediction may be formed using nearby motion vectors. In such a case, then the difference between the actual motion vector and the motion vector prediction is coded for transmission.
[0043] B-Pictures
[0044] Each B-pixelblock uses two motion vectors: a first motion vector referencing the aforementioned previous video picture and a second motion vector referencing the future video picture. From these two motion vectors, two prediction pixelblocks are computed. The two predicted pixelblocks are then combined together, using some function, to form a final predicted pixelblock. As above, the difference between the actual pixelblock in the B-frame picture and the final predicted pixelblock is then encoded for transmission.
[0045] As with P-pixelblocks, each motion vector (MV) of a B-pixelblock may be transmitted via predictive coding. Specifically, a predicted motion vector is formed using nearby motion vectors. Then, the difference between the actual motion vector and the predicted is coded for transmission.
[0046] However, with B-pixelblocks the opportunity exists for interpolating motion vectors from motion vectors in the nearest stored picture pixelblock. Such motion vector interpolation is carried out both in the digital video encoder and the digital video decoder.
[0047] This motion vector interpolation works particularly well on video pictures from a video sequence where a camera is slowly panning across a stationary background. In fact, such motion vector interpolation may be good enough to be used alone. Specifically, this means that no differential information needs be calculated or transmitted for these B-pixelblock motion vectors encoded using interpolation.
[0048] To illustrate further, in the above scenario let us represent the inter-picture display time between pictures i and j as D i,j , i.e., if the display times of the pictures are T i and T j , respectively, then
D
i,j
=T
i
−T
j
[0049] from which it follows that
D
i,k
=D
i,j
+D
j,k
D
i,k
=−D
k,i
[0050] Note that D i,j may be negative in some cases.
[0051] Thus, if MV 5,1 is a motion vector for a P 5 pixelblock as referenced to I 1 , then for the corresponding pixelblocks in B 2 , B 3 and B 4 the motion vectors as referenced to I 1 and P 5 , respectively would be interpolated by
MV
2,1
=MV
5,1
*D
2,1
/D
5,1
MV
5,2
=MV
5,1
*D
5,2
/D
5,1
MV
3,1
=MV
5,1
*D
3,1
/D
5,1
MV
5,3
=MV
5,1
*D
5,3
/D
5,1
MV
4,1
=MV
5,1
*D
4,1
/D
5,1
MV
5,4
=MV
5,1
*D
5,4
/D
5,1
[0052] Note that since ratios of display times are used for motion vector prediction, absolute display times are not needed. Thus, relative display times may be used for D i,j inter-picture display time values.
[0053] This scenario may be generalized, as for example in the H.264 standard. In the generalization, a P or B picture may use any previously transmitted picture for its motion vector prediction. Thus, in the above case picture B 3 may use picture I 1 and picture B 2 in its prediction. Moreover, motion vectors may be extrapolated, not just interpolated. Thus, in this case we would have:
MV
3,1
=MV
2,1
*D
3,1
/D
2,1
[0054] Such motion vector extrapolation (or interpolation) may also be used in the prediction process for predictive coding of motion vectors.
Encoding Inter-Picture Display Times
[0055] The variable inter-picture display times of video sequences should be encoded and transmitted in a manner that renders it possible to obtain a very high coding efficiency and has selectable accuracy such that it meets the requirements of a video decoder. Ideally, the encoding system should simplify the tasks for the decoder such that relatively simple computer systems can decode the digital video.
[0056] The variable inter-picture display times are potentially needed in a number of different video encoding systems in order to compute differential motion vectors, Direct Mode motion vectors, and/or Implicit B Prediction Block Weighting.
[0057] The problem of variable inter-picture display times in video sequences is intertwined with the use of temporal references. Ideally, the derivation of correct pixel values in the output pictures in a video CODEC should be independent of the time at which that picture is decoded or displayed. Hence, timing issues and time references should be resolved outside the CODEC layer.
[0058] There are both coding-related and systems-related reasons underlying the desired time independence. In a video CODEC, time references are used for two purposes:
[0059] (1) To establish an ordering for reference picture selection; and
[0060] (2) To interpolate motion vectors between pictures.
[0061] To establish an ordering for reference picture selection, one may simply send a relative position value. For example, the difference between the frame position N in decode order and the frame position M in the display order, i.e., N−M. In such an embodiment, time-stamps or other time references would not be required. To interpolate motion vectors, temporal distances would be useful if the temporal distances could be related to the interpolation distance. However, this may not be true if the motion is non-linear. Therefore, sending parameters other than temporal information for motion vector interpolation seems more appropriate.
[0062] In terms of systems, one can expect that a typical video CODEC is part of a larger system where the video CODEC coexists with other video (and audio) CODECs. In such multi-CODEC systems, good system layering and design requires that general functions, which are logically CODEC-independent such as timing, be handled by the layer outside the CODEC. The management of timing by the system and not by each CODEC independently is critical to achieving consistent handling of common functions such as synchronization. For instance in systems that handle more than one stream simultaneously, Such as a video/audio presentation, timing adjustments may sometimes be needed within the streams in order to keep the different streams synchronized. Similarly, in a system that handles a stream from a remote system with a different clock timing adjustments may be needed to keep synchronization with the remote system. Such timing adjustments may be achieved using time stamps. For example, time stamps that are linked by means of “Sender Reports” from the transmitter and supplied in RTP in the RTP layer for each stream may be used for synchronization. These sender reports may take the form of:
[0063] Video RTP TimeStamp X is aligned with reference timestamp Y
[0064] Audio RTP TimeStamp W is aligned with reference timestamp Z
[0065] Wherein the wall-clock rate of the reference timestamps is known, allowing the two streams to be aligned. However, these timestamp references arrive both periodically and separately for the two streams, and they may cause some needed re-alignment of the two streams. This is generally achieved by adjusting the video stream to match the audio or vice-versa. System handling of time stamps should not affect the values of the pixels being displayed. More generally, system handling of temporal information should be performed outside the CODEC.
[0066] A SPECIFIC EXAMPLE
[0067] As set forth in the previous section, the problem in the case of non uniform inter-picture times is to transmit the inter-picture display time values D i,j to the digital video receiver in an efficient manner. One method of accomplishing this goal is to have the system transmit the display time difference between the current picture and the most recently transmitted stored picture for each picture after the first picture. For error resilience, the transmission could be repeated several times within the picture. For example, the display time difference may be repeated in the slice headers of the MPEG or H.264 standards. If all slice headers are lost, then presumably other pictures that rely on the lost picture for decoding information cannot be decoded either.
[0068] Thus, with reference to the example of the preceding section, a system would transmit the following inter-picture display time values:
[0069] D 5,1 D 2,5 D 3,5 D 4,5 D 10,5 D 6,10 D 7,10 D 8,10 D 9,10 D 12,10 D 11,12 D 14,12 D 13,14 . . .
[0070] For the purpose of motion vector estimation, the accuracy requirements for the inter-picture display times D i,j may vary from picture to picture. For example, if there is only a single B-frame picture B 6 halfway between two P-frame pictures P 5 and P 7 , then it suffices to send only:
D 7,5 =2 and D 6,7 =−1
[0071] where the D i,j inter-picture display time values are relative time values.
[0072] If, instead, video picture B 6 is only one quarter the distance between video picture P 5 and video picture P 7 then the appropriate D i,j inter-picture display time values to send would be:
D 7,5 =4 and D 6,7 =−1
[0073] Note that in both of the preceding examples, the display time between the video picture B 6 and video picture video picture P 7 (inter-picture display time D 6,7 ) is being used as the display time “unit” value. In the most recent example, the display time difference between video picture P 5 and picture video picture P 7 (inter-picture display time D 6,7 ) is four display time “units” (4*D 6,7 )
[0074] Improving Decoding Efficiency
[0075] In general, motion vector estimation calculations are greatly simplified if divisors are powers of two. This is easily achieved in our embodiment if D i,j (the inter-picture time) between two stored pictures is chosen to be a power of two as graphically illustrated in FIG. 4. Alternatively, the estimation procedure could be defined to truncate or round all divisors to a power of two.
[0076] In the case where an inter-picture time is to be a power of two, the number of data bits can be reduced if only the integer power (of two) is transmitted instead of the full value of the inter-picture time. FIG. 4 graphically illustrates a case wherein the distances between pictures are chosen to be powers of two. In such a case, the D 3,1 display time value of 2 between video picture P 1 and picture video picture P 3 is transmitted as 1 (since 2 1 =2) and the D 7,3 display time value of 4 between video picture P 7 and picture video picture P 3 can be transmitted as 2 (since 2 2 =4).
[0077] Alternatively, the motion vector interpolation of extrapolation operation can be approximated to any desired accuracy by scaling in such a way that the denominator is a power of two. (With a power of two in the denominator division may be performed by simply shifting the bits in the value to be divided.) For example,
D 5,4 /D 5,1 ˜Z 5,4 /P
[0078] Where the value P is a power of two and Z 5,4 =P*D 5,4 /D 5,1 is rounded or truncated to the nearest integer. The value of P may be periodically transmitted or set as a constant for the system. In one embodiment, the value of P is set as P=2 8 =256.
[0079] The advantage of this approach is that the decoder only needs to compute Z 5,4 once per picture or in many cases the decoder may pre-compute and store the Z value. This allows the decoder to avoid having to divide by D 5,1 for every motion vector in the picture such that motion vector interpolation may be done much more efficiently. For example, the normal motion vector calculation would be:
MV 5,4 =MV 5,1 *D 5,4 /D 5,1
[0080] But if we calculate and store Z 5,4 wherein Z 5,4 =P*D 5,4 /D 5,1 then
MV
5,4
=MV
5,1
*Z
5,4
/P
[0081] But since the P value has been chosen to be a power of two, the division by P is merely a simple shift of the bits. Thus, only a single multiplication and a single shift are required to calculate motion vectors for subsequent pixelblocks once the Z value has been calculated for the video picture. Furthermore, the system may keep the accuracy high by performing all divisions last such that significant bits are not lost during the calculation. In this manner, the decoder may perform exactly the same as the motion vector interpolation as the encoder thus avoiding any mismatch problems that might otherwise arise.
[0082] Since division (except for division by powers of two) is a much more computationally intensive task for a digital computer system than addition or multiplication, this approach can greatly reduce the computations required to reconstruct pictures that use motion vector interpolation or extrapolation.
[0083] In some cases, motion vector interpolation may not be used. However, it is still necessary to transmit the display order of the video pictures to the receiver/player system such that the receiver/player system will display the video pictures in the proper order. In this case, simple signed integer values for D i,j suffice irrespective of the actual display times. In some applications only the sign (positive or negative) may be needed to reconstruct the picture ordering.
[0084] The inter-picture times D i,j may simply be transmitted as simple signed integer values. However, many methods may be used for encoding the D i,j values to achieve additional compression. For example, a sign bit followed by a variable length coded magnitude is relatively easy to implement and provides coding efficiency.
[0085] One such variable length coding system that may be used is known as UVLC (Universal Variable Length Code). The UVLC variable length coding system is given by the code words:
1 = 1 2 = 010 3 = 011 4 = 00100 5 = 00101 6 = 00110 7 = 00111 8 = 0001000
[0086] Another method of encoding the inter-picture times may be to use arithmetic coding. Typically, arithmetic coding utilizes conditional probabilities to effect a very high compression of the data bits.
[0087] Thus, the present invention introduces a simple but powerful method of encoding and transmitting inter-picture display times and methods for decoding those inter-picture display times for use in motion vector estimation. The encoding of inter-picture display times can be made very efficient by using variable length coding or arithmetic coding. Furthermore, a desired accuracy can be chosen to meet the needs of the video codec, but no more.
[0088] The foregoing has described a system for specifying variable accuracy inter-picture timing in a multimedia compression and encoding system. It is contemplated that changes and modifications may be made by one of ordinary skill in the art, to the materials and arrangements of elements of the present invention without departing from the scope of the invention.
|
A method and apparatus for performing motion estimation in a digital video system is disclosed. Specifically, the present invention discloses a system that quickly calculates estimated motion vectors in a very efficient manner. In one embodiment, a first multiplicand is determined by multiplying a first display time difference between a first video picture and a second video picture by a power of two scale value. This step scales up a numerator for a ratio. Next, the system determines a scaled ratio by dividing that scaled numerator by a second first display time difference between said second video picture and a third video picture. The scaled ratio is then stored calculating motion vector estimations. By storing the scaled ratio, all the estimated motion vectors can be calculated quickly with good precision since the scaled ratio saves significant bits and reducing the scale is performed by simple shifts.
| 7
|
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application relates to and claims priority to European Patent Application No. 09159343.4, filed May 4, 2009.
FIELD
The invention relates to appliances having a drainage pump and to methods for controlling the supply voltage delivered to the drainage pump.
BACKGROUND
Washing household appliances such as dishwashers and/or washing machines comprise a water circulation pump unit to recirculate the water during the washing processes, and a drainage pump unit to drain water during a drainage process, which normally rotates at a specific speed of rotation and for a specific time.
Drainage pump units comprise an impeller and, generally, a permanent-magnet synchronous motor to allow the impeller to rotate at a determined speed of rotation and thereby drain the water, as is the case, for example, of those disclosed in patent documents EP 287984 B1 and ES 2162544 B1. Synchronous motors are connected to the mains supply, and comprise a determined network frequency, the speed of rotation of the impeller depending on the network frequency which is normally substantially constant. The drainage flow depends on the speed of rotation of the impeller and therefore on the frequency applied to the synchronous motor.
Washing household appliances can also comprise control means for controlling the supply to the drainage pump unit, which allow the units to activate at a specific time and which deactivate following a specific time interval, when the programme cycle has finished or when it is deemed convenient. This may be set beforehand depending on the washing program to be used, for example, and the control means have the function of activating the pump unit to begin the drainage process during which the drainage pump unit allows the drainage of the water, and of deactivating the unit to finish the drainage process. As a result, the drainage processes require that the drainage pump unit is active for a preset time at the preset frequency, without taking into consideration parameters that may optimise or improve the efficiency of the processes or which may even improve the reliability of the drainage pump units. This may result in a premature fault in the drainage pump unit, and due to the tendency to concentrate components in washing appliances it may become increasingly difficult to replace the unit.
There are known washing household appliances that overcome this drawback by providing the pump unit with more generous dimensions that increase pump capacity and decrease activation time of the pump. A problem with this solution is that it results in increased manufacturing costs and adversely affects the ability to scale the dimensions of the appliance in which the drain pump is incorporated. Some washing household appliances comprise control means to resolve these drawbacks, thereby avoiding the need for a provision of more generous dimensions, the control means being adapted to control the supply to the drainage pump unit not only to start and end the drainage process, but also to control the supply during the drainage process.
Document EP1942219A1, for example, discloses a washing household appliance of this type. The control means comprised in the appliance may allow the drainage pump unit to activate and/or deactivate during the drainage process. The household appliance thus comprises level sensors to detect the level of the water, and the control means may determine the level in accordance with the detection of the level sensor. The control means thus allow, during the drainage process, the drainage pump unit to activate at a specific frequency or to deactivate the pump unit, in accordance with the detected level, thereby creating a more effective process and also increasing the reliability of the drainage pump unit as it is active for less time in each drainage process.
In some washing household appliances a variable-frequency drainage pump unit is used and which comprises an impeller and a BLDC type motor to allow the rotation of the impeller. Document EP1783264A2, for example, discloses an appliance that comprises a motor of this type, and also discloses a control method for improving control over the drainage pump unit. The consumption current of the motor is determined, and the current is linked to a water level. The frequency of the motor supply voltage is changed to vary the flow of drainage water in accordance with the associated water level. As a result, the control means also compare the associated level with a preset level.
SUMMARY
It is an object of the invention to provide a drainage pump unit offering improved reliability in a simple and economical way. Another objective of the invention is to provide a control method for a drainage pump.
It is an object of the invention to provide a washing household appliance that comprises a drainage pump unit offering improved reliability in a simple and economical way. Another objective of the invention is to provide a control method for a washing household appliance.
One aspect of the invention relates to a washing household appliance that comprises a drainage pump unit with an impeller and a motor supplied with an alternating supply voltage of a frequency selected from several preset frequencies, and control means adapted for monitoring the current of the motor and for controlling the motor in accordance with the current, regulating the frequency of the motor between the plurality of preset frequencies. Another aspect of the invention relates to a control method for the washing appliance.
In one implementation the washing household appliance of the invention also comprises storage means where, for each of the possible preset frequencies, the following are stored: an optimal consumption current of the motor that corresponds with the consumption current of the motor which guarantees a full-flow drainage process is completed correctly, during which a minimum drainage flow is guaranteed; a maximum consumption current of the motor allowed during the full-flow drainage process; and a minimum consumption current of the motor allowed during the full-flow drainage process. In one implementation the control means determines whether the monitored current is within a range of currents delimited by the maximum and minimum currents, and, if this is the case, a comparison of the current with the corresponding optimal current is made. In accordance with the comparison, the control means regulates the frequency of the motor supply voltage so that the current of the motor is as close as possible or is substantially equal to the optimal current, from the preset frequencies.
As a result, a more optimal and reliable use of the pump unit may be achieved as the unit is able to provide a correct full-flow drainage process with a frequency that provides optimal current consumption (the minimum required to ensure the installation conditions of the household appliance and guarantee its correct operation). As a result, the pump unit operates under less strain in most cases, as far away as possible from the current limit values. This may also be achieved in a direct and simple way by comparing values obtained directly from a measurement (current) with other values of the same type (currents), with the prior storage of a very small amount of information also being required.
These and other advantages and characteristics of the invention will be made evident in the light of the drawings and the detailed description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically shows a washing household appliance in one implementation.
FIG. 2 shows exemplary characteristic curves of a drainage pump unit.
FIG. 3 shows an exemplary working area of a drainage pump unit.
FIG. 4 shows an exemplary working area of a drainage pump unit for a full-flow drainage process.
FIG. 5 shows an exemplary working area in a graph that links the current and the frequency of the motor of the pump unit.
FIG. 6 shows a first example for controlling the motor of a drainage pump in accordance with one implementation.
FIG. 7 shows a second example for controlling the motor of a drainage pump in accordance with one implementation.
FIG. 8 shows a third example for controlling the motor of a drainage pump in accordance with one implementation.
FIG. 9 shows an example for controlling the motor of a drainage pump in which the motor is allowed to operate in a range outside the limits set by the installation curves H 1 and H 2 .
FIG. 10 shows a flow chart of a control method in accordance with one implementation of the present invention.
DETAILED DESCRIPTION
FIG. 1 schematically shows a washing household appliance 100 in accordance with one implementation of the present invention, which in this case corresponds with a dishwasher but which may also correspond, for example, with a washing machine or a host of other appliances employing the use of a motor driven drainage pump. The appliance 100 comprises a drainage pump unit 1 to drain the water from its interior, which comprises an impeller and a motor that allows the rotation of the impeller at a speed of rotation Vg to start the drainage, and control means 3 to monitor a consumption current Iq of the motor and to control the motor in accordance with the monitored current Iq. The control means 3 may comprise, for example a microprocessor, a controller, an FPGA or an equivalent device.
The motor is supplied by a variable alternating supply voltage with a determined frequency F, and thus allows the rotation of the impeller at a speed of rotation Vg determined by the number of poles of the motor, in accordance with the following equation:
Vg = F * 60 P .
Where:
Vg: speed of rotation of the impeller,
F: frequency of the motor supply voltage, and
P: number of pairs of poles of the motor.
The speed of rotation Vg depends on the frequency F of the motor supply voltage, and by regulating the frequency F the speed of rotation Vg is also regulated, thus enabling the regulation of the operating conditions of the pump unit 1 in the installation in which it is disposed.
The pump unit 1 may carry out different drainage processes. One may be, for example, a specific process that occurs in the spin cycle of a washing machine, during the course of which the flow Q of water that is drained off gradually reduces as the specific drainage process advances due to the reduction of the water in the appliance and not to the speed of rotation of the impeller. In another drainage process, known as a full-flow drainage process, the flow Q of water that is drained off is kept constant unless the speed of rotation of the impeller is altered as a result of a change in the frequency F of the motor supply voltage. The present invention is directed to a full-flow drainage process.
For the full-flow drainage process the manufacturer defines or presets a plurality of possible frequencies F for the motor supply voltage, limited by a maximum possible frequency Fmax and a minimum frequency Fmin. The maximum and minimum frequencies Fmax and Fmin are selected in accordance with hydraulic and mechanical factors so as not to strain the pump unit 1 . The preset frequencies F are therefore within a delimited range between the maximum and minimum frequencies Fmax and Fmin, the maximum and minimum frequencies Fmax and Fmin being included between the preset frequencies F. By way of example, the maximum and minimum frequencies Fmax and Fmin may be 60 Hz and 30 Hz respectively, and five intermediate frequencies F of 35, 40, 45, 50 and 55 Hz may be preset. This example is not restrictive, as other frequency F values may be selected, and a different number of intermediate frequencies F. The appliance 100 also comprises storage means 4 , which correspond with a memory that may be integrated into the control means 3 or which may comprise a member external to the control means 3 (an EEPROM, for example), where the preset frequencies F may be stored, so that the control means 3 may regulate the frequency F, assigning only preset values to it (those stored in the storage means).
In one implementation the motor is a BLDC type motor and the current Iq of the motor, which is monitored by the control means 3 , is determined by an appropriate control for that purpose, which may be integrated into the control means 3 , which is known and used in this type of motors and which allows the current I of the motor (monitored current Iq by the control means 3 ) to be associated to the frequency F of the motor supply voltage. For a determined frequency F the current in the motor produces a torque that allows the rotation of the impeller, thereby providing a specific drainage flow Q, and in one implementation the appropriate control adapts the current consumption I, Iq of the motor to always create a flow with the minimum possible current consumption. Thus, the manufacturer may preset or define a pump unit 1 for the appliance 100 , whose characteristics are represented in FIG. 2 . The FIG. 2 shows the characteristics of the pump unit 1 , which associate the current I consumption of the motor to its supply frequency F (frequencies F 1 , F 2 and F 3 in this case) and the characteristics of the installation (manometric height H and flow Q).
The manufacturer also presets or defines some limit parameters for the installation of the appliance 100 and within which the pump unit 1 must operate. FIG. 3 shows an example of such limits in the form of installation curves H 1 and H 2 that represent, for a given appliance 100 and taking into consideration the different installation options (type of drainage pipe, the diameter and length of the pipe), the minimum and maximum height respectively at which a drainage point may be disposed for the installation. These installation curves H 1 and H 2 link the drainage flow Q of the pump unit 1 (x-axis) with the manometric height H (pressure, v-axis) that the pump unit 1 generates in the corresponding installation, the pump unit being designed to operate between both curves H 1 and H 2 .
The manufacturer also presets or defines a minimum flow Qmin that must be guaranteed for any possible installation of the appliance 100 , to provide a correct full-flow drainage process. FIG. 4 shows an example of a working area AT of the pump unit 1 for the full-flow drainage process, which is delimited by the installation curves H 1 and H 2 , by the maximum and minimum frequencies Fmax and Fmin allowed for the motor supply voltage, and by the minimum flow Qmin (which is represented with a straight line in the FIG. 4 ). When the pump unit 1 is operating in the working area AT, it meets the necessary requirements for providing a correct full-flow drainage process: it ensures the minimum flow Qmin by operating within the preset limits of frequency Fmax and Fmin. In the graph linking the manometric height H with the flow Q, the working area AT is delimited by the points A, B, C, D and E, whereas in the graph linking the flow Q with the current I of the motor the working area AT′ is delimited by the points A′, B′, C′, D′ and E′, which correspond respectively with the points A, B, C, D and E of the graph linking the manometric height H with the flow Q.
A minimum current consumption Imin for each frequency F (air-water limit) is set for drainage processes different to the full-flow process, the control means 3 determining that it is a different drainage process to the full-flow process when the monitored current Iq is below the air-water limit. The control means 3 thus determine that the full-flow drainage process is being performed when the monitored current Iq of the motor is between the corresponding minimum current Imin and a maximum preset current Imax. To ensure that the control means 3 can determine whether it is a full-flow drainage process or not, the maximum current Imax and the minimum current Imin for each frequency F are stored in the storage means 4 , so that the control means 3 may compare the monitored current Iq of the motor with the maximum and minimum currents Imax and Imin.
In accordance with one aspect of the present invention it is an aim that the pump unit 1 operate under as little strain as allowed in the installation in the full-flow drainage process, so that once it is determined that a full-flow drainage process is being performed, the control means 3 allow the pump unit 1 to operate under as little strain as possible. To operate under as little strain as possible means to operate at frequencies and/or currents that are as far as possible from the Imax and Fmax limits that ensure a minimum flow Qmin. This is achieved by allowing the pump unit 1 to operate on the C′, D′, E′ line shown in the example of FIG. 4 , which corresponds with the situation in which the drainage flow Q is substantially equal to the required minimum flow Qmin (line D′-E′) or to the situation in which the frequency F of the motor supply voltage is equal to the permitted minimum frequency Fmin (line C′-D′). These lines correspond with a specific operating condition that can easily be reproduced, as a result of which the manufacturer may associate previously and for each frequency F, an optimal current lop in accordance with various possible installations. In some cases the optimal current lop corresponds with a current I of the motor that is associated to the preset minimum flow Qmin (line D′-E′) and in other cases it corresponds with the preset minimum frequency Fmin.
Thus, the optimal current lop is generally the smallest possible current of the motor that ensures the required function of the pump unit 1 in the full-flow drainage process, so that the pump unit 1 operates under as little strain as possible and with a frequency F of the motor supply voltage that is as low as possible, the optimal current lop being the objective or setting current for the motor. In one implementation an optimal current lop of the motor that is set previously for each preset frequency F of the motor supply voltage is stored in storage means 4 , the control means 3 being capable of determining whether the monitored current Iq is substantially equal to the corresponding optimal current lop or not.
FIG. 5 shows the working area AT′ of FIG. 4 transformed at a ratio between the current I of the motor and the frequency F of the supply voltage of the motor, and also shows the limit fixed by the minimum current Imin for the full-flow drainage process (air-water limit). The limit Imin shown is not restrictive, and may comprise different shapes to the curved line shown in FIG. 5 . The points A″, B″, C″, D″ and E″ correspond with the points A′, B′, C′, D′ and E′ of FIG. 4 respectively, and the optimal current lop corresponds with the D″-E-G″ (the line E″-G″ is outside the delimited range between the installation curves H 1 and H 2 ).
In one implementation the control means 3 of appliance 100 supplies the motor with a suitable voltage of a frequency F comprised between the maximum and minimum frequencies Fmax and Fmin (or even at a frequency F equal to the maximum or minimum frequency Fmax or Fmin) and determines whether the monitored current Iq of the motor is within a range of currents delimited by the maximum and minimum currents Imax and Imin, to determine whether it is a full-flow drainage process or not. If a full-flow drainage process is determined (monitored current Iq inside the range), the control means 3 compares the monitored current Iq with the optimal current lop corresponding to the current frequency F of the motor supply voltage stored in the storage means 4 , and, in accordance with the result of the comparison, regulates the frequency F so that the monitored current Iq more closely matches or is substantially equal to the optimal current lop or is as close as possible to the optimal current lop. If the monitored current Iq is greater than the optimal current lop, the control means 3 causes a reduction of the frequency F until a current I is substantially equal to the optimal current lop (or as close as possible to the optimal current lop). If monitored current Iq is smaller than the optimal current lop, the control means 3 causes an increase in the frequency F until a current I more closely matches the optimal current, and preferably is substantially equal to the optimal current lop or as close as possible to the optimal current lop. If the control means 3 determines that the monitored current Iq is substantially equal to the optimal current lop, the frequency F is maintained. As a result, in an appliance 100 of the present invention only three items of data need to be stored in the storage means 4 for each preset frequency F to ensure that the pump unit 1 operates under less strain. These are:
1) The allowed maximum current Imax for the motor in the full-flow drainage process, 2) The allowed minimum current Imin for the motor in the full-flow drainage process, and 3) The optimal current lop defined to allow the motor to operate under as little strain as possible in a full-flow drainage process, within the set working area AT′.
FIGS. 6 , 7 and 8 show three examples of the way in which the control means 3 acts in a full-flow drainage process for an installation curve H given by way of example in each case. FIGS. 6 to 8 show a plurality of preset frequencies F 1 , F 2 and F 3 for the motor supply voltage, the working area AT′ and a line corresponding with the allowed minimum current Imin in the motor for the full-flow drainage process. For each frequency F 1 , F 2 and F 3 the three values stored in the storage means 4 are shown by means of black circular dots: maximum current Imax (corresponds with the curve H 1 ), minimum current Imin (with the curve Imin) and optimal current lop (with the line D″-E-G″).
In the first example shown in FIG. 6 , the motor is supplied with a supply voltage with a preset frequency F 1 . The control means determine that the monitored current Iq (point L) of the motor at that frequency F 1 is smaller than the optimal current lop preset for the frequency F 1 (a point of the line D″-E″ in this case), and increases the frequency F of the supply voltage to a frequency F 2 . At the frequency F 2 the control means 3 determines that the monitored current Iq (represented by an X) continues to be smaller than the optimal current lop preset for the frequency F 2 (a point of the line D″-E″ in this case), and increases the frequency F up to a frequency F 3 . At the frequency F 3 the control means 3 determines that the monitored current Iq (point L′) is substantially equal to the optimal current lop preset for the frequency F 3 and maintains the frequency F 3 of the supply voltage until the full-flow drainage function is completed. In one implementation, once the frequency F 3 has been set, the control means 3 continues checking on a cyclical basis if the current of the motor is kept substantially equal to the optimal current lop, which occurs for as long as the full-flow phase lasts. When the water has finished and the monitored current Iq is less than the minimum current Imin (air-water limit) the control means 3 detects the situation and acts accordingly.
In the second example shown in FIG. 7 , the motor is supplied with a supply voltage with a preset frequency F 3 . The control means 3 determines that the monitored current Iq (point K) of the motor at that frequency F 3 is greater than the optimal current preset for the frequency F 3 (a point of the line D″-E″ in this case), and reduces the frequency of the supply voltage up to a frequency F 2 . At the frequency F 2 the control means 3 determines that the monitored current Iq (represented by an X) continues to be greater than the optimal current lop preset for the frequency F 2 (a point of the line D″-E″ in this case) and reduces the frequency F of the supply voltage to a frequency F 1 . At the frequency F 1 the control means 3 determines that the monitored current Iq (point K′) is substantially equal to the optimal current lop preset for the frequency F 1 and maintains the frequency F 1 of the supply voltage until the full-flow drainage function is completed. In one implementation, once the frequency F 1 has been set, the control means 3 continues checking on a cyclical basis if the monitored current Iq of the motor is kept substantially equal to the optimal current lop, which occurs for as long as the full-flow drainage process lasts. When the water has finished and the monitored current Iq is less than the minimum current Imin (air-water limit) the control means 3 detects the situation and acts accordingly.
In the third example shown in FIG. 8 , the motor is supplied with a supply voltage with a preset frequency F 3 . The control means 3 determines that the monitored current Iq (point M) of the motor at that frequency F 3 is greater than the optimal current preset for the frequency F 3 (a point of the line D″-E″ in this case), and reduces the frequency of the supply voltage to a frequency F 2 . At the frequency F 2 the control means 3 determines that the monitored current Iq (represented by an X) continues to be greater than the optimal current lop preset for the frequency F 2 , and reduces the frequency F of the supply voltage to a frequency F 1 . As the frequency F 1 corresponds with the minimum frequency Fmin, the control means 3 determines that the frequency F cannot continue to fall and maintains the operating point at M′ with a current Iq greater than the optimal current lop corresponding with the minimum frequency Fmin, until the full-flow drainage process is completed. When the water has finished and the monitored current Iq is smaller than the minimum current Imin (air-water limit) the control means 3 detects the situation and acts accordingly.
In one implementation a control means of an appliance acts in the following way in response to possible cases:
a) If the monitored current Iq of the motor is less than the minimum current Imin, the control means 3 determines that the appliance is not in a full-flow drainage process and performs the pertinent functions for the corresponding process. b) If the monitored current Iq of the motor is between the minimum current Imin and the maximum current Imax and is smaller than the optimal current lop, the control means 3 increases the frequency F of the motor supply voltage as a result of determining the full-flow drainage process is not being performed correctly. c) If the monitored current Iq of the motor is substantially equal to the corresponding optimal current lop, the control means 3 maintain the frequency F of the supply voltage of the motor. d) If the monitored current Iq of the motor is between the minimum current Imin and the maximum current Imax and is greater than the optimal current lop, the control means 3 reduce the frequency F of the motor supply voltage as a result of determining that the pump unit 1 can operate under less strain. e) If the monitored current Iq of the motor is greater than the maximum current Imax, the control means 3 determine that the pump unit 1 is working outside the working area AT, in an undesirable area, and acts accordingly.
In some cases the pump unit 1 may be allowed to operate in a range outside the limits set by the installation curves H 1 and H 2 , cases in which the appliance 100 operates as if it were inside the ranges (the example in FIG. 9 ). For this case, the optimal current lop corresponds with the line D″-E″-G″.
A control method for performing a full-flow drainage process in a washing household appliance 100 in one implementation is illustrated in the flow diagram of FIG. 10 . In the exemplary method of FIG. 10 the control means 3 monitors the current Iq of the motor in a monitoring phase Em and determines if the current Iq is between the corresponding current Imax and the corresponding current Imin in an intermediate phase Ei. If the current Iq is between Imax and Imin, the control means 3 compares the current Iq with the optimal current lop in a comparison phase Ec and regulates the frequency F of the motor supply voltage in an adjustment phase Ea in a manner previously described.
In one implementation the appliance 100 also comprises means (not shown in the figures) for detecting the temperature of the motor, the control means 3 compensating the monitored current Iq in accordance with the temperature detected, a compensated current thus being obtained. The control means 3 use the compensated current in the intermediate phase Ei, in the comparison phase Ec and in the adjustment phase Ea, instead of the monitored current Iq. The compensated current may be determined in a conventional manner.
|
An appliance having a drain pump with a motor adapted to be supplied with an alternating supply voltage. A controller is adapted to monitor a current value supplied to the motor and to control the frequency of the supply voltage among a plurality of predetermined frequencies when the drain pump is operated in a full drainage mode. A storage medium associated with the controller stores for each predetermined frequency a maximum current value, a minimum current value and an optimal current value. The controller may stores computer implemented instructions for (a) determining if the monitored current value is between the maximum current value and the minimum current value, (b) comparing the monitored current value with the optimal current value, and (c) adjusting the frequency of the alternating supply voltage among the plurality of predetermined frequencies to cause the monitored current to more closely match the optimal current value.
| 3
|
BACKGROUND OF THE INVENTION
The present invention relates to liquid purification systems and particularly to a system for removing free oil and fine solids from fluids utilized in industrial machining operations.
Machining operations generally require the use of coolants to prevent damage to tools due to excessive heat. Typically, a coolant comprises an oil-in-water emulsion wherein water is the continuous phase, oil is the disperse phase, and soap is the emulsifying agent. The emulsion is stabilized by electro-mechanical forces which are weakened or destroyed by contaminants in the form of metallic ions, free oil bacterial action, and fine solids.
The most serious culprit in coolant deterioration is free or "tramp" oil which must be removed to maintain the stability and equilibrium of the emulsion.
SUMMARY OF THE INVENTION
The aforesaid problems are solved, in accordance with a preferred constructed embodiment of the present invention, by an oil injection system utilized in conjunction with an oil separator and/or coalescer. Tramp oil removal can be substantially improved by injecting a fraction of collected tramp oil into the separator inlet stream. The tramp oil injected into the bulk coolant functions as a coalescing agent and as such, actually reduces the total amount of tramp oil in the system.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional view of a preferred constructed embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a system for extracting oil from industrial coolants or washer fluids comprises an inlet conduit 10 and a closed cylindrical tank 11 for the acceptance of bulk coolant under system pressure. Coolant pressure and flow volume to an inlet chamber 12 of the tank 11 are controlled by an adjustable feed valve 14.
The entire coolant flow must pass through an oil extraction element 16 in the tank 11. In the preferred constructed embodiment, the element 16 comprises a plurality of nested horizontally oriented polymeric tubes 18. The tubes 18 are preferably made from high density polyethylene or polypropylene and have an inside diameter of 5/16" and an outside diameter of 3/8". The tubes 18 are provided with angularly oriented end faces 20 and 22 at opposite ends, respectively, to ensure coolant flow into and out of the tubes 18. A perforated input plate 24 and a perforated output plate 26 position the tubes 18. The holes in the perforated plates 24 and 26 are less than 3/8" in diameter to ensure containment of the tubes 18 yet provide for flow of the coolant to a first integrated settling chamber 28.
After passing through the tubes 18, coalesced oil droplets 30 migrate to the top of the chamber 28. A return-to-system conduit 32 extends vertically downwardly into chamber 28 for return of purified fluid to the system. A sludge drain valve 34 is located at the bottom of chamber 28 to facilitate drainage of sludge 36 to a waste tank 38. An oil decant valve 40 and conduit 41 at the top of the chamber 28 are connected to a second stage settling chamber 42 for the transfer of only the coalesced "tramp" oil 30 thereto.
A return-to-system conduit 44 extends vertically downwardly into chamber 42 for removal of purified fluid to the coolant system through a valve 46. A sludge drain valve 48 is located at the bottom of chamber 42 to facilitate drainage of sludge therefrom. A coalesced "tramp" oil decant valve 50 at the top of the chamber 42 controls the flow of "tramp" oil to the waste oil tank 38.
In accordance with the present invention, an injection valve 52, also fluidly communicating with chamber 42, controls the flow of "tramp" oil into and through an injection conduit 54. Free oil passing through conduit 54 is thus directed into inlet conduit 10 thereby enhancing oil separation.
In operation, contaminated coolant flows through inlet conduit 10 into supply chamber 12 of the tank 11 thence through the horizontal tubes 18 and thence through settling chambers 28 and 42. Most of the tramp oil separated from the bulk coolant is routed to waste via waste oil conduit 50. A fraction of the tramp oil, however, is diverted through injection valve 52 and injection conduit 54 and then into conduit 10 for injection into the inlet contaminated oil stream.
Table 1, as shown below, compares the efficiency of an oil separator with and without tramp oil injection.
TABLE 1______________________________________Oil Separator Efficiency With .1% (1000 ppm) Tramp Oil Injection. Exit Quality Exit QualityIncoming Oil Without Tramp With TrampContamination Oil Addition Oil Addition % Efficiency(ppm) (ppm) (ppm) Improvement______________________________________982 767 712 5.2870 690 640 6.9743 635 570 7.9518 450 406 9.7407 372 327 12.1______________________________________
Most conventional separators operate by separation of tramp oil from the bulk fluid. After separation, the tramp oil is then decanted to waste. In contrast, in accordance with the present invention, tramp oil is reintroduced into the contaminated inlet stream in relatively small amounts. The results in Table 1 were generated by passing respective samples of equal volume through 5 micron hydrophobic membrane filters. As shown, total tramp oil within the fluid exiting the oil separator is actually reduced by adding small amounts of tramp oil into the inlet stream.
It is believed that the injected oil functions as a coalescing agent and provides a greater oil interface for oil globule attraction thereto. Because tramp oil globules within the bulk fluid have an affinity for other tramp oil globules therein, separation efficiency is increased.
It will be understood that the invention should not be construed as limited to coolant applications, but is meant to encompass any machining fluid, for example a washer fluid used in industrial processes, or any oil contaminated bulk fluid. Furthermore, the foregoing description of the preferred embodiment of the present invention is for illustrative purposes only, and the various structural and operational features herein disclosed are susceptible to a number of modifications, none of which departs from the spirit and scope of the present invention as defined in the appended claims.
|
A method and improvement for extracting free or "tramp" oil from an oil contaminated fluid wherein oil contaminated fluid entering an oil separator is injected with a fraction of free oil. Coalescence of minute oil globules within the inlet stream is significantly enhanced thereby improving oil separation.
| 1
|
FIELD OF THE INVENTION
This invention relates to process for improving the activity of fluid catalytic cracking (FCC) or moving bed cracking (TCC) catalyst, including any additives containing zeolitic material as one of the active components and which may be employed with each type catalyst, which process can be integrated with the operations of the hydrocarbon processing unit in which the catalyst is employed.
BACKGROUND OF THE INVENTION
Zeolites are very common materials in nature and there are many types of synthetic zeolites. It is estimated that there are about 100 types of synthetic zeolites and some of these are used in cracking catalysts. Examples of such cracking catalysts are those used in the well known fluid catalytic cracking (FCC) process and those used in the moving bed (TCC) process as described in U.S. Pat. No. 2,548,912. These types of catalyst contain crystalline zeolites, often referred to as molecular sieves, and are now used in almost 100% of the FCC and TCC type units, which process about 10 million barrels of oil per day.
Zeolites, or molecular sieves, have pores of uniform size, typically ranging from 3 to 10 angstroms, which are uniquely determined by the unit structure of the crystal. These pores will completely exclude molecules which are larger than the pore diameter. As formed in nature or synthesized, zeolites are crystalline, hydrated aluminosilicates of the Group I and Group II elements, in particular, sodium, potassium, magnesium, calcium, strontium, and barium, which can be exchanged with higher polyvalent ions, such as rare earths or with hydrogen. Structurally, the zeolites are "framework" aluminosilicates which are based on an infinitely extending three-dimensional network of AlO 4 and SiO 2 tetrahedra linked to each other by sharing all of the oxygens. The framework contains channels and interconnected voids which are occupied by the cation and water molecules. The cations are quite mobile and may be exchanged, to varying degrees, by other cations. Intercrystalline "zeolitic" water in many zeolites is removed continuously and reversibly. In many other zeolites, mineral and synthetic cation exchange or dehydration may produce structural changes in the framework.
As stated above, the uses for zeolites are many, but they typically must be combined with other materials when they are used in process applications. As an example, a synthesized zeolitic material, which is usually less than 4 microns in size, is combined with a binding agent, such as kaolin clay, silica sol, or amorphous silica, alumina, and zirconia as described in Demmel's U.S. Pat. No. 4,826,793 and then spray dried or extruded to produce a finished material that has the properties desired for the intended use. These properties may include attrition resistance, crush strength, particle size distribution, surface area, matrix area, activity and stability. Another method of producing a finished zeolite-containing product would be to produce the zeolite in-situ as described in Hayden's U.S. Pat. No. 3,647,718. While these patents deal mainly with FCC type catalyst, similar procedures are used in the production of zeolitic materials for TCC process applications. It is believed that in the manufacture of zeolitic moving bed and FCC type catalyst that some of the zeolite pores are blocked or buried within the matrix material and that the process described herein can remove this blockage and increase the available zeolite. So not only is the present process applicable to regenerated equilibrium catalyst, but it can also be used on the fresh zeolitic catalyst or additives before they are added to the FCC or TCC process for the first time.
An objective in refining crude petroleum oil has always been to produce maximum quantities of the highest value added products in order to improve the profitability of refining. Except for specialty products with limited markets, the highest value added products of oil refining with the largest market have been transportation fuels, such as gasoline, jet fuel and diesel fuels. Historically, a major problem in the refining of crude oil has been to maximize the production of transportation fuels. This requires a refining process or method which can economically convert the heavy residual oil, the crude oil fraction boiling above about 1000° F., into the lighter boiling range transportation fuels. A major obstacle to the processing of this heavy residual oil has been the concentration of refining catalyst poisons, such as metals, nitrogen, sulfur, and asphaltenes (coke precursors), in this portion of the crude oil.
Since most of the oil refineries in the world use the well known fluid catalytic cracking (FCC) process as the major process for the upgrading of heavy gas oils to transportation fuels, it is only natural that the FCC process should be considered for use in the processing of heavy residual oils. Indeed, this has been the case for the last ten to fifteen years. However, the amount of residual oil that a refiner has been able to economically convert in the FCC process has been limited by the cost of replacement catalyst required as a result of catalyst deactivation which results from the metals in the feedstock. The buildup of other catalyst poisons on the catalyst, such as the coke precursors, nitrogen and sulfur, can be effectively controlled by using catalyst coolers to negate the effect of coke formation from the asphaltene compounds, using regenerator flue gas treating to negate the environmental effects of feed sulfur, and using a short contact time FCC process, such as that described in my U.S. Pat. No. 4,985,136, to negate the effects of feed nitrogen, and to some degree, the feed metals.
For the past twenty or more years the most widely used FCC catalysts have been zeolitic catalysts, which are finely divided particles formed of a matrix, usually silica-alumina, alumina or the like, having a highly active zeolitic material dispersed in the matrix. As is well-known, the zeolites used in such catalysts are crystalline and typically have a structure of interconnecting pores having a pore size selected to permit the ingress of the hydrocarbon molecules to be converted, and the zeolite has a very high cracking activity. Therefore, the highly active zeolite is dispersed in a matrix having a lesser cracking activity in a ratio providing the desired activity for commercial use. Typically used zeolites are of the faujasitic type, e.g., X-, Y- or L- type synthetic zeolites, and from about 5 wt. % to about 70 wt. % of the zeolite is employed. Such zeolitic FCC catalysts, their manufacture and their use in the FCC process are well known by those working in the art.
It is commonly accepted in the oil refining industry that vanadium contained in the residual oil FCC feedstock will irreversibly deactivate the zeolite by attacking the structure, and that this vanadium effect is more pronounced at temperatures above about 1330 F. It is also commonly accepted that catalyst deactivation by hydrothermal deactivation or by metals (e.g., sodium and vanadium) attack is irreversible.
In the operation of an FCC process unit (FCU) the process economics are highly dependent upon the replacement rate of the circulating catalyst (equilibrium catalyst) with fresh catalyst including additives, such as ZSM-5 and other zeolitic materials used for specific purposes in the FCU. Equilibrium catalyst is FCC or TCC catalyst which has been circulated in the FCU or TCC unit between the reactor and regenerator over a number of cycles. The amount of fresh catalyst addition required, or the catalyst replacement rate, is determined by the catalyst loss rate and that rate necessary to maintain the desired equilibrium catalyst activity and selectivity to produce the optimum yield structure. In the case of operations wherein a feedstock containing residual oil is employed, it is also necessary to add sufficient replacement catalyst to maintain the metals level on the circulating catalyst at a level below which the yield structure is still economically viable. In many cases, low metal equilibrium catalyst with good activity is added along with fresh catalyst to maintain the proper catalyst activity at the lowest cost.
In the processing applications that utilize zeolites, the material must be replaced as it looses its ability to perform the desired function. That is, the zeolitic material deactivates under the conditions employed in the process. In some cases, such as FCC and TCC type catalytic applications, fresh zeolitic material, in this case zeolitic catalyst or additives such as ZSM-5 (described in U.S. Pat. No. 3,703,886), are added on a daily basis. Fresh zeolitic catalyst is added daily at a typical rate of from 1% to as high as 10% of the process unit inventory to maintain the desired activity in the unit. Typically, as fresh catalyst is added to the FCC and TCC unit inventory, the operator to maintain the unit catalyst inventory within the design limits must withdraw equilibrium catalyst from the unit for disposal.
Copending application Ser. No. 08/581,836 of Robert E. Davis and David B. Bartholic discloses a process for improving the activity of zeolitic catalyst containing one or more contaminants which block the pores of the zeolite and adversely affect the activity of the catalyst.
In accordance with such Davis-Bartholic process, a slurry is formed of contaminated zeolitic cracking catalyst and as aqueous solution of a suitable acid, detergent and/or surfactant; the slurry is agitated to solubilize and/or dislodge contaminants which block the pores of the zeolite, and a portion of the solution containing the solubilized and/or solubilized contaminants is withdrawn from the agitated slurry in order to remove such contaminants and prevent them from being redistributed in the pores. The resulting treated catalyst having a reduced level of contaminants and improved activity is then separated from the remaining solution, washed, and recovered for use in a hydrocarbon processing unit.
Surprisingly, I have now determined that the activity of such a contaminated cracking catalyst can be significantly enhanced by a simpler and less expensive process, which is described hereinbelow.
It is believed that much of the deactivation mechanism for zeolitic materials results from zeolitic pore blockage, which can be reversed. This pore blockage can occur during the production stage by the retention of silica or other binding or matrix material in the zeolite pores. The pore blockage can also occur during the processing stage by silica that migrates to the pores, hydrocarbons from the feed or reaction products, or other materials present in the feed, or catalyst itself, that deposit or migrate into the zeolite pores, thereby blocking off access and reducing the activity of the zeolite. There are indications that hydrocarbon material may help to bind the silica and other feed and matrix material in the pores of the zeolite, or only hydrocarbon material may block the pore. This blockage prevents the reactants from entering the zeolite pores and therefore reduces the activity of the zeolite. Another cause of zeolite deactivation is the dehydration of the zeolitic structure.
Based on laboratory work, it is believed that there are various methods for reactivating these zeolitic materials based on (1) chemical treatments, which loosen or solubilize the materials blocking the zeolite pores, and (2) agitation, which aids in mechanically removing the pore blockage material. It is also believed that the dislodged or solubilized contaminant material removed from the pores must be separated from the reactivated product and that the most economical method to accomplish this reactivation in-situ, i.e., in conjunction with the process operations, as is described below.
As will be seen from the following discussion, it is believed that zeolitic FCC and TCC catalysts can benefit from the present invention, because, contrary to popular belief, the major cause of zeolitic catalyst activity decline is zeolite pore blockage which can occur, even during the catalyst manufacturing process, due to free silica or alumina, or compounds of silica or alumina, or other materials which are left behind and block the zeolite pore openings.
The primary objective of the present process is to integrate the reactivation of equilibrium FCC, and TCC, zeolitic catalyst with the unit operations so as to improve the economics. This process eliminates the cost of transporting the catalyst to an off-site location for reactivation and eliminates catalyst disposal costs. Also, by integration of the present reactivation process with the TCC and FCC operations, the costs and environmental problems associated with off-site reactivation will be greatly reduced. Another object of the present invention is to enable the removal of zeolitic catalyst deactivating materials without destroying the integrity of the catalyst and, at the same time, to significantly improve the activity and selectivity of the reactivated equilibrium FCC- and TCC-type zeolitic catalyst and additives. Another object of the present process is to reactivate zeolite-containing equilibrium catalyst using an environmentally safe and acceptable process.
Another object of the present invention is to improve the activity of fresh zeolitic catalyst and additives. Still another objective of the invention is to reduce the requirement for fresh catalyst replacement to an FCC unit, which will reduce fresh catalyst costs, transportation costs, equilibrium catalyst disposal costs, and unit catalyst losses. Other objects of the invention will become apparent from the following description and/or practice of the invention.
SUMMARY OF THE PRESENT INVENTION
The above objects and other advantages of the present invention may be achieved by a process for improving the activity of a contaminated spent zeolite-containing cracking catalyst containing one or more contaminants which block the pores of the zeolite and adversely affect the activity of the catalyst which process comprises:
a. regenerating the spent cracking catalyst by burning carbonaceous deposits therefrom;
b. removing a portion of the regenerated catalyst from the active circulating catalyst inventory of an FCC or TCC process unit;
c. forming a slurry of such portion of the unit catalyst inventory with a liquid containing at least one activating agent selected from the group consisting of acids, detergents and surfactants, the agent being effective to solubilize or dislodge the contaminants;
d. agitating the slurry under activation conditions, including a temperature and a time sufficient to solubilize or dislodge the contaminants;
e. withdrawing the agitated slurry after the contaminants have been solubilized or dislodged and transferring the slurry to a drying stage to obtain a treated, reactivated zeolitie-containing catalyst having a level of activity greater than the activity of the active circulating catalyst inventory; and
f. contacting the treated, reactivated catalyst under cracking conditions with hydrocarbon feedstock charged to the unit.
In the present process, the preferred method is to withdraw hot regenerated catalyst from the regenerator of the unit and add it to a liquid solution containing the activating agent so that the hot catalyst will aid in increasing the temperature of the resulting slurry to the desired operating temperature. However, one could withdraw the regenerated catalyst from the FCC regenerator or TCC kiln into a intermediate storage hopper before adding it to the liquid solution. The chemical treatment is normally carried out at between 3 and 7 pH and at a temperature less than 212° F. This chemical treatment may be accomplished with activating agents such as enzymes containing degreasing/surfactants, malic acid, active fluorides, hydroxylamine hydrochloride, and other acidic materials, as well as detergents. One can raise the temperature above 212° F. to help obtain agitation by boiling, but then one must provide for fresh liquid makeup and recovery of the vapors. Another option, if a still higher temperature is desirable, is to conduct the operation under pressure, which is more costly. Increasing the temperature is considered beneficial to the reaction of solubilizing or dislodging the pore blockage materials. It is believed that the cycle time for reactivation can be shortened by increasing the temperature, but temperatures below the decomposition temperature of the reactivating agents, the boiling point of the liquid, and the aggressive attack on the catalytic structure by the activating agents should be employed in this process.
The agitation can be by any suitable method, e.g., stirring, aeration, or tumbling. The preferred method for small particle size materials, such as FCC-type catalyst, is to form a slurry of up to 75% concentration of solids, but more preferably at less than 30% slurry, and to keep the particulate solid suspended in the solution and also keep the maximum surface area of the solid exposed to the fresh chemical reaction by stirring and aeration. For larger particle size zeolitic materials, such as TCC-type zeolitic catalyst, stirring may not be as practical as pumping around the liquid in the contacting vessel so that it flows upward through the bed of pellets/extrudates along with the aeration media. The liquid pumparound may be removed below the upper liquid level and returned to the bottom of the contacting vessel to provide a mixing of the chemical liquid in the contactor and an upward flow of liquid with the aeration media to aid in agitation and stripping of the small particles from the zeolite pores. In either case, the small particles liberated from the zeolitic pores are kept in suspension by the constant agitation.
The time of treatment can be varied from several minutes to many hours, depending on the temperature, chemical concentration, percent solids, particle size of the zeolite material, and the nature of the material blocking the pores. It has been found that the chemical activating agent acts to dissolve and/or loosen the pore blockage material, while the aeration/stirring helps to separate the small particles that have been blocking the pores from the now reactivated zeolite material and to keep these materials suspended in the solution. The addition of surfactants and detergents to aid in the separation and suspension of the small particles may be desirable.
At the end of the reactivation cycle, the agitated slurry is transferred to a drying stage to obtain a treated, reactivated zeolite-containing catalyst having a level of activity greater than the activity of the deactivated circulating inventory. In the drying stage the catalyst is fluidized by a suitable fluidizing medium to separate the contaminants from the catalyst and to vaporize the liquid. In the preferred method, the slurry is transferred back to the circulating catalyst inventory of the unit which is used as the drying stage. This slurry can be added back to the regenerator or another part of the unit. However, it is preferred that the slurry be added back to the reactor section of the unit. It can also be added back to the reactor riser or the reactor vessel itself, where the liquid will be vaporized, leaving behind the reactivated catalyst. The vaporized liquid will exit with the reactor vapors. Any small particles will eventually exit from the reactor or regenerator system as fines. The residual activating agent will either decompose or be combusted in the regenerator.
It is preferred that the agitated slurry be transferred directly to the drying stage without permitting it to settle, so as to keep the contaminant particles suspended in the liquid, thereby reducing the likelihood of the separated contaminants re-entering the zeolite pores.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood by reference to the following description thereof read in conjunction with the accompanying FIG. 1 which is a schematic flow diagram of a preferred process in accordance with the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Since one of the largest markets for zeolites is in the manufacture of FCC catalyst, the following process description refers to the reactivation of regenerated FCC catalyst. However, the present invention is applicable to fresh FCC catalyst and additives or equilibrium and fresh TCC type catalyst. It is only necessary that the surface of the zeolite material have a low coke level or be essentially free of coke; that is the coke should be removed by regeneration e.g., contacting spent catalyst with an oxygen-containing gas at elevated temperature to burn the carbonaceous deposits from the catalyst.
The present invention comprises treating zeolite-containing FCC or TCC catalyst in an agitated slurry solution containing a chemical activating agent which has been chosen to loosen or solubilize the materials blocking the zeolite pores, and drying the treated zeolite material. This drying step serves several functions. It is used to vaporize the liquid and obtain the treated, reactivated zeolitic catalyst, while at the same time keeping all or a substantial amount of the dislodged or solubilized small particle size materials removed by chemical treatment/agitation from the zeolite pores from reentering the pores. It is believed that as the liquid is vaporized these small particles or solubilized materials will be dried and separated from the treated catalyst by fluidization, or else they will deposit on the surface, as will any remaining activating agent that is not decomposed or combusted in the drying process, and therefore will not contribute to the deactivation of the treated catalyst.
This liquid chemical treatment to remove the small particles from the pores of the zeolite can be accomplished in conjunction with other processing steps, such as, chemical removal of metals (Ni, V, Na, Fe, etc.) from equilibrium FCC or TCC catalyst, or exchange of the zeolite with rare earth elements or other cations to modify the activity or selectivity of the zeolite.
The first processing stage is to put the pore-blocking material into solution or to loosen the small particles blocking the pores. This may be accomplished by treatment of the zeolite-containing solid particles in an agitated solution containing, as the activating agent, an acid or mixture of acids, followed by drying the treated material and separation of contaminates from the pores of the treated catalyst. In the preferred processing method, the agitation of the acid solution is accomplished by both stirring and aeration. It has been found that use of a combination of acids for treatment is more effective, and this is the preferred method.
As will be evident from the following example, the mechanism of catalyst reactivation is contrary to the beliefs of those working in the catalyst art. Test results obtained by use of the present invention indicate that the method of catalyst deactivation may be contrary to the accepted theory of irreversible zeolite structure collapse resulting from hydrothermal conditions or metals, such as sodium and vanadium, attack. The results of the testing indicate that the method of catalyst deactivation is reversible. While the precise method of catalyst deactivation may not be known, the results of the testing lead to the theory that the primary method of catalyst deactivation is zeolitic pore blockage. This blockage is believed to result from the combination of feed components, such as heavy organic compounds, organometallic compounds or polymerization of zeolitic reaction products in the zeolite cage, and/or catalyst base materials, such as alumina and silica compounds.
The preferred acids for use in the present invention are weak acids, such as malic, acetic and ammonium bifluoride. For example, malic acid may be used to keep the pH at 3.0 or above to minimize the removal or attack on the alumina in the catalyst structure. However, it is believed the malic acid acts to loosen the material blocking the pores of the zeolite but is not strong enough to cause noticeable structural changes in the catalyst. The ammonium bifluoride, it is believed, also helps to loosen the pore blockage material, which appears to be rich in silica. One can use other fluorides to react with the silica, but very active fluorides such as HF are not recommended because of their environmental/safety concerns and their tendency to remove structural silica. Normally the amount of ammonium bifluoride added to the solution will be less than 10 wt % of the catalyst being reactivated and typically will be between 1 and 4 wt %. The malic acid will be normally less than 15 wt % of the catalyst being treated and typically will be between 5 and 10 wt %. As will be seen in one of the examples below, an enzyme, which contained both a detergent and a surfactant, and malic acid were used to reactivate an equilibrium FCC catalyst. In this case, the aeration media used caused a froth that separated the fine particles from the reactivated catalyst. The preferred enzymatic material contains both a surfactant and detergent which attacks the hydrocarbon binding or blocking agent so that the pore-blocking material in the zeolite cage can be removed and thereby reactivate the zeolite. The acid solubilizes, and the stirring/aeration agitation media combines with the surfactant in the enzymatic material to lift the small particles from the zeolite pores. The removal of these fine inorganic particles and/or hydrocarbon materials from the zeolite cage opens the zeolitic channels so that the interior of the zeolite is accessible to the vapor reactants, thereby reactivating the catalyst. It is also believed that the activity of fresh FCC and TCC zeolitic catalyst may be increased by this type treatment to remove any free alumina or silica compounds that might be retained in the pores of the zeolite during manufacture. This would also be the case for any fresh or equilibrium catalyst containing zeolites, such as ZSM-5.
The results of the testing indicate that agitation with air, as well as dispersion of the solid in the solution by stirring, is also highly desirable. It is theorized that finely dispersed bubble agitation of the solids is advantageous in removing the obstructions from the zeolite pores.
The following Example demonstrates the advantages of the present process when used to reactivate a commercial FCC catalyst formed of a silica-alumina matrix containing about 10-20 wt % of a type Y zeolite.
Example A: A sample of 50 gms of regenerated equilibrium FCC catalyst was placed into a solution of 200 ml of deionized water, 20 gms malic acid and 1 ml of a commercial enzyme and heated to about 130° F. in a magnetically stirred beaker for 12 hours. During this time the solution was aerated with compressed air. The combination of the aeration and detergent in enzyme caused a froth phase to develop on the top of the liquid level. The aeration and froth combined to separate the small particles from the reactivated material and conveyed these small particles upward to the beaker top where they were skimmed off. After 12 hours the treated catalyst was filtered and washed to remove any remaining liquid and contaminants and dried.
The equilibrium catalyst (before treatment) and the reactivated catalyst (after treatment) were each tested on a Micro Activity Testing (MAT) unit at a 3.1 catalyst to oil ratio, 16 WHSV, 960 F. using a standard gas oil. The fresh catalyst activity and the analytical results for the untreated starting catalyst and the treated catalyst are detailed below: (two numbers indicate two tests)
______________________________________ BEFORE AFTER TREATMENT TREATMENT______________________________________FRESH ACTIVITY 2.8CATALYST ACTIVITY 1.4 1.4 2.3 1.9MICRO ACTIVITY TEST:CONVERSION 59 59 70 66COKE FACTOR 1.8 3.1 1.4 1.7GAS FACTOR 12.1 5.3 2.2 4.9______________________________________
After extensive laboratory testing on zeolite reactivation to determine the proper procedure, five samples of equilibrium catalyst were obtained from five different operating FCC units. Each of these five equilibrium catalyst samples were more than likely mixtures of different types of fresh catalyst from different suppliers, since most FCC units change the type of fresh catalyst they add and also add outside equilibrium catalyst on occasion. However, it is known that these five samples of equilibrium catalyst have a very broad range of activities and metals levels (Ni/V) since these units operate on feeds which range from gas oil to residual oil operations. However, the fresh catalyst added to these units would typically have 20-30% of a Y or USY zeolite with different levels of active matrix. All of the five samples were treated in the following manner:
1. Regenerated the as received equilibrium catalyst in a muffle furnace at 1250 F. for 4 hours using an oxygen-containing gas.
2. Added 100 gms of the regenerated equilibrium to 500 cc of deionized water.
3. Added 4 gms of hydroxylamine so that pH was between 3.8 and 4.0 at 71 F. The hydroxylamine is used as a reducing agent, mainly to reduce the nickel on the catalyst.
4. Sample from step 3 was placed on magnetic stirrer-hot plate. At 125 F. added 2 gms ammonium bifluoride and 10 gms malic acid (pH of 3.0) and raised temperature to about 150 F.
5. After 2 hours at between 125 F. and 150 F., removed sample from stirrer-hot plate, and allowed the sample to settle until the majority of catalytic material was out of suspension but the fine particle size and colloidal material was still in solution, and decanted the sample to remove the fine particles that were still in solution.
6. Washed the decanted sample 3× with 300 ml of deionized water and decanted after each wash as described in 5 above. Samples of each of the five reactivated equilibrium samples was tested and the results are shown below.
7. 40 gms of each of the five washed reactivated samples from step 6 were exchanged with 3.64 gms of a rare earth element solution (27.46% rare earth element oxides consisting of 12.23 La2O3, 7.22% CeO2, 5.64% Nd2O3, 1.95% Pr6O4) in 100 cc of deionized water. After 2 hours at 190 F., the now rare earth exchanged reactivated samples were washed 2× with 150 cc of deionized water and dried overnight in a drying oven and put in the muffle furnace for 1 hour at 1000 F.
8. The regenerated equilibrium catalyst, the reactivated samples from step 6 and the rare earth exchanged samples from step 7 were tested as detailed below.
The testing was done on a Micro Activity Testing (MAT) unit at a 3:1 catalyst to oil ratio, 16 WHSV, 960 F. using a standard gas oil. Samples A and C were equilibrium catalyst from FCCU's operating on residual oil. The results of the MAT testing indicated the following:
______________________________________ MAT TEST RESULTS ACTI- COKE GASSAMPLE VITY FACTOR FACTOR______________________________________A REGENERATED EQUILIBRIUM 0.75 7.63 2.04A REACTIVATED 1.16 4.36 1.33A RARE EARTH EXCHANGED 1.34 4.29 1.01B REGENERATED EQUILIBRIUM 1.23 2.28 1.58B REACTIVATED 1.56 2.23 1.53B RARE EARTH EXCHANGED 1.72 2.32 1.69C REGENERATED EQUILIBRIUM 1.02 4.71 1.50C REACTIVATED 1.25 4.39 1.12C RARE EARTH EXCHANGED 1.56 3.75 0.97D REGENERATED EQUILIBRIUM 1.36 3.89 1.33D REACTIVATED 2.06 3.01 1.14D RARE EARTH EXCHANGED 1.70 3.91 1.45E REGENERATED EQUILIBRIUM 1.01 1.52 1.21E REACTIVATED 1.29 2.48 1.07B RARE EARTH EXCHANGED 1.20 3.29 1.17______________________________________
The MAT results above not only show an increase in activity for all of the reactivated samples, but also indicate a selectivity improvement in the reactivated catalyst as compared to the regenerated equilibrium. Samples A, B, and C indicate that there was available zeolite that exchanged with the rare earth elements, which resulted in increased activity and selectivity. Based upon these results, it is believed that the mechanism for zeolitic catalyst reactivation is the removal of small particle size material from the zeolitic pores. An analysis of this material indicated it is rich in silica along with the other components of the catalyst including alumina, nickel, and vanadium. It is theorized that the pore blockage material is deposited in the pores of the zeolite during the manufacture of the fresh catalyst and by the migration of silica during operation of the processing unit.
The above data indicates that contrary to popular belief, the activity and the selectivity of regenerated FCC catalyst can be greatly improved. Therefore, by practice of the present invention one can remove what is commonly referred to as equilibrium zeolitic catalyst from the processing unit, treat the catalyst as disclosed herein and reuse the treated catalyst having an improved activity and selectivity.
It is believed that the key to a successful zeolitic catalyst reactivation process is removing the zeolitic pore blockage material from the pores of the zeolite and separating this material from the reactivated zeolitic catalyst. The foregoing demonstrates that the material blocking the pores can be loosened by mild acids or combinations of acids that are reactive with the pore blockage material. The laboratory data also indicates that a mixture of mild acids such as ammonium bifluoride and malic acid at pH of 3 to 5 takes less time than malic acid on its own.
ZEOLITIC CATALYST REACTIVATION PROCESS
In a commercial operation using the zeolitic reactivation process of the present invention an essentially carbon free, regenerated, FCC or TCC equilibrium catalyst is mixed with a chemical solution containing the activating agent(s) in an agitated contactor vessel to form a slurry. After a designated period at the desired temperature, the reactivated slurry solution is transferred to a drying stage. The reactivated slurry solution contains the reactivated catalyst, residual activating agent(s), water, and solubilized and/or dislodged contaminant particles in suspension. Most preferably, the agitated reactivated slurry is transferred directly to a fluidized drying stage. That is, the agitated slurry should not be permitted to settle, since this provides an opportunity for the dislodged pore blocking particles to be redistributed in the zeolite pores before being transferred to the drying stage. By maintaining the agitation of the slurry, these fine particles can remain suspended in the solution. In the drying stage, the water is vaporized, the residual reactivating agent is decomposed, combusted, and/or the components of the activating agent are deposited on the surface of the reactivated catalyst. The solubilized or dislodged fine particles are dried and separated by fluidization in the drying stage from the treated, reactivated catalyst.
A commercial FCC or TCC catalyst reactivation process would comprise contacting a regenerated catalyst in an agitated (stirred or aerated) chemical solution containing an activating agent, that consists of a mild acid, such as malic, or a mixture of mild acids such as malic and ammonium bifluoride in a contacting vessel. After a period of time at the desired temperature, the treated activated FCC catalyst slurry solution is transferred directly to the reactor system of the FCU or TCC unit, where the heat from the circulating catalyst will vaporize the water, decompose or cause the components of the activating agent to deposit on the surface of the circulating catalyst to be combusted in the regenerator, and separate by fluidization the fine particles dislodged from the pores of the zeolite during the reactivation from the reactivated catalyst. Eventually these fines will leave the unit, as will the other components of the slurry solution except for the reactivated catalyst, with the regenerator or reactor exit gases and vapors.
Large sized zeolitic materials, such as the pelleted or extruded zeolitic TCC catalyst, can also be treated in stirred vessels. However, other forms of agitation, such as tumbling or ebulating beds, or only recirculation of the chemical solution to the bottom of the vessel to give a continuous upward flow of chemical in conjunction with the aeration media can also be used if desired.
The preferred aeration media in any embodiment of the present reactivation process is air, but other gases, such as nitrogen or light hydrocarbon gases, which will act along with the activating agent and the agitation may be used to maintain the dislodge particles in suspension.
FIG. 1 illustrates a preferred process flow for the practice of the present invention. Those skilled in the art may know of other equipment which may be employed in the process. It is important, however, that the equipment selected perform the functions described herein so that the desired reactions and results are obtained. In the preferred batch process diagramed in FIG. 1, reaction vessel 3 is filled with the desired weight of water, and activating agents from storage hoppers 5 and 6 to get the desired pH on pH indicator 7. Once the liquid level is established in reaction vessel 3, agitator 4 is commissioned and the desired weight of hot regenerated zeolitic FCC catalyst from FCC regenerator 1 to reaction vessel 3 is added to the liquid. In the preferred operation, hot regenerated FCC catalyst is withdrawn from the regenerator active catalyst inventory utilizing the device described in my U.S. Pat. No. 5,464,591, "Process and Apparatus for Controlling and Metering the Pneumatic Transfer of Solid Particulates". However, reaction vessel 3 can be equipped with load cells so that all of the liquid, catalyst, and activating agents could be added on weight. The hot regenerated catalyst is then added to the liquid activating agent, which is composed of water containing the desired amounts of mild acids, which are effective to dislodge and/or solubilize the pore-blocking contaminants in the zeolite pores. Reaction vessel 3 is agitated by mechanical stirrer 4 and air from line 8, which is injected into the bottom of the liquid through a distribution grid. Malic acid or a mixture of malic and ammonium bifluoride from storage hopper 5 and 6 is added into reaction vessel 3 on weight control to control the pH at between 3 and 7, with a pH of about 5.2 being preferred. A surfactant/detergent from storage tank 9 is added on weight control to control the concentration within a suitable range, which may be from about 1 ppm to 10 wt %, depending on the catalyst and conditions employed in reaction vessel 3. Such a surfactant and/or detergent forms a foam to aid in maintaining the small contaminant particles in suspension. If one uses a surfactant/detergent along with the agitation, the evidence of foam on the top of the liquid level in reaction vessel 3 will indicate there is sufficient active surfactant/detergent in the chemical solution. Therefore, if at any time during this batch process the foam disappears then more surfactant/detergent can be added to restore the surfactant/detergent action which aids in the removal by suspension of the small contaminant particles liberated from the zeolitic pores. Those skill in the art will know that this system can be completely automated and vessels 5, 6, 9, and 3 can all be equipped with load cells.
Reaction vessel 3 can be operated at ambient temperature, but it is preferred to operate at from about 1300° F. to 2000° F. but in no case at a temperature that will kill the surfactant/detergent activity or result in aggressive attack of the catalyst particle. The temperature in reaction vessel 3 can be controlled by an external heat source, such as, a steam coil or jacket on the vessel. Depending on the type of zeolitic material being treated and the chemicals and temperature employed in the processing, the treatment time can be as low as 10 minutes and as long as 36 hours, with 4 to 12 hours being normal.
If air emissions are a concern, the aeration supply 8 can be a closed system, if desired.
After the reactivation process is complete, the agitated slurry solution is transferred from the bottom of reaction vessel 3 directly to the FCC unit. While it can be transferred to any part of the unit, it is preferred that the slurry be added to the FCC reactor system 2, which serves as the fluidized drying stage.
Testing has indicated that the efficiency of this reactivation process can be improved by the addition of a suitable concentration of ammonium bifluoride to the activating liquid to aid in the removal of free silica from the pores of the zeolite.
An example of the commercial application of this process is a 25,000 BPD FCU that operates on residual oil, which requires the addition of 1 # of fresh catalyst per barrel of feed to maintain the activity and level on the equilibrium catalyst at the desired level. This requires 25,000 pounds (12.5 tons) per day of fresh catalyst. At a delivered price of $1500/ton, the fresh catalyst costs are $18,700.00 per day or $0.75 per barrel of feed. Add to this the disposal cost of $200/ton, and the costs approach $0.85 per barrel of feed. It is estimated that the use of the present process would require the reactivation of 16,000 #/day, which would reduce the fresh catalyst consumption to about 6000 #/day since about 30% of the fresh catalyst added to the unit is lost as water vapor or fines. That is, of the 25,000 #'s added to the unit, only 17,500 #'s (70%) is effective. This would reduce the fresh catalyst costs to $4500/day or $0.18/bbl. Since the reactivated catalyst should not have any losses, the 6000 #/day should be able to maintain the unit inventory and makeup for any activity differences between the fresh and reactivated catalyst. If one removes 16,000 #'s per day of regenerated catalyst from regenerator 1 into reaction vessel 3 to result in a slurry concentration of 25%, the resultant temperature of the slurry in reaction vessel 3 will be about 180° F. Therefore, if one insulates reaction vessel 3 there is not a need to add much, if any, heat during the reactivation cycle. After, the reactivation cycle is complete, the slurry can be added back to reactor 2. If the slurry is transferred to the FCC reactor or regenerator over an hour period, the result will be to increase the catalyst circulation by between 5 and 6 t/m. This will be an increase of about 20 to 25% in the catalyst circulation rate. If this is not acceptable, the transferring time can be increased, as desired, for up to 24 hours. Not counting capital costs, the operating costs associated with an the above-described on-site, or integrated, FCC or TCC catalyst reactivation plant should be less than half the costs of the fresh catalyst, so the refiner in this case could save upwards of $3,000,000.00 per year.
While the foregoing description of the present invention has been given with reference to a batch-type catalyst reactivation process, those skilled in the art will recognize that the present process can be operated on a continuous basis, using the continuous addition of regenerated catalyst to reaction vessel 3 and continuously withdrawing agitated slurry therefrom for transfer to a fluidized drying stage as described above.
Having described preferred embodiments of the present invention, it is to be understood that variations and modifications thereof falling within the spirit of the invention may become apparent to those skilled in this art, and the scope of the invention is to be determined by the appended claims and their equivalents.
As described above, the preferred fluidized drying stage is the reactor or regenerator section of the FCC or TCC unit; however it will be understood by those skilled in the art that other fluidized drying systems, e.g., a catalyst spray drier or catalyst calciner may be used instead to effect the drying of the slurry and separation of the fine contaminant particles from the treated reactivated catalyst. Most preferably, the present process is integrated with a processing unit, but there may arise some situations where it is desirable to take the regenerated catalyst off-site for reactivation by the present process.
|
A spent zeolite-containing hydrocarbon cracking catalyst is treated by regenerating it to remove carboneous deposits. A portion of the regenerated catalyst is withdrawn from the circulating catalyst inventory of a hydrocarbon processing unit and slurried with a liquid containing an activating agent to solubilize and/or dislodge contaminants which block the pores of the zeolite and adversely affect the activity of the catalyst. The slurry is agitated to dissolve or dislodge the contaminants from the zeolite pores, and the agitated slurry, without being permitted to settle, is transferred to a fluidized drying zone where the liquid and solubilized and/or dislodged contaminants are removed from the treated catalyst which has a level of cracking activity higher than that of the catalyst in the circulating catalyst inventory. The treated catalyst is then recycled to the unit and contacted with a hydrocarbon feedstock under cracking conditions.
| 2
|
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method for controlling a servomotor, and more particularly, to a drive control method for a servomotor, in which a high output can be fetched from the servomotor by means of a motor-current control unit of a simple construction.
2. Description of the Related Art
The recent mainstream of servomotor drive control is PWM control using semiconductor switching elements, such as power transistors, thyristors, etc. Also, there is a demand that a high output should be obtained from servomotors. In order to obtain a high output from a servomotor, a large current must be supplied to the semiconductor elements. It is difficult, however, to obtain semiconductor elements which permit a large current to be applied thereto. Even if a large current is allowed to flow through a semiconductor element, moreover, the semiconductor element has the property of generating heat in its active region, and hardly in its cut-off region and saturated region. Therefore, the calorific value of the semiconductor element increases in proportion to the chopping frequency, so that the chopping frequency must be lowered. If the chopping frequency is lowered, however, motor control inevitably becomes difficult. Thereupon, a tentative arrangement is provided such that each of the switching elements of a PWM control section is composed of a plurality of semiconductor elements, and the driving current of the servomotor is increased by reducing the currents flowing through the individual semiconductor elements. In such a case, however, current concentration in the semiconductor elements (or large current flow only in some of the semiconductor elements) is caused, so that the driving current cannot be increased in proportion to the number of parallel-connected semiconductor elements.
Conventionally, therefore, a high output is obtained by operating a plurality of motors in a parallel manner. In this case, however, it is necessary to mechanically connect the individual motors with one another and with an output shaft. This results in an increase in cost.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a drive control method for a servomotor, in which a high output can be fetched from the servomotor while preventing switching elements of a motor-current control unit from being damaged by excess current.
Another object of the present invention is to provide a drive control method for a servomotor which can be effected by using a motor-current control unit of a simple construction.
A method for controlling a servomotor according to the present invention comprises steps of integrating the deviation between a command current for each of two or more independent winding portions and a current flowing through each of the winding portions, with use of an integrating element corresponding to each of the winding portions, the two or more winding portions constituting an armature winding of each phase of the servomotor; amplifying the currents flowing through the individual winding portions by means of proportional elements corresponding to the individual winding portions; obtaining the deviations between the outputs of the individual integrating elements and the outputs of the proportional elements corresponding thereto; obtaining a control signal by adding the individual deviations; and controlling the currents supplied to the indivudal winding portions for substantially independent and equal values by the use of one PWM control means responsive to the control signal.
Thus, according to the present invention, the control signal is obtained with use of the integrating element and the proportional element corresponding to each of the plurality of winding portions, which constitute the armature winding of each phase of the servomotor. Therefore, the current flowing through the individual winding portions can be controlled independently for equal values by the use of one PWM control means. Thus, a high output can be obtained from the servomotor, and besides, a motor-current control section can be simplified in construction and lowered in cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a motor-current control unit to which is applied a method for controlling a servomotor according to an embodiment of the present invention;
FIG. 2 is a block diagram showing a typical example of a speed control section of a DC servomotor;
FIG. 3 is a block diagram showing an example of the arrangement of a current control section used for the control of a servomotor having an armature winding composed of a plurality of winding portions; and
FIG. 4 is a block diagram showing a modification of the arrangement of FIG. 3 in which a PWM control section and the like are used in common.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before describing the present invention, a typical example of speed control of a DC servomotor will be explained with reference to FIG. 2. FIG. 2 shows only those elements which are related to one phase of the motor. In FIG. 2, the difference between a speed command r delivered from an error register or the like and an actual speed V of the servomotor detected by a speed detector is amplified by an error amplifier 1, and is delivered as a current command Ir to an error amplifier 2. The difference between the current command Ir and a present drive current Ia detected by a current detector is amplified. Then, an armature winding of the servomotor is supplied with a drive current from a voltage amplifier 4, which is controlled by a PWM control section 3 operating in response to an output from the error amplifier 2. Numerals 5, 6 and 7 denote transfer functions based on an inductance La of the armature winding, a resistance Ra of the winding, and a back electromotive voltage constant Ka of the servomotor, respectively. Numeral 8 denotes a transfer function for conversion from an output torque of the servomotor to a speed. Symbols Kt and Jm designate a torque constant and a resultant moment of inertia of the servomotor and a load, respectively.
In order to increase the servomotor output without applying excess current to semiconductor elements of the PWM control section 3, the inventors hereof first devised an arrangement shown in FIG. 3, in which the armature winding of each phase of the motor is composed of two independent winding portions, and in which a PWM-controlled drive current is fed to each of the winding portions.
The two independent winding portions, which constitute each phase, are located relatively to the slots (not shown) of an armature so as to act equally on a rotor in phasic relation. Namely, the winding of each phase of a conventional servomotor is divided so that each phase includes two independent winding portions. The simplest way to attain this, for example, is to arrange to independent winding portions of the same phase in the same slot of the armature. Also when arranging two winding portions of the same phase in different slots, it is necessary only that the two winding portions be relatively located so as to act equally on the rotor.
In FIG. 3, elements 2 to 7 identical with the elements shown in FIG. 2 are arranged corresponding to a first winding portion, while similar elements 2' to 7' are arranged corresponding to a second winding portion. Symbols La, Ra, and Ka designate an inductance, resistance, and back electromotive voltage constant, respectively, at the first winding portion, the symbol Ia designates a current flowing through the first winding portion. Symbols Lb, Rb, and Kb designate an inductance, resistance, and back electromotive voltage constant at the second winding portion, and symbol Ib designates a current flowing through the second winding portion.
If error amplifiers 2 and 2', PWM control sections 3 and 3', voltage amplifiers 4 and 4', etc., are arranged in their corresponding winding portions, as shown in FIG. 3, the individual winding portions are controlled independently. Accordingly, there is no interference between the currents flowing through the winding portions, and this arrangement is equivalent to one which controls two motors. This arrangement is uneconomical, however, since it requires the error amplifiers, PWM control sections, and voltage amplifiers in pairs.
Thereupon, an arrangement of FIG. 4 has been contrived in which the current control section shown in FIG. 3 is modified so that the error amplifier and the PWM control section 3 are used in common for the first and second winding portions.
Analyzing the block diagram of FIG. 4, we obtain the following eqs. (1) to (3):
{(2Ir-Ia-Ib)·G(S)·Kv-Ia·La·S-V.multidot.Ka}·(1/Ra)=Ia, (1)
{(2Ir-Ia-Ib)·G(S)·Kv-Ib·Lb·S-V.multidot.Kb}·(1/Rb)=Ib, (2)
(Ia+Ib)·(Kt/Jm·S)=V, (3)
where G(S) is the transfer function of the error amplifier 2 and the PWM control section 3, and Kv is the transfer function of the voltage amplifiers 4 and 4'.
Rearranging eq. (1), we obtain
(2Ir-Ib)·G(S)·Kv-Ka·V={Ra+La·S+G(S).multidot.Kv}Ia. (4)
Rearranging eq. (2), we obtain
(2Ir-Ia)·G(S)·Kv-Kb·V={Rb+Lb·S+G(S).multidot.Kv}Ib. (5)
Substituting for eqs. (4) and (5) from eq. (3) and rearranging the resulting equations, we obtain the following eqs. (6) and (7). ##EQU1##
As seen from eq. (8), the currents Ia and Ib flowing through the two winding portions are not independent of each other and are different from each other, with their ratios to the speed command Ir varying according to variations of parameters.
Based on the above consideration, the present invention is arranged so that the currents Ia and Ib flowing through the two winding portions are independent of each other. More specifically, integrating elements 9 and 9' (FIG. 1), each of which has a transfer function which is Ki/S, are arranged individually in the stages preceding the error amplifier 2, whereby the deviations between the command current Ir for the first and second winding portions and the currents Ia and Ib flowing through the winding portions are integrated. Also, the currents Ia and Ib flowing through the first and second winding portions are amplified, respectively, by proportional elements 10 and 10' whose transfer function is Kp. Further, the deviations between the outputs of the integrating elements 9 and 9' and the proportional elements 10 and 10' are obtained, and the sum total of these deviations is then supplied to the PWM control section 3 via the error amplifier 2.
Referring now to the block diagram of FIG. 1, an analysis will be made.
First, if the total transfer function of the error amplifier 2, PWM control section 3, and voltage amplifier 4 and that of the error amplifier 2, PWM control section 3, and voltage amplifier 4' are Kv(1) and Kv(2), respectively, the following eqs. (9) to (11) hold for the currents Ia and Ib flowing through the first and second winding portions. ##EQU2##
Substituting for V of eq. (9) from the left side of eq. (11) and rearranging the resulting equation, we obtain the following eq. (12). ##EQU3##
Substituting for V of eq. (10) from the left side of eq. (11) and rearranging the resulting equation, moreover, we obtain the following eq. (13). ##EQU4##
Here if we have Kv(1), Kv(2)>>1 and Kv(1)=Kv(2)=Kv, eq. (12) can be approximated by the following eq. (14). ##EQU5##
Likewise, eq. (13) can be approximated by the following eq. (15). ##EQU6##
Since the respective left sides of eqs. (14) and (15) are identical, the following eq. (16) holds true. ##EQU7##
Since Ki·Kv/S is used in common for both sides of eq. (16), the following equation can be obtained by rearranging eq. (16). ##EQU8##
Further rearranging eq. (17), we obtain ##EQU9##
Here if Kp·Kv>>1, and if other parameters are negligible, we obtain
Ia≈Ib. (19)
If the proportional constant Kv of the transfer function of the elements 2 to 4 and 2 to 4' and the proportional constant Kp of the transfer function of the interposed proportional elements 10 and 10', as shown in FIG. 1, are made greater than the other parameters, at least the PWM control section 3 can be used in common for the two winding portions. Also, the currents Ia and Ib flowing through the individual winding portions have substantially independent and equal values. Accordingly, the rotor of the servomotor is rotated by substantially equal rotational forces which are attributable to the currents flowing through the two winding portions. Thus, the servomotor can produce a large output torque.
Although the DC servomotor has been described in connection with the above embodiment, an AC servomotor may be used with the same result.
|
In a method of controlling a servomotor, a high output can be fetched from the servomotor by a motor-current control unit of a simple construction, while protecting switching elements of the control unit against excess current. The deviation between a command current (Ir) for of a plurality of winding portions constituting an armature winding of each phase and a current (Ia, Ib) flowing through each winding portion is integrated by an integrating element (9, 9'). The current (Ia, Ib) is amplified by means of a proportional element (10, 10'), and the individual currents (Ia, Ib) are controlled for substantially independent and equal values by means of one PWM control section (3) operating in response to a control signal which is obtained by adding outputs from both the elements (9˜10').
| 7
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuing application, under 35 U.S.C. §120, of copending International Application PCT/EP 2004/008560, filed Jul. 30, 2004, which designated the United States; this application also claims the priority, under 35 U.S.C. §119, of German Patent Application 103 37 265.2, filed Aug. 13, 2003; the prior applications are herewith incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The present invention relates to a process for producing a body for exhaust gas treatment, which has a plurality of metallic layers forming passages through which a gas stream can flow. Bodies of that type are used in particular for purifying the exhaust gases from mobile internal combustion engines, such as spark ignition or diesel engines. Primary application areas in this context are passenger automobiles as well as trucks and motorcycles. It is also known for such bodies to be used in exhaust systems of portable hand-held appliances such as, for example, power saws, lawnmowers, etc. Bodies of that type have a number of different functions. For example, they are used as catalyst carrier bodies, as adsorbers, as filters, as flow mixers or as mufflers. The body is usually distinguished by a favorable ratio of surface area to volume, i.e. it has a relatively large surface area and therefore ensures intensive contact with the gas stream flowing through it.
[0003] With regard to catalyst carrier bodies, the surface or body is provided with a catalytically active coating, which preferably includes a washcoat. The washcoat has a particularly fissured surface, so that the ratio of surface area to volume can be improved even further. The washcoat is impregnated with various catalysts, for example platinum, rhodium or the like.
[0004] Adsorbers substantially have a similar basic structure to that selected for bodies used as catalyst carrier bodies. However, a different objective is pursued with regard to the coating, so that consequently different coatings are used. The purpose of the adsorbers is, for example, to retain nitrogen oxides until suitable reaction partners and/or temperatures are present to allow those constituents of the exhaust gas to be converted as fully as possible.
[0005] Flow mixers are distinguished by the fact that their bodies have a multiplicity of passages which are flow-connected to one another. At the same time, guide surfaces, which allow the partial gas streams to be diverted, are provided in the interior of the body or of the passages. In that way, the gas stream is made more uniform in terms of its pollutant concentration, its flow properties, its temperature, etc.
[0006] A wide range of different structural forms are known for the above-mentioned bodies as catalyst carrier bodies, adsorbers, mufflers and flow mixers. Those forms include, for example, honeycomb bodies having at least partially structured sheet-metal foils. As compared to known bodies made from ceramic material, the metallic honeycomb bodies have a considerably greater flexibility in terms of their intended use and also allow a greater degree of design freedom. It should also be borne in mind that particularly effective conversion processes with regard to the pollutant concentration are ensured due to good heat conduction and extremely low area-specific heat capacity.
[0007] A distinction is drawn in particular between two typical structures of metallic honeycomb bodies. An early structure, of which German Published, Non-Prosecuted Patent Application DE 29 02 779 A1, corresponding to U.S. Pat. No. 4,273,681 shows typical examples, is the helical structure, in which substantially one smooth and one corrugated sheet-metal layer are placed on top of one another and wound helically. In another structure, the honeycomb body is constructed from a multiplicity of alternately disposed smooth and corrugated or differently corrugated sheet-metal layers, the sheet-metal layers initially forming one or more stacks which are then intertwined. In that case, the ends of all of the sheet-metal layers come to lay on the outside and can be connected to a housing or tubular casing, producing numerous connections, which increase the durability of the honeycomb body. Typical examples of those structures are described in European Patent EP 0 245 737 B1, corresponding to U.S. Pat. Nos. 4,946,822; 4,923,109; 4,832,998 and 4,803,189, or International Publication No. WO 90/03220, corresponding to U.S. Pat. Nos. 5,139,844; 5,135,794 and 5,105,539. It has also long been known to equip the sheet-metal layers with additional structures in order to influence the flow and/or bring about cross-mixing between the individual flow passages. Typical examples of those configurations include International Publication No. WO 91/01178, corresponding to U.S. Pat. No. 5,403,559, International Publication No. WO 91/01807, corresponding to U.S. Pat. Nos. 5,130,208 and 5,045,403, and International Publication No. WO 90/08249, corresponding to U.S. Pat. No. 5,157,010. Finally, there are also conical honeycomb bodies, optionally also with further additional structures for influencing the flow. A honeycomb body of that type is described, for example, in International Publication No. WO 97/49905, corresponding to U.S. Pat. No. 6,190,784. Furthermore, it is also known to leave free a cutout in a honeycomb body for a sensor, in particular for accommodating a lambda sensor. One such example is described in German Utility Model DE 88 16 154 U1.
[0008] Of course, the structures described above are also suitable for forming filter bodies. Basically, two different principles are known for those or other filter bodies. One principle relates to what is known as the “closed particulate filter”, in which the passages formed by the body are closed on alternate sides, therefore forcing the gas stream to pass through passage walls including filter material. That leads to the accumulation of particulates or solids contained in the gas stream, which are burnt and/or oxidized continuously or at predeterminable intervals. An alternative known structure is that of the “open particulate filter”, which is not closed on alternate sides, but rather has flow diversion points in the interior of the passages, which cause the partial gas streams to be swirled up in such a way that at least 80% of the partial gas streams pass through the filter wall, preferably a number of times. The major advantage of the “open particulate filter” is that blockage of the filter material caused by an excessive accumulation of particulates is avoided. A particulate filter is described as “open” if particulates can fundamentally flow completely through it, specifically including particulates which are considerably larger than the particulates that are actually to be filtered out. As a result, a filter of that type cannot become blocked even in the event of an agglomeration of particulates during operation. A suitable method for measuring the openness of a particulate filter is, for example, to test the diameter up to which spherical particles can still trickle through a filter of that type. In present applications, a filter is open in particular if spheres with a diameter of greater than or equal to 0.1 mm can still trickle through it, preferably spheres with a diameter of over 0.2 mm. One such example is given in German Utility Model DE 201 17 873 U1, to which reference is made in full for the purposes of explanation.
[0009] In addition to those bodies with wound or intertwined layers, it is also known to use what are known as plate filters, which include a plurality of in particular sheet-like or substantially planar filter plates that are disposed spaced apart from one another. Plate filters of that type are usually also constructed in accordance with the principle of passages that are closed on alternate sides, but it is in principle also possible to realize an “open particulate filter”.
[0010] Whereas wound structures and plate structures of that type have the gas stream flowing through them substantially axially, bodies or filter bodies which the gas stream flows through radially are also known. Such bodies usually have an inner flow passage and an outer flow passage which is annular in form and is generally disposed coaxially with respect to the inner flow passage. The inner flow passage is generally delimited by an inner tube, which is provided with openings through which the gas stream to be purified is passed. Layers of a filter material are disposed around the inner tube. Substantially two different concepts are known in that respect. The first concept can be described on the basis of a “star shape”, which is realized when the filter plates are viewed in the direction of the inner tube or a cross section perpendicular to the inner tube. That means in other words that the filter plates form folds which extend substantially parallel to the axial extent of the inner tube. Another known concept involves the formation of folds in the circumferential direction, in which case a plurality of the folds are positioned on the inner tube, spaced apart from one another in the axial direction. According to the routing of the flow, the gas stream that is to be purified is fed to the filter material from the inside (or from the outside), penetrates through the filter material and is discharged again on the opposite side.
[0011] The bodies described above generally include a plurality or multiplicity of different components made from in some cases different materials. Considering the high thermal and dynamic stresses in the exhaust system of mobile internal combustion engines, those individual components have to be permanently connected to one another. Numerous different connection techniques are known for that purpose, for example brazing and/or welding. With regard to those connection techniques, it should be noted that they have to be suitable for at least medium-sized series production. In that respect, cost aspects also play an important role, such as cycle rates, connection quality, process reliability, etc. Known processes used to form connections by technical joining (in particular in the structure including the filter surfaces and/or the layers) require an additional material such as, for example, brazing material or weld filler. It is particularly difficult in that case for the filler to be applied at precisely the location at which a join is subsequently to be produced. Moreover, it should be noted that increasingly thin-walled materials need to be used, since such materials very quickly adapt to the temperature of the exhaust gas and accordingly have highly dynamic reaction properties. In order to ensure the long-term functionality of those bodies, however, a spatially tightly delimited introduction of heat is required to form the connections by technical joining. Heretofore, that has not been achievable to a satisfactory extent, and indeed brazing generally requires heating of the entire body in a high-temperature vacuum furnace, and welding has heretofore usually also been carried out through the outer housing, and consequently in that case too considerable temperature gradients have been realized across a large part of the body.
SUMMARY OF THE INVENTION
[0012] It is accordingly an object of the invention to provide a roller seam welded body for exhaust gas treatment and a process for producing the body, which overcome the hereinafore-mentioned disadvantages and technical problems of the heretofore-known devices and processes of this general type, in which the process for producing metallic bodies of this type for exhaust gas purification is inexpensive, simple, effective and reliable and is suitable for automation as far as possible, producing connections by joining which are distinguished by a particularly long service life, and in which the corresponding body for exhaust gas treatment can be configured variably and is versatile in use.
[0013] With the foregoing and other objects in view there is provided, in accordance with the invention, a process for producing a body for exhaust gas treatment. The process comprises bringing a plurality of metallic layers into contact with one another in a connection region. A connection of the layers is produced by a continuous resistance welding process, causing the layers to form passages or channels through which a gas stream can at least partially flow. In other words, this means in particular that the connection between layers disposed adjacent one another is effected by the continuous resistant welding process.
[0014] In this context, it should be noted that the term “continuous” may mean that the welding takes place along one welding track, in which case the weld seam that is generated is made uninterrupted. However, this need not necessarily be the case. For example, it is also possible for a plurality of weld seams which are spaced apart to be provided along the welding track, in which case the proportion in which the weld seams are present along the welding track is advantageously significantly greater than the proportion formed by the interruptions. It is particularly preferable for the proportion formed by the weld seam, based on the welding track, to amount to at least 80%, in particular even more than 90%.
[0015] With regard to the “passages”, it should also be noted that these passages need not necessarily have a tube-like structure. Rather, this term is to be understood as meaning a limited flow path which has a spatial boundary. In this case, the boundary is generally configured in such a way that it encloses the flow path over at least 60% (in particular 80%) of the circumference, with the length of the flow path advantageously being greater than the circumference.
[0016] In view of the fact that the above-mentioned body may also be constructed as a filter, it will be clear that the passages do not necessarily need to have a gastight passage wall, i.e. it is also eminently possible for the layers to be configured so as to be at least partially gas-permeable. In particular in this case, the gas stream does not flow completely through the passage, in which case although the passage does have a suitable cross section, the gas stream nevertheless uses a different route. Therefore, it is considered sufficient for the passage to offer the option of at least partially allowing a gas stream to flow through it, in particular with open end sides.
[0017] In accordance with another mode of the invention, the continuous resistance welding process includes roller seam welding and/or projection seam welding.
[0018] Roller seam welding and projection seam welding processes belong to pressure-joining welding processes, in particular resistance pressure welding or conductive pressure welding. In the resistance pressure welding process, the heating at the welding location takes place as a result of Joule resistance heating when current flows and through the use of an electrical conductor. The current is supplied through electrodes with a convex or planar working surface. Two roller-like (driven) electrodes are used for the roller seam welding. The metal sheets to be welded are disposed predominantly overlapping in this case. In practice, roller seam welding is a continuous spot welding, but using roller-like electrodes. Unlike the case when using resistance spot welding, the electrodes remain in contact after the first weld spot has been produced and are then rolled continuously onward. Further current flows at the locations where a weld spot is to be formed. Spot seams or sealed seams with overlapping weld nuggets or weld spots are produced, depending on the feed rate of the electrodes and the frequency of the welding current. Permanent direct current likewise produces a sealed seam.
[0019] The use of this production process to connect the layers has proven particularly advantageous in particular with a view toward series production of these bodies. The process in which the two layers adjacent or lying on top of one another are passed through the rotating electrodes is surprisingly well able to withstand the high thermal and dynamic stresses, for example in the exhaust system of automobiles. It has also been established that even in the case of very thin metal foils which are connected to one another in this way, sealed weld seams can be produced in very short working cycles. As a result, it is possible to achieve in particular a cost benefit, which was unexpected in view of the additional material that is required for the overlap between the two layers. Roller seam welding is suitable in particular for connection regions which have a certain length, i.e. extend over a predetermined portion. This should generally amount to at least 5 cm, in particular at least 15 cm, and the work can be carried out at particularly low cost beyond a length of 25 cm. The roller seam welding makes do without filler. Furthermore, in many cases it is also possible to do without a step of cleaning the layers, since the introduction of the electrode force ensures that contact between the electrodes and/or the layers which is sufficient for the flow of current and the formation of the weld spot is already ensured to a considerable extent. Moreover, only an insignificant change in the microstructure of the layer adjacent the weld nugget can be established. Accordingly, the use of this manufacturing process offers numerous advantages and at the same time overcomes all of the technical problems listed in the introduction hereto at once. Moreover, the process can also be applied to each of the types of bodies mentioned in the introduction hereto.
[0020] In accordance with a further mode of the invention, a weld seam in which there are at least overlapping weld spots is formed, at least in part. This applies in particular to the case in which the ends or edge regions of the layers are to be fixed to one another. These edge regions or edges, for example, close up flow paths, so that the exhaust gas to be purified is forced to pass through a filter material. In order to ensure the principle of a “closed particulate filter”, a sealed seam should be at least partially present. This is to be understood as meaning that the welding current pulses take place in succession at such short time intervals that the respectively adjacent weld spots or weld nuggets merge into one another, i.e. there are no unconnected locations on the layers between adjacent weld spots. As has already been stated above, a sealed seam of this type is achieved by virtue of the frequency of the current pulses being selected to be relatively short, the feed rate being relatively low or by the presence of direct current, i.e. current flows continuously between the electrodes during the feeding.
[0021] In accordance with an added mode of the invention, a feed rate during roller seam welding in a range of from 0.5 cm/s to 30 m/s, in particular in a range of from 0.5 m/min to 30 m/min, is used.
[0022] This feed rate is used in particular when connecting metallic foil material which has a thickness of from 0.03 to 0.1 mm. In this case, the material to be connected preferably includes the following constituents: from 0.1 to 7.5% by weight of aluminum, and from 17 to 25% by weight of chromium. Another preferred material includes from 12 to 32% by weight of nickel.
[0023] In accordance with an additional mode of the invention, during the welding operation, the electrodes exert a force of from 10 N to 20 kN, in particular from 200 N to 6 kN, on the layers. This ensures that, for example, any rolling oil or similar impurities adhering to the layers are forced out of the welding location. The result is both intensive contact between the components which are to be connected to one another and between the components and the electrodes. At the same time, this ensures that when the material is heated, the heated or molten materials are intimately mixed, so as to achieve a permanent connection.
[0024] In accordance with yet another mode of the invention, the layers, at least in an edge region, are laid on top of one another, are welded at least over a portion in this edge region and are then deformed, so as to form the passages. In other words, this also means that the weld seam at least partially delimits the passage through which the exhaust gas can flow. With regard to the preferred magnitudes of the length of the portion, reference should be made to the statements given above. In principle, however, it should also be noted that it is customary for the complete edge regions to be connected to one another, i.e. accordingly the portion corresponds to the longest extent of the edge region.
[0025] In accordance with yet a further mode of the invention, the layers are formed with at least one metallic foil which is made from a high-temperature-resistant and corrosion-resistant material and is preferably at least partially structured and/or allows a fluid to flow through it at least in regions. With regard to the material of the metallic foil, reference should be made at this point to the composition listed above. Furthermore, however, a person skilled in the art will be aware of a large number of further materials which are suitable for use in mobile exhaust gas systems. In this case, reference should be made to the large number of different materials which are given in the known prior art. When making a choice, it should also be borne in mind that this material must in general terms be suitable for resistance welding, i.e. in particular must also conduct current.
[0026] The preferred configuration of the metallic foil with structures or apertures, pores, holes or the like in this case is predominantly located outside the edge regions which are used for connection by roller seam welding. Examples of suitable structures include corrugations, guide vanes, stamped formations or other structures. They are usually used to guide or swirl up the exhaust gas flowing along the metallic foil, in order to ensure intimate contact with the surface of the body in this way. Furthermore, these structures can also be used to make sure that the layers are at a predeterminable distance from one another. In this case, the structure represents a type of spacer. The effect of the foil being configured such that medium can flow through it at least in regions is that gas exchange can take place through the metallic foil. This usually depends on a forced flow, for example imposed by diverting vanes, sealing materials, etc. or by pressure differences in adjacent passages, which are in each case partially delimited by the metallic foil.
[0027] In accordance with yet an added mode of the invention, the layers are formed with a filter fabric which may be a nonwoven or fleece filter fabric or a supporting structure including a filter material. The filter fabric includes in particular knitted fabrics, woven fabrics or similar configurations of chips, fibers or other particles which are bonded to one another. They are held together, for example, by sintered connections, brazed connections, welding connections or combinations thereof. The filter fabrics may be composed of metallic or ceramic material. Furthermore, it is also possible to provide a supporting structure on or in which a filter material is provided. Suitable supporting structures are once again woven fabrics, knitted fabrics, expanded metals or the like, in particular coarse-mesh formations, in the cavities of which the filter material is provided. It is in this context particularly advantageous for the supporting structure to be metallic in form, in which case both ceramic and metallic materials can be used as filter material. The filter material is connected to the supporting structure through the use of sintered connections, diffusion bonds, if appropriate also using filler materials, or combinations of these connection techniques. The connection according to the invention between the layers using a continuous resistance weld seam can also be carried out so as to incorporate this supporting structure, in particular by the layers being welded to one another exclusively through the supporting structures.
[0028] The filter material itself forms an extremely high surface area with a multiplicity of pores, openings, flow passages and cavities. As the gas stream flows through the filter material, the undesired particulates stick to the surface and are converted into gaseous constituents when heat and/or reaction partners contained in the exhaust gas are supplied.
[0029] In accordance with yet an additional mode of the invention, the layers have a multi-part structure, and the layers are provided with a metallic foil in the connecting region, so that the metallic foils of layers disposed adjacent one another are connected through the use of roller seam welding. This means in particular that the foils are provided only in the edge region of the layers. In this case, for a filter material or a supporting structure, they preferably form a construction which is suitable for roller seam welding. It is in this way possible to adapt components of the body which cannot normally be connected by such a process, to the requirements of roller seam welding.
[0030] In accordance with again another mode of the invention, the layer includes a filter fabric. The filter fabric, in the edge region which subsequently forms the connecting region, is surrounded, and preferably also flanged, by in each case one metallic foil. Finally, a plurality of layers produced in this way are welded to one another. In this case, the layers are configured in particular as a filter composite or filter layer as proposed by German Published, Non-Prosecuted Patent Application 101 53 284 A1, corresponding to U.S. patent application Ser. No. 10/823,996, filed Apr. 13, 2004 and U.S. Patent Application Publication No. US2004/0187456 A1 and German Published, Non-Prosecuted Patent Application 101 53 283 A1 corresponding U.S. patent application Ser. No. 10/828,813, filed Apr. 20, 2004 and to U.S. Patent Application Publication No. US2004/0194440 A1. With regard to the construction of filter layers or filter composites of this type, reference is made to the above-referenced publications in full, and consequently the descriptions given therein are used to explain the present situation and they are incorporated herein fully by reference.
[0031] In accordance with again a further mode of the invention, with regard to the above process variant for production of the body, it is particularly advantageous if the flanging and the roller seam welding are carried out simultaneously. By way of example, structured rolled electrodes are used for this purpose, which on one hand allows the metallic foil to be hooked to the filter fabric and at the same time, due to the flow of current, allows a material or cohesive connection by technical joining. In this case, the welding process can also be carried out in such a way that flanged connections and welded connections alternate in the welding direction. In the present context, the term flanging is to be understood in particular as meaning manual or mechanical bending-over of the edges of sheet-metal parts to remove the sharpness of the edge and/or to reinforce the workpiece.
[0032] In accordance with again an added mode of the invention, the layers are welded together in such a way that they are connected in the edge regions on alternate sides to an adjacent layer in each case, so as to form a fold in each case. The procedure described herein for the production of a body is suitable in particular for producing filter bodies. In this case, the layers, which preferably also include filter fabric or a filter material, are connected to one another at their edge regions, in order to realize the principle of the “closed particulate filter”. After two adjacent layers have been welded together, the layers can be folded open so that they form an angle relative to one another in an edge region. The intermediate space which has formed between the layers is referred to as a fold. This represents a passage or flow passage, in particular in the case of radial-flow particulate filters.
[0033] In accordance with again an additional mode of the invention, the layers are constructed with supports, which are preferably disposed in a passage and/or in a fold. The term support is to be understood in particular as meaning spacers, reinforcing structures, spacer pieces or similar devices which ensure that the predetermined position of the layers with respect to one another is retained even during subsequent use in the exhaust system of mobile internal combustion engines.
[0034] In accordance with still another mode of the invention, the supports are connected to the layer by the roller seam welding manufacturing process, preferably at the same time as a connection of the layers to one another is being executed. By way of example, the supports may be formed as a structure of the metallic foil, which therefore bear against regions of the adjacent layer and ensure the aperture angle or the spacing of the layers that are spaced apart from one another. The connection of the layers according to the invention by using a continuous resistance weld seam can also be carried out by incorporating these supports. Under certain circumstances, the layers are even welded to one another exclusively through the supports.
[0035] In accordance with still a further mode of the invention, the welded layers are connected to at least one housing, preferably by welding or brazing. In the case of axial-flow bodies, direct connection of the layers to the housing located on the outer side is preferred. Known brazing or welding techniques can be used for this purpose. If the body realizes a radial-flow structure, a connection to an outer housing is generally realized only indirectly, i.e. through additional elements. In structures of this type, a housing which is directly connected to the layers and is disposed on the outer periphery of the body is usually avoided, since this annular space is usually required for the incoming and/or outgoing flow of the gas stream. The outer housing is then fixed through any additional components, such as spacers, cover plates, collars or the like.
[0036] In accordance with still an added mode of the invention, in particular in the context of the radial-flow concept, it is proposed that the housing be an inner tube with a central axis, to the outer lateral surface of which inner tube the layers are secured. For this purpose, the inner tube is provided with holes or flow passages which allow the exhaust gas to flow through the inner tube without generating a high flow resistance. This makes is easy to connect the cavity disposed in the interior of the tubular casing toward the folds, which have been formed by the layers disposed on the outside. The connection of the layers toward the inner tube can be realized by mechanical connections or by thermal joining. In particular with a view toward securing by using mechanical securing measures, it is to be assumed that the inner tube preferably has a multi-part construction. The inner tube is usually equipped with a closed end, in order to divert the gas stream toward the filter surfaces.
[0037] In accordance with still an additional mode of the invention, the layers are to be disposed in such a way that the connecting regions or the folds or passages formed by the layers run in the direction of the central axis. With regard to the words “in the direction of the central axis”, it should be pointed out for clarification that this does not require any particular accuracy, but rather relatively large tolerances are possible under certain circumstances. In this case, therefore, there are a plurality of folds which are disposed adjacent one another in the circumferential direction and preferably extend over a large portion of the inner tube. The connection regions between the individual layers and between the layers and the inner tube in this case run in the axial direction parallel to the central axis.
[0038] In accordance with a concomitant mode of the invention, in an alternative configuration, the layers are disposed in such a way that the connecting regions and/or the folds or passages formed by the layers run perpendicular to the central axis. With regard to the words “perpendicular to the central axis”, it should be pointed out for clarification that this does not require any particular accuracy, but rather relatively large tolerances are possible under certain circumstances. The feature means in particular that the fold is constructed as an annular passage extending in the circumferential direction. A plurality of these annular folds are disposed spaced apart from one another (as seen in the direction of the central axis). The connection regions between the individual layers and between the layers and the inner tube run in the circumferential direction.
[0039] With the objects of the invention in view, there is also provided a body for treating exhaust gases from mobile internal combustion engines, in particular produced by one of the processes described above. The body comprises a plurality of metallic layers in contact with one another in a connecting region. At least some of the layers have a roller seam welded joint therebetween. The layers form passages through which a fluid can flow. A body of this type is suitable for use as a catalyst carrier body, an adsorber, a filter body or a flow mixer. It is also possible for the body to be configured in such a way as to form zones with different functions, for example by having different coatings in different zones. It is also possible for the layers to be constructed differently with regard to the gas permeability and/or the structuring in these zones, so that different exhaust-gas purification steps are passed through sequentially in the direction of flow.
[0040] The invention and the technical background will now be explained in more detail with reference to the figures. The figures show particularly preferred exemplary embodiments, although the invention is not restricted to these embodiments. Rather, the production process of roller seam welding can be used for numerous different structures of bodies for exhaust-gas purification, with in particular the connection between the layers forming the flow passages being produced by using these manufacturing processes.
[0041] Other features and further advantageous configurations which are considered as characteristic for the invention and are set forth in the appended claims, can be combined with one another in any desired way.
[0042] Although the invention is illustrated and described herein as embodied in a roller seam welded body for exhaust gas treatment and a process for producing the body, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0043] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 is a diagrammatic and schematic view illustrating a sequence of an implementation of a process for producing a body for exhaust-gas treatment;
[0045] FIG. 2 is a fragmentary, sectional view of a variant embodiment of a body for exhaust-gas treatment;
[0046] FIG. 3 is a further fragmentary, sectional view of an exemplary embodiment of the body;
[0047] FIG. 4 is a partly broken-away, perspective view of an exemplary embodiment of a body with longitudinal folds;
[0048] FIG. 5 is a perspective view of a further configuration of a body with coaxial folds;
[0049] FIG. 5A is an enlarged view of a portion VA of FIG. 5 ; and
[0050] FIG. 6 is a further sectional view of a body with folds in the circumferential direction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] Referring now to the figures of the drawings in detail and first, particularly, to FIG. 1 thereof, there is seen a diagrammatic and schematic illustration of a sequence involved in the production process of roller seam welding, which is used in this case to produce a body for exhaust gas treatment. FIG. 1 illustrates two metallic foils 12 which are brought into contact with one another. The foils 12 , while resting on top of one another, are passed at a feed rate 7 through two rotating electrodes 8 . In the process, the two electrodes 8 press on the surface of the foils 12 with a force 9 . The two electrodes 8 are connected to one another through a current source 26 , with current flowing between the electrodes 8 and therefore also locally through the foils 12 with a predetermined frequency. The current leads to heating of the foils 12 , so that they become at least partially molten. The foils 12 in this case have a thickness 22 which is, for example, in the range from 0.02 to 0.1 mm. As a result of Joule resistance heating, a multiplicity of weld spots 6 , which preferably merge into one another so as to form a sealed seam 5 , are formed in a contact region between the two foils 12 .
[0052] FIG. 2 diagrammatically illustrates a fragmentary view of a connecting region 3 , which is formed between two adjacent layers 2 . The layers 2 are formed with a filter fabric 13 which may be a nonwoven or fleece filter fabric, and which is provided near an edge region 10 with a foil 12 that has been flanged. The foils 12 project beyond the filter fabric 13 and form the edge region 10 , which is finally pushed through the rotating electrodes 8 , so that a roller seam welded connection is produced between the two foils 12 . Whereas the filter fabric 13 has a gas-permeable structure, as is indicated by dashed arrows, the foil 12 itself in this case is impermeable to gases. The foil 12 in this case serves simultaneously to fix a support 17 , ensuring a defined position of the layers 2 with respect to one another, so that folds 16 are always of a desired shape.
[0053] FIG. 3 shows a body 1 with a plate construction, having the layers 2 disposed substantially parallel to one another. The plate-like layers 2 in the illustrated embodiment include a supporting structure 14 in which a filter material 15 has been integrated. A connecting region 3 is formed in each case in the edge regions on alternate sides of the layers 2 . The connecting regions 3 again include roller seam welded connections. The connection regions 3 bear directly against a housing 18 and are connected to it by technical joining. A support 17 disposed between the layers 2 is formed, for example, of structured metal foils or structures of the layers 2 themselves, which prevent the layers 2 from bearing directly flat against one another. It can also be seen that through the use of the illustrated body 1 , the principle of a “closed particulate filter” has been implemented, in which adjacent passages 4 are provided with a closure 24 , so that the gas stream has to pass through the layers 2 in a direction of flow 23 .
[0054] FIG. 4 shows another variant embodiment of a body 1 for exhaust gas treatment, which is used in particular as a filter. This figure shows a radial-flow concept, in which the gas stream that is to be purified first of all enters an inner region in the direction of a central axis 21 through a cover plate 25 . A rear-side cover plate 25 closes off the inner flow passage and therefore forces the exhaust gas to pass through the layers 2 which form the folds 16 . The illustrated body 1 again has a support 17 , which ensures the position of the layers 2 with respect to one another even in the event of pressure fluctuations occurring in the gas flow. In the illustrated exemplary embodiment, the layers 2 are disposed in such a way that the connection regions 3 and the folds 16 formed by the layers 2 run in the direction of the central axis 21 . The connection regions 3 are in each case formed over a portion 11 .
[0055] FIG. 5 shows a further variant embodiment of a body 1 , in particular a filter body. In this case, the folds 16 run substantially coaxially with respect to the central axis 21 . The layers 2 are mounted on end sides of a cover plate 25 which at least partially allows the exhaust gas to flow through it. The connection regions 3 of the layers 2 which are disposed adjacent one another are disposed substantially coaxially to the central axis 21 , once again realizing the principle of a “closed particulate filter”. The layers 2 in this case include a supporting structure 14 in which the filter material 15 is additionally provided, as is seen in FIG. 5A .
[0056] FIG. 6 shows a body 1 in which the layers 2 are disposed in such a way that the connection regions 3 and the folds 16 formed by the layers 2 run substantially perpendicular to the central axis 21 . The layers 2 are secured to an outer lateral surface 20 of an inner tube 19 . The inner tube 19 has openings through which the gas stream can enter radially inwardly, as is shown by arrows indicating a direction of flow 23 . Additional supports 17 are disposed between the layers 2 outside the folds 16 which are illustrated by dots. In this case, these supports 17 are connected on one side to the inner tube 19 and on the other side to the layers 2 . Moreover, the entire configuration is enclosed by a housing 18 spaced apart from the layers 2 . The connection regions 3 , which have been generated by using the roller seam welding process, are formed on the outer periphery and the inner periphery of the layers 2 . They produce a connection in each case between the layers 2 which are disposed adjacent one another. The preferred manner of producing the technical joining connection is by brazing. However, a sintering process or even welding may be used as well.
|
A process for producing a body for exhaust gas treatment having a plurality of metallic layers, includes bringing the layers into contact with each other in a connection region. A connection is made by a roller seam welding process in such a way that the layers form passages through which a gas stream can flow. A corresponding body for exhaust gas treatment can especially be used as a filter or catalyst carrier body in the automobile industry.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Divisional of U.S. application Ser. No. 12/704,712, filed Feb. 12, 2010 (now U.S. Pat. No. 8,161,626), which application is based upon and claims the benefit of priority from prior Chinese Patent Application No. 200910006550.3, filed Feb. 17, 2009, the entire contents of both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a load beam constituting a part of a suspension of a disk drive, suspension with the load beam, and a manufacturing method for the suspension.
2. Description of the Related Art
Conventionally, a magnetic disk device, such as a hard disk drive (HDD) or magneto-optical drive, comprises a magnetic head. The head flies above a magnetic disk rotating at high speed with a fine space therebetween. Data on the disk is read or written by the head.
An example of a suspension is disclosed in, for example, Jpn. Pat. Appln. KOKAI Publication No. 10-162532 or 9-91909.
In recent years, the head size and flying height (above the disk surface) have been reduced with the development of disk devices with higher recording densities. In order to accurately read and write magnetic disk data, it is important to suppress vibration of a head portion, thereby precisely positioning the head.
As shown in FIG. 10 , a disk drive with a suspension generally comprises a magnetic head 1 , a suspension 2 supporting the head 1 , a block 3 to which the suspension 2 is fixed, etc. The suspension 2 generally comprises a load beam 10 formed of a precise thin-plate spring, a baseplate 11 , a flexure 12 formed of a plate spring thinner than the load beam 10 , etc. The magnetic head 1 is located on a gimbal portion formed at the distal end of the flexure 12 .
A head portion comprising the magnetic head 1 receives vibration from a device for driving the head portion, a motor (not shown) for rotating a disk 13 , etc. Thus, the suspension 2 formed of a plate spring, may be deformed so that the magnetic head 1 is dislocated. This results in a read or write error. Thereupon, the damper 14 , such as the one shown in FIG. 11 , may be used to reduce or remove vibration of the suspension 2 . The damper 14 is also referred to as a vibration damping member. The damper 14 comprises a metallic restrainer 15 and viscoelastic member 16 of a viscoelastic material, which are laminated thickness-wise. The damper 14 is affixed to the load beam 10 of the suspension 2 .
According to the suspension 2 with the damper 14 , the viscoelastic member 16 sandwiched between the vibrating suspension 2 and restrainer 15 is deformed as the suspension 2 vibrates. Molecular friction of the viscoelastic member 16 produces internal resistance, thereby converting vibrational energy into thermal energy. Thus, the vibrational energy directly received by the suspension 2 is greatly reduced, so that a vibration dumping effect can be obtained. FIG. 12A shows vibration characteristics observed before the damper 14 is affixed to the load beam 10 . FIG. 12B shows vibration characteristics observed after the damper 14 is affixed to the load beam 10 . As shown in FIG. 12B , a damping effect obtained from the damper 14 affixed to the load beam 10 lowers the peak value of a gain in each vibration mode and provides the vibration damping effect.
As shown in FIGS. 3A and 4A , transversely opposite side edge portions 10 a of the load beam 10 are bent in order to enhance the rigidity of the load beam 10 . In this specification, the bending of the bent side edge portions 10 a is referred to as “rib bending”. In order to maintain an appropriate flying height of the magnetic head 1 above the surface of the disk, moreover, a proximal portion 10 b of the load beam 10 is slightly bent, as viewed laterally relative to the load beam 10 , as shown in FIG. 4A . The proximal portion 10 b is located near the block 3 and also functions as a hinge portion for warping the load beam 10 thickness-wise. In this specification, the bending of the proximal portion 10 b is referred to as “load bending”. If the damper 14 is affixed to the load beam 10 before this load bending, it may undesirably interfere with a bending tool during the rib or load bending. In actual manufacturing processes, therefore, the damper 14 is affixed to the load beam 10 after the load beam 10 is bent, as shown in FIGS. 9A to 9D .
In order to cause the viscoelastic member 16 to adhere closely to the load beam 10 in affixing the damper 14 to the load beam 10 , however, the damper needs to be pressed against the load beam 10 with a predetermined load. In some cases, the load beam 10 may be deformed by a pressing force on the damper 14 that is affixed to the bent load beam. If the load beam 10 is deformed, static properties, such as spring load, and dynamic properties, such as resonance, may vary. Variations of these properties impair the commodity value and working properties of the suspension.
If the damper is dislocated with respect to the load beam when it is affixed to the load beam, moreover, it may adversely affect the properties of the suspension. Conventionally, it is difficult to accurately position the damper, since the damper is affixed to the load beam formed of a flat thin-plate spring that carries no indication of a damper mounting position.
According to the conventional manufacturing processes in which the damper is affixed to the bent load beam, the opposite side edge portions 10 a that are bent like ribs hinder the operation for affixing the damper 14 . Since one damper 14 is affixed to each load beam 10 , furthermore, the affixing operation is time-consuming, that is, work performance is poor.
Conventionally, the viscoelastic member is sometimes caused to project much from the periphery of the damper by the pressing force on the damper that is affixed to the load beam. In such a case, it is troublesome and difficult to thoroughly remove a projecting part of the viscoelastic member. In some cases, the periphery of the viscoelastic member is covered by a resin coating material after the damper is affixed to the load beam. In these cases, the usage of the coating material is too much to reduce the weight of the load beam.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to provide a load beam having stable properties such that it is less deformed by a damper affixed thereto, a suspension, and a manufacturing method for the suspension.
A load beam of the invention is formed of a thin-plate spring and constitutes a part of a suspension which supports a magnetic head, and a recess is formed in a part of the load beam so as to accommodate the damper. The recess may be formed by either partial etching or pressing. Alternatively, the recess may be formed by boring a through-hole greater than the damper in one of two plates which are superposed to each other to form the load beam. The depth of the recess should preferably be greater than the thickness of the damper.
A suspension according to the invention is the one which supports the magnetic head and comprises the above-described load beam, the damper being affixed to a bottom surface of the recess of the load beam.
In a method for manufacturing the suspension, the load beam is bent after the damper is affixed to the bottom surface of the recess of the load beam.
Further, the suspension manufacturing method described above may comprise fabricating a continuous load beam blank comprising a plurality of the load beams from a thin-plate spring material, forming the recess for accommodating the damper in each of the load beams of the load beam blank, affixing the damper to the bottom surface of the recess of each of the load beams, and bending each of the load beams after the damper is affixed thereto and separating the load beam from a scrap portion of the load beam blank.
According to the present invention, as described above, the recess greater than the damper is formed in the load beam, corresponding to a position where the damper is affixed. The damper is contained in the recess. Thus, the damper can be prevented from interfering with a bending tool even if the load beam is bent with the damper affixed thereto. Therefore, the damper can be affixed to the unbent flat load beam. Accordingly, the load beam cannot be easily deformed, so that the static and dynamic properties of the suspension can be prevented from varying. The recess should only be sufficiently large to accommodate the damper. In consideration of the work performance for the affixture of the damper to the load beam and the projection of the viscoelastic member, the recess should preferably be slightly larger than the damper.
The recess is formed by, for example, partial etching. Since the recess formed by partial etching can be used as a guide for the affixture of the damper, the damper can be easily positioned with respect to the load beam.
Since the damper can be affixed to the unbent flat load beam, moreover, the operation for affixing the damper can be easily automated. Since the damper can be affixed to each load beam of the continuous load beam blank that comprises a plurality of unbent load beams, in particular, the damper affixing operation can be automated with higher speed and accuracy and less deformation. In this case, the efficiency of the damper affixing operation can be further improved.
As the damper is pressed against and affixed to the load beam, a part of its viscoelastic member may sometimes be caused to project from the periphery of the restrainer. According to the present invention, however, the damper is contained in the recess, so that the projecting part of the viscoelastic member can be confined within a groove defined between the inner side surface of the recess and the side surface of the damper. Thus, the viscoelastic member can be prevented from projecting outside the load beam. Since the groove exists inside the recess, moreover, a coating material (e.g., resin) can be easily filled around the damper, and the usage of the coating material can be reduced.
Thus, according to the present invention, the damper is contained in the recess formed in the load beam. The weight of the load beam itself can be reduced by a margin corresponding to the recess. Consequently, an increase in weight attributable to the presence of the damper can be compensated with a reduction of the weight of the load beam, so that the suspension can be made lighter in weight.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1A is a plan view of a conventional suspension;
FIG. 1B is a plan view of a suspension according to one embodiment of the invention;
FIG. 2 is a partial sectional view typically showing a load beam and damper of the suspension shown in FIG. 1B ;
FIG. 3A is a sectional view of the suspension taken along line 3 A- 3 A of FIG. 1A ;
FIG. 3B is a sectional view of the suspension taken along line 3 B- 3 B of FIG. 1B ;
FIG. 4A is a sectional view of the suspension taken along line 4 A- 4 A of FIG. 1A ;
FIG. 4B is a sectional view of the suspension taken along line 4 B- 4 B of FIG. 1B ;
FIG. 5A is a sectional view showing how a viscoelastic member of a damper of the conventional suspension projects from the periphery of a restrainer;
FIG. 5B is a sectional view showing how a viscoelastic member of a damper of the suspension according to the invention projects from the periphery of a restrainer;
FIG. 6A is a sectional view showing how the periphery of the damper of the conventional suspension is covered by a coating material;
FIG. 6B is a sectional view showing how the periphery of the damper of the suspension of the invention is covered by a coating material;
FIG. 6C is a sectional view showing another example of the load beam of the suspension of the invention;
FIG. 7A is a sectional view showing the load beam formed with a recess before bending work;
FIG. 7B is a sectional view showing the load beam shown in FIG. 7A and the damper before affixture;
FIG. 7C is a sectional view showing how the damper shown in FIG. 7B is affixed to the load beam;
FIG. 7D is a sectional view showing the load beam and damper after rib bending;
FIG. 8A is a plan view showing a load beam blank with recesses;
FIG. 8B is a plan view showing how each load beam of the load beam blank shown in FIG. 8A is provided with the damper;
FIG. 9A is a sectional view showing a conventional load beam before bending work;
FIG. 9B is a sectional view showing the conventional load beam after the bending work;
FIG. 9C is a sectional view showing the conventional load beam and the damper before affixture;
FIG. 9D is a sectional view showing how the damper is affixed to the conventional load beam;
FIG. 10 is a perspective view showing a part of a disk drive;
FIG. 11 is a sectional view showing a part of the damper;
FIG. 12A is a diagram showing vibration characteristics of a suspension without a damper; and
FIG. 12B is a diagram showing vibration characteristics of a suspension with a damper.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the present invention will now be described with reference to the accompanying drawings.
FIG. 1A is a plan view of the suspension 2 comprising the conventional load beam 10 . FIG. 1B is a plan view of a suspension 2 ′ comprising a load beam 10 ′ according to the invention. FIG. 2 is a sectional view typically showing the load beam 10 ′ and a damper 14 according to the invention. A recess 20 is formed in a part of the load beam 10 ′. FIG. 3A is an enlarged sectional view taken along line 3 A- 3 A of FIG. 1A . FIG. 3B is an enlarged sectional view taken along line 3 B- 3 B of FIG. 1B . FIG. 4A is an enlarged sectional view taken along line 4 A- 4 A of FIG. 1A . FIG. 4B is an enlarged sectional view taken along line 4 B- 4 B of FIG. 1B .
The load beam 10 shown in FIG. 3A is bent so that its transversely opposite side edge portions 10 a rise like ribs. A central part of the conventional load beam 10 has a flat surface. In the load beam 10 shown in FIG. 4A , the proximal portion 10 b near the block 3 ( FIG. 10 ) is slightly bent. In the conventional load beam 10 , the damper 14 is affixed to the flat surface between the side edge portions 10 a. Thus, in the conventional suspension 2 , the damper 14 projects to a height equal to its thickness above the flat surface of the load beam 10 .
As shown in FIG. 3B , on the other hand, the load beam 10 ′ according to the present invention is formed with the recess 20 larger than the damper 14 in that part thereof on which the damper is located. The “recess greater than the damper” implies that the recess 20 is wider than the damper 14 when the load beam 10 ′ is viewed vertically from above ( FIG. 1B ). The damper 14 is contained in the recess 20 . The load beam 10 ′ is formed of a thin-plate spring. This thin-plate spring is a springy stainless-steel plate with a thickness of, for example, 50 to 100 μm.
As shown in FIG. 4B , a proximal portion 10 b of the load beam 10 ′ is slightly bent thickness-wise, as viewed laterally relative to the load beam. The proximal portion 10 b is located near the block 3 and also functions as a hinge portion for warping the load beam 10 ′ thickness-wise. The recess 20 is formed in a region including this hinge portion (or proximal portion 10 b ). Thus, a part of the damper 14 is located in the hinge portion (or proximal portion 10 b ).
As shown in FIG. 11 , the damper 14 comprises a metallic restrainer 15 and viscoelastic member 16 , which are laminated thickness-wise. The restrainer 15 is affixed to a bottom surface 20 a of the recess 20 with the viscoelastic member 16 between them. As shown in FIG. 2 , the upper surface of the restrainer 15 , that is, a surface 14 a of the damper 14 , is located within the recess 20 . In other words, the surface 14 a of the damper 14 does not project outside a surface 10 d of the load beam 10 ′.
According to the load beam 10 ′ of the present embodiment, therefore, interference of a bending tool with the damper 14 can be avoided while the load beam with the damper 14 thereon is being bent. Thus, the load beam 10 ′ can be bent after the damper 14 is affixed thereto. In addition, the recess 20 can be used as a positioning guide in affixing the damper 14 to the load beam 10 ′. Accordingly, the damper 14 can be easily positioned with respect to the load beam 10 ′.
In affixing the damper 14 to the bottom surface 20 a of the recess 20 , the damper 14 is pressed against the load beam 10 ′. By this pressing force, a part of the viscoelastic member 16 may sometimes be caused to project from the periphery of the restrainer 15 . In the case of the conventional suspension 2 shown in FIG. 5A , a part 16 a of the viscoelastic member projects much from the periphery of the restrainer 15 if the pressing force on the damper 14 is heavy. Thus, an operation is needed to remove the projecting part 16 a of the viscoelastic member.
According to the load beam 10 ′ of the present invention, however, a groove 25 is formed between an inner side surface 20 b of the recess 20 and the side surface of the restrainer 15 , as shown in FIG. 5B . Thus, the part 16 a of the viscoelastic member projecting from the periphery of the restrainer 15 is confined within the groove 25 . Consequently, the operation to remove the projecting part 16 a of the viscoelastic member can be omitted.
Conventionally, as shown in FIG. 6A , the side surface of the damper 14 is located outside the load beam 10 , so that a considerable amount of a coating material 30 is used to cover the side surface of the damper.
According to the suspension of the present invention, however, a coating material 30 is filled into the groove 25 between the inner side surface 20 b of the recess 20 and the damper 14 after the damper 14 is affixed to the bottom surface 20 a of the recess 20 , as shown in FIG. 6B . Thereupon, the side surface of the damper 14 is covered by the coating material 30 . Thus, the usage of the coating material 30 can be reduced compared to the conventional case.
FIG. 8A shows a load beam blank 41 comprising a plurality of load beams 10 ′ and scrap portions 40 . The load beam blank 41 is formed by, for example, etching. Each recess 20 should preferably be formed by partial etching as the load beam blank 41 is etched. Further, the recess 20 may be formed by pressing.
Alternatively, as shown in FIG. 6C , each load beam 10 ′ may be formed by superposing two thin plates 50 and 51 on each other, and each recess 20 may be formed by boring a through-hole 52 greater than each damper 14 in the one plate 50 .
Each load beam 10 ′ is bent with the damper 14 affixed to the bottom surface 20 a of the recess 20 . In order to avoid interference between the bending tool and damper 14 , a depth D 1 ( FIG. 2 ) of the recess 20 should preferably be made greater than a thickness T 1 of the damper 14 . In this embodiment, the recess 20 is formed in that one of the obverse and reverse surfaces of the load beam 10 ′ which is located opposite from a flexure 12 . Alternatively, however, the recess 20 may be formed in the same surface as the flexure 12 .
The following is a description of processes for manufacturing the suspension with the load beam 10 ′. As shown in FIG. 7A , the recess 20 is formed in the load beam 10 ′ that is not yet bent. As shown in
FIG. 7B , thereafter, the damper 14 is opposed to the bottom surface 20 a of the recess 20 . Then, the damper 14 is affixed to the bottom surface 20 a of the recess 20 , as shown in FIG. 7C . Thereafter, the rib bending and load bending of the load beam 10 ′ are performed by means of the bending tool, e.g., a die set (not shown).
According to this embodiment, the damper 14 is affixed to the unbent flat load beam 10 ′ ( FIGS. 7A to 7C ). Therefore, rib-like opposite side edge portions 10 a can be prevented from interfering with a device for affixing the damper 14 . Thus, the operation for affixing the damper 14 to the load beam 10 ′ can be automated more easily than in the case of the conventional suspension 2 ( FIG. 1A ).
As shown in FIG. 8A , the continuous load beam blank 41 comprising the plurality of load beams 10 ′ may be formed by etching. As shown in FIG. 8B , in this case, the damper 14 should be affixed to the recess 20 of each load beam 10 ′ of the load beam blank 41 . By doing this, the damper affixing operation can be automated with higher speed and accuracy and less deformation, so that the operation efficiency can be further improved.
The present invention is not limited to the embodiment described herein, and its constituent elements may be embodied in various forms without departing from the scope or spirit of the invention. Further, the invention is also applicable to suspensions of other disk drives than hard disk drives.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
|
A suspension for supporting a magnetic head is provided with a load beam formed of a thin-plate spring. A recess for accommodating a damper is formed in the load beam. The damper is affixed to a bottom surface of the recess.
| 8
|
BACKGROUND OF THE INVENTION
This invention relates to an enclosed electrical switchboard and more particularly a shutter mechanism therefor.
Generally, in an enclosed electrical switchboard, a circuit breaker is housed in an enclosed cubicle to be movable therein, and a disconnecting switch is constructed so that it will be separated automatically from the circuit breaker when it moves. Regarding the shutter mechanism which covers the stationery contact of this disconnecting switch, JEM 1153 provides that "in F 2 and G type enclosed switchboard, a shutter should be provided for the opening of an automatically connecting-type disconnecting switch in a main circuit for covering the stationary contact of the disconnecting switch thus securing the safeness of persons who may approach to the opening after the drawn-out of apparatus through the opening. However, the shutter may be eliminated only in a case where substantially no space exists for a person who approaches to the opening of the disconnecting switch and where a live portion is located in the enclosed switchboard at a portion sufficiently remote from a partition wall not touchable by a person unconsciously."
However, the above provision is not applicable in almost all foreign countries and enclosed electrical switchboards for export must include a shutter mechanism. Furthermore, there are many detailed requirements for the shutter mechanism in many foreign countries. Accordingly, to accommodate the various foreign country requirements it has been necessary to provide a shutter mechanism satisfying all such provisions, because design changes in the shutter mechanism for every foreign country is extremely disadvantageous from a manufacturing standpoint as it requires changes in the construction of the circuit breaker and the enclosed switchboard frame mechanism for each country.
Foreign standards (particularly, the U.S. standard: ANSI, the British standard: BS, and, the International standard: IEC) for the shutter mechanism of an enclosed electrical switchboard are summarized as follows:
1. Thickness of plate (ANSI C37.20)
It is requested to use a steel plate having a thickness of more than 2mm and to change the thickness thereof if a plate of other metal is utilized.
2. Operation (ANSI C37.20 IEC 298)
The shutter mechanism should be constructed so that it will be closed automatically at the disconnected position, test position, and drawn-out position of the switchboard.
3. Protection at the shutter closed position (IEC 298)
The degree of protection is classified by the following symbols:
A. IPH 2: to prevent fingers of an operator from approaching the live portion or contacting with an internal movable part.
B. IPH 3: to prevent a wire or a tool having a thickness of more than 2.5mm from approaching the live portion or contacting with an internal movable part.
c. IPH 6: to prevent completely a human body or other equipment from approaching the live portion or contacting with an internal movable part.
4. Locking (IEC 298,BS 162)
A shutter should be provided with means for locking the same at the shutter closed position.
5. Indication of bus bar side (BS 162)
The bus bar side of a shutter should be indicated by a name plate or painting.
6. Manual forced opening (BS 162)
After drawing-out the unit the live portion and no-voltage portion should be openable independently of each other and if the operator's hand is removed, the unit should return automatically to the original position.
SUMMARY OF THE INVENTION
Accordingly, a main object of this invention is to provide an enclosed electrical switchboard having an improved shutter mechanism.
Another object of this invention is to provide a shutter mechanism for an enclosed electrical switchboard which satisfies not only the JEM standard, but also various foregin standards (Items 1 through 6 mentioned above).
According to the present invention, there is provided an enclosed electrical switchboard of the type in which a circuit breaker is housed movably in a closed cubicle and when the circuit breaker is moved a movable contact of a disconnecting switch contacts with or separates from the stationary contact of the disconnecting switch contact mounted on a frame in said cubicle. The improvement in the described enclosed electrical switchboard comprises a cover which covers a frame in the cubicle supporting the stationary contacts of the disconnecting switch and is provided with a window at a portion facing the stationary contacts of the disconnecting switch, a pair of guide rods disposed vertically along both sides of the stationary contacts, a shutter cover having an area larger than that of the window, guide means for slidably guiding the shutter cover along the guide rods, a lever connected with the guide means and vertically movably along the guide rod in a manner which causes the shutter cover shut the window at the lowermost position of the lever, and a driving mechanism connected with the lever and arranged such that the lever lifts the shutter cover in accordance with movement of a driving member provided for the circuit breaker when the circuit breaker approaches towards the stationary contact of the disconnecting switch.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the present invention will be more readily understood from the following detailed description of a preferred embodiment thereof taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows a vertical sectional view of an embodiment of the enclosed electrical switchboard embodying the present invention;
FIG. 2a is a front view of a shutter mechanism embodying this invention;
FIG. 2b is a side view of the shutter mechanism;
FIG. 3 is a view taken along the line III--III of FIG. 2b;
FIG. 4 is a sectional view taken along the line IV--IV of FIG. 2a; and
FIG. 5 is a perspective view of a shutter cover to be used for the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an enclosed electrical switchboard comprises a closed cubicle 1, upper and lower circuit breakers 2, disconnecting switches 3a each of which comprises a movable male contact 2' and a stationary female contact 3 and shutter covers 4. In FIG. 1, the upper circuit breaker 2 is shown in its disconnecting position and the associated shutter in its closed condition, whereas the lower circuit breaker 2 is shown in its closed position and the associated shutter in its opened condition.
The shutter mechanism will now be described in detail in conjunction with FIGS. 2a, 2b, 3 and 4.
A pair of guide rods 5 are disposed on both sides of the disconnecting switches 3. Vertically movable levers 6 are provided which are operated by link mechanisms including links 7, 7' to be movable along guide rods 5. Each link mechanism is operated by a guide plate 8 in engagement with a driving member 10 provided on each side of the circuit breaker 2, and the link 7 and the guide plate 8 are pivotally mounted on a supporting plate 9 having its lower side secured to the cubicle 1. Along one side of each shutter cover 4 there is provided a locking plate 12 and both can be locked together by a lock 11. A cover 13 is provided to cover the stationary contacts 3 of the disconnecting switches 3a. The detail of the construction of each element mentioned above will be clarified through the following descriptions.
The two ends of each shutter cover 4 are bent, as shown in FIG. 4, substantially at right angles, and the bent ends are provided with holes 4', as shown in FIG. 2b, to lock the locking plate 12 and the cover 4 at the opened or closed position of the shutter. Bosses 15 which are slidably engageable with the guide rods 5 are welded to the cover 4 so as to slide the cover vertically. Each guide rod 5 is provided with threaded ends, the upper end of which is attached to a vertical frame 16 for supporting the stationary contacts 3 of the disconnecting switches 3a and the lower end of the guide rod is fixed to the cover 13 by means of a double nut. In this embodiment, the movable contacts of the disconnecting switches are constituted by contacts 2' mounted on the circuit breakers 2. Each guide rod 5 passes through the boss 15 attached to the shutter cover 4 and two L-shaped supporting flanges 17 are secured at vertically spaced points to the vertically movable lever 6 which is formed as a flat plate. Each supporting flange 17 is provided with a hole through which the guide rod 5 passes and the flange 17 supports the boss 15 fixed to the shutter cover 4 so as to allow for the separation of the boss from the flange and the upward movement of the boss and its associated cover 4.
The link 7 is pivotally coupled at one end to the lower end of the lever 6 by a pin 14 and at the other end to the supporting plate 9 fixed to the side of the cubicle 1. The guide plate 8 is bent substantially in a doglegged shape and to this bent portion a triangular plate is welded to reinforce the same, and one end of this guide plate 8 is pivotally connected by a pin with the supporting plate 9 and the other end is also pivotally connected through the link 7' with the intermediate portion of the link 7 near the pivot point. The supporting plate 9 is bent in a L-shape and provided with two holes at its both ends for inserting the pins to pivotally support the guide plate 8 and the link 7. As a driving member 10 for the circuit breaker 2 there is utilized a pin of the wheel of the circuit breaker 2 as shown in FIG. 3. The locking plates 12 are located on both sides of the shutter cover 4 and provided with holes 12', as shown in FIGS. 2a and 2b, to lock the shutter cover 4 and the plate 12 by means of a lock 11. The cover 13 is disposed so as to cover the frame 16, in other words, the supporting plate on which the stationary contacts 3 of the disconnecting switches 3a project, as shown in FIG. 5. On the surface of the cover 13 there are formed windows 13' which face the projected stationary contacts of the disconnecting switches.
The enclosed switchboard according to this invention operates as follows.
FIGS. 2a and 2b show the closed position of the shutter covers 4 in which the circuit breakers 2 are separated from the disconnecting switches 3a, and when the circuit breakers 2 are moved forwardly from this position, i.e., rightwardly as viewed in FIG. 2b, the steeply inclined portion of the dogleg shaped guide plate 8 contacts with the driving member 10 and when the driving members 10 are moved by a stroke l 2 , the plates 8 are rotated about the pivoted ends of the supporting plates 9. This rotary movement of the guide plates 8 is transmitted to the levers 6 through the link mechanisms 7, 7' and the levers 6 are forced upwardly by a stroke l 3 which is sufficient to open the shutter covers 4. The distance l 1 between the movable contact 2' mounted on the circuit breakers 2 and the shutter covers 4 is determined to be larger than the stroke l 2 , so that the movable contact 2' fit in the stationary contacts 3 of the disconnecting switches 3a without colliding with the shutter covers 4. When the driving members 10 fixed to both sides of the circuit breakers 2 are advanced by the stroke l 2 , the slightly inclined portions of the dogleg shaped guide plates 8 are also rotated to the horizontal position thereby maintaining the shutter covers 4 at their open positions. Conversely, when the circuit breakers 2 are drawn out, an operation reverse to that described above will be performed, and when the movable contacts 2' mounted on the circuit breakers 2 are separated completely from the windows 13' of the cover 13, the guide plates 8 are lowered in accordance with the return movement of the driving members 10 attached to the circuit breakers 2, whereby the shutter covers 4 begin to close. This closing operation can be performed by the weight of the shutter covers themselves and the like without the necessity of applying an external force, for example, a spring force.
According to the present invention, the foregoing Items 1 through 6 of the foreign standards can be satisfied with the following characteristics 1' through 6', respectively.
1'. Each shutter cover 4 is made of a steel plate having a thickness of 2.3mm and the movable contacts 2' mounted on the circuit breakers 2 are insulated electrically.
2'. The shutter covers 4 can be closed automatically and safely when the circuit breakers 2 are in the disconnected position.
3'. Regarding the protection at the shutter closed position, the stationary contacts 3 of the disconnecting switches 3a are entirely covered by the cover 13 as shown in FIG. 5, and the windows 13' of the cover 13 are further covered by the shutter covers 4.
4'. Concerning the locking of the shutter, as shown in FIG. 4, there is provided a lock 11 which performs the locking of the shutter cover 4 and the locking plate 12 at the shutter closed position. Furthermore, there is provided a locking hole 12' on the locking plate 12 for also holding the shutter cover 4 at its opened position so that the cleaning of the disconnecting switches 3 can be conveniently performed when the shutter is in its opened condition.
5'. It is apparent that attachment of letters N and P or painting for the indication of the bus bar side can easily be made, although a detailed explanation thereof is not made in this specification.
6'. Regarding the manual opening operation, since the supporting flanges 17 attached to the vertically movable levers 6 and the upper and lower shutter covers 4 are constructed to be separable from each other, an operator can move upwardly the desired one of the shutter covers 4 independently of the link mechanism 7, 7' and the shutter can return to its original position when the operator releases his hand.
As is understood clearly from the above, the shutter mechanism of this invention satisfies not only JEM standard but also foreign standards (in U.S.A., Great Britain, Europe) and it is very convenient and advantageous to standardize an enclosed switchboard because it is not necessary to modify the shutter mechanism to satisfy various foreign standards once the circuit breaker, a frame mechanism, etc. are designed.
Furthermore, according to this invention, due consideration is paid to facilitating the assembly of the enclosed electrical switch-board, and the improvement in assemblying the enclosed switch-board is achieved advantageously by constructing one unit including the disconnecting switches 3a, the shutter cover 4, the guide rods 5 and the movable levers 6, and another unit including the link mechanisms 7, 7' and the guide plates 8 attached to the supporting plates 9 and the frame 16, with both units being joined with each other by means of pins.
Further it is to be understood by those skilled in the art that foregoing description refers to a preferred embodiment of this invention and that various modifications and changes may be made without departing from the scope and spirit of the invention as defined in the appended claims.
|
An enclosed electrical switchboard, in which a circuit breaker including a movable contact is drawn out from or pushed in toward a stationary contact of a disconnecting switch, is provided with a cover for covering the stationary contact of the disconnecting switch. The cover is provided with a window facing the stationary contact, and a shutter cover is provided to close the window. A mechanism moves the shutter cover to close or clear the window in accordance with the draw out and push in movements of the circuit breaker.
| 7
|
BACKGROUND
[0001] 1. Field of the Invention
[0002] Embodiments of the invention relate to systems which can directly manipulate pages of memory by modifying a Translation Table (TT) associated with the dynamically allocated main memory.
[0003] 2. Discussion of the Related Art
[0004] In computer systems it is customary that there be a one-to-one correspondence between a memory address produced by a processor and a specific area in a physical memory of a system. It is an error for the processor to request access to an address which does not have an associated physical memory area. This limits the operating system (OS) and applications to an address space determined by the actual physical memory installed in the system. Modern computer systems have overcome this limitation through the use of virtual memory that implements a Translation Table (TT) to map program addresses to real memory addresses.
[0005] With virtual memory the program works in an address space limited only by processor architecture. It is a function of the OS to ensure that data and code of a program is in main memory and that the TT can map the virtual address to the real address correctly.
[0006] In a virtual memory system, the allocation of memory is most commonly performed by operating system software. This requires an interrupt of an instruction sequence so that privileged kernel code can allocate physical memory to the area being accessed so that normal program flow can continue without error. This interrupt and the kernel processing to allocate physical memory require a significant amount of processing time and upset the normal pipelining of instructions through a central processing unit (CPU).
[0007] However, in a computing system that has introduced a central storage mechanism which increases the maximum amount of central storage in the system above a previously architected limit, such as the IBM z/OS operating system, the majority of applications that run on that system are not able to easily take advantage of the additional central storage.
[0008] The z/OS operating system is a 64-bit server operating system from IBM. It is the successor to the IBM mainframe operating system OS/390, combining Multiple Virtual Storage (MVS) and UNIX System Services (a POSIX-compliant mainframe implementation of UNIX formerly known as MVS Open Edition). z/OS is a highly secure, scalable, high-performance enterprise operating system on which to build and deploy Internet and Java-enabled applications or legacy applications, providing a comprehensive and diverse application execution environment.
[0009] An important feature of new software products is the ability to work with a company's legacy applications, or at least be able to import data from them. In information technology, legacy applications and data are those that have been inherited from languages, platforms, and techniques earlier than current technology. Most enterprises that utilize computers have legacy applications and databases that serve critical business needs.
[0010] In the case being addressed here, these legacy applications function based on old architectural limits of central storage addressability. Under certain circumstances, these legacy applications place “constraint” on the management of central storage up to the old architected limit disproportionate to the system's central storage as a whole.
[0011] Therefore, in the software operating system (e.g., IBM z/OS) there exists a need to design a means to specifically handle disproportionate “constraint” placed on a central storage below the old limit. This mechanism must also perform its function with maximization of efficiency to minimize the intrusion of the operating system with regard to the number of machine “cycles” used to perform the function. The more cycles consumed by the operating system, the fewer cycles that are available to the customer's applications being used to achieve the customer's business goals.
[0012] During the new legacy storage relief process considerable central processing unit (CPU) resources are expended when the legacy storage becomes constrained. Under severe constraint conditions the result can be movement of thousands of pages per second from legacy frames to high frames (central storage in the addressing range beyond the previously architected limit.)
[0013] Considering the fact that the movement must copy bits and bytes from one physical storage location to another it is no surprise that the result is high CPU consumption.
[0014] Consequently, it would be highly desirable to provide a computer system that uses dynamically allocated physical memory and a Translation Table (TT) for managing this memory and a mechanism for performing these page operations without requiring the use of the processor. It would also be desirable to successfully manage disproportionate “constraint” placed on the central storage, minimize the number of machine “cycles” used to perform functions and minimize CPU consumption and to present a system that has the ability to virtually remove physical storage from the computing environment.
SUMMARY OF THE INVENTION
[0015] Embodiments of the invention include a method and computer program product for moving data between memory addresses in a computer system in which data referenced by memory addresses is stored in physical memory. The method comprises providing a translation mechanism for mapping respective pages of contiguous memory addresses to corresponding locations in the physical memory in accordance with a specified mapping, whereby a first page of memory addresses is mapped to a first location in the physical memory and a second page of memory addresses is mapped to a second location in the physical memory; and changing the specified mapping of the translation mechanism to a new mapping in which the second page of memory addresses is mapped to the first location in the physical memory, thereby effectively moving the data stored at the first location from the first page of memory addresses to the second page of memory addresses without moving the data between locations in the physical memory.
[0016] Another embodiment of the invention is a computing system for performing data page operations, the computing system including a physical memory in which data referenced by memory addresses is stored; a processing device for generating one or more real addresses associated with memory locations of the physical memory for reading and writing data; a translation mechanism for mapping respective pages of contiguous memory addresses to corresponding locations in the physical memory in accordance with a specified mapping, whereby a first page of memory addresses is mapped to a first location in the physical memory and a second page of memory addresses is mapped to a second location in the physical memory; the translation mechanism changing the specified mapping to a new mapping in which the second page of memory addresses is mapped to the first location in the physical memory, thereby effectively moving the data stored at the first location from the first page of memory addresses to the second page of memory addresses without moving the data between locations in the physical memory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Further features, aspects and advantages of the apparatus and methods of the embodiments of the invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
[0018] FIG. 1 depicts the currently functioning mechanism in use by many computing systems requiring the physical movement of bits and bytes from one physical storage location to another.
[0019] FIG. 2 illustrates a mechanism for reassigning real addresses from one physical chip location to another physical chip location at the real frame level as the structures may appear prior to the execution of the RRF instruction, according to the embodiments of the invention.
[0020] FIG. 3 illustrates a mechanism for reassigning real addresses from one physical chip location to another physical chip location at the real frame level according to the embodiments of the invention after RRF execution and cleanup.
[0021] FIG. 4 illustrates a mechanism for reassigning real addresses from one physical chip location to another physical chip location at the real frame level according to the embodiments of the invention which supports reconfiguration of storage, after RRF execution and cleanup.
[0022] FIG. 5 shows the conventional translation from a virtual address to a real address and ultimately to a physical address.
[0023] FIG. 6 shows the conventional translation from a virtual address to a real address.
[0024] FIG. 7 shows the conventional translation from a real address to a physical address.
[0025] FIG. 8 shows the translation from a real address to a physical address in accordance with a first embodiment of the present invention.
[0026] FIG. 9 shows the translation from a real address to a physical address in accordance with a second embodiment of the present invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0027] This application relates to data processing systems and in particular to data processing systems that dynamically allocate main memory for use by an operating system and/or application software. Embodiments of the invention relate to a translation mechanism that includes a Translation Table (TT) associated with dynamically allocating main memory. More specifically, embodiments of the invention have a second TT for disconnecting a logical computer address from a first physical address and reconnecting the logical computer address to a second physical address for accomplishing what appears to be data movement when no data movement really occurs.
[0028] The embodiments of the invention provide for a computer system that uses dynamically allocated physical memory and a Translation Table (TT) for managing this memory, a mechanism for performing the page operations without requiring intervention of the processor.
[0029] The embodiments of the invention disconnect two real addresses from their physical chip locations and point each of the disconnected physical addresses to the other chip location. Moreover, the embodiments of the invention maintain a single copy of data for use by all processors. This is accomplished by what appears to be data movement when no data movement really occurs.
[0030] In order to understand the functionality of the embodiments of the invention, an introduction on Processor Resource/System Manager (PR/SM) and Logical Partitioning (LPAR) is given below.
[0031] A physical server may be partitioned into multiple logical servers. This feature, known as Logical Partitioning (LPAR), allows up to fifteen logical servers to be configured within one physical server.
[0032] Processors such as the IBM System/390 (S/390) processor and its follow-ons, the zSeries and System z9 processors, have a hardware partitioning capability called Processor Resource/System Manager (PR/SM). Each logical partition can be isolated from all other logical partitions. Each logical partition runs its own z/OS or other operating system and its own workload. Each logical partition appears to the software running on it as one or more logical processors having the same instruction set architecture (ISA) as the underlying physical processors. While the present invention is not limited to any particular ISA, in the description that follows it will be assumed that each such logical processor executes (except for the new instruction described below) in accordance with z/Architecture as defined, for example, in z/Architecture Principles of Operation, SA22-7832-04 (September 2005). As described in that publication, each architected central processing unit (CPU) contains, among other facilities, 16 general purpose registers, which may be used to specify operands as described further below.
[0033] Processor Resource/Systems Manager (PR/SM) hardware circuits and microcode are built into IBM System/390 and follow-on mainframes and support logical partitions (LPARs). LPARs are a logical segmentation of a mainframe's memory and other resources that allow it to run its own copy of the operating system and associated applications. LPARs are caused by special hardware circuits and microcode and allow multiple system images to run in one machine. This can be multiple instances of the same operating system or different operating systems.
[0034] LPARs allow the running of multiple system images on a single processor complex. Each such image has a full complement of CPUs (dedicated or shared), central storage, expanded storage and channels. PR/SM is a hardware (microcode) facility that permits one to partition a physical server into several logical servers (LPARs). PR/SM maps/schedules individual operating system instances to separate CPUs or time slices them to a single CPU.
[0035] In a PR/SM capable computer each LPAR has its own set of real addresses ranging from address zero to the maximum real address allowed for the amount of physical chip storage allocated to that particular LPAR. Also, the LPAR capable machine has the ability to dynamically reconfigure central storage from one LPAR to another with the same single physical computer.
[0036] This reconfiguration takes a physical chip location, which was assigned one real address on one LPAR, and assigns that physical chip location to the other LPAR, possibly giving it a completely different real address on the receiving LPAR. This capability works at the storage increment level and relies on the presence of a second translation mechanism within the machine, which translates a real or absolute address, as surfaced to the operating system, to a physical chip location in accordance with a mapping defined by a second translation table.
[0037] The translation from real address to chip location is done via this second translation mechanism, which works at the storage increment level. For example, a real address range starting at a storage increment boundary is translated to some chip location at the chip's storage increment boundary. By employing this translation mechanism the machine is capable of taking a single physical chip storage increment range and reassigning a different range of real storage addresses to that physical increment.
[0038] When an application attempts to access a storage location the machine translates the virtual storage location to a real storage location via dynamic address translation (DAT).
[0039] With the real storage address in hand the machine then manipulates the real address to obtain the storage increment number that particular real address is associated with by consulting the increment translation structure to determine the physical chip location and then uses the remaining bits in the real storage address as a displacement from the start of the physical chip's storage increment boundary to locate the precise chip location at which to perform the requested operation. For example, in a 31-bit addressing mode, a real storage address may consist of bits 1 - 31 , with bit 1 being the most significant address bit and bit 31 being the most significant address bit. If we assume an increment size of 1 megabyte (MB) (2 20 bytes) and a page size of 4 kilobytes (KB) (2 12 bytes), then of these address bits, bits 1 - 11 may identify a particular 1 MB increment, bits 12 - 19 may identify a particular 4 KB page within the 1 MB increment, and bits 20 - 31 may identify a particular location within a 4 KB page.
[0040] The problem of the high cost of moving full real frames of data from one real frame to another can be resolved by reassigning real addresses from one physical chip location to another, at the real frame level, through the embodiments of the invention, which describe an additional vector table which sits below the increment (hardware/microcode) translation mechanism described below with reference to FIGS. 1-4 .
[0041] In an indirectly addressed memory system, certain common operations may be performed by directly manipulating the entries in a translation table (TT), without actually accessing the data bytes. These types of operations are commonly performed on pages of memory. A page is the unit of allocation used by the virtual memory manager in the operating system to assign real memory resources to processes in the system. Virtual memory pages are usually a fixed size of a few thousand bytes, 4096 bytes being the most often-used page size. It is understood that the page of memory operated on may have any size, and embodiments of the invention are not limited to pages of 4096 bytes.
[0042] FIG. 1 depicts a mechanism for moving data from one physical chip location to another physical chip location at the real frame level prior to the embodiments of the invention.
[0043] FIG. 1 is used as a starting point for several examples of page operations. FIG. 1 depicts a source page 2 and a target page 4 . Each of the page frame table entries (PFTEs) (A, B, C, D) is a software representation of a single real address on the system. Each PFTE has a one-to-one correspondence 12 with one of the frames of real storage 8 in the system/LPAR. In turn, each frame of real storage 8 has a one-to-one correspondence to an equivalent size page of physical chip storage 10 assigned to the system/LPAR. Specifically, in this embodiment the page frame table entries (PFTEs) 6 are one page.
[0044] The flow of a real frame reassignment is as follows. Element 8 denotes the real frames. When the operating system determines it needs to move data from one real frame E to another, it already has in place the mechanism to locate a second unused real frame F into which it can direct the data transfer. Once the two frames E, F are obtained, the bits and bytes are transferred from the source to the target physical chip locations using any of a number of computing instructions well known to those skilled in the art.
[0045] Once the instruction is issued, the microcode/hardware takes the real address, manipulates the real address to obtain the real address increment number corresponding to the input real address, then locates the correct displacement into the physical increment. Physical movement of data then takes place by transfer of data G to the storage location previously storing data H. As can be seen in FIG. 1 physical data movement occurs only in one physical chip (single increment) as shown by element 10 . For the sake of simplicity, FIG. 1 shows a single physical storage increment. In reality there may well be any number of physical increments assigned to the system and physical data movement can take place from any location in any increment to any location in any other increment as well as transfer within the individual increments.) In other words, physical movement is the movement of data G into the storage location previously storing data H, as illustrated in FIG. 1 .
[0046] FIGS. 5-7 show the system of FIG. 1 in terms of its hardware translation structures. Thus, FIG. 5 shows a system 500 in which a virtual address 502 as understood by a program is transformed by a first translation mechanism 504 into a real address 506 as understood by the particular logical partition in which the program is running. Real address 506 is in turn translated by a second translation mechanism 508 into a physical address 510 representing the actual location of the data in physical storage.
[0047] FIG. 6 shows the virtual-to-real address translation step of FIG. 5 in more detail. Virtual address 506 may be regarded as being formed of a virtual page portion 602 and an offset portion 604 . The virtual page portion 602 , the higher-order address portion, indicates a particular page—a contiguous set of 4096, or 2 12 , bytes—in which the data is located in virtual address space. The offset portion 604 , the lower-order address portion consisting of the 12 least significant bits (LSBs), indicates the byte offset of the data from the beginning of the page.
[0048] As also shown in FIG. 6 , the first translation mechanism 504 comprises a first translation table 606 containing a plurality of page frame table entries (PFTEs) 608 . Each such entry 608 indicates a corresponding real page (or real frame) corresponding to the virtual page, with virtual page portion 602 serving as an index into the table 606 . The table entry 608 obtained in this manner is concatenated with the original byte offset 604 to produce a real address 506 comprising a page portion 610 and an offset portion 612 . The granularity of virtual-to-real address translation is thus a page, consisting of 4096 (or 2 12 ) bytes. In practice, several successive lookups are used to perform this virtual-to-real address translation in z/Architecture, but they can be represented logically by the single table 606 .
[0049] Referring now to FIG. 7 , a similar table lookup procedure is used to obtain the physical address 510 from the real address 508 . For this purpose, real address 506 may be regarded as comprising a high-order increment portion 702 and a low-order displacement portion 704 . The increment portion 702 indicates a particular physical chip increment 710 on which the data is stored (at a storage location 712 ). The increment portion 702 is used as an index into a second translation table 706 (implementing the second translation mechanism 506 ) used to look up the base address 708 of the chip increment 710 . The displacement portion 704 represents the displacement (in bytes) of the storage location 712 from the base address 708 of the chip increment 710 .
[0050] The particular dividing line between the increment portion 702 and the displacement portion 704 of the real address 506 depends on the size of the chip increment 710 . For example, if the chip increment 710 has a size of 1 megabyte (i.e., 2 20 bytes), then the displacement portion 704 would consist of the 20 LSBs of the real address 506 , while the increment portion 702 would consist of the remaining bits of the real address. For chip increments 710 of different size, the increment portion 508 and the displacement portion 510 would vary in size correspondingly. Note that in contrast to the virtual-to-real address translation of FIG. 6 , the granularity of this conventional real-to-physical address translation is basically the size of the chip increment 710 , in this case 1 megabyte. Real pages thus cannot be arbitrarily relocated relative to one another in this conventional configuration unless they reside on different chip increments 710 .
[0051] The present invention overcomes this limitation of conventional configurations by performing the real-to-physical address translation with the page granularity of the virtual-to-real address translation of FIG. 6 . Pages of physical memory can thus be arbitrarily reassigned from one real page to another, enabling the movement of data from one real address to another without requiring any corresponding movement in physical memory. Rather than actual moving the data in physical memory, the real-to-physical translation tables are changed to reflect the address reassignment, as explained further below.
[0052] FIG. 8 shows an address translation mechanism 508 - 1 for performing a real-to-physical address translation in accordance with the present invention. For this purpose, the real address 506 is analyzed into a high-order page portion 802 and a low-order offset portion 804 , which are identical to the portions 610 and 612 shown in FIG. 6 . Offset portion 804 contains the 12 LSBs of the real address 506 , while page portion 802 contains the remaining bits of the real address.
[0053] Page portion 804 serves as an index into a second translation table 806 containing entries 808 . In a manner similar to the PFTEs 608 in the first translation table 606 ( FIG. 6 ), each entry 808 in the second translation table 806 indicates an increment portion 810 and a page portion 812 of the physical address 510 , which also contains an offset portion 814 . Increment portion 810 points to (i.e., contains the base address of) a particular physical increment 710 on which the data is stored (at storage location 712 ). Page portion 812 indicates the particular 4096-byte page (not separately shown) within that increment 710 within which the data is stored, while offset portion 814 (which is the same as offset portion 804 of the real address 506 ) represents the byte offset of the data within the particular page. Page portion 812 is concatenated with offset portion 814 to form an index into the increment 710 to access storage location 712 . Note that in contrast to the conventional configuration shown in FIG. 7 , successive real pages in this configuration of the invention can be arbitrarily mapped to different physical pages, even on different chip increments 710 .
[0054] FIG. 9 shows an alternative address translation mechanism 508 - 2 for performing a real-to-physical address translation in accordance with the present invention. From the standpoint of the overall real-to-physical address translation, translation mechanism 508 - 2 operates in a manner similar to that of the translation mechanism 508 - 1 shown in FIG. 8 . However, translation mechanism 508 - 2 differs from translation mechanism 508 - 1 by using two successive translation tables to perform the lookup. For this purpose, the page portion 804 ( FIG. 8 ) of real address 506 is further analyzed into an increment portion 902 and a page portion 904 . Increment portion 902 serves as an index into an increment table 906 containing entries 908 , each of which points to (i.e., stores the base address of) a page table 910 . Each page table 910 in turn contains entries 912 that are similar to the entries 808 in page table 806 ( FIG. 8 ) and are used in a similar manner to generate a physical address 510 . Except for this use of two tables, the operation of the translation mechanism 508 - 2 is the same as for the translation mechanism 508 - 1 shown in FIG. 8 .
[0055] FIG. 2 illustrates a scheme for reassigning real addresses from one physical chip location to another physical chip location at the real frame level according to the embodiments of the invention, using a translation vector table (TVT) implemented by a translation mechanism such as translation mechanism 508 - 1 ( FIG. 8 ) or 508 - 2 ( FIG. 9 ). FIG. 3 shows the status after REASSIGN REAL FRAME (RRF) execution and cleanup, discussed below. The operands of the RRF instruction are the contents of two general-purpose registers r1 and r2, where register r1 is the first operand location and register r2 is the second operand location. While the present invention is not limited to any particular instruction format, one possible format for the RRF instruction (the so-called RR format in z/Architecture) has an 8-bit opcode followed by two 4-bit register specifications r1 and r2, as shown below:
[0000] Opcode r1 r2
Contained within the first general purpose register (r1) is the real address into which the operating system wants the data to appear (target). The second general-purpose register (r2) contains the real address where the data resides prior to issuance of the instruction (source). Prior to RRF execution, real address 3000 is free to be allocated to any virtual page in the system. This is indicated in FIG. 2 by showing a corresponding PFTE of “Avail” for real address 3000 (meaning that no PFTE points to real address 3000 at this time). At that point the real frame translates through the translation vector table (TVT) to be described to physical location 1xx0. In the (TVT) entry “1xx0”, the leftmost digit “1” specifies the physical increment the real frame is being mapped to, while the rightmost digit “0” (together with the intermediate digits “xx”) indicates the displacement of the frame origin from the origin of the increment.
[0056] At some point prior to RRF execution, a virtual address becomes assigned (i.e., its PFTE is updated to point) to the target real page. FIG. 2 illustrates page frame table entries (PFTEs) 20 , each of which corresponds to one page of data. Elements of FIG. 2 similar to elements of FIG. 1 will not be described. The states of the entries 20 are Avail (or empty), 9000 , 2000 and C 000 , where each of these values is the corresponding virtual address if one exists and “Avail” if no corresponding virtual address exists. There is a one-to-one correspondence between the real frames 22 with addresses ( 1000 , 2000 , 3000 , 4000 ) and the PFTE entries 20 . Although for purposes of explanation the virtual addresses are shown in FIG. 2 as being contained in the PFTEs 20 , it will be apparent to those skilled in the art (as well as from FIG. 6 ) that the virtual addresses are indices into the translation tables containing the PFTEs and that each PFTE contains a pointer to a corresponding real page; thus, virtual page 3000 indexes a PFTE containing a pointer to real page 1000 , virtual page 9000 indexes a PFTE containing a pointer to real page 2000 , and so on. Moreover, there is a one-to-one correspondence between the real addresses ( 1000 , 2000 , 3000 , 4000 ) and the entries in a translation vector table 24 which contain pointers (3xx1, 1xx2, 1xx0 and 2003). Element 28 denotes a first physical storage increment assigned to the system, element 30 denotes a second physical storage increment assigned to the system, and element 32 denotes a third physical storage increment assigned to this system.
[0057] The mechanism of FIG. 2 is a processing mechanism for generating one or more real addresses associated with memory locations of a real memory system for reading and writing data. The real addresses ( 1000 , 2000 , 3000 , 4000 ) are depicted as elements 22 , which TVT 24 maps to specific memory locations in storage increments 28 - 32 . The real addresses 22 and the PFTEs 20 are conceptually part of the real memory system.
[0058] The PFTEs 20 , the real memory addresses 22 , and the entries in translation vector table TVT 24 all correspond to real memory for storing data. Each of these elements ( 20 , 22 , entries in 24 ) can be considered as representing a page of data that are contiguous bytes of a physical memory.
[0059] FIG. 2 illustrates a new real address Translation Vector Table (TVT) 24 that would be a table of entries which are indexed to using that portion of the real address (corresponding to the page portion 904 shown in FIG. 9 ) following the lowest corresponding increment boundary and excluding the index into the frame (corresponding to the offset portion 804 shown in FIG. 9 and currently the rightmost 12 bits when using a 4096 byte page). The exact starting bit offset within the real address used in calculating the index is variable since the size of a storage increment is variable in any given machine, due to the increment size being based on the amount of installed physical central storage.
[0060] The translation vector table is a table of entries, wherein as noted above the entries are indexed to by a portion of the real address following a lowest increment boundary and excluding the index into a real frame, and wherein each of said entries of the second translation table has at least a chip increment location and a displacement to a frame boundary.
[0061] Also, the number of entries in this table is variable because it is based on the number of real frames contained in a storage increment. Each entry in the table is of sufficient size to contain the chip increment location and the displacement to the frame boundary (as shown in FIG. 9 ). There is one such table assigned to each real storage increment in the machine.
[0062] Given there is now a one-to-one correspondence between a real address ( 1000 , 2000 , 3000 and 4000 ) and a given chip location in increment pages 28 , 30 and 32 within a physical increment, the TVT now injects itself as the one-to-one correspondence between its table entries and the real storage address as well as the physical increment.
[0063] The flow of a real frame reassignment is as follows. When the operating system determines it needs to move data from one real frame to another, it already has in place the mechanism to locate a second unused real frame (AVAIL) into which it can direct the data transfer. Once the two frames are obtained, the operating system's storage manager would issue a new instruction named REASSIGN REAL FRAME (RRF).
[0064] The input operands to the RRF instruction include general-purpose register numbers. Contained within the first general purpose register (r1) is the real address into which the operating system wants the data to appear (target or real address 3000 ). The second general-purpose register (r2) contains the real address where the data resides prior to issuance of the instruction (source or real address 1000 ).
[0065] Once the instruction is issued the microcode/hardware takes the real address in r2 and manipulates the real address (by analyzing it as shown in FIG. 9 ) to obtain the real address increment number. It then translates the real address increment number to obtain the TVT start location. Using the real address it manipulates the address to obtain the index into the TVT to obtain the entry that corresponds to the source real address (r2). The TVT corresponding to the source real address (r2) directs the microcode/hardware to index 1 of storage increment 3 ( 32 ), which contains data GHI.
[0066] With the source TVT entry located, the microcode/hardware takes the target real address in r1 and manipulates the real address to obtain the real address increment number. It then translates the real address increment number to obtain the TVT start location. Using the real address it manipulates the address to obtain the index into the TVT to obtain the entry that corresponds to the target real address (r1) in which the data ends up.
[0067] Elements of FIG. 3 similar to elements of FIGS. 1 and 2 will not be described. FIG. 3 illustrates a mechanism for reassigning real addresses from one physical chip location to another physical chip location at the real frame level according to the embodiments of the invention. This view represents the state changes from the initial view ( FIG. 2 ) after execution of the RRF instruction.
[0068] Referring to FIG. 3 , at this point, the entries in TVT 24 for both source 2 and target 4 have been located. The current contents of each TVT entry are then simply swapped. For instance, prior to execution of the RRF instruction ( FIG. 2 ) the TVT 24 entry (1xx0) corresponding to real address 3000 ( 22 ) points to the location of page zero in physical increment 1 ( 28 ) and the TVT 24 entry (3xx1) corresponding to real address 1000 ( 22 ) points to the location of page 1 in physical increment 3 ( 32 ) and reveals data GHI. Following execution of the RRF instruction ( FIG. 3 ) the contents of the TVT ( 24 ) entry corresponding to real address 3000 ( 22 ) have been exchanged with the contents of the TVT ( 24 ) entry corresponding to real address 1000 ( 22 ), thus revealing data GHI to real address 3000 ( 22 ). The TVT ( 24 ) entry corresponding to real address 1000 ( 22 ) is filled in with the pointer 1xx0, which causes real address 1000 to now translate to the page zero index of storage increment 1 ( 28 ). The PFTE representing real address 1000 ( 22 ) is then made available. All other TVT entries remain unchanged during the instruction execution.
[0069] Therefore, the table entry for the target real address points to the physical chip location at which the source data resides. Also, the table entry for the source real address points to the physical chip location that the target real address used to point to.
[0070] FIG. 4 illustrates a mechanism for reassigning real addresses from one physical chip location to another physical chip location at the real frame level according to the embodiments of the invention which supports reconfiguration of storage, after RRF execution and cleanup.
[0071] After having performed the RRF instruction, under normal circumstances, the operating system would simply free the old source real address 1000 and it would be available for reassignment to some other virtual page.
[0072] Eventually, the relationship between real address and physical chip location becomes highly randomized. In an operating system environment that supports dynamic central storage reconfiguration this randomization would be problematic given the fact that central storage is reconfigured by real address range which corresponds to sequential physical increment storage.
[0073] Therefore, on a central storage reconfiguration request the operating system must be able to know which real frames correspond to the physical location of which other real frame. By knowing this relationship the operating system can reassign the real frames of the two locations such that the real storage range can be restored to its original state of being represented by its initial physical increment.
[0074] Referring to FIG. 2 , because the TVT 24 maintains a one-to-one correspondence between a real address ( 1000 , 2000 , 3000 , 4000 ) and a physical chip location (e.g., ABC, DEF, GHI), a single TVT entry can be located by knowing the real address or by knowing the physical chip location. In the RRF execution diagrams and descriptions above with reference to FIGS. 2 and 3 , the TVT entries were updated with only the physical location that the entry now points to. By expanding a table entry to include a second field 26 it is also possible to include, in the entry, which real address's/increment's TVT entry points ( 26 ) to this TVT entry's corresponding physical chip location. Because the RRF instruction always swaps two locations per execution this information is known at execution and can be saved in the TVT fields 26 . TVT fields 26 are the inverse of fields 24 . First fields 24 map a real address to get to the physical chip location. TVT second fields 26 map the physical chip location (increment and index) to the entry in first fields 24 that points to that physical chip location. In other words, first fields 24 translate top down in FIG. 4 . Second fields 26 translate bottom up in FIG. 4 . The TVT second fields 26 may reference TVT first fields through an index and increment format as shown in FIG. 4 . To see how this works, consider the final assignment of real frames to physical chip locations shown in FIG. 3 . For this purpose, the real frames corresponding to TVT 24 entries will be identified as frames 1xx0, 1xx1, 1xx2 and 1xx3, respectively; the address of real frame 1xx0, for example, may be thought of as having an increment portion 1 and a page portion xx0. As shown in that figure, the TVT 24 entries successively point to chip locations 1xx0, 1xx2, 3xx1 and 2003, as indicated by this correspondence table:
[0000]
Real Frame
Chip Location
1xx0
1xx0
1xx1
1xx2
1xx2
3xx1
1xx3
2003
[0075] If the columns of the above table are swapped and the table is sorted by what is now the first column, the following table is obtained, containing the same information but indexed by the chip location rather than the real frame:
[0000]
Chip Location
Real Frame
1xx0
1xx0
1xx2
1xx1
2003
1xx3
3xx1
1xx2
[0076] As shown in the first of the above tables, after RRF instruction execution real frame 1xx0 is assigned to chip location 1xx0 while real frame 1xx1 is assigned to chip location 1xx2. Equivalently, as shown in the second of the above tables, after RRF instruction execution chip location 1xx0 is assigned to real frame 1xx0 while chip location 1xx2 is assigned to chip location 1xx1. As shown in FIG. 4 , this correspondence is indicated by a second field entry of 1xx0 for chip location 1xx0 (the first of the four entries shown) and a second field entry of 1xx1 for chip location 1xx2 (the third of the four entries shown). In a similar manner, the real frames assigned to chip locations 2003 and 3xx1 are indicated by corresponding second field entries in the TVTs (not shown) for increments 30 and 32 . Finally, the TVT second field entries 3xx3 and 3xx0 for chip locations 1xx1 and 1xx3 (the second and fourth of the TVT second field entries shown in FIG. 4 ) are obtained from corresponding first field entries in the TVT (not shown) for increment 32 .
[0077] Being able to translate both directions provides for reconfiguration to be able to undo the changes all of the RRF instruction executions have made in the event a physical memory increment is taken offline.
[0078] At reconfiguration time it would be a simple matter to query the service processor through a variation of the current service processor interfaces to obtain the real address which points to the physical chip location, which corresponds to the real address being taken offline.
[0079] Another way of obtaining the real address which points to this real address's corresponding physical chip location would be a variation of the RRF instruction itself such as having a bit in general purpose register 0 which signals instruction execution that this is a request to return the real address whose TVT entry points to the supplied real address's corresponding physical chip location.
[0080] With the returned real address in hand, the operating system's reconfiguration processor can issue the RRF to swap the two real addresses, returning the offline targeted real address's TVT entry to point to its original physical chip location.
[0081] Therefore, the embodiments of the invention disconnect two real addresses from their physical chip location and point each of the disconnected physical addresses to the other chips location. Moreover, the embodiments of the invention maintain a single copy of data for use by all processors. This is accomplished by what appears to be data movement when no data movement really occurs. In addition, the embodiments allow for the ability to remove physical storage from the computing environment.
[0082] Thus, according to the embodiments of the invention, the actual data of the pages involved in the operation are never accessed by the processor and therefore it is never required in the memory cache hierarchy, thus eliminating the cache damage normally associated with these page operations. Further the manipulation of the translation table involves reading and writing a few bytes to perform the operation as opposed to reading and writing the hundreds or thousands of bytes in the pages being manipulated.
[0083] Such a method and apparatus of the embodiments of the invention result in a significant savings in time to perform the actual operation and further represents a smaller performance impact on other activities of the processor. Preferably, the method and apparatus of the embodiments of the invention may be implemented in the design of the compressed memory management systems for server devices, PCs and the like, implementing compression/decompression algorithms.
[0084] As described above, the embodiments of the invention may be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. Embodiments of the invention may also be embodied in the form of computer program code containing instructions embodied in tangible media, such as system memory, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. The present invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic events.
[0085] While the invention has been particularly shown and described with respect to illustrative and preformed embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention which should be limited only by the scope of the appended claims.
|
A method for moving the data between the memory addresses in a computer system in which data referenced by memory addresses is stored in physical memory. The method comprises providing a translation mechanism for mapping respective pages of contiguous memory addresses to corresponding locations in the physical memory in accordance with a specified mapping, whereby a first page of memory addresses is mapped to a first location in the physical memory and a second page of memory addresses is mapped to a second location in the physical memory; and changing the specified mapping of the translation mechanism to a new mapping in which the second page of memory addresses is mapped to the first location in the physical memory, thereby effectively moving the data stored at the first location from the first page of memory addresses to the second page of memory addresses without moving the data between locations in the physical memory.
| 6
|
[0001] This utility patent application claims the priority of provisional application of U.S. Ser. No. 61-631,388 filed on Jan. 3, 2012
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Taking the following specifications in conjunction with the accompanying drawings will cause the invention to be better understood regarding these and other features and advantages. The specifications reference the annexed drawings wherein:
[0003] FIG. 1 is a perspective view of multifunctional environmental control unit depicting a multitude of functions including display, communication, and entertainment.
[0004] FIG. 2 is a more detailed perspective view of additional communication functions.
[0005] FIG. 3 is a more detailed perspective of lighting functions.
[0006] FIG. 4 is a more detailed perspective view security, fire detection, smoke detection, air quality monitoring functions.
[0007] FIG. 5 is a perspective view of other occupied space locations for the controlling unit enabling the multifunctional capabilities.
[0008] FIG. 6 is a detailed view of the best implementation of the environmental controlling unit
[0009] FIG. 7 is an exploded perspective view of the best implementation of the “iris” environmental controlling unit.
[0010] FIG. 8 is a more detailed perspective exploded view of “iris” type moveable baffle approach for supply pressure control and energy scavenging components in the controlling unit.
[0011] FIG. 9 is a more detailed exploded perspective view of “iris” type moveable baffle approach for room thermal control operation
[0012] FIG. 10 is a detailed view of an alternate rotating cylinder design for the temperature controlling unit.
[0013] FIG. 11 is another exploded perspective view of an alternate design for the controlling unit showing flow directional control.
[0014] FIG. 12 is a perspective view of a complete HVAC System.
[0015] FIG. 13 is a schematic of the control functions for a complete HVAC System.
[0016] FIG. 14 is a schematic of the control algorithm for the thermal environment control.
[0017] FIG. 15 is a schematic of the control algorithm for the pressure/sound/air quality control.
[0018] FIG. 16 is a perspective view of an intelligent window/shutter/damper control unit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] While describing the invention and its embodiments, various terms will be used for the sake of clarity. These terms are intended to not only include the recited embodiments, but also all equivalents that perform substantially the same function, in substantially the same manner to achieve the same result.
[0020] Now referring to FIG. 1 which discloses a preferred embodiment of the present invention, a multifunctional environmental control unit generally referenced by numeral 100 which is depicted in a closed environment, such as a room or office wherein the unit 100 has the functionality of the following, it can sense external and internal properties, such as temperature, pressure, and position, and control the movement of conditioned air for thermal control as well as, communicate wirelessly, display images and text, sound alarms, and illuminate. A remote display unit, for example, a computer, generally referenced by numeral 110 , a wall mounted display generally referenced by numeral 120 , an integral visible display referenced by numeral 130 . All communicate wirelessly with bidirectional transmitter/receiver unit referenced by numeral 140 . An integral projector referenced by numeral 150 can project images on an appropriate surface. Occupants, whether working or resting, healthy or sick, referenced by numerals 160 and 170 , will benefit from the multifunctional capabilities of the control unit. The integral wireless communication module for room communication is generally referenced by numeral 140 . The integral wireless communication module for communication with other system components is generally referenced by numeral 180 .
[0021] Now referring to FIG. 2 which discloses an expanded display functionality of the control unit. Remote communication units are referenced by numeral 210 for a wall mounted device, numeral 220 for a desk top device, numeral 230 for a desktop display, numeral 240 for a desk top phone, and numeral 250 for a mobile device. An enclosure to house and environmentally protect the electronics interfacing with sensors, actuators, display devices, and allowing wireless communication with enclosed communication modules, and allowing computation of control logic referenced by numeral 190 .
[0022] Now referring to FIG. 3 which discloses an expanded illumination capability. The luminaries can be integral with the controlling unit 100 as referenced by numeral 310 and at any height on any wall as referenced by numeral 320 . Illumination On-Off or dimming signals can be relayed through the controlling unit numeral 100 to the luminaries 320 and 310 , by sending signals from a human interface device referenced by numeral 220 for a table top device or numeral 250 for a mobile device
[0023] Now referring to FIG. 4 which discloses an expanded security and safety capability. The controlling unit numeral 100 incorporates integral sensors referenced by numeral 410 for motion detection, numeral 420 for fire detection, numeral 430 for smoke detection and numeral 480 for CO2 sensing to monitor air quality. The objects detected are referenced by numerals 440 for an intruder, numeral 450 for fire, and numeral 460 for generated smoke. The alarm signal detected by controlling unit is transmitted by the bidirectional transmitter/receiver unit referenced by numeral 140 is sent to receiving unit typically referenced by mobile device referenced by numeral 250 located on non-intruder referenced by numeral 470 . For quality of air monitoring and control, wireless communication is enabled between bidirectional transmitter/receiver unit referenced by numeral 140 located in controlling unit numeral 100 and a separate module referenced by numeral 490 in a preferred location in the occupied space.
[0024] Now referring to FIG. 5 which discloses optional locations for the controlling unit. Optional locations for controlling unit include centrally located in the ceiling referenced by numeral 510 , at the ceiling/wall corner along a long wall in a rectangular room referenced by numeral 520 at the wall/ceiling corner along a short wall in a rectangular room referenced by numeral 530 , at a wall/wall corner referenced by numeral 540 , at a wall/floor corner referenced by numeral 550 , at a under floor location referenced by numeral 560 , at a corner apex referenced by numeral 570 .
[0025] Now referring to FIG. 6 which discloses the one possible internal construction of the controlling unit which embodies the improvement capabilities described above. Internal components include an internal sensing element for occupied space detection and communication 140 and sensor for the measurement of external environmental thermal conditions (preferably an infrared temperature sensor with a single sensing element or a multi-element with individual addressable elements, referenced by numeral 610 , and system supply communication referenced by numeral 180 , a moveable horizontal flow baffle referenced by numeral 630 , an actuator for positioning the moveable horizontal flow baffle 630 referenced by numeral 640 , a moveable vertical flow baffle referenced by numeral 660 , an actuator for positioning the moveable vertical flow baffle 660 referenced by numeral 670 , a moveable supply flow baffle referenced by 690 , a actuator to position the moveable supply flow baffle 690 referenced by 695 , an internal temperature sensor referenced by numeral 696 , an internal pressure sensor referenced by numeral 697 with a tube referenced by numeral 617 to communicate internal pressure to the pressure sensor 697 , a position sensor for the moveable horizontal flow baffle 630 referenced by numeral 632 , a position sensor for the moveable vertical flow baffle 660 referenced by numeral 661 , a position sensor for the moveable supply baffle 690 referenced by numeral 691 , a housing for the electronic control unit referenced by numeral 600 , and a mounting plate for the baffle motors referenced by numeral 607 , and the housing for the complete assembly referenced by numeral 601 . In the best implementation of air movement control for thermal comfort, the horizontal and vertical directional air directional control is incorporated into a single baffle assembly with extended rotational movement driven by a gear or belt referenced by numeral 631
[0026] Now referring to FIG. 7 , which further discloses a more detailed exploded view of the control unit depicted in FIG. 6 . Components are referenced by numerals 150 , 180 , 600 , 601 , 610 , 630 , 631 , 632 , 640 , 660 , 661 , 670 , 690 , 691 , 695 , 696 , 697 and Additional components include bearings referenced by numeral 604 under each moveable wings of the horizontal baffles 630 , posts referenced by numeral 603 guiding the horizontal baffle wings 630 and bearings 604 , a rotating plate referenced by numeral 631 with attached pins or gear whereby the pins or gear engage slots or gears referenced by numeral 605 in the horizontal baffle wings 630 to rotate them thereby exposing a flow gap between the housing 601 and a fixed face plate referenced by numeral 689 , a actuator mounting plate referenced by numeral 607 to support actuators 640 and 670 , a cam like or gear drive mechanism referenced by numeral 609 attached to actuator 640 to rotate the rotating ring or gear referenced by numeral 606 , a slotted arm (shown) or gear referenced by numeral 611 attached to actuator 670 to drive a pin (shown) or gear referenced by numeral 618 attached to vertical moving baffle 660 thereby exposing a flow gap between the fixed plate referenced by numeral 689 and vertical moving baffle 660 , center shaft assembly referenced by numeral 612 mounting the complete horizontal and vertical baffle assembly to the housing 601 , a gas impermeable flexible fabric referenced by numeral 613 to block the supply air upon actuation of the supply damper 690 , a fixed support plate referenced by numeral 614 with attached pins referenced by numeral 615 to guide the bearings referenced by numeral 616 and the individual arms of supply damper 690 , a pressure sensing tube referenced by numeral 617 to communicate internal static pressure to internal pressure sensor 697 . In the best implementation of the concept, the horizontal and vertical flow baffle function is incorporated into a single gear driven mechanism utilizing the baffles wings 630 , rotating gear 606 and gears 605 attached to the individual baffle wings 630 .
[0027] Now referring to FIG. 8 which further discloses an explode view of the components on the supply side of the controlling unit. The a partial section of the housing 601 is shown below the moveable supply baffle 690 incorporating a multiple of geared arms referenced by numeral 891 synchronized by a central gear referenced by numeral 892 . The gear assembly is driven by the actuator referenced by numeral 695 rigidly incorporating a gear referenced by numeral 893 which drives the central gear referenced by numeral 892 to in turn drive in a synchronized fashion the multiple gears of arms referenced by numeral 891 . Above is also shown a small turbine blade assemble referenced by numeral 710 used to generate energy to operate the controls and supply storage energy for future use. The power to drive the turbine is extracted from the energy in the air flow supplied by the system blower upstream. Also shown are components for energy harvesting related to piezoelectric vibration as referenced by numeral 820 and thermoelectric power generation referenced by numeral 830 . Sensing components referenced by numerals 617 , 696 , 697 and structural components referenced by numerals 613 , 614 , 615 and 616 are as described in FIG. 6 .
[0028] Now referring to FIG. 9 which discloses a further exploded view of the room temperature control assembly depicted in FIG. 6 and FIG. 7 . Components are referenced by numerals 600 , 604 , 605 , 606 , 607 , 609 , 611 , 630 , 631 , 640 , 660 , 670 .
[0029] Now referring to FIG. 10 which discloses an alternate construction for the controlling unit. The improvements over the current state of the art also apply to this alternate construction. Internal components include a multiplicity rotating slotted cylinders for controlling the volumetric flow and flow direction as typically referenced by numeral 1010 displaying orientation for horizontal air movement and numeral 1011 displaying orientation for vertical air movement, a multiplicity sealing surfaces for reducing uncontrolled flow bypassing the cylinder as typically referenced by numeral 1020 , a multiplicity of actuators used to drive the rotation of the rotating cylinders as referenced by numeral 1030 . The housing as referenced by numeral 1040 and face plate as referenced by numeral 1050 serve a similar purpose of enclosing the internal operational parts as the assembly described in FIG. 6 except the construction would be different to be compatible with these shown internal parts. Sensing components 610 , 617 , 696 , 697 would be of similar construction and location as the assembly described in FIG. 6 .
[0030] Now referring to FIG. 11 which discloses detailed exploded view of the control unit depicted in FIG. 10 . Components on the supply side of the assembly for pressure control, sensing and energy harvesting are identical to components in FIG. 3 , FIG. 4 , FIG. 6 , FIG. 7 and FIG. 8 referenced by numerals 130 , 140 , 150 , 190 , 310 , 410 , 420 , 430 , 440 , 450 , 460 , 470 , 480 , 490 , 612 , 613 , 614 , 615 , 616 , 617 , 690 , 691 , 695 , 696 , 697 , 820 , 830 , 891 , 892 , and 893 . The alternate temperature control assembly include numerals 1010 , 1011 , 1030 , 1040 , 1050 , Additional components include gears referenced by numeral 1060 synchronizing the rotation of the cylinders.
[0031] Now referring to FIG. 12 , which discloses the components of the system providing the conditioned air to thermally control the occupied space. Two possible sources of conditioned air, whether working in parallel or independently, are an electrically powered blower as referenced by numeral 1210 and a solar collector structure producing solar heated air moved mechanical with a blower or hydronic water flow system and by natural buoyancy forces as referenced by numeral 1220 . The blower 1210 when feeding through a heating/cooling chamber referenced by numeral 1230 can produce the temperature and pressure of condition for the proposed controlling unit 100 . Wireless or wired communication between the controlling unit 100 and electronic communication/control modules on the blower and heating/cooling unit as referenced by numerals 1240 allow the energy conservation algorithm in the controlling unit 100 to optimized performance. The operation of the solar collector 1220 for heating/ventilation/ventilation cooling with ductwork and dampers controlled by the energy conservation algorithm n the controlling unit 100 is covered in detail in patent application #13230835. Alternate locations for the controlling unit 100 are referenced by numerals 510 , 560 , 530 , 540 , 550 . The return air diffuser allowing air passage back to the system blower numeral 1210 is referenced by numeral 1250 .
[0032] Now referring to FIG. 13 which discloses a schematic for the completed system outlining the logic applied to the individual components for optimum energy efficiency control. Signals are received from a multitude of Multifunctional Environmental Control Units described in FIGS. 1-12 as referenced by process numeral 1301 . User input information is received to “weight” the value of each Multifunctional Environmental Control Unit referenced by numeral 1301 as to its effect on the operation of the system cooling unit, the system heating unit, the system refrigeration unit referenced by numeral 1305 , the blower motor control referenced by numeral 1310 , and the damper control referenced by numeral 1309 . The system control algorithm applies the weight factors from the user input referenced by process step numeral 1302 and Multifunctional Environmental Control Units numeral 1301 as referenced by process step numeral 1303 and determines if the system should be in heating, cooling, or recirculation referenced by numeral 1305 and the speed of the blower motor referenced by 1310 , and the position of the system flow control damper referenced by 1309 as referenced by process control step numeral 1304 . As a function of the user input referenced by numeral 1302 the system can be utilized to maximize comfort while minimizing energy usage. This “just enough on time’ concept is enabled as a result of detailed feedback from each Multifunctional Environmental Control Unit detailed in FIGS. 1-12 .
[0033] Now referring to FIG. 14 which discloses the logic for the temperature control of the occupied space environmental control system. The algorithm is stored in a integrated circuit referenced by numeral 1401 that receives the dynamic sensor inputs during the control operation referenced by numeral 1402 and receives the fixed inputs, whether factory default or user dictated, referenced by numeral 1403 . The algorithm applies the correction factors to the current measurement from sensor numeral in process steps referenced by numerals 1404 and 1405 . The algorithm stores each consecutive temperature sensor reading from the room temperature sensor referenced by numeral 610 and supply temperature sensor referenced by numeral 696 . The logical steps based on the algorithm follows the process steps referenced by numerals 1409 - 1422 . The next step, after storing the factory and user input, is to determine a time delay period during which the electronics within the enclosure referenced by numeral 190 powers down to minimum and no signal is sent to actuators referenced by process numerals 1414 , 1415 , 1418 and 1420 . Each process cycle indexes a counter in the registry for number of cycles in the cooling mode referenced by process numeral 1411 or the heating mode referenced by process numeral 1410 or the recirculation mode referenced by process numeral 1416 . The duration of consecutive cycles in each mode dictates the time delay initiated in process numeral 1409 . An exception to the complete electronics power down during the time delay is initiated in medical applications. A health monitor sensor would send a wireless signal to the wireless receiving unit numeral 140 more frequently for critical life monitoring referenced by process numeral 1421 . After the time delay has expired, the algorithm determines if the system temperature is room temperature by a specified amount initiating the heating mode referenced by process numeral 1410 , if the supply temperature is below room temperature by a specified amount initiating the cooling mode referenced by process numeral 1411 , or if the supply temperature if within the plus and minus dead band (Tdb) around the room temperature initiating the recirculation mode referenced by process numeral 1416 . Typically, but not exclusively, in the heating mode numeral 1410 , a signal is sent to actuator numeral 640 to close the horizontal baffles numeral 630 . Similarly, in the cooling mode numeral 1411 , a signal is sent to actuator numeral 670 to close the vertical baffles numeral 660 . In the cooling mode operation, if the room temperature is greater the cooling set point plus Tdb and the temperature control baffle is in an intermediate position between full open and full closed, an opening signal is sent to the actuator numeral 640 in accordance with process numerals 1413 and 1414 . In the heating mode operation, if the room temperature is less the heating set point minus Tdb and the temperature control baffle is in a intermediate position between full open and full closed an opening signal is sent to the actuator numeral 670 in accordance with process numerals 1422 and 1415 . In either the heating mode numeral 1410 or cooling mode numeral 1411 , no signal is sent to actuators numeral 640 and numeral 670 , thereby maintaining current open position.
[0034] Now referring to FIG. 15 which discloses the control operation of the pressure supply baffle. The first step is to store in memory all factory default inputs and user defined inputs referenced by process numeral 1503 . All related sensor inputs for pressure referenced by process numeral 1502 are recorded in memory. Determine if there is a microphone input for sound measurements as reference by process numeral 1500 . If the sound level is unacceptable as referenced by process numeral 1506 , then the customer user set point input referenced by process numeral 1512 is adjusted. Recalibration of the relationship between the pressure sensor readings referenced by process numeral 1513 and microphone sensor referenced by process numeral 1514 is performed as referenced by process numeral 1504 . A new relationship between microphone readings and sound rating are calculated and stored as referenced by process numeral 1507 . With all the operational inputs stored, the first step in the control operation is to determine if the temperature control baffles actuator position sensors referenced by numerals 632 and 661 are in the fully closed position. If they are then the pressure control baffle actuator position sensor referenced by numeral 691 is driven to its fully closed position and the program starts over at the next iteration. If they are not, then the program continues with process steps referenced by numerals 1501 , 1509 , 1510 , and 1511 to control internal pressure sensor input from pressure sensor numeral 697 . If the pressure is above set point the pressure control actuator 695 is actuated to close the baffle to a position dictated by the control algorithm and measured by pressure actuator position sensor numeral 691 as referenced by process step 1511 . If the pressure is below set point the pressure control actuator 695 is actuated to open the baffle to a position dictated by the control algorithm and measured by pressure actuator position sensor numeral 691 as referenced by process step 1509 .
[0035] Now referring to FIG. 16 which discloses the operation of a smart window. When thermal radiation referenced by numeral 1602 from the sun referenced by numeral 1601 passes through a window referenced by numeral 1603 and heats the floor area referenced by numeral 1604 . The heated air rises as referenced by numeral 1612 rises and raises the temperature within the enclosed space referenced by numeral 1607 . An infrared sensor referenced by numeral 1605 with its cone of surface temperature measurement referenced by numeral 1606 measures the temperature of the floor area numeral 1604 near the window numeral 1603 . If the surface temperature measurement exceeds a preset set point and the outside ambient temperature as measured by the ambient air temperature sensor referenced by numeral 1610 is below the set point, the control algorithm within the control module referenced by numeral 1608 sends a signal to actuator referenced by numeral 1609 to open the window. Cooler air flows into room driven by ambient outside wind or negative pressure within the space. This negative pressure is created by mechanical fans referenced by numeral 1613 or the buoyancy effect of the heated area within the room rises upward through a vertical tower referenced by numeral 1614 to ambient conditions. No power is required for this system as a result of energy harvesting from a thermoelectric module referenced by numeral 1611 . The system would include a battery or super capacitor for energy storage. The system would include a moisture/humidity sensor referenced by numeral 1615 to signal the control module referenced by numeral 1608 to close the window in the event of rain or high humidity (i.e. fog). The system incorporates a low energy wireless communication module referenced by numeral 1616 to communicate with a remote CO2 module located in the multifunctional environmental control unit numeral 100 as referenced by numeral 480 or a separate module referenced by numeral 490 in a preferred location in the occupied space for quality of air monitoring and control.
[0036] The invention has been described in terms of the preferred embodiment. One skilled in the art will recognize that it would be possible to construct the elements of the present invention from a variety of means and to modify the placement of the components in a variety of ways. While the embodiments of the invention have been described in detail and shown in the accompanying drawings, it will be evident that various further modifications are possible without departing from the scope of the invention and it is not required to provide claims in a provisional application the following claims will help the invention to be better understood
|
A novel stand alone multifunctional electro-mechanical device for sensing, monitoring, and controlling environmental conditions within an occupied space, such as thermal control, room pressure, and light levels. The device utilizes a standard VAV Diffuser, an intelligently controlled window, or an intelligently controlled shutter that would optimize functionality and satisfy the aesthetic needs of occupants, designers, and architects while utilizing energy harvesting combined with ultra-low power operations to reduce the long term operational costs and installation costs, due to its stand alone configuration. The device has the capability and versatility to perform additional functions, such as life safety monitoring, fire detection, vital sign monitoring of occupants, entertainment features such as audio and video displays in conjunction with wireless and network communication features.
| 5
|
BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to nock assemblies for arrows. More particularly, the field of the invention is that of nocks that are mechanically secured to arrow shafts.
2. The Background Art
Presently nocks are mounted to arrow shafts using one of the following techniques. Each of these techniques has a number of inherent problems and disadvantages.
The first technique consists of a gluing the nock directly onto a tapered or swedged arrow. Typically, the shaft of an aluminum arrow is a cylindrical tube with an inner bore and a relatively thin rigid outer wall. On prior art aluminum arrows, a tapered nock mounting surface is produced for supporting a nock attached thereto by adhesive. However, swedging the end of an arrow shaft produces a tapered surface which is often off-center or split and thus causes problems in performance of the arrow such as erratic flight paths. In addition to possible defects in the swedged end, the swedging process is also a relatively expensive process which can create a significant amount of scrap.
Another technique of mounting a nock to an arrow shaft consists of gluing a nock mounting adapter into the arrow shaft. The nock mounting adapter has a tapered end to which the nock is glued. This mounting method eliminates the problems associated with defects caused by the swedging process. The nock adapter is inserted into the end of the arrow to provide a nock mounting surface. Such nock mounting adapters are well suited to have nocks glued to them; however the nock adapter must itself be glued into the shaft. This process is time consuming and difficult to perform in the field. Moreover, it can result in the nock and shaft not being concentric as a consequence of the gluing steps. A variation in nock concentricity can cause erratic flight of the arrow.
The third nock mounting technique consists of gluing a thin-walled nock adapter bushing or ring in the end of the arrow shaft. A nock having a round protrusion on the insert end the same diameter as the hole in the nock adapter bushing is pressed into this nock adapter ring. One such design is described in U.S. Pat. No. 5,067,731 (issued on Nov. 26, 1991 to Bickel). These prior art nock and bushing assemblies work well when the arrow shafts are exactly the right diameter, the bushing outside and inside diameters are machined exactly to the right diameters, and the assembly is used at moderate temperatures. This mounting method relies on the press fit of the nock into the nock adapter bushing to hold it securely to the arrow shaft. However, as temperature conditions vary (due to the varying rates of thermal expansions of the nock, bushing and shaft materials) and as the tolerance dimensions of the bushing, nock, and arrow shaft vary, the nock subsequently becomes either too loose or too tight.
Additional mounting techniques include screwing together modular threaded components, as shown for example in U.S. Pat. No. 4,706,965 (issued on Nov. 17, 1987 to Schaar) and U.S. Pat. No. 4,533,146 (issued on Aug. 6, 1985 to Schaar). However, such techniques, as they might be applied to arrow nocks, introduce the disadvantages of the threaded components inadvertently unscrewing, and the difficulty of aligning the bowstring slot with the fletches.
There is thus a need for a nock which can be easily and quickly installed into an arrow shaft without glue, thereby allowing for in-the-field installation. There is a further need for a nock which can be installed so as to be uniformly concentric with the shaft to provide the most accurate arrow flight. The nock needs to be rotatably adjustable and thereby capable of alignment with the arrow fletches (feathers) and/or the broadhead tip. This alignment feature assures the best possible arrow tuning, and subsequent trajectory.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an arrow nock which is mechanically secured to the arrow shaft.
It is a further object of this invention to provide a nock locking mechanism that eliminates the need to use glue or adhesives to secure the nock to the arrow shaft.
It is a further object of this invention to provide a nock locking mechanism that is self aligning, and as the nock is secured to the arrow shaft it aligns itself so as to be concentric with the arrow shaft.
It is a further object of this invention to provide a nock locking mechanism that can be loosened and adjusted, so as to be indexable with fletches and/or broadhead arrow tips.
It is a specific objective of this invention to provide an arrow nock that can be easily removed and accurately replaced.
Other objects and features of the present invention with respect to the following detailed description, taken in combination with the drawings.
The above objects and others not specifically recited are realized in a specific illustrative embodiment of a nock that mounts to an arrow shaft. The nock is designed of a light weight plastic material. It incorporates the use of a mechanical locking mechanism to secure it to the end of an arrow shaft. The portion of the nock that is inserted into the arrow shaft, or the insert end of the nock, is expanded by a small set screw located inside a cavity in the insert end of the nock. This expansion of the nock presses against the inside walls of the arrow consequently locking the nock in place. The nock is designed to mount securely to the arrow shaft without the use of adhesives or glue.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the invention will become apparent from a consideration of the subsequent detailed description presented in connection with the accompanying drawings in which:
FIG. 1 illustrates a side cross sectional view of an arrow nock made in accordance with the present invention, shown in conjunction with a tubular arrow shaft;
FIG. 2 illustrates a side, cross sectional view of the nock of FIG. 1 in relaxed condition;
FIG. 3 illustrates a side, cross sectional view of the nock of FIGS. 1-2 in a locked condition;
FIG. 4 illustrates a cross sectional view of the nock of FIG. 1, taken along section B--B;
FIG. 5 illustrates an alternative embodiment of the nock of FIG. 4;
FIG. 6 illustrates a side, perspective of the nock of FIG. 1 installed into a tubular arrow shaft;
FIG. 7 illustrates an alternative embodiment of the reverse-tapered arrow nock of FIG. 1.
FIG. 8 illustrates an alternative embodiment of the reverse-tapered arrow nock of FIG. 1.
FIG. 9 illustrates an alternative embodiment of the reverse-tapered arrow nock of FIG. 1.
DETAILED DESCRIPTION
Reference will now be made to the drawings wherein like structures will be provided with like reference numerals.
Referring now to FIG. 1, there is shown an arrow nock, generally designated at 100. The nock 100 includes an insert end 12 integrally connected to a nock end 19, and including an annular shoulder 21 at the junction therebetween. The lockable arrow nock 100 is designed to be inserted directly into a hollow shaft 1 and subsequently locked into place by means of a mechanical locking device 6. The hollow arrow shaft 1 includes a proximal end face 24 and interior side walls 8 defining an open receiving cavity 26. The mechanical locking device 6 frictionally secures the nock 100 to the shaft 1, and thus eliminates the need for gluing. The nock 100 is less sensitive to small variations in the tolerances, and is similarly not sensitive to atmospheric temperature changes.
The nock end 19 includes a notch 11 designed to receive a bow string therein. Bow string receptacles 10 define the notch 11. The insert end 12 includes a plurality of finger-like protrusions 2 configured and dimensioned for telescopic insertion into the receiving cavity 26 of the shaft 1 to frictionally engage with the interior side walls 8. The nock 100 thereby accepts and transfers the launching force of a bow and string to an arrow shaft 1. The protrusions 2 are laterally spaced apart to form small slits 3 that extend typically from the shoulder 21 to distal ends 28 of the protrusions. The purpose of the slits 3 is to provide lateral flexibility to the finger-like protrusions 2. The finger-like protrusions 2 include inner side walls 2a which collectively form a receiving compartment 5. The compartment 5 is profiled such that its cross-sectional area adjacent the distal ends 28 is smaller than its cross-sectional area adjacent the shoulder 21.
Within the compartment 5 resides a small set-screw 6. The diameter of the set-screw 6 is approximately the same as or slightly smaller than the diameter of the compartment near the shoulder 21, but is slightly larger than the diameter of the compartment 5 near the distal ends 28. The nock 100 includes an access hole 9 formed between the compartment 5 and the notch 11 to provide access to the set-screw 6. An Allen™ or hex wrench 13 can be used to screw the set-screw 6 into the inner side walls 2a to thereby move the protrusions 2 into frictional engagement with the interior side walls 8 of the shaft 1.
To install the nock into an arrow shaft, the insert end 12 of the nock is inserted into the cavity 26 of the arrow shaft 1. The finger-like protrusions 2 slide into said shaft. When the nock is fully inserted into the cavity 26 the proximal end face 24 of the shaft abuts against the should 21 of the nock. The nock can then be rotated in directions 18 shown in FIG. 6 so as to be aligned with arrow fletches 17 as desired. When the nock is properly adjusted, the Allen™ wrench 13 is inserted through the access hole 9 and into a polygonal recess 23 of the set-screw 6. The set-screw 6 is then screwed from its relaxed position 14 shown in FIG. 2, to a locked position 15 as shown in FIG. 3. The set-screw is screwed axially toward the distal ends 28 of the protrusions 2. Since the compartment 5 is smaller at the distal ends 28 than the set-screw 6, the flexible, finger-like protrusions are pressed radially outward and exterior side walls 4 of said protrusions are wedged against the interior side walls 8 of the arrow shaft 1. The outward spreading of the protrusions 2 is depicted by arrows 16 in FIG. 3. This wedging action of the nock 100 locks it securely in the arrow shaft 1 in frictional engagement.
To remove the nock, the Allen™ or hex wrench is again inserted into the access hole 9 and into the recess 23 of the set-screw 6. The set-screw 6 is then screwed axially away from the distal ends 28 of the protrusions 2 and releases the insert end 12 from frictional engagement with the interior side walls 8 of the shaft 1.
It is to be understood that the structures and features described herein can be embodied in many different forms. The presently preferred embodiment as illustrated in FIGS. 1-3 includes the inner side walls 2a in a reverse tapered configuration, i.e. the inner side walls 2a taper radially inward toward the distal ends 28 of the protrusions 2. The exterior side walls 4 and preferably straight and cylindrical. It will be appreciated that this combination of features results in the exterior side walls 4 being pushed radially outward when the set screw 6 is advanced toward the distal ends 28. Alternatively and by illustration only, the inner side walls 2a can be straight and non-tapered while the exterior side walls 4 are outwardly tapered as in FIG. 7, with the set screw 6 being preferably wider than the compartment 5 formed by the side walls 2a. The alternative embodiment of FIG. 8 illustrates stepped interior side walls 2a, including stepped structure 32 wherein at least the distal portion of the compartment 5 is narrower than the set screw 6. The embodiment of FIG. 9 depicts the cylindrical exterior side walls 4 and inwardly-tapered interior side walls 2a as in FIGS. 1-3, but includes a plug 30, instead of the set screw 6, which is advanceable toward the distal ends 28 in any suitable manner to push the walls 4 radially outward. As a further alternative shown in FIG. 1, a tapered plug 34 could be designed to be inserted through the access hole 9 to matingly engage with the inner side walls 2a of the protrusions 2 to force the protrusions laterally outward into frictional contact with the interior side walls 8 of the shaft 1. Removal of the plug 34 releases the protrusions 2 from frictional engagement with the interior side walls 8 of the shaft 1.
It will be appreciated that advancement of the set screw 6 in the embodiments of FIGS. 1-3 and 7-8 operates to press the exterior side walls 4 radially outward, and that advancement of the plug 30 in FIG. 9 also accomplishes the radially outward advancement of the side walls 4. It can thus be seen from the alternatives of FIGS. 1 and 7-9 that any suitable means for moving the exterior side walls 4 of the protrusions 2 radially against the interior side walls 8 of the shaft 1, and/or releasing said exterior side walls 4 from engagement with said interior side walls 8, is within the scope of the present invention.
It is preferable that the insert end 12 be of a circular exterior shape to conform with circular interior side walls 8 of the shaft 12, but the side walls 8 and the insert end 12 may alternatively form any other shape suitable for the purposes of the invention.
There are preferably three protrusions 2 as shown in FIG. 4, although four protrusions 2 as in FIG. 5 or more or less protrusions may be used to design an embodiment of the present invention. Alternatively, the nock 100 may comprise a solid tubular wall without any protrusions wherein the tubular wall is made of resilient expandable material which expands radially outward responsive to advancement of the set screw 6 within the compartment 5. The protrusions 2 are preferably of a common, uniform size and dimension, and are preferably positioned such that the receiving compartment 5 resides in a substantial co-axial orientation relative to the entire nock 100. It will be appreciated that such a configuration provides a self-centering, self-aligning capacity to the nock 100. As the set screw 6 is advanced axially toward the distal ends 28 to press the protrusions 2 laterally against the interior side walls 8, the entire nock 100 is brought into a co-axial alignment with respect to the receiving cavity 26 of the shaft 1.
It will be appreciated that the mechanical locking feature described herein provides the ability to selectively screw/unscrew the set screw 6 in order to lock/unlock the nock 100 to the shaft 1. The recess 23 and the wrench 13 may be of any correspondingly polygonal shapes, or any other suitable noncircular shapes in enable radial engagement therebetween. The nock 100 is preferably made of polycarbonate or plastic, but may be made from any other suitable material including metal. As the set screw 6 is screwed axially toward the distal ends 28 of the protrusions 2 and thus in lateral engagement with the protrusions, threads of the set screw tap their own grooves into the plastic material.
A preferred method for fabricating an arrow nock in accordance with the present invention includes the steps of:
(a) forming a nock body including an insert end portion and an opposing nock end portion, such that said insert end portion includes exterior side walls and is configured and dimensioned for telescopic insertion into the open receiving cavity of the shaft, and such that said nock end portion includes a receiving slot configured for receiving a bowstring therein; and
(b) forming locking means engagable with the nock body for selectively moving the exterior side walls of the insert end portion radially outward into contact with the interior side walls of the shaft such that said insert end portion is held in frictional engagement with said interior side walls to thereby lock said insert end portion to the shaft.
The present invention represents a significant advance in the field of arrow nocks. It is noted that many of the advantages of the present invention accrue from the combination of a one-piece nock 100 having a notch 11 in communication with a receiving compartment 5 via an access hole 9. This combination permits utilization of the set screw 6 to selectively lock/unlock the nock 100 onto/from the arrow shaft 1 in a purely mechanical manner. The mechanical nature of the invention negates the need for glue and enables the nock 100 to be loosened and tightened repeatably. The mechanically lockable/releasable aspect of the invention permits rotational adjustment of the nock 100 with respect to the fletches 17 at any time. The disadvantages in the prior art noted above and others not discussed are overcome to a significant degree by the present invention. Those skilled in the art will appreciate from the preceding disclosure that the objectives stated above are advantageously achieved by the present invention.
It is to be understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the present invention and the appended claims are intended to cover such modifications and arrangements.
|
A nock that mounts to an arrow shaft. The nock is designed of a light weight plastic material. It incorporates the use of a mechanical locking mechanism to secure it to the end of an arrow shaft. The portion of the nock that is inserted into the arrow shaft, or the insert end of the nock, is expanded by a small set screw located inside a cavity in the insert end of the nock. This expansion of the nock presses against the inside walls of the arrow consequently locking the nock in place. The nock is designed to mount securely to the arrow shaft without the use of adhesives or glue.
| 8
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority under 35 U.S.C. §119(e) of provisional application Ser. No. 60/737,210, filed Nov. 16, 2005.
BACKGROUND
[0002] Paperboard cartons are often used for packaging beverage containers cans and bottles. During packaging, cold or chilled beverage containers may be placed into the cartons and condensation from the air may form on the containers and drip onto the inside surfaces of the paperboard carton. This may weaken the carton, or cause reduced adhesion of external coatings resulting in deterioration or rub-off of graphics printed on the external coatings.
[0003] To protect against moisture absorption, the inside of the paperboard carton may be coated with a waterproofing or water resisting material. However, such materials reduce the adhesion of sealants used upon the flaps of the paperboard carton, so that the integrity of the carton may be compromised. To retain sealant adhesion, it is desirable that the waterproofing material be selectively applied to the interior surface of the paperboard, with the material not applied to areas intended for gluing. For other purposes, selective application may typically be done by a printing method, such as flexographic, rotogravure, or offset printing, but such methods typically cannot apply sufficient coat weights of the waterproofing material. Coat weights in range of 2.5 lb/1000 ft 2 are required, which can be applied by technologies such as rod coating used in papermaking, but these typically coat the entire surface. A method is desired that will allow the waterproofing material to be selectively applied at the higher coat weights that are typically achieved by paper machine coaters.
SUMMARY
[0004] The present invention provides a method whereby sufficiently high coat weights of waterproofing materials are applied to the “inside ” surface of a paperboard intended for use as a packaging material. Selected areas of the inside surface, preferably those areas to be glued, are left without the waterproofing material, in order to provide superior glue adhesion.
[0005] A method for producing a paperboard product having separate coated and uncoated areas is provided, in which a substrate web is moved over a rotating applicator roll so as to define a region of contact between the web and the roll. A coating material is applied to the surface of the applicator roll at an application location remote from the region of contact. A coating removal device is positioned adjacent the roll between the application location and the region of contact to remove a portion of the coating material from at least one area on the roll. Contact between the web and the roll transfers the coating material to the web, creating a coated surface except for a stripe corresponding to the portion of the coating material removed the said roll.
[0006] The method may include removing the coating material by a wiping action. The coating removal device may include a doctor blade disposed in contact with the surface of the roll.
[0007] The coating material may be applied to the roll by positioning a coating reservoir containing the coating material adjacent to the roll at the application location so that the surface of the roll contacts the coating material.
[0008] The applicator roll may also include at least one recessed area defined in the surface of the roll, whereby no contact is made between the roll and the web along said recessed area, thereby defining an uncoated area on the web corresponding to the recessed area.
[0009] In accordance with another embodiment of the invention, a method for producing a paperboard product having separate coated and uncoated areas includes the steps of extruding a coating material from an extruder having an elongated slot for the coating material to create a film of coating material. A portion of the slot is blocked to create a gap in the film of coating material. The film of coating material is then applied to a substrate web to produce a coated substrate web with at least one uncoated area thereon.
[0010] In accordance with still another embodiment of the invention, a method for producing a paperboard carton blank includes moving a substrate web over a rotating applicator roll so as to define a region of contact between the web and the roll. A coating material is applied to the surface of the applicator roll at an application location remote from the region of contact. A coating removal device is positioned adjacent the roll between the application location and the region of contact to remove a portion of the coating material from at least one area on the roll. Contact between the web and the roll transfers the coating material to the web, creating a coated surface except for a stripe corresponding to the portion of the coating material removed from the roll. A carton blank is then cut from the web so that an uncoated area of the blank is formed from substrate located along the stripe.
[0011] The uncoated area of the blank may be used to form the flaps of the carton.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a typical prior art coating process;
[0013] FIG. 2 illustrates an embodiment of the invention directed to providing uncoated stripes on a paperboard product;
[0014] FIG. 3 illustrates a paperboard carton blank with uncoated areas intended for gluing;
[0015] FIG. 4 illustrates an alternative embodiment of the invention directed to providing patterned uncoated areas on a paperboard product.
DETAILED DESCRIPTION
[0016] FIG. 1 illustrates a typical coating process. An applicator roll 110 rotates in a pan 120 containing a coating material 122 . The rotation of the applicator roll 110 through the coating material 122 results in a film of coating material upon the surface of the applicator roll 110 in the region indicated at 124 . A web 150 , for example of paper or paperboard, moves in contact with applicator roll 110 , causing part of the coating film to be transferred onto the web 150 , for example in a contact area or meniscus 126 .
[0017] Typically there may be an excess of coating deposited onto the web. To remove excess coating, a device such as rod 130 may be placed in contact with web 150 . The rod 130 may be supported by rod bed 135 . A backing roll 140 may be provided to form a nip between the backing roll 140 and the rod 130 , through which the web 150 passes, thus removing excess coating from the web, as shown by excess coating 137 draining away from the rod 130 , and back into pan 120 . Finally, the coated web 150 ′ continues on, for example to a drying process.
[0018] In accordance with a preferred embodiment of the invention, FIG. 2 illustrates a method for providing an uncoated stripe on a web. To accomplish this, a holder 210 holds a wiper 220 against the applicator roll 110 , so that the coating material film 124 may be wiped clean from the applicator roll as shown by area 230 . The wiper 220 may be a rigid, semi-rigid, or flexible device, for example a doctor blade, squeegee, wiper, roller, air blast, etc. When the web 150 contacts the applicator roll 110 , the web is left with a dry stripe 235 . Upon contact with the rod 130 , there may be some spreading of the coating upon the web, but typically there will still remain a dry stripe on the web in the machine direction, as evidenced by an area 240 of no excess wipe-off by the rod 130 . It may be necessary to use a short series of trials to determine the best placement and width of wiper 220 in order to provide the correct width of the final dry stripe 237 upon web 150 . The wiper 220 may be supported upon a support beam 215 , from whence its position may be adjusted. More than one wiper may be used to give multiple dry stripes.
[0019] The coated web may be used in the manufacture of paperboard articles such as cartons. The web 150 ′, after leaving the coating apparatus may be wound into a roll and transported to separate equipment for carton manufacture. Alternatively, the coating apparatus may be incorporated into the carton manufacturing equipment. In such case, the web 150 ′ may be fed into one or more printing stations where the web is printed using flexographic, gravure, or other printing methods on the side opposite the applied coating 124 . The printed web is then directed into cutting equipment that cuts printed carton blanks from the moving web.
[0020] FIG. 3 illustrates the formation of two paperboard carton blanks 300 , 302 from the coated web. Although only two are shown for illustration purposes, typically several blanks would be fitted in the cross direction of a paperboard web, and hundreds or thousands would fit in the machine (long) direction of a paperboard web. The blanks may be offset slightly in the long direction (as shown) in order to minimize waste of the paperboard material. The carton blanks have flaps 310 that are typically folded and glued during assembly. These flaps 310 fit in areas 320 , 322 , 324 that are not coated. The non-flap portions of the carton blanks fit in areas 330 , 332 that are coated, for example with a waterproofing material. The coating may preferably extend partway onto the flaps 310 provided uncoated area sufficient for gluing is left uncoated on the tabs. However, depending on the carton design, the coating areas 330 , etc. may be narrower or wider than shown.
[0021] In addition to imparting water resistance or water proofing, the coating may impart additional strength to the carton blank, and allow the use of lighter weight or lower caliper paperboard. The coating may itself provide strength, or may prevent loss of strength that may occur if the paperboard were to become wetted.
[0022] Carton blanks with portions coated to provide desirable properties (such as water resistance or water proofing) and other portions not coated to provide other desirable properties (such as superior gluability) may also be produced by methods such as extrusion coating. For example, to create uncoated stripes using an extrusion coater, portions of the extruder die slot may be closed, for example with blocks, to prevent flow from those areas of the slot. An extrusion coating upon exit from a die may exhibit “die swell” and upon travel from the die to the substrate may exhibit “neck-down”, either of which may cause the width of the uncoated stripe to differ from the width of a block in the die opening. Simple experimentation will suffice to determine the appropriate block width to achieve the desired uncoated stripe width.
[0023] FIG. 4 illustrates an alternate embodiment for the present invention in which further areas of the web may be left uncoated. This can be particularly useful, e.g., if a transverse region of a carton blank is to be used for gluing. The apparatus is the same as that shown in FIG. 2 , except that a recess 350 is formed into the surface of applicator roll 110 to correspond to the desired uncoated area. As roll is rotated through the coating material 122 , either no coating material will adhere to the roll on the recess 350 , or if it does, it will be carried at the bottom of recess 350 . In either case, no coating will be transferred to web 150 in this area, with the result that an uncoated area 360 will be formed repeatedly in a corresponding pattern on web 150 ′. By properly selecting and positioning one or more recesses 350 on roll 110 , the desired uncoated pattern may be produced.
[0024] Suitable coating materials are known to those skilled in the art. Such materials may be selected based upon the desired properties to be achieved by coating. For example, such coatings may be used to provide enhanced water resistance, grease or oil resistance, or improved tearing strength.
[0025] Methods of making and using the paperboard and the paperboard carton in accordance with the invention should be readily apparent from the mere description as provided herein. No further discussion or illustration of such products or methods, therefore, is deemed necessary.
[0026] While preferred embodiments of the invention have been described and illustrated, it should be apparent that many modifications to the embodiments and implementations of the invention can be made without departing from the spirit or scope of the invention. Although the preferred embodiments illustrated herein have been described in connection with a paperboard structure with a waterproofing material applied in a pattern through a particular coating process, these embodiments may easily be implemented in accordance with the invention in other structures or to by other application methods.
[0027] It is to be understood therefore that the invention is not limited to the particular embodiments disclosed (or apparent from the disclosure) herein, but only limited by the claims appended hereto.
|
A method of producing paperboard and cartons made therefrom is described incorporating a waterproof or water resistant coating applied to the interior of the carton except for areas intended for gluing. A coating material is applied to the surface of an applicator roll, and a portion of the coating material is then removed from the roll. Contact between a paperboard web and the roll transfers coating material to the web, creating a coated surface except for an uncoated stripe. A carton may be formed from the coated web with the uncoated portion of the carton cut from the uncoated strip.
| 3
|
RELATED APPLICATIONS
This is a continuation-in-part of co-pending application Ser. No. 07/627,507, filed Dec. 14, 1990, now U.S. Pat. No. 5,145,365, which is a continuation of application Ser. No. 07/358,715, filed May 26, 1989, now U.S. Pat. No. 5,032,081.
BACKGROUND OF THE INVENTION
In the field of orthodontics there has been an increasing demand for brackets that are aesthetic. In response to this need, various materials have been suggested for use in orthodontics brackets. Plastic materials have been found to be unsatisfactory due to their inability to provide the appropriate strength necessary for an orthodontic bracket. Various ceramic materials have been suggested in the prior art. However, prior art brackets made from these materials are quite brittle and are subject to fracture. Orthodontic brackets made of single crystalline alumina or cubic zirconia have been suggested. While these have been found to provide the strength necessary for use as an orthodontic bracket, they are relatively expensive materials, and are relatively difficult to machine due to their hardness and are subject to fracture due to their extreme hardness.
It has also been suggested to make orthodontic brackets from an ion exchange strengthened glass, such as illustrated and set forth in U.S. Pat. No. 4,784,606. This patent discloses strengthening the glass by subjecting it to an ion exchange reaction. The ion exchange treatment is carried out by immersing the glass bracket in a bath of molten salt at elevated temperatures above the strain point and below the softening point of the glass. The treatment time can vary from 2-24 hours. After it is removed from the bath, the bracket is washed clean of excessive salt. This, of course, adds substantial manufacturing cost. Additionally, the ion layer formed is very thin, and as a result, is subject to early wear which can result in failure of the part due to stress risers that can form.
It has been further suggested in the prior art to produce orthodontic brackets of a glass ceramic having dual crystalline structure, such as illustrated in U.S. Pat. No. 4,789,649. This patent discloses a bracket structure having relatively large crystals covered by a layer of smaller, flat crystals. While this structure may provide increased strength, its central crystalline structure is relatively difficult to machine and is subject to fracture in the same manner as other crystalline type brackets of the prior art.
Applicants have invented an orthodontic bracket which is made of a relatively inexpensive glass which can provide the desired strength, is easy to manufacture, relatively resistant to fracture, and does not require bath solutions or cleaning operations in order to enhance the strength of the material.
SUMMARY OF THE INVENTION
In one aspect of the present invention there is provided an orthodontic bracket which includes a base portion having a tooth contacting surface and a body member. The body member includes walls defining an arch wire slot. The bracket is made of an amorphous glass material having an outer crystalline strengthening layer. The combination of amorphous glass and a crystalline strengthening outer layer is advantageous over brackets consisting solely of amorphous or crystalline glass since these materials are independently weak.
In another aspect of the present invention, there is provided a method of making a glass orthodontic bracket having an outer crystalline strengthening layer comprising the steps of:
(a) forming the bracket from a glass material which is crystallizable when subjected to a heat treatment process; and
(b) subjecting the bracket to a heat treatment wherein a thin surface layer of the bracket is crystallized.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a perspective view of an orthodontic bracket made in accordance with the present invention;
FIG. 2 is a perspective view of a portion of a glass plate from which the orthodontic bracket of FIG. 1 can be made;
FIG. 3 is a top plan view of FIG. 2 illustrating, in solid line, the outline of an orthodontic bracket blank to be cut therefrom;
FIG. 4 is a perspective view of the orthodontic bracket blank cut from the plate illustrated in FIG. 3;
FIG. 5 is a perspective view of the bracket blank of FIG. 4, after the slot has been machined;
FIG. 6 is a top plan view of the orthodontic bracket after machining the notching illustrated by dash lines in FIG. 5;
FIG. 7 is a bottom perspective of the bracket of FIG. 1; and
FIG. 8 is a greatly enlarged cross-sectional view of a portion of the bracket illustrated in FIG. 1 identified by dash lines 8--8.
DETAILED DESCRIPTION OF THE INVENTION
In referring to FIG. 1 there is illustrated an orthodontic bracket 10 made in accordance with the present invention. Bracket 10 comprises a pair of tie wings 12 and 14 respectively, which are supported by a base 20 having a tooth contact surface 21 for attachment to the tooth and a connecting portion 15 which connects tie wings 12, 14. The tie wings 12, 14 and connecting portion 15 form a pair of side walls 18 which form an aligned archwire slot 20 for receiving an orthodontic archwire (not shown) as is typically done in the prior art. A substantially flat bottom wall 19 connects side walls 18 and forms the bottom of slot 20. It should be understood that the bracket 10 may be of any desired configuration used in the art, with the one shown in FIG. 1 being for the purpose of illustration only.
The bracket 10 of the present invention is manufactured from a sheet of glass 26 provided in a sheet form as illustrated in FIG. 2. Referring to FIG. 3, there is illustrated, in solid line, the outline of an orthodontic bracket blank 30 to be cut from the plate 26. In a preferred form of the present invention, ultrasonic machining techniques are used to cut a plurality of individual bracket blanks 30 from plate 26. The bracket blank 30 cut therefrom, see FIG. 4, are then subjected to a plurality of further machining operations so as to form bracket 10. The dash line 27 indicates the outline of the slot 20 to be machined into bracket blank 30. In the present invention, the slot 20, is formed by diamond wheel grinding. The dashed lines 29 in FIG. 5 illustrate the next machining step to be conducted on bracket blank 30. In the next machining operation, the tie wings 12, 14 and connecting portions 15 are formed. In the preferred form of the present invention, diamond wheel cutting is used for this operation. Thereafter, ultrasonic machining is conducted on the bottom of the bracket blank 30 to finally form bracket 10 to form contact surface 31 for attachment to the tooth. In the preferred form of the present invention, ultrasonic machining techniques are used for cutting blanks 30 from plate 30 and forming contact surface 31. It is to be understood that various other machining techniques such as diamond wheel grinding of the whole bracket may be used in order to form the orthodontic bracket. Other techniques produce equally acceptable brackets and the production technique preference depends on the individual situations.
After the bracket 10 has been finally formed, it is then subjected to a heat treatment process wherein a thin crystalline outer layer 38 (providing strengthening by compressive forces) is formed on the surface of the bracket 10 as illustrated in FIG. 8. A glass composition that is useful in providing an outer crystalline layer consisting essentially of the following oxides in approximate weight percentages set forth below, exclusive of minor impurities:
TABLE I______________________________________Material Percentage Preferred Percentages______________________________________SiO.sub.2 55-70 56-63Al.sub.2 O.sub.3 15-28 17-72ZnO 0-14 10-14Li.sub.2 O 3-7 4-6Na.sub.2 O 0-7 1.5-5Sb.sub.2 O.sub.3 0-2 .5-2K.sub.2 O 0-3 .1-1BaO 0-7 --MgO 0-5 --TiO.sub.2 0-.6 --______________________________________
In the particular embodiment illustrated, a glass made from the following oxides in the appropriate weight percentage was used:
TABLE II______________________________________Material Percentage______________________________________SiO.sub.2 58.8%Al.sub.2 O.sub.3 18.5%ZnO 12.5%Li.sub.2 O 5.3%Na.sub.2 O 3.3%Sb.sub.2 O.sub.3 1.5%K.sub.2 O .1%______________________________________
The bracket 10 using the appropriate glass composition provides an inner amorphous portion 39 within the outer crystalline layer 38. The thin outer layer 38 does not substantially affect the clarity of the glass, thus, leaving the bracket substantially transparent or translucent. The thin crystalline layer 38 has a thickness t in the range of 0.0005 to 0.005 inches (0.0127-0.127 mm), preferably between about 0.001 to 0.004 inches (0.0254-0.102 mm). The outer crystalline layer 38 provides a compressive force on the surface, resulting in the substantial increase in the strength and fracture toughness of the bracket 10. The thickness t of layer 38 should not be too thick in relationship to the size of the product, as this can cause too great a compressive force to be produced which can result in failure of the part. The thickness t of layer 38 is preferably no greater than about 25% of the cross sectional thickness of the product at it's thinnest point.
It is important in order to appropriately initiate the crystalline growth at the surface during the heat treatment process, that the surface have an appropriate roughness. Applicants found that the surface roughness, after the machining operation should be no less than about 4 RMS (root means squared) and generally no greater than about 250 RMS. It is important that the crystallization formed during the heat treatments initiate on the surface and not in the interior of the bracket 10, because if this happens, it will have the opposite results that is, weakening of the bracket. If the surface finish is too smooth, crystalline growth may initiate internally of the product. Preferably the surface roughness is between about 30 to 125 RMS. Applicants have found that the particular orthodontic bracket 10 in FIG. 1, having the composition set forth in Table II, should be heated to a temperature in the range of 600°-800° C. It is important that the bracket 10 be heat treated under the optimal conditions to initiate crystallization on the surface. Applicants have found that the time and temperature required is sensitive to the particular composition being used. Thus, a little experimentation may be necessary for any particular composition being used to determine the appropriate time temperature necessary for optimum crystallization. Generally, the higher the temperature, the shorter the time period necessary to obtain the thin outer crystalline layer 30. In the particular embodiment illustrated, Applicants have found that a heat treatment conducted at a temperature of about 700° C. for 1 to 2 hours provides the desired results.
Applicants have also found that the environment in which the brackets are heat treated can have a significant affect. For example, the orthodontic brackets are typically placed in a boat, which is placed into an appropriate oven wherein it is heat treated. Applicants have also found that the material of the boat and whether the boat is covered or not can have an effect upon its ultimate fracture toughness.
In an evaluation of fracture toughness in accordance with various heat treatment conditions, the fracture toughness was tested for specimens made out of the material from Table II, and tested for fracture toughness in accordance with ASTM-procedure. A control test specimen, identified as C, was made but not subjected to any heat treatment. A first test specimen (Sample 1) was made and subjected to a heat treatment process of 700° C. for about 1 hour which was heated in an aluminum oxide boat which was uncovered. Sample 2, a second test specimen was heat treated for approximately 35 minutes in an aluminum oxide tray which was uncovered. Sample 3, a third test specimen, was heat treated at 690° C. for approximately 1 hour in an aluminum oxide tray which was uncovered. A fourth test specimen (Sample 4) was heat treated at 700° C. for approximately an hour in a stainless steel boat which was placed on bricks on its removal from the oven to be cooled. All Samples in No. 4 were fractured. It is important to place the bracket in a boat or tray having a thermal conductivity substantially similar to that of the material of the bracket. The following Table III sets forth a comparison of the fracture toughness of the control and heat treated specimens 1, 2, and 3 set forth above.
TABLE III______________________________________ Fracture Toughness K.sub.1c (MPa√m) Fracture Stress orSample (MPa) (MPam1/2)______________________________________C 84 ± 18 1.1 ± 0.11 372 ± 70 4.6 ± 0.82 279 3.9 ± 1.83 268 ± 152 3.2 ± 1.8______________________________________
As it can be seen from the foregoing, the first test specimen (Sample #1), i.e., which was heat treated for 60 minutes in an uncovered aluminum oxide tray, showed the greatest fracture toughness. Fracture toughness increased by a factor of approximately 4, as opposed to an unheat treated product. Thus, heat treating the bracket under appropriate conditions provided significant improvement in the fracture toughness of the material. As can be seen from sample #3, the 690° C. temperature simply did not provide the desired crystalline depth outer layer. Thus, it would appear that with this particular composition that the time and temperature used was insufficient to obtain the full fracture toughness capable of being obtained from the composition.
Applicants have compared orthodontic brackets made from the glass material of the present invention and heat treated in accordance with the present invention with brackets made of sapphire, cubic zirconium and polycrystalline aluminum materials of the prior art. As can be seen from the following Table IV below, the brackets made out of the glass and heat treated according to the present invention, exhibited strength values equal to or better than sapphire and cubic zirconia, and markedly improved value over polycrystalline materials of the prior art. While the single crystal zirconia and alumina brackets showed a wide range of strength, approximately 20% of the brackets broke at values below acceptable levels. The strength of the glass materials was found to be more consistently high value, thus, providing more brackets in the acceptable strength range. Subjecting the glass bracket 10 to the heat treatment according to the present invention results in a complete change to the structure of the outer surface. The heat treatment provides a fresh new thin crystalline layer which has very few surface flaws, thus, minimizing or eliminating the effects of the machining conducted thereon.
TABLE IV______________________________________Bracket Material Relative FractureDescription Torque Values (Nm)______________________________________T.T. Glass .07Sapphire .065PCA .045CZ .07______________________________________
Bracket Material Description
It is to be understood that various modifications may be made to the present invention without departing from the scope thereof. For example, various other compositions may be used so long as the appropriate compressive crystalline strengthening outer layer may be formed. Other additives or impurities may be present which do not affect the structure or performance of the bracket. Another example of a composition believed to provide adequate performance is set forth below in Table V.
TABLE V______________________________________Material Percentage______________________________________SiO.sub.2 61.8%Al.sub.2 O.sub.3 18.5%ZnO 12.5%Li.sub.2 O .3%TiO.sub.2 1.0%Sb.sub.2 O.sub.3 .5%Na.sub.2 O .3%K.sub.2 O .1%______________________________________
Additional example of glass compositions suitable for use in the brackets of the present invention are provided in Table VI below. Preferably, upon suitable heat treatments the outer crystalline strengthening layer has a thickness in the range of about 0.0005 to 0.005 inches, and more preferably in the range of about 0.0015 to 0.003 inches.
TABLE VI______________________________________ Material Percentages______________________________________ SiO.sub.2 50.0-70.0% Al.sub.2 O.sub.3 10.0-25.0% Li.sub.2 O 3.0-10.0% TiO.sub.2 0.0-2.0% MgO 0.0-10.0% Sb.sub.2 O 0.0-5.0% CaO 0.0-5.0% BaO 0.0-20.0% Zn0 0.0-7.0%______________________________________
The present invention being limited by the following claims.
|
An orthodontic bracket made of a partially crystallized amorphous glass material and method for making same. The orthodontic bracket has a thin compressive outer crystalline layer.
| 2
|
FIELD OF THE INVENTION
[0001] This invention relates generally to an arrangement for an axle which is anchored at two points situated at the ends of the axle and, more specifically, to an arrangement for an axle for a bearing-mounted hinge by means of which very stable fixing of the inner race of the bearing can be obtained.
BACKGROUND OF THE INVENTION
[0002] The conventional way to achieve pivotability in a connection between two machine parts is to use a hinge journalled in bearings, comprising one or more bearings arranged on an axle which is fixed in between a pair of mounting cheeks or the like on one of the machine parts. The inner race of the bearing or bearings is disposed on the axle and, possibly with the aid of distancing rings, bridges the distance between the fixing cheeks, while the outer race of the bearing or bearings is effectively connected to the second machine part. Since relative movement between the inner bearing race and the axle produces progressively increasing wear resulting in excessive play and perhaps fracture of the axle, the race has to be fixed relative to the axle by means of nuts screwed onto the respective axle ends. It is important that the nuts are tightened just the right amount, since excessive tightening may jeopardize the attachment of the mounting cheeks, and excessive play may arise as a result of insufficient tightening, with the results mentioned above
[0003] Therefore, a need existed to provide a system and method to overcome the above problem. The system and method would provide an arrangement for an axle for a bearing-mounted hinge by means of which very stable fixing of the inner race of the bearing can be obtained, thereby preventing the disadvantages described above.
SUMMARY OF THE INVENTION
[0004] A pin assembly for providing a stable anchor on multiple ends has an axle having a pair of end members formed on each end of the axle. The axle is placed in a first opening in a first mounting end of a component part and extends to a second opening in a second mounting end of the component part. A bearing is mounted on a central section of the axle. A spacer is positioned between the bearing and one of the first or second mounting ends. A pair of expansion sleeves is provided wherein one of the pair of expansion sleeves is positioned over each of the end members of the axle. A pair of locking devices is provided wherein one of the pair of locking devices is coupled to each of the end members. When tightened, the locking devices cause the expansion sleeves to press against interior walls of the first and second openings to anchor the axle
[0005] A method of installing a pin assembly for providing a stable anchor on multiple ends comprises: providing a pin assembly comprising: an axle having a first and second end members formed on the axle; a bearing mounted on a central section of the axle; a spacer; a pair of expansion sleeves, wherein one of the pair of expansion sleeves is positioned over each of the end members of the axle; and a pair of locking devices; positioning the spacer between the bearing and one of the first or second mounting ends; positioning the axle so that the axle is placed in a first opening in a first mounting end of a component part and extends to a second opening in a second mounting end of the component part, the axle passing through the bearing and the spacer element and through the second opening; attaching one of the pair of fastening element to the second end member to eliminate axial play; placing one of the pair of expansion sleeves over the first end member of the axle; and attaching a second of the pair of fastening elements to the first end member and tightening so that the one of the pair of expansion sleeves expands and press against an interior wall of the first opening.
[0006] The present invention is best understood by reference to the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of the stepped pin assembly used to connect two machine parts;
[0008] FIG. 2 is an exploded view of the stepped pin assembly; and
[0009] FIG. 3A-3D shows a method of installing the stepped pin of the present invention.
[0010] Common reference numerals are used throughout the drawings and detailed description to indicate like elements.
DETAILED DESCRIPTION
[0011] The present invention provides an arrangement for an axle for a bearing-mounted hinge for which a very stable fixing of the inner race of the bearing can be obtained. Referring to FIGS. 1 and 2 , a stepped pin assembly 100 is shown. The stepped pin assembly 100 is used to pivotally couple two component parts 102 and 104 of a machine together. In the embodiment shown in FIGS. 1 and 2 , the stepped pin assembly 100 is positioned between two mounting cheeks 106 of the component part 102 . A spacer element 108 is generally positioned between the lower component part 104 and the mounting cheeks 106 .
[0012] The pin assembly 102 will have an axle 110 . A pair of end members 112 is formed on each end of the axle 110 . In the embodiment shown in FIGS. 1 and 2 , the end members 112 are tapered so that the distal end of the end members 112 is narrower than the proximal end. However, this is just shown as an example. The end members may be cylindrical in shape as will be discussed below.
[0013] The axle 110 is passed through through-bores 114 and 116 formed in the mounting cheeks 106 and fixed relative to them by means of a pair of fastening devices 118 coupled to each end member 112 . In the embodiment depicted in FIGS. 1 and 2 , each end member has a threaded channel formed down a portion of the length of the end member 112 . The fastening elements 118 are rotateably coupled to each end member 112 of the pin assembly 102 outside of the mounting cheeks 106 . On a central section of the axle 110 is bearing 120 is mounted. The space between the bearing 120 and the mounting cheeks 106 is bridged by the spacer element 108 .
[0014] In the embodiment depicted in FIGS. 1 and 2 , a pair of expansion sleeves 122 is inserted in the through-bores 114 and 116 . Each expansion sleeve 122 has a housing 122 A. In accordance with one embodiment of the present invention, the housing 122 A is cylindrical in shape while the end member 112 of the pin assembly 102 is conical. However, in accordance with another embodiment of the present invention, the housing 122 A is conical in shape while the end member 112 of the pin assembly 102 is cylindrical.
[0015] Each housing 122 A is hollow and has a pair of open ends. A plurality of slots 122 B is formed in the housing 122 A and goes through the housing 120 into the hollow section of the housing 122 A. The slots 122 B generally run along a length of the housing 122 A. At least one of the plurality of slots 122 B will run an entire length of the housing 122 A. The slots 122 B act as annular wedges, with the apex pointing towards the central section of the axle 110 . The number of slots 122 B formed in the housing 122 is based on the diameter of the housing 122 . The larger the diameter of the housing 122 the more slots 122 B are generally needed. In general, four to six slots 122 B are formed in each housing 122 . The slots 122 B will run vertically down the side of the housing 122 . One slot 122 B may run the length of the housing 122 . The housing 122 is generally made of a sturdy metallic material. In accordance with one embodiment of the present invention, a treated yellow chrome oxide is used to form the housing 122 .
[0016] The expansion sleeves 122 are used for anchoring of the axle 110 in the respective mounting cheeks 106 . This is accomplished by causing the respective expansion sleeves 122 to expand over the end members 112 of the axle 110 by means of the fastening elements 118 and a pair of washer elements 124 A and 124 B so that the expansion sleeves 122 are pressed against the interior walls of the through-bores 114 and 116 respectively. When the fastening element 118 is tightened, the spacer element 108 presses the inner race of the bearing 120 . The slots 122 B allow the expansion sleeves 122 to expand and press against the interior walls of the through-bores 116 thus securing the inner race to be fixed properly without risk of deformation. In accordance with one embodiment of the present invention, the fastening elements 118 are a pair of locking screws rotateably coupled to the end members 112 of the axle 110 . Each locking screw would engage the threaded channel formed down a portion of the length of each of the end member 112 .
[0017] After the fastening element 118 is tightened to a proper level, a lock nut 126 is attached. The lock nut 126 is used to further secure the pin assembly 102 in position and eliminate any possibility of axial movement. In accordance with one embodiment of the present invention, a threaded washer 124 A and a torque lock nut 126 is used. The torque lock nut 126 will engage threads formed on the threaded washer 124 A. By tightening the torque lock nut 126 onto the threaded washer 124 A, this will further secure the pin assembly 102 in position and eliminate any possibility of axial movement.
[0018] Referring to FIGS. 3A-3D , a method of installing the stepped pin assembly 100 will be disclosed. As shown in FIG. 3A , two component parts 102 and 104 need to be coupled together with the stepped pin assembly 100 . In the embodiment shown in FIG. 3A , a component part 104 is positioned between two mounting cheeks 114 and 116 . A spacer element 108 should be positioned between the component part 104 and the lower mounting cheek 106 . The spacer element 108 should be positioned between the component part 104 and the lower mounting cheek 106 so that a bevel side 108 A is facing the bearing 120 on the axle 110 when the stepped pin assembly 100 is installed.
[0019] As shown in FIG. 3B , the axle 110 of the stepped pin assembly 100 is passed through the through-bores 114 and 116 in the mounting cheeks 106 . After the axle 110 has been passed through the through-bore 116 , the bearing 120 and the spacer element 108 in that order are threaded over the axle 110 , after which the axle 110 is passed through the through-bore 114 so that it is finally located outside the lower mounting cheek 106 . It will be appreciated that one prerequisite for the axle 110 being able to be pushed through the through bore 114 is that the inner diameter of the fixed spacer element 108 should be less than the diameter of the through-bore 116 . A fastening element 118 , a threaded washer element 124 A, and the torque lock nut 126 are then rotateably coupled to the lower end member 112 of the pin assembly 102 outside of the mounting cheek 106 to eliminate any axial play.
[0020] An expansion sleeve 122 is first placed over an upper end member 112 of the axle 110 . One of the fastening elements 118 and the washer elements 124 B is rotateably coupled to the upper end member 112 and tightened. The expansion sleeve 122 has an internal diameter such that the expansion sleeve 122 is not influenced when the fastening element 118 is tightened. When the fastening element 118 is tightened, the spacer element 108 presses the inner race of the bearing 120 . The slots 122 B allow the expansion sleeves 122 to expand and press against the interior walls of the through-bores 116 thus securing the inner race to be fixed properly without risk of deformation. In order to achieve secure mounting of the axle 110 relative to the mounting cheeks 102 , the expansion sleeve 122 is first put on the axle end which is situated furthest away from the spacer element 108 which is rigidly fixed on the axle 10 .
[0021] As shown in FIG. 3D , an expansion sleeve 122 then needs to be placed over the lower end member 112 of the axle 110 . The fastening element 118 and the washer element 124 A are then rotateably removed from the lower end member 112 of the pin assembly 102 . An expansion sleeve 122 is then placed over the lower end member 112 of the axle 110 . The fastening element 118 and the washer elements 124 A are then again rotateably coupled to the lower end member 112 and tightened. The slots 122 B allow the expansion sleeves 122 to expand and press against the interior walls of the through-bores 114 thus securing the inner race to be fixed properly without risk of deformation.
[0022] The pin assembly 102 provides for an arrangement for an axle 110 which is anchored at two points situated at the end 112 of the axle 110 , generally in mounting cheeks 106 or the like provided with through-bores 114 and 116 for the axle 110 . Anchoring is accomplished by means of fastening elements 118 which can be rotateably coupled on outside the fixing points. On a central cylindrical part of the axle 110 is designed to have a bearing 120 mounted thereon which is fixed by means of a spacer element 108 disposed on the axle 110 and bridging the distance between the respective fixing points and the bearing 120 . Two expanding sleeves 122 can be inserted in the through-bores 114 and 116 over the respective fixing points onto the ends 112 of the axle 110 . The expansion sleeves 122 act as annular wedges with their apex pointing towards the cylindrical part of the axle 110 so that by means of the fastening elements 118 the respective expansion sleeves 122 can be caused to expand against or be pressed in by the wall of the through-bores 114 and 116 thereby accomplishing the anchoring of the axle 110 .
[0023] After the fastening element 118 is tightened to a proper level, a lock nut 126 is attached. The lock nut 126 is used to further secure the pin assembly 102 in position and eliminate any possibility of axial movement. In accordance with one embodiment of the present invention, a threaded washer 124 A and a torque lock nut 126 is used. The torque lock nut 126 will engage threads formed on the threaded washer 124 A. By tightening the threaded torque lock nut 126 onto the washer 124 A, this will further secure the pin assembly 102 in position and eliminate any possibility of axial movement.
[0024] This disclosure provides exemplary embodiments of the present invention. The scope of the present invention is not limited by these exemplary embodiments. Numerous variations, whether explicitly provided for by the specification or implied by the specification, such as variations in structure, dimension, type of material and manufacturing process may be implemented by one of skill in the art in view of this disclosure.
|
A pin assembly for providing a stable anchor on multiple ends has an axle having a pair of end members formed on each end of the axle. The axle is placed in a first opening in a first mounting end of a component part and extends to a second opening in a second mounting end of the component part. A bearing is mounted on a central section of the axle. A spacer is positioned between the bearing and one of the first or second mounting ends. A pair of expansion sleeves is provided wherein one of the pair of expansion sleeves is positioned over each of the end members of the axle. A pair of locking devices is provided wherein one of the pair of locking devices is coupled to each of the end members. When tightened, the locking devices cause the expansion sleeves to press against interior walls of the first and second openings to anchor the axle.
| 8
|
CROSS-REFERENCE TO PROVISIONAL APPLICATION(S)
This application claims the benefit of U.S. Provisional Application No. 60/586,760, filed Jul. 9, 2004, which disclosure is incorporated by this reference thereto.
BACKGROUND AND SUMMARY OF THE INVENTION
The invention relates to exhaust fans for exhausting “dirty” or “lab” air (more generically, “inlet” air) and, more particularly, to exhaust fans which mix the inlet air flow with an induced air flow (sometimes otherwise referred to as “dilution” or “rooftop” air).
As a matter of background, exhaust emissions have long been provided with exhaust stacks in order to ensure that the “effective” stack height of the emissions is at least the physical stack height. However, “effective” stack height is more accurately the sum of the physical stack height plus the gains gotten from other effects such as efflux velocity and flowrate, or in other cases buoyancy, and so on. Looked at another way, “effective” stack height is the point where (ignoring buoyancy) the contributions end from such other effects as efflux velocity and flowrate. At that point, the emissions are at the mercy of the dispersions of the localized ambient.
It is an object of the invention to provide exhaust fan systems which minimize physical stack height but through other design factors maximize effective stack height.
It is an alternative object of the invention to achieve the foregoing in combination with mixing an induced or dilution air flow with the given inlet (eg., “dirty” or “lab”) air flow such that the efflux comprises a mixed flow.
It is an additional object of the invention to provide the foregoing with dual driven-impeller packages such that they operate as counterparts to each other. That is, one impeller is optimized for suctioning out the inlet flow from a converging network of ducts having origins in remote diverse intake ports. In contrast, the other impeller is optimized for expelling the mixed exhaust in a tall, columnar plume.
These and other aspects and objects of the invention are provided by an exhaust apparatus for diluting a forced, primary flow of gases with a secondary flow and expelling the consequential diluted flow. One embodiment of such an apparatus comprises the following. That is, it has a passageway for delivering the forced, primary flow. The passageway terminates in an outlet port therefor.
There is also a center body that axially extends from the outlet port to a spaced terminal end. The center body is radially contoured in the axial direction from the outlet port toward the terminal end to include a flaring portion, a convex transition portion, and then a tapering portion. The center body is positioned with respect to the outlet port to accept the delivery of the primary flow to outflow therefrom and be flared out by traversing along the flaring portion.
There is furthermore a windband or, in alternative terminology, a collar. Such a collar axially extends between an input end and a spaced output end. The collar is radially sized to surround the center body and define an annular flow passage therewith. The collar furthermore includes an intermediate hoop section that is sized and disposed to define an annular throat in combination with the center body's convex transition portion.
Given the foregoing, the collar being disposed such that the input end is aimed to channel the outflow of the primary flow from the outlet port toward said throat. Additionally, the collar's input end is spaced away from the passageway's outlet port to allow the introduction of the secondary flow to the primary flow such that the consequential diluted flow flows through said throat and is expelled out the output end.
The invention might more particularly be situated in an environment whereby the passageway comprises an exhaust stack. Such an exhaust stack extends into ambient air and therefore the collar might be reckoned as shaped in a funnel form. That is, from a reference of the hoop section, the funnel form generally flares out toward the input end as well as tapers in toward the output end. In this context, the secondary flow generally comprises drawn in ambient air.
The invention might further be conceived of as including a driven fan downstream from the outlet port for forcing the primary flow. In this context, the primary flow can be reckoned as exhaust gases which are pre-selected to be diluted by ambient air.
In the context of the passageway comprising an exhaust stack, the center body might optionally include a circumferential seam below the convex transition portion for draining adhering rainwater into an interior well. Moreover, the collar might be advantageously shaped to taper toward the output end in spaced correspondence with the center body's tapering portion in order to define an annular nozzle passage sized to forcibly expel the diluted flow.
An alternate embodiment of such an exhaust apparatus operates to combine a forced, first flow of gases with a second flow, thereafter forcibly expel the consequential combined flow. Such an apparatus includes an inventive impeller wheel for forcing the second flow in a direction from a suction side to a pressure side.
Such an impeller wheel includes a hub for rotation about a spin axis, a coaxial rim annularly spaced from the hub and axially extending between a pressure-side edge and a suction-side edge, apertured webbing radially spacing and interconnecting the hub and rim, and angularly spaced blades extending radially out from the rim to tip edges.
A like passageway as described previously is provided for delivering the forced, first flow. Such a passageway terminates in an outlet port, which is disposed to match up closely with the rim's suction-side edge for channeling the forced, first flow to pass through the apertured webbing from the suction side to the pressure side.
Given the foregoing, the blades of the spinning impeller wheel axially force the second flow to annularly wrap around a core of the forced, first flow and thereby afford the flows to combine into the combined flow on the pressure side of the impeller wheel.
This alternate embodiment of an exhaust stack apparatus might optionally include a windband as well, or in alternate terminology, a shroud. Such a shroud would preferably have a circumferential sidewall axially extending between an input end and a spaced output end. It would also preferably have a hoop section that is axially-spaced from the output end. More preferred still is if this particular hoop section is radially-sized and positioned to closely surround a periphery of the tip edges of impeller wheel blades. Overall, the shroud should be positioned such that the input end channels a supply of the second flow toward the impeller blades from the suction side. In consequence, the output end will expel the consequential combined flow.
This alternate embodiment of an exhaust stack apparatus might further be designed as a package including a driven fan downstream from the impeller wheel for forcing the first flow. That way, if the drive for the impeller wheel is adjustable for expelling the diluted flow, then driven fan might be independently adjustable for the loads it is designed to carry in suctioning out exhaust gases from a building or the like.
It is an aspect of the invention that the aforementioned apertured webbing might be realized in any of a variety of designs, including without limitation being designed as angularly-distributed spokes.
A number of additional features and objects will be apparent in connection with the following discussion of preferred embodiments and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
There are shown in the drawings certain exemplary embodiments of the invention as presently preferred. It should be understood that the invention is not limited to the embodiments disclosed as examples, and is capable of variation within the scope of the appended claims. In the drawings,
FIG. 1 is a partial sectional view of an exhaust stack system in accordance with the invention, taken along line I-I in FIG. 4 ;
FIG. 2 a is a side elevational view of the windband, center bulb and one version of the lower outer housing of FIG. 1 ;
FIG. 2 b is a sectional view taken along line IIB-IIB in FIG. 2 a;
FIG. 3 a is a side elevational view of the windband, center bulb and an alternate version of the lower outer housing of FIG. 1 ;
FIG. 3 b is a sectional view taken along line IIIB-IIIB in FIG. 3 a;
FIG. 4 is a side elevational view of FIG. 1 ;
FIG. 5 is an enlarged sectional detail taken from FIG. 1 of the center bulb and windband to show the dilution of the primary flow with the induced flow of rooftop air and show the consequent production of a plume of the diluted flow;
FIG. 6 is partial sectional view comparable to FIG. 1 except showing an alternate embodiment of an exhaust stack system in accordance with the invention;
FIG. 7 is a side elevational view thereof;
FIG. 8 is an exploded view thereof, with portions shown in hidden lines, other portions removed from the view, and other portions shown in a compressed perspective;
FIG. 9 is an enlarged scale perspective view of the induced air impeller thereof;
FIG. 10 is a top plan view of FIG. 9 ; and
FIG. 11 is a side elevational view thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 5 shows a first embodiment of an exhaust stack system 10 in accordance with the invention. It comprises an intake duct 12 to situate directly on top of the upper terminus of an inlet-air blower 14 . The inlet-air blower 14 operates in part to suction out the inlet flow from a converging terminus 16 of a network of ducts (not shown) having origins in remote diverse intake ports (not shown). It is an aspect of the invention to draw in a dilution air flow to mix with the inlet air flow and then thereafter expel the mix in a tall, columnar plume by a relatively compact stack so that the effective height of the stack far exceeds the comparatively diminutive, physical height of the stack. This aspect is achieved in part by the following.
There is a center (inner) tapered housing 18 surrounded by a companion outer housing 19 ( 2 ) or 19 ( 3 ). The outer housing 19 ( 2 ) or 19 ( 3 ) terminates in an upper end which defines a (lower) exhaust port 20 for the inlet flow. FIG. 1 shows one version of the outer housing 19 ( 3 ). This version of the outer housing 19 ( 3 ) is shown better by FIGS. 3 a and 3 b . This version of the outer housing 19 ( 3 ) is designed for high efficiency operation, in contrast to high discharge velocity operation. An alternate version of the outer housing 19 ( 2 ) is shown better by FIGS. 2 a and 2 b . This version of the outer housing 19 ( 2 ) is designed for high discharge velocity operation, in contrast to high efficiency operation. That is, the high discharge velocity version of the outer housing 19 ( 2 ) defines a relatively more constricted exhaust port 20 than the high efficiency version of the outer housing 19 ( 3 ). Hence the high discharge velocity version of the outer housing 19 ( 2 ) with its relatively more constricted exhaust port 20 makes the fan motor 15 work harder than the high efficiency version of the outer housing 19 ( 3 ).
With either version of the outer housing 19 ( 2 ) or 19 ( 3 ), the air inlet flow is discharged through the exhaust port 20 into a windband 22 . Again, the upper termination of the outer housing 19 ( 2 ) or 19 ( 3 ) defines the elevation of the (lower) exhaust port 20 .
In contrast, the center (inner) housing 18 extends above the elevation of the (lower) exhaust port 20 . From this elevation and above, the center (inner) housing 18 is more particularly referenced as a center bulb 26 . The center bulb 26 very approximately resembles a toadstool cap. The windband 22 has an open lower skirt portion 24 for dragging in a dilution (or “rooftop”) air flow. The windband 22 extends upwardly and surrounding the center bulb 26 . The windband 22 and center bulb 26 are cooperatively shaped and arranged to form an upper venturi throat 28 , which is designed to expel the mix of inlet and dilution air in a tall, columnar plume.
The center (inner) housing 18 has an intermediate partition 27 . This intermediate partition 27 functions in part as a rainwater gutter. Rainwater landing on top of the center bulb 26 is blocked from dripping directly down onto the inlet-air blower 14 . Instead, the rainwater dribbles down the sidewall of the center bulb 26 as well as continuing down where the center bulb transitions into the center (inner) housing 18 due to the property of surface adhesion or the like. Whenever the dribbling rainwater reaches the level of the intermediate partition 27 , the dribbling rainwater continues to follow the contour until it drips off into a well (the well is not illustrated) for the drip-off that is provided inside the center (inner) housing 18 . The well is sized to catch the rainfall during rainy periods. The well has a drainpipe (now shown) for draining the caught rainfall out onto the rooftop.
FIG. 5 shows the physical factors involved which force the dilution of the primary flow with the induced flow of rooftop air and thereby obtain the consequent production of a plume of the diluted flow.
The center bulb 26 extends axially from the exhaust port 20 to the center bulb 26 's terminal cap with a contour as follows. That is, the center bulb 26 has a flaring portion 26 f that changes into a convex transition portion 26 x that then changes into a tapering portion 26 y . The lower exhaust port (eg., 20 , but not shown in FIG. 5 ) delivers the primary flow to outflow therefrom and be flared out by traversing along the flaring portion 26 f . Rooftop air is induced to flow through the throat 28 by various forces. For streams of the rooftop air in closest proximity with the primary flow, these streams are dragged along by shear forces. Other streams of rooftop air are suctioned in by a low pressure belt created around the waist of the flaring portion 26 f . Together these streams of rooftop air along with the primary air flow through the venturi throat 28 and mass together likely because of both a venturi effect and a Coanda effect.
Briefly, the venturi effect describes the case of a flow flowing through a constriction (ie., the throat 28 ). The flow speeds up in the restriction, producing a reduction in pressure and a partial vacuum. One way to visualize the venturi effect is to squeeze a (very) flexible garden hose carrying water. If the flow is strong enough, the constriction will remain in the hose even if the hose would normally spring back to its normal shape:—the partial vacuum produced in the constriction is sufficient to keep the hose collapsed. The Coanda effect, on the other hand, is the tendency of a flow to stay attached to a convex surface rather than follow a straight line in its original direction.
The combination of the venturi effect and Coanda effect can be visualized as follows. The back of a spoon can be held close to (but not touching) a stream of water running freely out of a tap (faucet), and it will be discovered that the stream of water will deflect from vertical, attach to the spoon and thereafter run over the back of the spoon. In this example, the venturi effect explains that a drop in pressure between the spoon and the stream causes the stream to deflect towards the spoon. The Coanda effect explains that, once the stream hits the back of the spoon, the stream keeps running over the convex surface of the back of the spoon.
Hence in FIG. 5 , the primary flow drags one stream of rooftop air because of shear forces. As the primary flow swells out along the flaring section 26 f , it accelerates. Such acceleration amplifies the venturi effect, which suctions in more rooftop air because of the venturi effect. Once the combined flows of the primary air and the streams of rooftop air traverse the convex transition portion 26 x , the Coanda effect takes over and tends to cause the adherence of the combined flows along the surface of the center bulb 26 .
FIGS. 6 through 8 show another embodiment of an exhaust stack system 30 in accordance with the invention. With general reference to FIGS. 6 through 8 , this embodiment of an exhaust stack system 30 in accordance with the invention comprises the following. That is, it has a lower outer housing 32 and lower inner housing 34 . The lower inner housing 34 may optionally function as a compartment for encasing a second motor 36 (see FIG. 8 ). However, this second motor 36 can be mounted elsewhere, as on a shelf (this is not shown) completely on the outside of the exhaust stack system 30 . Together, the lower inner and outer housings 34 and 32 form an annular intake channel 38 for the inlet-air blower 14 's output.
FIG. 6 shows (as does FIG. 1 ) fixed airfoils 39 airfoils 42 which function to straighten the output of the inlet-air blower 14 . The second motor 36 turns a shaft 44 which by means of an optional overhead bearing (not shown) rotates an inventive impeller 50 to be described more particularly below.
This exhaust stack system 30 also has an upper outer housing 62 and upper inner housing 64 for encasing the drive shaft 44 and optional bearing further provide an annular passage 66 for conducting the inlet air flow upwards. The upper outer housing 62 supports a series of brackets 68 on its outside wall for supporting the windband 70 as shown. This windband 70 likewise has an open lower skirt portion 72 for dragging in a dilution (or “rooftop”) air flow. This windband 70 extends upwardly to form a discharge nozzle for producing a tall, columnar plume. This windband 70 , at about its “waist” closely surrounds the inventive impeller 50 .
FIGS. 9 through 11 better show the inventive impeller 50 . It generally falls in the classification of axial impellers. It comprises a central hub 52 , a series of aerodynamic spokes 53 originating in the hub and extending to terminations in an intermediate ring 54 . The intermediate ring 54 supports the origins of a series of angularly-spaced blades 56 which define the “working” impeller portion of this impeller package as a whole. In alternative terminology, this inventive impeller package might be construed as a ribbon impeller, wherein the spokes space away the intermediate ring (eg., ribbon) such that the origins of the blades circuit an orbit spaced away from the hub. The annular region occupied by the spokes defines an inlet flow “bypass” 58 .
Given the foregoing, the following inventive objects are achieved. The inlet-air blower 14 can be designed to optimize its function for suctioning out the inlet flow from a converging network of ducts (not shown) having origins in remote diverse intake ports (not shown). Generally, the air-inlet blower 14 is optimized by a package which works best at high pressure duty, but not necessarily high volume duty. Indeed, most conventional air-inlet blowers are either centrifugal flow or mixed flow designs (and FIGS. 1 and 4 through 8 show a mixed flow impeller 14 by way of a non-limiting example).
In contrast, the induced (or “dilution” or else alternatively “rooftop”) air impeller 50 is optimized for opposite conditions, or that is, to produce high volume flow in a low pressure environment. In consequence, it is an aspect of the invention to equip an axial flow design for the impeller 50 in service here.
Several advantages are achieved by the foregoing. The inlet-air blower 14 may be separately controlled from the induced-air impeller 50 such that the inlet-air blower 14 might have a horsepower rating of 20 h.p. (ie., horsepower), but variably controlled as circumstances dictate to run at a fraction of its rating but at whatever power level is required to service the demand at hand. When demand is low, the inlet-air blower 14 can run at low power. When demand is highest, the inlet-air blower 14 might be throttled to full power. Regardless, the induced-air impeller 50 will certainly be powered by a much smaller motor, say, for instance, anywhere from down as low to a ½ h.p. to a 3 h.p. motor. That way, a tall, columnar plume can be produced largely by the effects produced by the induced-air impeller 50 , and largely independent of the inlet-air blower 14 . Thus, a tall, columnar plume can be produced with running the induced-air blower 50 at 3 h.p. while holding the air-inlet blower 14 , in low demand times, down to a 2 h.p. load.
Otherwise, if the only driver of the efflux is a lone air-inlet blower 14 of a centrifugal or mixed flow design, it might have to be run at 20 h.p. not because of the demand for suctioning out the inlet air from the converging duct network but because of the need to develop enough efflux velocity and flowrate through the exit nozzle.
The invention having been disclosed in connection with the foregoing variations and examples, additional variations will now be apparent to persons skilled in the art. The invention is not intended to be limited to the variations specifically mentioned, and accordingly reference should be made to the appended claims rather than the foregoing discussion of preferred examples, to assess the scope of the invention in which exclusive rights are claimed.
|
Exhaust apparatus for exhausting “dirty” exhaust gases accept a core flow of such exhaust gases and combine that with an annularly-surrounding “rooftop” flow of ambient air for diluting the exhaust gases as well as expelling the diluted flow in a forcibly expelled plume in order to ensure that the “effective” expulsion distance of the expelled diluted flow is at least the physical length of the exhaust apparatus plus the gains gotten from efflux velocity and flowrate.
| 5
|
BACKGROUND
[0001] The present invention concerns a sheet formation process to produce a pulp web with improved fibre orientation in a paper or board machine, as well as an appropriate wet end for implementing the sheet formation process.
[0002] In order to form a pulp web in a paper machine, a pulp suspension is applied to a wire with the aid of a headbox. The headbox comprises a distributing device to distribute the pulp suspension over the machine width, a turbulence block made up of a large number of turbulence tubes, and a headbox nozzle. In order to achieve good sheet formation it is important that the pulp suspension jet impinges onto the wire as evenly as possible over the entire machine width. The jet from the headbox broadens, however, after exiting from the headbox nozzle, and there is further broadening of the jet after the open jet hits the wire. Thus, a wire edge limitation is needed to guide the open jet and the pulp suspension onto the wire. Without the wire edge limitation the suspension would run off the wire at the sides, which would cause a drop in the basis weight and disrupt the fibre orientation in the areas at the edge of the web.
[0003] The wire edge limitation, however, also has undesirable effects. On the one hand, the fibre orientation is disrupted due to edge friction between the lateral headbox nozzle wall or wire edge limitation and the pulp suspension, and an uneven speed profile develops in the suspension, with a higher speed in the middle of the wire in running direction than at the edges. On the other hand, the wire edge limitation creates a reflected wave towards the center of the wire when the suspension hits the wire edge limitation. This undesirable effect is mitigated by wire edge limitations that widen in the machine running direction. However, the pulp suspension flows into the areas laid open by this widening, which results in formation of a pulp mat with a thinner edge.
[0004] Various solutions to these two problems are known from the state of the art. EP 1 619 298 A2, for example, discloses a headbox in which the turbulence channels at the edge of the turbulence generator are separated from the remaining turbulence generating area. These lateral turbulence channels each have feed pipes for an edge flow that can be used to influence the fibre orientation profile. EP 0 857 816 B1 describes a headbox with an integrated edge feed arrangement in the vicinity of the turbulence block. Infeed of an edge flow in the turbulence block, however has the disadvantage that very large quantities of edge flow must be supplied in order to be able to compensate or reduce subsequent edge friction effects. This considerable overdosing leads to disruption of the flow before the jet exists from the headbox, and thus to disruption of the fibre orientation.
SUMMARY
[0005] The object of the invention is to provide an improved sheet formation process and a paper or board machine wet end suitable for this process that circumvents the above mentioned disadvantages, thus reducing disruption of fibre orientation and forming a fibre mat with improved basis weight distribution over the entire machine width.
[0006] This object is achieved by a sheet formation process in which a fluid is added to the pulp suspension from the side through openings located after a turbulence block in a headbox at the machine wet end. This leads to improved suspension guiding and to a reduction or compensation of edge friction. If the wire edge limitation widens in addition, the areas laid open by this widening fill up with the fluid and thus prevent the suspension from running off the wire in these edge areas.
[0007] The fluid used here is preferably white water, which permits a particularly simple process flow because a large quantity of white water is produced at the wet end anyway.
[0008] In another favorable embodiment the fluid used is a pulp suspension that can also have a lower or higher consistency than the pulp suspension fed to the headbox distributor. Due to this additional input of pulp, the differences in basis weight across the machine running direction can be compensated more effectively. With a wire edge limitation that widens in machine running direction, the space formed by widening fills up with pulp suspension because of this additional input of pulp, thus achieving a uniform suspension height on the wire. This favors uniform basis weight distribution over the entire width of the pulp web.
[0009] The fluid used can also be a gas, particularly air. This can also achieve a reduction in edge friction without additional liquid having to be added to the pulp mat forming.
[0010] It is an advantage if the fluid is already added to the suspension inside the headbox nozzle and conventional wire edge limitations can still be used as a result.
[0011] Another possibility, however, is not to add the fluid until the wire edge limitation, as a result of which edge friction directly in the sheet formation area can be reduced particularly well.
[0012] It is practical if the liquid is added largely in the machine running direction as this facilitates formation of a fluid film between the wire edge limitation and the pulp suspension. Here, it is an advantage if the flow speed of the fluid in the machine running direction is greater than the speed of the pulp suspension.
[0013] The fluid can be added in the machine running direction at several points located one after the other, where the fluid can be added at different flow speeds or in different quantities at the individual points. It is preferable if the quantity and/or the flow speed of the fluid increases from one addition point to the next in the machine running direction because the pulp suspension thickens as a result of the dewatering process, thus the effort required to compensate edge friction increases.
[0014] The invention is also directed to a wet end for sheet formation, where feed channels with openings for feeding a fluid to the pulp suspension are provided in the wire edge limitation and/or headbox nozzle after a turbulence block. The fluid exiting from the openings reduces edge friction and improves sheet formation.
[0015] The openings can be located either in a side wall of the headbox nozzle or in a side wall of the wire edge limitation. Addition of fluid in the headbox nozzle has the advantage that existing wire edge limitations do not have to be modified, whereas addition via the wire edge limitation allows improved minimizing of edge friction until final formation of the sheet.
[0016] In a favorable embodiment the feed channels end at the side wall, largely in parallel with the machine running direction. This has the advantage that the fluid flows largely in machine running direction.
[0017] It is favorable here if the openings for adding fluid are provided on both sides of the wet end because this minimizes edge friction and forms a symmetrical basis weight profile.
[0018] It is expedient if the side wall has at least one recess after the opening, which recess has a narrowing cross-section in the machine running direction, where the side wall serves as a guiding surface for the fluid added in the area of the recess. Due to this special design of the side wall, the fluid is added to the pulp suspension roughly in machine running direction and formation of a friction-reducing fluid film is enhanced.
[0019] In a favorable embodiment of the wet end, several exit openings are provided, preferably one after the other viewed in the machine running direction. By adding the fluid at several points at the wet end, the area in which edge friction is reduced and/or pulp is added can be enlarged.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Two examples of embodiments of the invention are described in the following with reference to the drawings in which:
[0021] FIG. 1 shows a schematic diagram of a wet end according to the invention;
[0022] FIG. 2 shows a schematic diagram of a further variant of a wet end according to the invention;
[0023] FIG. 3 shows a schematic side view of FIG. 1 ; and
[0024] FIG. 4 shows a perspective detailed view of FIG. 1 .
DETAILED DESCRIPTION
[0025] The configuration shown in FIG. 1 includes a headbox 1 consisting of a distributor 2 , a turbulence block 3 , which comprises a large number of turbulence tubes 4 , and a subsequent headbox nozzle 5 through which the pulp suspension fed in by the distributor 2 is discharged onto a wire 6 . The machine running direction is indicated by an arrow 15 . At the edge of the wire there is a wire edge limitation 7 that prevents the pulp suspension that impinges onto the wire 6 from running off the wire 6 at the sides. The openings 9 of feed channels 10 are located in the side wall 8 of the wire edge limitation 7 . A fluid, for example water, dilution water or pulp suspension, air, or a mixture of these components is added through these feed channels 10 . As a result of this fluid being added, edge friction between the pulp suspension and the side wall 8 of the wire edge limitation 7 is reduced because the fluid forms a boundary film between the suspension and the side wall 8 . Here, the fluid is largely introduced through nozzles in the machine running direction, where the flow speed of the fluid is greater than the speed of the pulp suspension on the wire. The openings 9 in the side wall 8 of the wire edge limitation 7 are located in recesses 11 . Due to these recesses 11 the fluid is introduced through nozzles as parallel as possible to the machine running direction between the side wall 8 of the wire edge limitation 7 and the pulp suspension coming out of the headbox 1 .
[0026] FIG. 2 illustrates a further embodiment of the invention, where the reference figures correspond to those used in FIG. 1 . In this embodiment, however, the fluid is added via feed channels 10 ′ through openings 9 ′ in the side wall 8 ′, thus enhancing fluid feed in the machine running direction.
[0027] FIG. 3 shows a side view of FIG. 1 , where the wire 6 that is deflected by a breast roll 12 under the headbox 1 can be seen particularly clearly. The pulp suspension leaving the headbox nozzle 5 hits the wire 6 at the impingement point 13 . The opening 9 and the recess 1 in the side wall 8 of the wire edge limitation 7 are indicated.
[0028] In FIG. 4 , a perspective detailed view of FIG. 1 is provided and clearly shows the shape of the recess 11 in the side wall 8 . The pulp suspension exists here from the nozzle opening 14 of the headbox nozzle 5 and hits the wire 6 at the impingement point 13 . The fluid exits from the opening 9 . The opening 9 is arranged vertically to the machine running direction in the recess 11 of the side wall 8 and in a slot shape. The recess 11 cross-section narrows continuously in the machine running direction.
[0029] During operation a pulp suspension is fed through the distributor 2 to the headbox 1 . Here, part of the suspension can also be removed through a return flow 2 ′. The pulp suspension flows in the headbox 1 through a large number of turbulence pipes 4 into the headbox nuzzle 5 . After leaving the headbox nozzle 5 , the pulp suspension hits the wire 6 at the impingement point 13 . A fluid to alter the speed profile of the pulp suspension is injected through feed channels 10 , 10 ′ in the wire edge limitation 7 or the headbox nozzle 5 . The flow speed of the fluid in the machine running direction is preferably higher than the speed of the pulp suspension, and also has lower viscosity and consistency than the pulp suspension, if applicable. Due to the higher flow speed of the fluid, the pulp suspension in the edge zones is accelerated in machine running direction. As a result, an even speed profile is formed over the entire width of the pulp suspension.
[0030] The embodiments shown in the drawings merely show some of the embodiment of the invention. The invention also relates to other embodiments, e.g., injecting a fluid through the side wall 8 ′ of the headbox nozzle 5 and through the side wall 8 of the wire edge limitation 7 . It would also be conceivable to have several openings 9 , 9 ′ arranged in the machine running direction. In this case, the fluid can be added at different speeds and/or in different quantities through each opening. It is an advantage if the speed of the fluid added through the individual openings 9 , 9 ′ increases in the machine running direction because the pulp suspension thickens on the wire 6 due to the dewatering process, thus requiring greater effort to compensate edge friction.
|
A sheet formation process and associated wet end to produce a pulp web with improved fibre orientation in a paper or board machine. A fluid is added to the pulp suspension from the side through openings ( 9, 9′ ) located after a turbulence block ( 3 ) in a headbox ( 1 ) at the machine wet end.
| 3
|
TECHNICAL FIELD
The present invention relates to a drip irrigation dripper (hereinafter may simply referred to as a “dripper”) and a drip irrigation apparatus including the dripper, and particularly to a dripper and a drip irrigation apparatus including the dripper which are suitable for growing plants.
BACKGROUND ART
Conventionally, as means of supplying irrigation liquids such as water or liquid fertilizer to the plants to be grown on the soil in the agricultural land, the plantation or the like, drip irrigation apparatuses that regulate the supply speed of the irrigation liquid have been employed. The use of the drip irrigation apparatus enables the saving of the irrigation liquid and the management of the growth of the plants.
Such a drip irrigation apparatus includes a dripper for controlling the ejection amount of the irrigation liquid per unit time when ejecting the irrigation liquid having flowed into a flow tube from the water source side (pump side) toward the plants.
One example of such drip irrigation apparatuses is what is called an on-line dripper. The on-line dripper is used by being inserted into holes bored in a tube wall (side wall) of polyethylene pipe or into the opening of the end portion of a microtube. The on-line dripper is conveniently employed not only in soil culture but also in nutriculture or pot culture when used for greenhouse culture, raising seedling, fruit growing, and the like.
As such an on-line dripper, a dripper with what is called a differential pressure control mechanism (pressure correction function) being installed is known. The dripper is configured, for example, with a three-component structure in which an elastic film (e.g., silicone rubber film) such as a diaphragm is sandwiched by an inlet side member and an outlet side member (see PTLS 1 and 2, for example).
The dripper utilizes the operation of the diaphragm (film) in accordance with the liquid pressure of the irrigation liquid having flowed from the inlet of the dripper to control the inflow of the irrigation liquid toward a pressure reduction channel on the downstream side of the inlet and to control the amount of the outflow of the irrigation liquid from the outlet of the dripper after pressure reduction by the pressure reduction channel.
More specifically, in the dripper, when the inflow liquid pressure of the irrigation liquid toward the inlet is increased to a certain level, the diaphragm that is disposed to shield the pressure reduction channel is deflected by the inflow liquid pressure toward the outlet. Due to the deformation of the diaphragm, the reduction pressure channel is opened, and thus the irrigation liquid flows into the pressure reduction channel. The irrigation liquid having flowed into the pressure reduction channel moves toward the outlet while the pressure of the irrigation liquid is reduced in the pressure reduction channel to flow out of the dripper from the outlet. When the inflow liquid pressure toward the inlet is further increased, the amount of the deflection of the diaphragm toward the outlet becomes larger. In association with the larger amount of the deflection of the diaphragm, the sectional size of the channel at the outlet is reduced, and thus the outflow of the irrigation liquid is regulated.
CITATION LIST
Patent Literature
PTL 1
U.S. Pat. No. 5,413,282
PTL 2
U.S. Pat. No. 5,820,029
SUMMARY OF INVENTION
Technical Problem
However, the dripper has the following three problems.
First Problem
When an error occurs in assembling the above-mentioned three components for the dripper, the assembly error greatly affects the performance of the dripper. Thus, variation occurs in the operation of the diaphragm (film), causing the ejection amount of the irrigation liquid to be unstable.
Second Problem
In the dripper, the material cost is raised when silicone rubber is used for the diaphragm.
Third Problem
The dripper requires a manufacturing process in which the three components are separately manufactured, and thereafter they are further assembled. Therefore, the manufacturing cost is raised.
In addition, the dripper requires a liquid pressure that is high to a certain degree to open the pressure reduction channel by causing the diaphragm to be elastically deformed. Therefore, when the dripper is used under relatively high liquid pressure with a high pressure pump being employed, the original functions can be performed with no problem. However, when the dripper is used under low liquid pressure, there is a concern that the diaphragm might not be elastically deformed in a proper manner, causing the original functions not to be sufficiently performed.
The present invention has been achieved taking into consideration the above-mentioned problems. A first object of the present invention is to provide a dripper which makes it possible to stabilize the ejection amount of the irrigation liquid and to further achieve cost reduction by reducing the manufacturing cost, number of components and manufacturing processes, and a drip irrigation apparatus including the dripper.
In addition, a second object of the present invention is to provide a dripper which makes it possible to properly perform drip irrigation even when the liquid pressure of irrigation liquid is low, and a drip irrigation apparatus including the dripper.
Solution to Problem
To achieve at least the above-mentioned first object, the present invention provides the following dripper.
[1] A drip irrigation dripper for controlling an ejection amount of irrigation liquid, having flowed from an inflow part, from an ejection port to eject the irrigation liquid, the drip irrigation dripper including:
a first member integrally formed of a resin material and composing one part on the inflow part side of the drip irrigation dripper; and
a second member integrally formed of a resin material and composing the other part on the ejection port side of the drip irrigation dripper, the second member being fixed to the first member,
wherein
the first member includes:
a first plate-like part having a first inner surface to be brought into close contact with the second member and a first outer surface at a side opposite to the first inner surface;
a first protrusion part being protruded from the first outer surface toward a side opposite to the second member and having the inflow part at a tip portion of the first protrusion part;
a first guide channel formed from the inflow part to the first inner surface and guiding the irrigation liquid having flowed from the inflow part toward the first inner surface; and
a pressure reduction channel part for forming, between the first inner surface and the second member, a pressure reduction channel connected continuously to a terminal of an inner surface of the first guide channel and allowing the irrigation liquid having been guided by the first guide channel to flow toward the ejection port while reducing a pressure of the irrigation liquid, and
the second member includes:
a second plate-like part having a second inner surface to be brought into close contact with the first inner surface and forming the pressure reduction channel together with the pressure reduction channel part and a second outer surface at a side opposite to the second inner surface;
a second guide channel formed from a terminal position of the pressure reduction channel at the second inner surface to the ejection port and for guiding the irrigation liquid of which pressure is reduced by the pressure reduction channel to the ejection port; and
a diaphragm part formed at a terminal of the first guide channel so as to form a part of an inner surface of the second guide channel and being to be deformed toward the second guide channel upon receiving a liquid pressure of the irrigation liquid having been guided by the first guide channel to regulate a width of the second guide channel so as to be smaller as the liquid pressure is increased.
[2] The drip irrigation dripper according to [1], wherein the diaphragm part includes:
a dome-shaped center wall part curved so as to be protruded toward the first member;
a peripheral wall part connected to an outer peripheral end of the center wall part to surround the center wall part and being inclined toward the first member as being outward from the center wall part in a radial direction of the center wall part when viewed in a plan view; and wherein
a connection part, between the center wall part and the peripheral wall part, is configured to regulate the width of the second guide channel.
[3] The drip irrigation dripper according to [2], wherein an end edge portion on the connection part side of each of the center wall part and the peripheral wall part has a thinner wall thickness than the connection part and portions other than the end edge portion of the center wall part. [4] The drip irrigation dripper according to any one of [1] to [3], wherein a starting end of the second guide channel is disposed in the vicinity of the diaphragm part. [5] The drip irrigation dripper according to any one of [1] to [4], wherein the ejection port opens to the second outer surface. [6] The drip irrigation dripper according to any one of [1] to [4], wherein the ejection port is formed at a tip portion of a second protrusion part protruded from the second outer surface toward a side opposite to the first member.
In addition, to achieve at least the above-mentioned second object, the present invention provides the following drip irrigation dripper.
[7] A drip irrigation dripper for controlling an ejection amount of irrigation liquid, having flowed from an inflow part, from an ejection port to eject the irrigation liquid, the drip irrigation dripper including:
a plate-like body having a first outer surface on the inflow part side of the drip irrigation dripper and a second outer surface on the ejection port side at a side opposite to the first outer surface;
a first protrusion part being protruded from the first outer surface toward a side opposite to the second outer surface and having the inflow part at a tip portion of the first protrusion part;
a first guide channel formed from the inflow part into the plate-like body and guiding the irrigation liquid having flowed from the inflow part into the plate-like body;
a pressure reduction channel formed so as to be connected to a terminal of the first guide channel to allow the irrigation liquid having been guided by the first guide channel to flow toward the ejection port while reducing a pressure of the irrigation liquid; and
a second guide channel formed from a position connected to a terminal of the pressure reduction channel inside the plate-like body to the ejection port disposed on the second outer surface side of the drip irrigation dripper and for guiding the irrigation liquid of which pressure is reduced by the pressure reduction channel to the ejection port, wherein
the inflow part has hydrophobicity and prevents the irrigation liquid having a liquid pressure less than a predetermined liquid pressure from flowing into the inflow part.
[8] The drip irrigation dripper according to [7], wherein
the inflow part includes a substrate part that partially shields a starting end of the first guide channel,
the substrate part includes a plurality of inflow ports extending through the substrate part, and
at least a surface on a side, of the substrate part, opposite to the first guide channel has hydrophobicity.
[9] The drip irrigation dripper according to [8], wherein an inner peripheral surface of each of the inflow ports also has hydrophobicity. [10] The drip irrigation dripper according to [8] or [9], wherein the inflow part comprises a hydrophobic material having hydrophobicity. [11] The drip irrigation dripper according to [8] or [9], wherein the inflow part includes hydrophobic coating having hydrophobicity. [12] The drip irrigation dripper according to [10] or [11], wherein the inflow part has, on a hydrophobic surface, an irregular shape that reinforces the hydrophobicity. [13] The drip irrigation dripper according to any one of [7] to [12], further including a diaphragm part formed at the terminal of the first guide channel so as to form a part of an inner surface of the second guide channel and being to be deformed toward the second guide channel upon receiving the liquid pressure of the irrigation liquid having been guided by the first guide channel, the diaphragm part being for regulating a width of the second guide channel so as to be smaller as the liquid pressure is increased. [14] The drip irrigation dripper according to [13], including:
a first member integrally formed of a resin material and composing one part on the inflow part side of the drip irrigation dripper; and
a second member integrally formed of a resin material and composing the other part on the ejection port side of the drip irrigation dripper, the first member being fixed to the second member,
wherein
the first member includes:
a first plate-like part having a first inner surface to be brought into close contact with the second member and the first outer surface at a side opposite to the first inner surface;
the first protrusion part;
the first guide channel disposed from the inflow part to the first inner surface; and a pressure reduction channel part for forming, between the first inner surface and the second member, the pressure reduction channel connected continuously to a terminal of an inner surface of the first guide channel, and
the second member includes:
a second plate-like part having a second inner surface that is to be brought into close contact with the first inner surface and that forms the pressure reduction channel together with the pressure reduction channel part, and the second outer surface at a side opposite to the second inner surface;
the second guide channel disposed from a terminal of the pressure reduction channel part at the second inner surface to the ejection port; and
the diaphragm part.
Further, to achieve the above-mentioned first or second object, the present invention provides the following drip irrigation apparatus.
[15] A drip irrigation apparatus including:
the drip irrigation dripper according to any one of [1] to [14]; and
a flow tube through which the irrigation liquid flows,
wherein
when the first protrusion part of the drip irrigation dripper is inserted into a tube wall or an opening of the flow tube, the irrigation liquid in the flows tube to flow into a channel of the drip irrigation dripper from the inflow part.
Advantageous Effects of Invention
With the inventions according to any of [1] to [6], the ejection amount of the irrigation liquid can be stabilized, and in addition cost reduction can be achieved by reducing the manufacturing cost, number of components and manufacturing processes.
In particular, with the invention according to [1], a dripper excellent in controlling the ejection amount, capable of reducing the pressure of the irrigation liquid using the pressure reduction channel and of regulating the width of the second guide channel using the diaphragm part can be manufactured with less assembly error with only two components of the first member and the second member. Therefore, it is possible to stabilize the ejection amount of the irrigation liquid, and to achieve cost reduction by reducing the manufacturing cost, number of components and manufacturing processes.
In addition, with the invention according to [2], the diaphragm part can be formed into a suitable shape to be deformed toward a predetermined portion facing the diaphragm part in the inner surface of the second guide channel upon efficiently receiving the liquid pressure of the irrigation liquid before pressure reduction. Therefore, it is possible to regulate the channel width more properly.
In addition, with the invention according to [3], the rigidity near the connection part to be used for regulating the width of the channel in the diaphragm part is partially weakened, thereby enabling the connection part to be moved more efficiently depending on the liquid pressure. Therefore, it is possible to regulate the channel width more simply and properly.
In addition, with the invention according to [4], the shape of a metal mold for molding the second member from a resin can be simplified, compared with the case where the starting end of the second guide channel is disposed away from the diaphragm part. Therefore, it is possible to further reduce the manufacturing cost.
In addition, with the invention according to [5], the configuration of the second member can be simplified. Therefore, it is possible to further reduce the manufacturing cost.
In addition, with the invention according to [6], it is possible to select a suitable configuration to connect a tube to the ejection port to adjust the ejecting direction.
In addition, with the inventions according to any of [7] to [14], even when the liquid pressure of the irrigation liquid is low, drip irrigation can be performed properly.
In particular, with the invention according to [7], the lower limit of the liquid pressure of the irrigation liquid flowing from the inflow part can be controlled so as to be low due to hydrophobicity of the inflow part. Therefore, even when the liquid pressure of the irrigation liquid is low, the irrigation liquid can be properly used for the drip irrigation.
In addition, with the invention according to [8], a portion, out of the inflow part, to be exposed to the irrigation liquid outside of the dripper has hydrophobicity. Therefore, it is possible to regulate the inflow of the irrigation liquid more properly.
In addition, with the invention according to [9], capillary action in the inflow port can be surely suppressed. Therefore, it is possible to regulate the inflow of the irrigation liquid more properly.
In addition, with the invention according to [10], the hydrophobicity of the inflow part can be achieved with a smaller number of components.
In addition, with the invention according to [11], the hydrophobicity of the inflow part does not depend on the material of the inflow part. Therefore, it is possible to further enhance the freedom in selecting the material of the inflow part.
In addition, with the invention according to [12], the lower limit of the liquid pressure of the irrigation liquid flowing from the inflow part can also be adjusted to be somewhat higher. Therefore, it is possible to further enhance the freedom in selecting the pressure of the inflow liquid during the use of the dripper under low pressure.
In addition, with the invention according to [13], even when the dripper is used under high pressure, the flow rate of the irrigation liquid toward the ejection port can be regulated by the diaphragm part. Therefore, it is possible to control the ejection amount of the irrigation liquid more properly. In addition, the diaphragm part does not shield the pressure reduction channel, so as not to be involved in the regulation of the inflow into the pressure reduction channel. Therefore, with the invention according to [13], the diaphragm part does not constitute a cause for raising the lower limit of the liquid pressure to be used toward the high pressure side (i.e., a cause for hindering the drip irrigation using low-pressure irrigation liquid).
In addition, with the invention according to [14], the dripper excellent in controlling the ejection amount can be manufactured with less assembly error with only two components made of a resin material. Therefore, it is possible to stabilize the ejection amount of the irrigation liquid, and to achieve further cost reduction by reducing the manufacturing cost, number of components and manufacturing processes.
In addition, with the invention according to [15], it is possible to stabilize the ejection amount of the irrigation liquid, having flowed into the inflow part from the flow tube, from the ejection port, and to achieve cost reduction by reducing the manufacturing cost, number of components and manufacturing processes. Alternatively, with the invention according to [15], even when the liquid pressure of the irrigation liquid flowing through the flow tube is low, it is possible to allow this irrigation liquid to flow into the channel of the dripper to use the irrigation liquid for drip irrigation properly.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective bird's-eye view illustrating a dripper according to an embodiment of the present invention;
FIG. 2 is a transparent bird's-eye view illustrating the dripper;
FIG. 3 is a perspective upward view of the dripper;
FIG. 4 is a transparent upward view of the dripper;
FIG. 5 is a bottom view of a first member in the dripper;
FIG. 6 is a top view of a second member in the dripper;
FIG. 7 is a front view of the dripper;
FIG. 8 is a sectional view of the dripper taken along line A-A in FIG. 7 ;
FIG. 9 is a sectional view of the dripper taken along line B-B in FIG. 8 ;
FIG. 10 is a sectional view schematically illustrating a drip irrigation apparatus according to an embodiment of the present invention;
FIG. 11 is an enlarged sectional view of an inflow part in the dripper;
FIG. 12 is an enlarged sectional view illustrating one example of means to embody a low-pressure stop filter function of the inflow part;
FIG. 13 is an enlarged sectional view illustrating another example of means to embody the low-pressure stop filter function of the inflow part;
FIG. 14A is an enlarged sectional view of the inflow part before the inflow of irrigation liquid, FIG. 14B is an enlarged sectional view of the inflow part when the liquid pressure of irrigation liquid is less than fracture hydraulic pressure, and FIG. 14C is an enlarged sectional view of the inflow part into which irrigation liquid having equal to or more than fracture hydraulic pressure flows;
FIG. 15 is an enlarged sectional view of a diaphragm part and its periphery in the dripper;
FIG. 16A is an enlarged sectional view of the diaphragm part and its periphery before the inflow of the irrigation liquid into the dripper, FIG. 16B is an enlarged sectional view of the diaphragm part and its periphery having been deformed upon receiving the liquid pressure of the irrigation liquid having flowed into the dripper, and FIG. 16C is an enlarged sectional view of the diaphragm part and its periphery having been further deformed upon receiving the liquid pressure of the irrigation liquid having flowed into the dripper;
FIG. 17 is a perspective upward view illustrating a first modification of the dripper according to the present invention;
FIG. 18 is a perspective upward view illustrating a second modification of the dripper according to the present invention; and
FIG. 19 is an enlarged sectional view of a diaphragm part and its periphery in a third modification of the dripper according to the present invention.
DESCRIPTION OF EMBODIMENTS
In the following, embodiments of a dripper according to the present invention and a drip irrigation apparatus including the dripper will be described with reference to FIGS. 1 to 19 .
FIG. 1 is a perspective bird's-eye view illustrating dripper 1 in the present embodiment. FIG. 2 is a transparent birds-eye view illustrating dripper 1 . FIG. 3 is a perspective upward view of dripper 1 . FIG. 4 is a transparent upward view of dripper 1 . FIG. 5 is a bottom view of first member 2 to be described later in dripper 1 . FIG. 6 is a top view of second member 3 to be described later in dripper 1 . FIG. 7 is a front view of dripper 1 . FIG. 8 is a sectional view of dripper 1 taken along line A-A in FIG. 7 . FIG. 9 is a sectional view of dripper 1 taken along line B-B in FIG. 8 . FIG. 10 is a schematic sectional view illustrating drip irrigation apparatus 4 in the present embodiment.
As illustrated in FIG. 10 , drip irrigation apparatus 4 is composed of elongated tube 5 as a flow tube in which the irrigation liquid flows, and dripper 1 inserted into tube 5 through through-hole 51 bored in the side wall of tube 5 .
It is noted that, while not illustrated, dripper 1 may be used by being inserted into the opening of an end portion of the tube.
Dripper 1 , being inserted into tube 5 in this manner, controls the ejection amount of the irrigation liquid per unit time when the irrigation liquid in tube 5 is ejected to the outside.
It is noted that, while one dripper 1 and one through-hole 51 are illustrated for convenience in FIG. 10 , actually a plurality of drippers 1 and through-holes 51 are often disposed along the longitudinal direction of tube 5 at a predetermined interval.
In addition, in FIG. 10 , the right and left sides of the channel in tube 5 correspond to the upstream side and the downstream side, respectively.
Dripper 1 will be described further in detail. As illustrated in FIGS. 1 to 10 , dripper 1 is formed by fixing first member 2 and second member 3 to each other. Each of first member 2 and second member 3 is integrally formed of a resin material. The method of fixing first member 2 and second member 3 may be joining by means of adhesion using an adhesive, welding, or the like, or alternatively may be pressure joining by means of pressing. In addition, first member 2 and second member 3 may be formed of the same resin material, or alternatively may be formed of different resin materials. Further, as the resin material, an inexpensive resin material such as polypropylene may be employed. Furthermore, each of first member 2 and second member 3 may be integrally molded by injection molding.
[Specific Configuration of First Member]
<First Plate-Like Part>
As illustrated in FIGS. 1 to 5 and FIGS. 7 to 10 , first member 2 has disc-shaped first plate-like part 21 . The shape of first plate-like part 21 is circular in a plan view. However, the shape of the first plate-like part in the present invention does not need to be limited to a disc shape; for example, rectangular or other polygonal plate shapes may be employed.
First plate-like part 21 has first inner surface (bottom surface in FIGS. 8 and 9 ) 211 to be brought into close contact with second member 3 , and first outer surface (top surface in FIGS. 8 and 9 ) 212 at the side opposite to first inner surface 211 .
First inner surface 211 and first outer surface 212 are formed so as to be planes disposed parallel to each other across the thickness of first plate-like part 21 .
As illustrated in FIG. 5 , annular belt-shaped recess 2111 is formed at the center of first inner surface 211 . As illustrated in FIG. 8 , rim part 2112 of first inner surface 211 is protruded toward second member 3 . First plate-like part 21 composes plate-like body 11 (see FIGS. 1 and 8 ) together with second plate-like part 31 to be described later.
<First Protrusion Part and Inflow Part>
As illustrated in FIGS. 1 to 4 and FIGS. 7 to 10 , first member 2 has first protrusion part 22 . First protrusion part 22 is protruded from the center portion of first outer surface 212 of first plate-like part 21 toward the side opposite to second member 3 (upward in FIGS. 7 to 9 ).
The outer peripheral surface of first protrusion part 22 is formed of a cylindrical surface from the base end portion (lower end portion) to the tip portion (upper end portion) in the protrusion direction of first protrusion part 22 , and of a frustum surface formed at the tip side of the cylindrical surface. The frustum surface is a tapered surface formed such that the outer diameter of first protrusion part 22 is gradually decreased toward the tip side. The frustum surface is connected to the cylindrical surface through a plane expanding outwardly in the radial direction from that cylindrical surface. The frustum surface functions as a stopper when dripper 1 is inserted into tube 5 (see FIG. 10 ). However, the outer peripheral surface of the first protrusion part in the present invention does not need to be limited to the cylindrical surface and the frustum surface; a square tube surface, a prismoid surface, or the like may also be employed.
In addition, first protrusion part 22 is formed into a hollow shape (tubular shape) by the presence of first guide channel 23 to be described later.
Further, inflow part 221 is formed near the tip portion of first protrusion part 22 . FIG. 11 is an enlarged sectional view of inflow part 221 .
As illustrated in FIGS. 8 , 9 and 11 , inflow part 221 has substrate part 2211 orthogonal to the longitudinal direction of first protrusion part 22 , and a plurality of inflow ports 2212 extended vertically (in other words, in the longitudinal direction of first protrusion part 22 ) through substrate part 2211 . Inflow port 2212 is a column-shaped pore.
As illustrated in FIG. 11 , the starting end portion (upper end portion) of first guide channel 23 is partially shielded from the outer space outside of dripper 1 by substrate part 2211 of inflow part 221 , and is partially opened to the outer space through inflow ports 2212 extending through substrate part 2211 .
It is noted that, while in FIG. 5 each inflow port 2212 is disposed at an intersection of the rectangular lattice, the disposition of the inflow ports in the present invention does not need to be limited to one as in FIG. 5 .
Inflow part 221 is provided with a low-pressure stop filter function for not allowing irrigation liquid having less than a predetermined pressure (e.g., 0.005 MPa) to flow into the channel of dripper 1 .
There are several possibilities to be considered for the means to embody the low-pressure stop filter function. For example, when polypropylene is used as a material for dripper 1 , the low-pressure stop filter function can be imparted to inflow part 221 , since polypropylene itself is a high water-repellent (hydrophobic) material with a low surface energy.
Other than that, as illustrated in FIG. 12 , for example hydrophobic coating C such as fluorine coating by means of a fluorine coating agent is applied to surface 22111 of substrate part 2211 outside of dripper 1 (in other words, at the side opposite to first guide channel 23 to be described later) and, as needed, to the inner peripheral surface 22121 of inflow port 2212 . The hydrophobic coating C reduces the surface energy. In this case, the hydrophobic coating C can impart the low-pressure stop filter function to inflow part 221 locally without depending on the material of dripper 1 .
In addition, hydrophobicity may be reinforced by, for example, forming an irregular shape on the hydrophobic surface, as needed. The hydrophobic surface may be formed with the above-mentioned material or with the hydrophobic coating. As illustrated in FIG. 13 , the irregular shape may be burr 22122 formed at the upper opening edge of inflow port 2212 , or may be an irregular shape formed by transferring the irregular shape intentionally formed on the transfer surface of a metal mold.
In addition, it is also possible to optimize the low-pressure stop filter function by adjusting the inner diameter, pitch, number, opening shape and wall thickness of inflow port 2212 , the surface roughness of inflow part 221 , and the like.
When the liquid pressure of the irrigation liquid in tube 5 is raised to a predetermined pressure (fracture hydraulic pressure), inflow part 221 allows the irrigation liquid to flow into dripper 1 through inflow port 2212 . Here, from the viewpoint of allowing dripper 1 in the present embodiment to favorably function when being used under low pressure, it is desirable to select, as the predetermined pressure, a sufficiently low pressure of about 0.005 MPa exemplified earlier. However, the “predetermined pressure” is embodied (set) depending on the degree of hydrophobicity of inflow part 221 . Accordingly, when imparting hydrophobicity to inflow part 221 , necessary hydrophobicity-causing factors (the above-described material of inflow part 221 , type and film thickness of the hydrophobic coating, surface shape of the hydrophobic surface, and the like) may be selected based on experiment results or the like, taking into consideration the relationship between the hydrophobicity and the predetermined pressure that should be set.
FIGS. 14A , 14 B and 14 C illustrate specific examples of the operation of inflow part 221 .
First, as illustrated in FIG. 14A , when the external liquid pressure to which inflow part 221 is exposed is 0 MPa (in other words, there is no irrigation liquid in tube 5 ), the inflow regulation of the irrigation liquid by inflow part 221 is not performed as a matter of course.
Next, as illustrated in FIG. 14B , when the external liquid pressure is less than 0.005 MPa (the above-mentioned fracture hydraulic pressure), the low-pressure stop filter function works based on the hydrophobicity of inflow part 221 . As a result, the irrigation liquid outside of inflow part 221 (in other words, in tube 5 ) is dammed at outer surface 22111 of substrate part 2211 and at the upper opening end of inflow port 2212 . Therefore, the inflow into first guide channel 23 of dripper 1 is regulated (prevented).
Next, as illustrated in FIG. 14C , when the external liquid pressure is equal to or more than 0.005 MPa, the external liquid pressure surpasses the hydrophobicity of inflow part 221 . Therefore, the irrigation liquid outside of inflow part 221 flows into first guide channel 23 of dripper 1 from inflow port 2212 .
As has been described above, when the liquid pressure of the irrigation liquid in tube 5 is raised to the predetermined pressure (fracture hydraulic pressure), inflow part 221 allows the irrigation liquid to flow into dripper 1 through inflow port 2212 .
<First Guide Channel>
As illustrated in FIGS. 8 and 9 , first member 2 has first guide channel 23 as the most upstream channel of dripper 1 .
As illustrated in FIGS. 8 and 9 , first guide channel 23 is formed from inflow part 221 to first inner surface 211 of first plate-like part 21 (in other words, toward the inside of plate-like body 11 ). For example, first guide channel 23 is a hole extending through first protrusion part 22 along the longitudinal direction of first protrusion part 22 .
First guide channel 23 guides the irrigation liquid having flowed from inflow part 221 toward first inner surface 211 (downward in FIGS. 8 and 9 ).
It is noted that, while channel inner surface 231 (in other words, inner peripheral surface of first protrusion part 22 defining the shape of first guide channel 23 ) of first guide channel 23 is formed so as to be a cylindrical surface concentric with the outer peripheral surface of first protrusion part 22 , the shape of the channel inner surface in the present invention does not need to be limited to such a shape; for example, a square tube surface, or the like may also be employed.
<Pressure Reduction Channel>
As illustrated in FIG. 5 , first member 2 has pressure reduction channel part 213 provided as a recess on first inner surface 211 of first plate-like part 21 .
As illustrated in FIG. 5 , pressure reduction channel part 213 is composed of groove part 213 connected continuously to the terminal (in other words, downstream end) of channel inner surface 231 of first guide channel 23 .
As illustrated in FIG. 5 , groove part 213 is formed into a substantially U-shape. That is, groove part 213 is formed in such a shape as to extend outwardly in a serpentine manner in the radial direction of first inner surface 211 from the terminal of channel inner surface 231 of first guide channel 23 , and then to turn back before rim part 2112 of first inner surface 211 to return to the vicinity of the terminal of channel inner surface 231 without serpentine. That is, when first inner surface 211 is viewed in a plan view, groove part 213 includes a zig-zag part being extended along the radial direction of first inner surface 211 , and a turn-back part including a linear portion and being extended from the tip portion of the zig-zag part to a position overlapping the starting end of second guide channel to be described later.
Pressure reduction channel part 213 forms pressure reduction channel 8 (see FIG. 2 ) together with second member 3 . Pressure reduction channel 8 allows the irrigation liquid having been guided by first guide channel 23 to flow toward ejection port 321 to be described later while reducing the pressure of the irrigation liquid.
It is noted that the shape of the pressure reduction channel part in the present invention does not need to be limited to the shape illustrated in FIG. 5 as long as pressure reduction channel 8 can be connected to the terminal of first guide channel 23 . In addition, a plurality of pressure reduction channel parts 213 may be provided.
[Specific Configuration of Second Member]
<Second Plate-Like Part>
On the other hand, as illustrated in FIGS. 1 to 4 and FIGS. 6 to 10 , second member 3 has second plate-like part 31 . The shape of second plate-like part 31 is a circular disc-shape being concentric with and having the same diameter as that of first plate-like part 21 in a plan view. However, the shape of the second plate-like part in the present invention does not need to be limited to a disc shape; for example, rectangular or other polygonal plate shapes may be employed.
Second plate-like part 31 has second inner surface (top surface in FIGS. 8 and 9 ) 311 to be brought into close contact with first inner surface 211 in first plate-like part 21 , and second outer surface (bottom surface in FIGS. 8 and 9 ) 312 at the side opposite to second inner surface 311 .
Second inner surface 311 and second outer surface 312 are formed so as to be planes disposed parallel to each other across the thickness of second plate-like part 31 .
It is noted that second inner surface 311 may be joined to first inner surface 211 .
Rim part 3111 of second inner surface 311 is concaved by the same dimension as the protrusion dimension of rim part 2112 of first inner surface 211 (see FIG. 8 ). It is also possible to use rim parts 3111 and 2112 for positioning first member 2 and second member 3 .
<Second Protrusion Part and Ejection Port>
As illustrated in FIGS. 1 to 4 and FIGS. 7 to 10 , second member 3 has second protrusion part 32 . Second protrusion part 32 is protruded from the center portion of second outer surface 312 of second plate-like part 31 toward the side opposite to first member 2 (downward in FIGS. 7 to 9 ).
The outer peripheral surface of second protrusion part 32 is formed of a cylindrical surface from the base end portion (upper end portion) of second protrusion part 32 to the tip portion (lower end portion) in the protrusion direction of second protrusion part 32 , and of a frustum surface formed at the tip side of that cylindrical surface. The frustum surface is connected to the cylindrical surface through a plane expanding outwardly in the radial direction from that cylindrical surface. However, the outer peripheral surface of the second protrusion part in the present invention does not need to be limited to the cylindrical surface and the frustum surface; a square tube surface, a prismoid surface, or the like may also be employed.
In addition, second protrusion part 32 is formed into a hollow shape (tubular shape) by the presence of second guide channel 33 to be described later.
Further, ejection port 321 formed of a circular opening is formed at the tip portion of second protrusion part 32 .
<Second Guide Channel>
As illustrated in FIGS. 8 , 9 and 15 , second member 3 has second guide channel 33 .
As illustrated in FIGS. 8 and 15 , second guide channel 33 is formed from a position, opposed to terminal (in other words, downstream end) 213 E of pressure reduction channel part 213 , on second inner surface 311 of second plate-like part 31 (in other words, inside plate-like body 11 ) to ejection port 321 . For example, second guide channel 33 includes a hole extending through second protrusion part 32 along the longitudinal direction of second protrusion part 32 .
More specifically, as illustrated in FIG. 15 , second guide channel 33 is composed of starting end channel section (first section) 331 as a starting end portion, width-regulated channel section (second channel) 332 connected to the downstream side of first section 331 , and ejection guide channel section (third section) 333 connected to the downstream side of second section 332 . In first section 331 , the channel inner surface is formed into a rectangular shape. In addition, second section 332 is formed of a relatively narrow space surrounded by bottom surface (hereinafter, referred to as inner bottom surface) 3321 in the channel inner surface formed in second plate-like part 31 and of diaphragm part 34 to be described later. It is noted that inner bottom surface 3321 is continuously connected to inner bottom surface 3311 (see FIG. 15 ) of first section 331 in such a shape as to be in the same plane at the radially inner side. Further, the channel inner surface of third section 333 is formed so as to be a cylindrical surface concentric with first guide channel 23 . The third section in the present invention does not need to be limited to such a configuration, and may be formed to have a square tube surface, or the like, for example.
In addition, in second guide channel 33 , first section 331 is designed to be opposed to terminal 8 E (see FIG. 15 ) of pressure reduction channel 8 so as to bring first inner surface 211 and second inner surface 311 into close contact with each other, thereby allowing second guide channel 33 to communicate with pressure reduction channel 8 .
Second guide channel 33 guides the irrigation liquid after pressure reduction by pressure reduction channel 8 to ejection port 321 .
<Diaphragm Part>
Furthermore, as illustrated in FIGS. 8 to 10 and 15 , second member 3 has diaphragm part 34 at a position corresponding to the terminal of first guide channel 23 on second inner surface 311 of second plate-like part 31 .
Diaphragm part 34 is formed so as to separate first guide channel 23 and second guide channel 33 from each other except communication through pressure reduction channel 8 . That is, first guide channel 23 and third section 333 are separated from each other by diaphragm part 34 , and communicate with each other through pressure reduction channel 8 , first section 331 and second section 332 .
Further, diaphragm part 34 forms a part of the channel inner surface of second guide channel 33 , and, as described above, forms second section 332 together with inner bottom surface 3321 .
Diaphragm part 34 receives the liquid pressure of the irrigation liquid having been guided by first guide channel 23 . That irrigation liquid is led to pressure reduction channel 8 .
In addition, diaphragm part 34 is deformed toward inner bottom surface 3321 (i.e., a portion facing diaphragm part 34 in the channel inner surface of second guide channel 33 ) by the liquid pressure of the irrigation liquid. Diaphragm part 34 is deformed such that the width of the channel of second section 332 (i.e., the width of the channel of second guide channel 33 at a position where diaphragm part 34 is deformed) becomes smaller, as that liquid pressure is increased.
More specifically, as illustrated in FIG. 15 , diaphragm part 34 has dome-shaped center wall part 341 curved so as to be protruded toward first member 2 , and peripheral wall part 342 connected to the outer peripheral end of center wall part 341 to surround center wall part 341 . Peripheral wall part 342 is inclined toward first member 2 as being outward from center wall part 341 in the radial direction (radial direction of center wall part 341 when viewed in a plan view). That is, peripheral wall part 342 is formed in such a shape as to be gradually expanded toward inflow part 221 . Peripheral wall part 342 is connected to the inner rim of the lower end of first guide channel 23 by the close contact between first member 2 and second member 3 .
In addition, one portion 3431 in the circumferential direction (see FIG. 15 ), out of connection part 343 between center wall part 341 and peripheral wall part 342 , is disposed at a position near inner bottom surface 3321 so as to face inner bottom surface 3321 from above in FIG. 15 . For example, diaphragm part 34 is disposed such that the surface of portion 3431 is a plane orthogonal to a direction in which diaphragm part 34 is deformed (longitudinal direction of first guide channel 23 ).
Portion (hereinafter, referred to as “channel width-regulating portion” or “fourth portion”) 3431 is a part of connection part 343 , and regulates the width of the channel of second section 332 .
It is noted that portions near connection part 343 at each of center wall part 341 and peripheral wall part 342 (end edge portion of center wall part 341 and end edge portion of peripheral wall part 342 ) are desirably formed to be thinner, compared with connection part 343 and portions other than the portion near connection part 343 at center wall part 341 . For example, each of center wall part 341 and peripheral wall part 342 is desirably formed so as to have a thickness being gradually decreased toward connection part 343 .
As illustrated in FIG. 6 , first section 331 is disposed at a position near the radially outer side of diaphragm part 34 .
Here, FIGS. 16A , 16 B and 16 C illustrate specific examples of the operation of diaphragm part 34 .
First, as illustrated in FIG. 16A , when the liquid pressure is 0 MPa, i.e., there is no irrigation liquid in first guide channel 23 , the width regulation of second section 332 by diaphragm part 34 is not performed as a matter of course. That channel width in this case is 0.25 mm. It is noted that, as illustrated in FIG. 16A , the channel width is the shortest distance between fourth portion 3431 of diaphragm part 34 and inner bottom surface 3321 .
Next, as illustrated in FIG. 16B , when the liquid pressure is equal to or more than 0.005 MPa (the above-mentioned fracture hydraulic pressure) and less than 0.05 MPa, diaphragm part 34 is deformed by the liquid pressure of the irrigation liquid in first guide channel 23 . Therefore, fourth portion 3431 moves toward (downward) inner bottom surface 3321 . Thus, the channel width is regulated to 0.15 mm.
Next, as illustrated in FIG. 16C , when the liquid pressure is equal to or more than 0.05 MPa and equal to or less than 0.1 MPa, diaphragm part 34 is deformed further compared with the state illustrated in FIG. 16B . Therefore, fourth portion 3431 moves further toward inner bottom surface 3321 . Thus, the channel width is regulated to 0.1 mm.
[Operation and Effect of Present Embodiment].
According to the present embodiment, the irrigation liquid in tube 5 having reached the predetermined pressure flows into dripper 1 through inflow port 2212 of inflow part 221 .
According to the present embodiment, the lower limit of the liquid pressure of the irrigation liquid flowing into pressure reduction channel part 8 can be controlled to be lower than the conventional case (i.e., the case of shielding the pressure reduction channel using the elasticity of the diaphragm) using hydrophobicity of inflow part 221 . Therefore, even when the liquid pressure of the irrigation liquid outside of dripper 1 is low, that irrigation liquid can be properly used for drip irrigation.
In addition, at least surface 22111 outside of substrate part 2211 in inflow part 221 is formed so as to have hydrophobicity, thereby allowing a portion exposed to the external liquid pressure in inflow part 221 to have hydrophobicity. Therefore, the inflow of the irrigation liquid into the channel of dripper 1 can be properly controlled.
Further, when hydrophobicity is imparted to inner peripheral surface 22121 of inflow port 2212 , capillary action in inflow port 2212 can be surely suppressed, making it possible to control the inflow of the irrigation liquid more properly.
Furthermore, when inflow part 221 is formed of a hydrophobic material, the hydrophobicity of inflow part 221 can be achieved with a smaller number of components.
In addition, when the hydrophobicity of inflow part 221 is achieved by hydrophobic coating, the hydrophobicity of inflow part 221 does not depend on the material of inflow part 221 , and thus it is possible to further enhance the freedom in selecting the material of inflow part 221 .
Further, when an irregular shape is formed on the hydrophobic surface of inflow part 221 , the lower limit of the liquid pressure of the irrigation liquid flowing into the channel of dripper 1 can be adjusted to be somewhat higher. Therefore, it is possible to enhance the freedom in selecting the pressure of the inflow liquid during the use of dripper 1 under low pressure.
Furthermore, diaphragm part 34 provided in dripper 1 makes it possible to properly control the ejection amount of the irrigation liquid even when used under high pressure.
The irrigation liquid having flowed into dripper 1 reaches the terminal, where diaphragm part 34 is disposed, of first guide channel 23 through first guide channel 23 .
The irrigation liquid having reached the terminal of first guide channel 23 deforms diaphragm part 34 with its liquid pressure, while being inhibited from moving forward in such a manner as to be dammed by diaphragm part 34 , and as a result is led to pressure reduction channel 8 sideward as an escape.
The irrigation liquid introduced into pressure reduction channel 8 undergoes pressure reduction due to pressure loss caused by the shape of the channel of pressure reduction channel 8 .
The irrigation liquid of which pressure is reduced by pressure reduction channel 8 flows into first section 331 in second guide channel 33 connected to terminal 8 E of pressure reduction channel 8 , and then passes through second section 332 .
At that time, diaphragm part 34 is deformed by the liquid pressure of the irrigation liquid with which first guide channel 23 is filled, such that fourth portion 3431 moves toward inner bottom surface 3321 . Therefore, the width of the channel of second section 332 is decreased by an amount according to the amount of this deformation.
Accordingly, the flow rate of the irrigation liquid passing through second section 332 (flow rate moving toward third section 333 and ejection port 321 all at once) is regulated by the influence of the regulation on the channel width by diaphragm part 34 .
Here, two cases will be discussed in which the liquid pressure of the irrigation liquid flowing into dripper 1 is relatively high and is relatively low. The examples of the causes for such two cases include a position at which dripper 1 is attached on tube 5 (whether near to or distant from a pump), performance of the pump itself (whether high-pressure pump or low-pressure pump), and change of the performance of the pump itself over time.
First, when the pressure of the irrigation liquid is high, the inflow amount of the irrigation liquid into the channel of dripper 1 becomes relatively larger, but at the same time the amount of deformation of diaphragm part 34 becomes relatively larger. Thus, the flow rate of the irrigation liquid to be regulated by diaphragm part 34 also becomes relatively larger. Therefore, the ejection amount of the irrigation liquid from ejection port 321 does not become excessively large.
On the other hand, when the pressure of the irrigation liquid is low, the inflow amount of the irrigation liquid into the channel of dripper 1 becomes relatively smaller, but at the same time the amount of deformation of diaphragm part 34 becomes relatively smaller. Thus, the flow rate of the irrigation liquid to be regulated by diaphragm part 34 also becomes relatively smaller. Therefore, the ejection amount of the irrigation liquid from ejection port 321 does not become excessively small.
Thus, the ejection amount of the irrigation liquid from ejection port 321 can be suitably controlled so as to have less variation (such that the variation of that ejection amount is regulated to 5 to 10%, for example), irrespective of the liquid pressure of the irrigation liquid at the time of flowing into dripper 1 .
In addition, diaphragm part 34 has a structure in which pressure reduction channel 8 is not shielded, unlike the techniques set forth in PTLS 1 and 2, and pressure reduction channel 8 is constantly opened. Therefore, in the present embodiment, the inflow of the irrigation liquid into pressure reduction channel 8 is not regulated. Therefore, the presence of diaphragm part 34 does not constitute a cause for raising the lower limit of the liquid pressure of the irrigation liquid available for drip irrigation toward the high pressure side.
In addition, diaphragm part 34 is integrally molded with the same resin material as that of second member 3 . Therefore, in the present embodiment, such dripper 1 excellent in controlling the ejection amount of the irrigation liquid can be manufactured at a low cost and with less processes with only two components of first member 2 and second member 3 made of a resin material. In particular, there are quite large advantages in terms of costs and manufacturing efficiency when compared with the case of assembling a diaphragm made of an expensive material such as silicone rubber as an individual component.
In addition, since diaphragm part 34 is assembled into second member 3 as an integrally molded product, malfunction of diaphragm part 34 due to assembly error is less likely to occur, contributing to the stabilization of the ejection amount of the irrigation liquid.
Further, diaphragm part 34 is capable of regulating the channel width properly and efficiently by utilizing the pressure difference between the irrigation liquid in pressure reduction channel 8 after pressure reduction by pressure reduction channel 8 and the irrigation liquid in first guide channel 23 to which diaphragm part 34 is exposed. That is, the reduced liquid pressure of the irrigation liquid in second section 332 is sufficiently low. Therefore, that liquid pressure does not hinder the deformation operation of diaphragm part 34 by the irrigation liquid in first guide channel 23 having a relatively high pressure.
Furthermore, first section 331 of second guide channel 33 is disposed near diaphragm part 34 . Therefore, compared with the case where first section 331 is disposed away from diaphragm part 34 , the shape of a metal mold in which second member 3 is molded with resin can be simplified, and thus the manufacturing cost can be further reduced.
In addition, diaphragm part 34 is deflected so as to cancel the curvature toward first guide channel 23 utilizing the elasticity of the resin material to expand outwardly in the radial direction upon receiving the liquid pressure at center wall part 341 from first guide channel 23 side. At the same time, peripheral wall part 342 is rotated about a contact point where peripheral wall part 342 intersects with second plate-like part 31 as a rotation axis. Therefore, fourth portion 3431 can be smoothly displaced toward inner bottom surface 3321 of second section 332 .
Thus, diaphragm part 34 is formed into a suitable shape to be deformed toward inner bottom surface 3321 upon efficiently receiving the liquid pressure of the irrigation liquid in first guide channel 23 . Accordingly, the channel width can be regulated more properly. Such an effect can be further enhanced by forming a portion near fourth portion 3431 in diaphragm part 34 to be thinner. It is noted that the channel width may be regulated more stably by forming fourth portion 3431 to be further thicker.
As has been described above, according to the present embodiment, the dripper includes at least a pipe for penetrating the tube wall of the tube through which the irrigation liquid is supplied, a flange part extending outwardly from the outer periphery of that pipe, a partition wall that closes the inside of that pipe in that flange part, and a bypass channel that is formed inside the flange part and allows communication between two portions, of the pipe, partitioned by the partition wall, and that bypass channel includes a pressure reduction channel for reducing the pressure of the irrigation liquid flowing through the bypass channel. In addition, the dripper is composed of the above-mentioned first member and second member that divide the pipe part and flange part into two portions, and the partition wall is integrally formed with either of first member or second member.
In addition, when at least the partition wall is a diaphragm part that moves in such a direction so as to close the inside of the pipe or the bypass channel upon receiving the pressure of the irrigation liquid having flowed into the pipe, it is possible to provide a dripper enabling the ejection amount of the irrigation liquid to be stabilized, and cost reduction to be achieved by reducing the manufacturing cost, number of components and manufacturing processes, and a drip irrigation apparatus including the dripper. In this case, the above-mentioned low pressure stop filter function does not need to be provided at the inflow port disposed at the end of the pipe disposed in the tube. However, the dripper further including the above-mentioned low pressure stop filter function is more effective from the viewpoint of stabilizing the drop of the irrigation liquid when the liquid pressure of the irrigation liquid is low.
In addition, when at least the inflow port has the low pressure stop filter function, it is possible to provide a dripper enabling drip irrigation to be properly performed even when the liquid pressure of the irrigation liquid is low, and a drip irrigation apparatus including the dripper. In this case, the partition wall does not need to have the above-mentioned function of the diaphragm part. However, the partition wall being the diaphragm part is more effective from the viewpoint of stabilizing the drop of the irrigation liquid when the liquid pressure of the irrigation liquid fluctuates higher.
It is noted that the present invention is not limited to the above-described embodiment, and the above-described embodiment may be modified in various manners as long as the feature of the present invention is provided.
[Modification].
As illustrated in FIG. 17 , the dimension of second protrusion part 32 in the protrusion direction may be shorter, for example.
Alternatively, as illustrated in FIG. 18 , second protrusion part 32 itself does not need to be provided. In this case, ejection port 3121 can be formed on second outer surface 312 .
Alternatively, as illustrated in FIG. 19 , the end portion (upper end portion in FIG. 19 ) of diaphragm part 34 on first member 2 side may be extended to such a position as to abut recess 2111 . In this case, opening 3421 for allowing the inflow of the irrigation liquid into pressure reduction channel 8 can be formed on peripheral wall part 342 of diaphragm part 34 .
The disclosures of Japanese Patent Applications No. 2012-196149 filed on Sep. 6, 2012, and No. 2012-216574 filed on Sep. 28, 2012 including the specification, drawings and abstract are incorporated herein by reference in their entirety.
Industrial Applicability
The dripper according to the present invention is capable of dropping a stable amount of irrigation liquid without depending on the liquid pressure of the irrigation liquid. In addition, such dripper can be formed by the joining of two injection-molded products. Therefore, it is possible to manufacture the dripper at a low cost and in a large amount. Accordingly, it is expected that the dripper and drip irrigation apparatus according to the present invention are utilized not only in drip irrigation but also in various industries where stable dropwise addition of liquid is demanded.
REFERENCE SIGNS LIST
1 Dripper
2 First member
21 First plate-like part
211 First inner surface
212 First outer surface
213 Pressure reduction channel part
22 First protrusion part
221 Inflow part
23 First guide channel
3 Second member
31 Second plate-like part
311 Second inner surface
312 Second outer surface
321 Ejection port
33 Second guide channel
34 Diaphragm part
8 Pressure reduction channel
11 Plate-like body
|
A dripper obtained by incorporating together a first member and second member, which are both resin moldings. The first member is on the side into which an irrigating solution flows, and the second member is on the side from which the irrigating solution is discharged. The dripper has an inflow part having a low-pressure stop filter function, and/or a diaphragm part for narrowing a flow path by elevating the hydraulic pressure of the irrigating solution. The dripper makes it possible to stabilize the amount of irrigating solution discharged, irrespective of the hydraulic pressure of the irrigating solution, and also makes it possible to reduce costs.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a printing apparatus and to a control method therefor, and relates more specifically to a method for handling maintenance information in a printing apparatus that is part of a point-of-sale (POS) system or other financial transaction system.
2. Description of the Related Art
A conventional printing apparatus, hereafter simply “printer”, typically stores an operating history of the printer in an EEPROM (electrically erasable programmable ROM), flash ROM, or other type of nonvolatile storage. This operating history typically represents the total number of operating hours, the number of characters printed, or some other measure(s) that can be used as a guide to determine when maintenance is required. When the printer is turned on and initialized, this operating history is usually downloaded from the nonvolatile memory to volatile memory such as RAM. The operating history is thus updated in RAM during printer operation, and written back to the nonvolatile memory as part of a shutdown procedure when the power is turned off, or at some regular interval, such as at a constant time interval or when some specified value is reached.
The operating history can also be read, displayed or printed in response to a command from a host device or operator command for user confirmation.
Japan Unexamined Patent Publication (kokai) H6-3956 (1994-3956) discloses a method for resetting historical data and starting the counter for a particular part when a part is replaced.
Japan Unexamined Patent Publication (kokai) H4-305657 (1992-305657) also discloses a method for redundantly storing historical data to a plurality of memory devices, thereby avoiding the problem of maintenance history data being lost as a result of a memory error or similar problem.
A problem with a printer as noted above is that usage of individual parts cannot be specifically determined from the total operating time of the printer. For example, assuming the same total operating time, use of the print head and paper transportation mechanism differ when printing only a few characters on many lines and when printing many characters on only a few lines. As a result, it is not possible to accurately determine a part's wear from the total operating time.
Furthermore, historical data such as the number of characters printed is typically reset when a part's useful life is exhausted and the part(s) is replaced based on this data. This makes it impossible to determine the total operating time or total operating count of other mechanical parts used to drive the parts that were replaced.
Total operating count information makes it possible to determine how much a product is actually used by the end user, and is effective for quality assurance and troubleshooting purposes.
This information can also be taken into consideration in the development of new products to help the manufacturer provide products with desirable specifications.
OBJECTS OF THE INVENTION
Therefore, it is an object of the present invention to overcome the aforementioned problems.
An object of the present invention is to provide a printing apparatus that can store total operating information for individual parts and components of the printing apparatus.
A further object of the present invention is to provide a printing apparatus capable of separately storing historical data related to user-replaceable consumables, and historical data related to parts that are not replaceable by the user, including parts and assemblies for driving other parts.
SUMMARY OF THE INVENTION
To achieve the above objects, a printing apparatus according to the present invention comprises: a nonvolatile storage for holding stored content even when power is not supplied to the printing apparatus; an operation counter for counting a, value indicative of a printing apparatus operation; an operation counter storage for storing a historical operation count of the printing apparatus based on a value counted by the operation counter, and a processor for writing an interim count value and a cumulative count value to the nonvolatile storage.
Specific printer operations, such as the number of characters printed, distance of recording medium transportation, and the number of times the automatic paper cutter is operated, can be individually accumulated, and the historical counts, that is, the cumulative counts since the printer was first used, can be stored in memory.
The nonvolatile storage or memory preferably comprises a plurality of areas for storing a respective plurality of historical operation counts such that count values from the operation counter storage can be written to each of the plurality of areas to store historical operation count values for a plurality of printer operations, and to store both interim and cumulative counts for each operation.
This configuration enables the cumulative operations counts to be it maintained even after a part or component has been replaced and its associated interim count has been reset.
The printing apparatus preferably further comprises a timer for measuring an operating time period of the printing apparatus; and an evaluation unit for determining whether the printing apparatus is performing a specific process. In this configuration the evaluation unit determines whether the specific process is in progress following expiration of the measured operating time period, and the historical count stored in the operation counter storage is written to the nonvolatile storage when the evaluation unit determines that the specific process is not in progress.
This configuration makes it possible to reduce the count information that is lost when the power is interrupted, for example. Printer operations are also not disrupted because writing data to the nonvolatile memory is prohibited during certain printer operations, including actual printing and data processing operations.
The count data stored in the operation counter storage further is preferably written to the nonvolatile storage when the evaluation unit determines that the specific process is not in progress, or when the evaluation unit determines that the specific process is in progress but the timer measures a second time period, which is longer than the operating time period, has elapsed.
By thus forcing writing to nonvolatile memory when a specific printer operation takes a long time, it is possible to avoid the situation where data is not stored for an extended period of time. As a result, it is also possible to reduce the count information that is lost when the power is interrupted, for example.
A printing apparatus according to the present invention yet further preferably comprises an operation count changing unit for changing a historical operation count stored in the nonvolatile storage based on a specific command received from a host device, and prohibiting changing a historical operation count stored in one area of the plurality of areas.
Memory can therefore be divided into an area that includes an interim count that can be reset when a part is replaced, and an area that includes a cumulative count that cannot be reset. As a result, accurate historical information can be maintained when there are parts that are replaced at different times, based on a cumulative count corresponding to the replaced part.
A printing apparatus according to the present invention yet further preferably comprises an operation count transmission unit for reading and sending to the host device a historical operation count stored in the nonvolatile storage based on a specific command received from the host device; and an operation count conversion unit for converting a historical operation count to an index enabling service life evaluation. In this configuration the operation count transmission unit sends the converted service life evaluation index obtained from the operation count conversion unit when sending a historical operation count to the host device.
The host device can thus obtain count values in a form enabling easier determination of component service life, which is particularly useful when service life is a function of both component operation and frequency of operation.
Yet further preferably, this printing apparatus comprises data conversion for coding the historical operation count or converted service life evaluation index obtained from the operation count conversion means. In this case, the operation count transmission unit sends the coded data to the host device. As a result, data can be sent reliably to the host device even when certain data cannot be transmitted due to interface limitations.
Yet further preferably, this printing apparatus comprises a display for displaying the service life evaluation index obtained by the operation count, conversion unit, and/or the historical operation count stored in the nonvolatile storage. The service life evaluation index obtained by the operation count; conversion unit, and/or the historical operation count stored in the nonvolatile storage can also be printed.
The operator can therefore also obtain the count information at the printer and take whatever maintenance steps may be required.
The operation count can alternatively be written to the nonvolatile storage irrespective of the operating time measurement in response to a specific command received from the host device. Data can therefore be stored at an appropriate timing to reduce the counter information that is lost when the power is interrupted, for example.
The present invention can also be provided as a control method for a printing apparatus with the same benefits and effects described above.
The control method of the present invention can also be provided as a control program that can be executed by a control device, and can be provided on a recording medium for storing this control program. Usable recording media include Compact Disc-ROM (CD-ROM) media, floppy disks, hard disks, magneto-optical discs, various digital versatile disc (DVD) formats, including DVD-ROM, as well as magnetic tape. Furthermore, these recording media can be used to provide the program of the invention to existing printing apparatuses. In addition, the program of the invention can be made available for delivery via a network such as the World Wide Web, including directly from a Web site, for downloading to an existing printer apparatus.
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 DESCRIPTIONS OF THE DRAWINGS
These and other objects and features of the present invention will be readily understood from the following detailed description taken in conjunction with preferred embodiments thereof with reference to the accompanying drawings, in which like parts are designated by like reference numerals and in which:
FIG. 1 is a block diagram showing an exemplary printing apparatus according to a preferred embodiment of the present invention;
FIG. 1A is a block diagram of the CPU of the printing apparatus shown in. FIG. 1;
FIG. 2 is a flow chart of the write operation to a flash ROM device according to a first preferred embodiment of a printing apparatus shown in FIG. 1;
FIG. 3 is a flow chart of the write operation to a flash ROM device according to a second preferred embodiment of a printing apparatus shown in FIG. 1;
FIG. 4 is an example of a “change counter command” in the printing apparatus shown in FIG. 1;
FIG. 5 is an example of a “send counter command” in the printing apparatus shown in FIG. 1; and
FIG. 6 is a display or print sample from a test print mode in the printing apparatus shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of a printing apparatus according to the present invention is described below with reference to the accompanying figures.
FIG. 1 is a block diagram showing an exemplary printing apparatus (“printer” below) according to a preferred embodiment of the present invention. As shown in FIG. 1, a printer 1 exemplary of the invention comprises a central processing unit (CPU) 2 for overall control of the printer 1 ; random access memory (RAM) 3 that is used as primary working memory; read-only memory (ROM) 4 for storing control data, an application program, and related information; flash ROM memory 5 for storing information relating to the operating status of the printer 1 ; a mechanical part 6 enabling printing to paper using a print head; and an interface 7 for connecting the printer 1 to a host device 70 . The method of the present invention can also be stored on a recording media 72 , such as compact disc, floppy disk, hard disk, etc., and read into printer 1 through media drive 74 , such as CD drive, floppy drive, hard drive, etc., and interface 7 . The method of the present invention can also be stored at a remote location and transferred over network 76 , e.g. LAN, WAN, WEB, to printer 1 via interface 7 .
When printer 1 is connected to host device 70 , print data, control commands, and other information is communicated between the printer 1 and host device via interface 7 . Communicated data is buffered to RAM 3 , which also provides temporary storage. The interface 7 can also be used to reset the CPU 2 by means of a signal line connected to the host device 70 .
When CPU 2 initializes due to printer 1 power turning on or a signal from the host device via the interface 7 (referred to below as simply “initialization” ), CPU 2 reads a program from ROM 4 , and executes the program to control printer 1 . CPU 2 also interprets data received through interface 7 and buffered to RAM 3 . If the buffered data is a control command for printing, CPU 2 accesses font data from ROM 4 , and develops a print image in RAM 3 . CPU 2 then controls driving mechanical part 6 to print the print image.
In a printer 1 according to this preferred embodiment, mechanical part 6 comprises a mechanism for printing on roll paper, that is, a roll paper transportation unit 61 , a roll paper print head 62 , and a roll paper cutter 63 ; and a mechanism for printing on cut-sheet forms, that is, a cut-sheet transportation unit 64 , and a cut-sheet print head 65 ; and a magnetic ink character reader (MICR) head 66 .
As shown in FIG. 1A, CPU 2 further comprises an internal timer 21 for issuing a timer interrupt at a preset interval. Time is thus counted according to a timer interrupt program stored in ROM 4 to measure the operating time of printer 1 .
Flash ROM 5 can be read and written by CPU 2 , and can hold stored content even when power is not supplied, i.e. it is nonvolatile. During printer 1 initialization, CPU 2 loads the printer operation count stored in flash ROM 5 into RAM 3 , and thereafter updates the printer operation count by updating the value stored in RAM 3 . The updated printer operation count is then written back to flash ROM 5 at a specific time interval together with the printer 1 operating time measured using the internal timer 21 of the CPU 2 .
The time measurement operation executed according to the timer interrupt process noted above measures both the operating time of the printer 1 , and measures the time interval for writing the count values from RAM 3 to the flash ROM 5 . Data is written to flash ROM 5 at a specific write time interval, which in this preferred embodiment is defined as every time the timer 21 interrupt process detects that 2 minutes has passed.
It should be noted that this write time interval is appropriately determined with consideration given to flash ROM 5 life (number of write operations possible) and other printer 1 hardware considerations. For example, this write time interval will be different when the printer 1 shutdown procedure, i.e., the procedure controlling what events occur when the printer 1 power switch is turned off, (1) simply stops power supply immediately when the power switch is turned off, and (2) when the shutdown procedure first executes a software procedure for storing essential data before stopping the printer power supply when the printer power switch is turned off. In the first case (1), data will be lost if the power switch is turned off before the data has been stored, and more frequent updating is therefore desirable. As a result, the write time interval is set to a short interval, for example, 2 minutes. In the second case (2), however, data can be stored even after the power switch is turned off. The write time interval can therefore be set to a longer interval, such as 1 hour.
Exemplary printer operations to be counted and stored in flash ROM 5 are shown below. Note that each printer operation is tracked using two of a plurality of counter codes, which are used in an exemplary control command further described below. Exemplary counter codes for different printer operations follow:
cut-sheet form line feeds
counter a = 10
counter b = 138
cut-sheet form printed characters
counter a = 11
counter b = 139
roll paper line feeds
counter a = 20
counter b = 148
roll paper print head, power on
counter a = 21
counter b = 149
roll paper cutter drive operations
counter a = 50
counter b = 178
MICR read operations
counter a = 60
counter b = 188
Product operating hours
counter a = 70
counter b = 198
As shown above and in FIG. 1A, printer 1 of this preferred embodiment has two counters a 1 , a 2 . . . a n , b 1 , b 2 . . . b n for each monitored operation. Each of the counters, a and b, is independent of the other and is separately updated to track the same operation. The interim count value of counters a 1 . . . a n can be changed using a control command; the cumulative count values of counters b 1 . . . b n , however, cannot be changed using a control command.
FIG. 2 is a flow chart of a flash ROM write control procedure. As count values from counters a 1 . . . a n , b 1 . . . b n are updated in RAM 3 during printer 1 operation, they are regularly written to flash ROM 5 according to the procedure shown in FIG. 2 and described below.
During printer 1 initialization, count values for the counters stored in flash ROM 5 are loaded into RAM 3 , and time measurement using the internal timer 21 begins ( 201 ). When a predetermined period, for example, 1 hour in this preferred embodiment, elapses ( 202 ) after time measurement begins, decision step 203 determines whether the printer is printing or processing data. If neither operation is in progress, the current count values are written to flash ROM 5 ( 204 ). Time measurement using the internal timer is then reset ( 205 ), and the procedure loops back to decision step 202 . If decision step 203 determines that the printer is printing or processing data ( 203 ;Yes), however, data is not written to flash ROM 5 . A drop in printer throughput resulting from writing to flash ROM 5 is thus avoided by writing to flash ROM 5 only when the printer is not printing or processing data, and not writing to flash ROM 5 when either operation is in progress.
FIG. 3 is a flow chart of an alternative flash ROM write control procedure according to this preferred embodiment. This procedure differs from that shown in FIG. 2 in that time measurement continues when either printing or data processing is in progress, and flash ROM 5 is written within a second specified period ( 306 ) regardless of whether or not printing or data processing is still in progress .
During printer 1 initialization, count values for the counters stored in flash ROM 5 are written into RAM 3 , and time measurement using the internal timer begins ( 301 ). When a first predetermined period elapses ( 302 ) after time measurement begins, decision step 303 determines whether the printer is printing or processing data. The decision as to whether or not the printer is printing or processing data is made by evaluation unit 22 . Although evaluation unit 22 is shown as a separate block in FIG. 1A for illustration purposes, it will preferably comprise CPU 2 performing status checks (for the printer printing or processing data) under control of a software routine stored in ROM 4 . However, evaluation unit 22 could also comprise dedicated logic or an ASIC. If neither operation is in progress ( 303 ;No), updated count values are written to flash ROM 5 ( 304 ). Time measurement using the internal timer is then reset ( 305 ), and the procedure loops back to decision step 302 .
If decision step 303 determines that the printer is printing or processing data ( 303 ;Yes), however, data is not written to flash ROM 5 , and the procedure branches to a second timing loop ( 306 ) in which a second period is counted using the internal timer.
This second period is longer than the first period, for example, 1 hour 10 minutes in this preferred embodiment. Whether both printing and data processing operations have stopped is continuously monitored ( 303 ) by evaluation unit 22 during this second period. If both printing and data processing operations stop ( 303 ;No) before this second period elapses, data is written to flash ROM 5 ( 304 ), time measurement using the internal timer is then reset ( 305 ), and the procedure loops back to step 302 .
However, if printing or data processing are still in progress when the second period has elapsed ( 306 ;Yes), data is written to flash ROM 5 ( 304 ) anyway.
With the first timing method described above writing to flash ROM 5 is delayed when either printing or data processing is in progress. This method can therefore result in a long interval between flash ROM 5 writes, which can result in control information loss if, for example, the printer power is turned off or a CPU 2 being reset by a command posted over the signal line from the host device 70 via interface 7 and executed while writing to flash ROM 5 is delayed.
With a POS printer, for example, flash ROM writing could be delayed for an extended period of time while printing a daily sales report, a task that can take many minutes. Count values and control information will also continue to change as printing proceeds. If the power is then turned off and data is lost, count error increases and more control information is lost.
This problem can be avoided in a printer 1 according to this preferred embodiment by writing to flash ROM 5 within a maximum write interval determined by the second period ( 306 ) whether or not printing or data processing is in progress.
A control command for reading and writing count values from host device 70 is described next below. It will be noted that the cumulative values of the “b” counters above cannot be changed by this control command.
A typical control command for changing a counter “a” value is shown in FIG. 4 . This change counter command 40 comprises a command code part 41 and a parameter part 42 . The command code part 41 comprises an extension 43 and function code 44 , and the parameter part 42 comprises a function extension parameter 45 and a counter ID 46 . The extension 43 is the ASCII control character “GS” for the hexadecimal character code 1 D. The function code 44 is a code string for specifying the change counter function; two character codes are combined to specify the change counter function. The function extension parameter 45 specifies the key for changing the counter. The counter ID 46 identifies the counter number to change.
The operation count changing unit 24 of CPU 2 performs the following operations in response to the change counter command 40 . Although operation count changing unit 24 is shown as a separate functional block in FIG. 1A, it will preferably comprise CPU 2 performing the following functions under control of a software routine stored in ROM 4 . However, operation count changing unit 24 could also comprise dedicated logic or an ASIC.
(1) The key specified by the function extension parameter 45 is compared with a predetermined key; if the keys match, the specified counter value is changed. If the keys do not match, changing the counter is prohibited.
(2) The counter number specified by the counter ID 46 is compared with the interim counters “a” that can be changed. If the specified counter matches a counter “a”, the value of the specified counter is changed. In this example, the counter is reinitialized to zero (0). If the specified counter does not match a counter “a”, no counter is changed. As a result, the value of a cumulative “b” counter will not be changed.
(3) The change counter process is not executed if a print mode has been selected for printing by a print command after print data received from the host device has been developed in memory and buffered to the one-line print buffer, and unprinted data remain in the one-line print buffer. This prevents loss of unprinted data resulting from printer operations being stopped based on a memory error in the above change counter process, and thus protects unprinted print data.
(4) The change counter process is not executed if a print mode has been selected for printing by a print command after print data received from the host device has been developed in memory and buffered to the multiple line print buffer, and an area in which will be developed print data is set in the multiple line print buffer if no print data is developed in the area. This prevents loss of unprinted data resulting from printer operations being stopped based on a memory error in the above change counter process, and thus protects unprinted print data.
(5) If a write error occurs during writing, the error is announced using an LED or buzzer, and/or by sending an error status signal or changing the state of the signal line to the host device via the interface 7 . The operator or host device can thus be informed that the counter could not be normally updated as a result of an error occurring in the printer 1 .
(6) Count values of counters stored in RAM 3 are written to flash ROM 5 even if the timer interrupt process of the internal timer does not indicate it is the normal flash ROM 5 write timing. The flash ROM 5 is also written when the change counter command 40 is processed to prevent loss of any count values; changed by the change counter command 40 as a result of CPU 2 being reset by a command posted over the signal line from the host device, via the interface 7 , before the changed counter is written to flash ROM 5 according to the normal flash ROM write timing. It will also be obvious that the same result can be achieved by providing a separate flash ROM 5 write command, and using the flash ROM write command together with the change counter command 40 .
A typical control command for reading a count value of a counter from a host device is shown in FIG. 5 . This send counter command 50 comprises a command code part 51 and a parameter part 52 . The command code part 51 comprises an extension 53 and function code 54 , and the parameter part 52 comprises a function extension parameter 55 and a counter ID 56 . The extension 53 is the ASCII control character “GS” for the hexadecimal character code iD. The function code 54 is a code string for specifying the send counter function; two character codes are combined to specify the send counter function. The function extension parameter 55 specifies the send counter function key. The counter ID 56 identifies the counter number to send.
The operation count transmission unit of CPU 2 performs the following operations in response to the send counter command 50 received from the host device. Although operation count transmission unit 26 is shown as a separate functional block in FIG. 1A, it will preferably comprise CPU 2 performing the following functions under control of a software routine stored in ROM 4 . However, operation count transmission unit 26 could also comprise dedicated logic or an ASIC.
(1) The key specified by the function extension parameter 55 is compared with a predetermined key; if the keys match, the count value of the specified counter is sent. If the keys do not match, sending is prohibited.
(2) If the counter specified by the counter ID 56 is a counter that is being counted (tracked), the counter value stored in RAM 3 is read. If the specified counter ID does not match that of any counter, the send command is ignored.
(3) If a read error occurs during transmission, the error is announced using an LED or buzzer, and/or by sending an error status signal or changing the state of the signal line to the host device via the interface 7 . The operator or host device can thus be informed that the counter could not be sent as a result of an error occurring in the printer 1 .
(4) A header code or terminate code can be added to the transmitted data to enable the host device, for example, to easily recognize the beginning and end of the transmitted data.
The operation count conversion unit 28 of CPU 2 also executes the following process before transmitting a count value to the host device. Although operation count conversion unit 28 is shown as a separate functional block in FIG. 1A, it will preferably comprise CPU 2 performing the following functions under control of a software routine stored in ROM 4 . However, operation count conversion unit 28 could also comprise dedicated logic or an ASIC.
(5) Step 1: Convert the count value
Count values that can be used for determining component service life include values that can be easily used directly, and values that are difficult to use directly. For easy-to-use count values, the data can be sent directly. Values that are difficult to use, however, typically need to be converted to an expression that can be easily interpreted for service life determinations.
Consider, for example, the line feed count for cut-sheet forms. The drive power source for the cut-sheet transportation unit 64 is a stepping motor (not shown in the figures). The CPU 2 counts the number of steps taken by the stepping motor, and stores this simple step count. For the user, however, it is extremely difficult to grasp how much paper has been advanced using this step count.
The line feed distance of a printer 1 according to this preferred embodiment is ⅙ inch, and the cut-sheet transportation unit 64 must drive the stepping motor 24 steps to advance a cut-sheet form ⅙ inch. The CPU 2 therefore obtains a line feed count by dividing this step count by 24.
(6) Step 2: Convert count values and converted count values for transmission
Various problems can arise with sending count values and converted count values directly to the host device. For example, a transmitted value could match another control code and prevent normal operation. In some cases data cannot be sent in 7-bit words. The data conversion unit 29 according to this preferred embodiment therefore converts the count values and converted count values to a decimal character code before transmission. Although data conversion unit 29 is shown as a separate functional block in FIG. 1A, it will preferably comprise CPU 2 performing data conversion under control of a software routine stored in ROM 4 . However, data conversion unit 29 could also comprise dedicated logic or an ASIC.
For example, consider the converted cut-sheet form line feed count 00001100H. This value converts easily to the four bytes 00H, 00H, 11H, 00H where 11H is the same as the XON code and could result in a handshake error. The line feed count 00001100H is therefore converted to the decimal code 4352 D, which is transmitted using the four bytes 34 H, 33 H, 35 H, 32 H.
A printer 1 according to the present invention also has a test printing mode in which data not received from the host device is printed. This test printing mode can be accessed in a printer 1 according to the present embodiment by, for example, turning the power switch on while holding the paper feed switch depressed.
When this test printing mode is selected, printer 1 displays on display 78 or prints with mechanical printer part 6 the same counter information sent to the host device when it receives a send counter command 50 . As shown in FIG. 6, which illustrates a sample of the display or printer output in the test printing mode, the test printing mode printout includes the maintenance items 60 being counted, and count values 61 and 62 corresponding to interim counter a and cumulative counter b values for each item.
It should be further noted that the count values can be checked and confirmed by a printer 1 according to the present embodiment even when the printer 1 is not connected to a host device.
The counters also continue to increment while printing in the test printing mode. The test printing mode does not continue for the two minute write interval of the present embodiment, however, and RAM 3 content can therefore be lost if the power is turned off before the flash ROM 5 write timing. To prevent data loss in this case, data is updated to the flash ROM 5 even before the timer interrupt process of the internal timer detects the flash ROM write timing.
Although the present invention has been described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims, unless they depart therefrom.
The present invention has been described using counters that can be reset and counters that cannot be reset. It will be obvious to one with ordinary knowledge in the related art, however, that the same effect can be achieved using only one counter by storing any counter values to a non-volatile memory when a component is replaced. For example, if only resettable counters are used, the total or cumulative operating count can be derived from the sum of the current counter value and the stored counter value. Furthermore, if only non-resettable counters are used, component service life can be derived from the difference between the current counter value and the stored counter value.
It will also be obvious that while flash ROM has been described as the nonvolatile memory for storing historical operating data for the printer 1 , an EEPROM or other nonvolatile storage device can be used.
The data stored in nonvolatile memory shall also not be limited to that described above. For example, any data relating to the operating status of the printer can be used, or a subset of any of the above data can be used. Nonvolatile memory can also be used to store font data, application program data, or other information in addition to the above-noted operating status and counter data.
Furthermore, a real-time clock or other device can be used in place of the internal timer of the CPU described above as being used for measuring total operating time, write time, and other time-based parameters.
A printer 1 according to this preferred embodiment has also been described as determining at a constant time interval whether a specific process is executing. However, this interval can be defined on the basis of some other value that changes with printer operation, including the number of pages printed or the number of lines printed.
It is therefore possible by means of the present invention to easily check the wear on consumables, the service life of non-replaceable components associated with consumables, and other information associated with printer quality assurance, by storing a historical operating count for the printer 1 to a plurality of storage areas or memory device.
While the invention has been described in conjunction with several specific embodiments, it is evident to those skilled in the art that many further alternatives, modifications and variations will be apparent in light of the foregoing description. 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.
|
A printing apparatus for storing total operation counters for individual consumable and nonconsumable parts of a printing apparatus. A nonvolatile storage retains stored count information even when power is not supplied to the printing apparatus. An operations counter counts a value indicative of a printing apparatus operation. A counter storage stores a historical counter indicative of the printing apparatus operation history to the nonvolatile storage means based on a value counted by the operations counter, and stores a total printing apparatus operations count to the storage means. Specific printer operations, such as the number of characters printed, distance of recording medium transportation, and the number of times the automatic paper cutter is operated, can thus be individually accumulated, and the historical counts, that is, the cumulative counts since the printer was first used, can be stored to memory.
| 1
|
FIELD OF THE INVENTION
[0001] This invention relates to room temperature cured compositions of diorganopolysiloxanes polymer blends having reduced gas permeability and methods of using these compositions. The compositions are particularly well suited for use in the window area as an insulating glass sealant and in applications such as coatings, adhesives and gaskets.
BACKGROUND OF THE INVENTION
[0002] Room temperature curable compositions are well known for their use as sealants. In the manufacture of Insulating glass (IGU), for example, panels of glass are placed parallel to each other and sealed at their periphery such that the space between the panels, or the inner space, is completely enclosed. The inner space is typically filled with a low conductivity gas or mixture of gases.
[0003] One of the disadvantages of sealant compositions is their permeability to low conductivity energy transfer gases (e.g. argon) used to enhance the performance of insulated glass units. As a result of this permeability, the reduced energy transfer maintained by the gas between the panels of glass is lost over time.
[0004] There remains a need for sealants with good barrier protection that overcomes the deficiencies described above, and is highly suitable for applications that are easy to apply and have excellent adhesion.
SUMMARY OF THE INVENTION
[0005] The present invention is based on the discovery that a diorganopolysiloxane polymer or blend thereof exhibiting permeability to a gas and at least one polymer having a permeability to a gas or mixture of gases that is less than the permeability of diorganopolysiloxane polymer provides a sealant that has improved gas barrier properties along with the desired characteristics of softness, processability, and elasticity. Specifically, the present invention relates to a curable sealant composition comprising: (a) diorganopolysiloxane exhibiting permeability to gas; (b) at least one polymer having a permeability to gas that is less than the permeability of diorganopolysiloxane polymer (a); (c) cross-linker; and (d) catalyst for the cross-linker reaction.
[0006] These compositions advantageously provide for longer service life of insulated glass units (IGU).
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a graph illustration of the permeability of Examples 1-3 to argon gas.
[0008] FIG. 2 is a graph illustration of the permeability of Example 5-7 to argon gas.
[0009] FIG. 3 is a graph illustration of percent decrease in permeability of Example 5-7 to argon gas.
DETAILED DESCRIPTION OF THE INVENTION
[0010] In accordance with the present invention, the sealant compositions exhibit lowered permeability to gas, or mixtures of gases, by blending diorganopolysiloxane exhibiting permeability to gas; (b) at least one polymer having a permeability to gas that is less than the permeability of diorganopolysiloxane polymer. (a); (c) cross-linker; and (d) catalyst for the cross-linker reaction.
[0011] The sealant composition of the present invention may further comprise an optional component, such as, filler, adhesion promoter, non-ionic surfactant, and the like and mixtures thereof.
[0012] The present invention comprises diorganopolysiloxane polymer or blend thereof and at least one additional polymer. A general description of each of the components of the formulation are given as follows:
(a) a diorganopolysiloxane or blend of diorganopolysiloxanes exhibiting permeability to a gas or mixtures of gases wherein the silicon atom at each polymer chain end is silanol terminated; whereby the viscosity of the siloxanes can be from about 1,000 to 200,000 cps at 25° C.; (b) a polymer exhibiting permeability to a gas or mixture of gases that is less than the permeability of diorganopolysiloxane polymer (a); (c) an alkylsilicate cross-linker of the general formula:
(R 14 O)(R 15 O)(R 16 O)(R 17 O)Si;
(d) a catalyst useful for facilitating crosslinking in silicone sealant compositions.
[0017] The silanol terminated diorganopolysiloxane polymer (a), generally has the formula:
M a D b D′ c
with the subscript a=2 and b equal to or greater than 1 and with the subscript c zero or positive where
M=(HO) 3-x-y R 1 x R 2 y SiO 1/2 ;
with the subscript x=0, 1 or 2 and the subscript y is either 0 or 1, subject to the limitation that x+y is less than or equal to 2, where R 1 and R 2 are independently chosen monovalent C 1 to C 60 hydrocarbon radicals; where
D=R 3 R 4 SiO 1/2 ;
where R 3 and R 4 are independently chosen monovalent C 1 to C 60 hydrocarbon radicals; where
D′=R 5 R 6 SiO 2/2 ;
where R 5 and R 6 are independently chosen monovalent C 1 to C 60 hydrocarbon radicals.
[0018] In one embodiment of the invention, the level of incorporation of the diorganopolysiloxane wherein the silicon atom at each polymer chain end is silanol terminated (a) ranges from about 50 weight percent to about 99 weight percent of the total composition. In another embodiment of the invention, the level of incorporation of the diorganopolysiloxane polymer or blends of diorganopolysiloxane polymers (a) ranges from about 60 weight percent to about 95 weight percent of the total composition. In yet another embodiment of the present invention, the diorganopolysiloxane polymer or blends of diorganopolysiloxane polymers (a) ranges from about 65 weight percent to about 95 weight percent of the total composition.
[0019] The silicone composition of the present invention further comprises at least one polymer (b) exhibiting permeability to a gas or mixture of gases that is less than the permeability of diorganopolysiloxane polymer (a).
[0020] Suitable polymers include, but are not limited to, polyethylenes, such as, low density polyethylene (LDPE), very low density polyethylene (VLDPE), linear low density polyethylene (LLDPE) and high density polyethylene (HDPE); polypropylene (PP), polyisobutylene (PIB), polyvinyl acetate(PVAc), polyvinyl alcohol (PVoH), polystyrene, polycarbonate, polyester, such as, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene napthalate (PEN), glycol-modified polyethylene terephthalate (PETG); polyvinylchloride (PVC), polyvinylidene chloride, polyvinylidene floride, thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), polymethylmethacrylate (PMMA), polyvinyl fluoride (PVF), Polyamides (nylons), polymethylpentene, polyimide (PI), polyetherimide (PEI), polether ether ketone (PEEK), polysulfone, polyether sulfone, ethylene chlorotrifluoroethylene, polytetrafluoroethylene (PTFE), cellulose acetate, cellulose acetate butyrate, plasticized polyvinyl chloride, ionomers (Surtyn), polyphenylene sulfide (PPS), styrene-maleic anhydride, modified polyphenylene oxide (PPO), and the like and mixture thereof.
[0021] The polymers can also be elastomeric in nature, examples include, but are not limited to ethylene- propylene rubber (EPDM), polybutadiene, polychloroprene, polyisoprene, polyurethane (TPU), styrene-butadiene-styrene (SBS), styrene-ethylene-butadiene-styrene (SEEBS), polymethylphenyl siloxane (PMPS), and the like.
[0022] These polymers can be blended either alone or in combinations or in the form of coplymers, e.g. polycarbonate-ABS blends, polycarbonate polyester blends, grafted polymers such as, silane grafted polyethylenes, and silane grafted polyurethanes.
[0023] In one embodiment of the present invention, the sealant composition has a polymer selected from the group consisting of low density polyethylene (LDPE), very low density polyethylene (VLDPE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), and mixtures thereof. In another embodiment of the invention, the sealant composition has a polymer selected from the group consisting of low density polyethylene (LDPE), very low density polyethylene (VLDPE), linear low density polyethylene (LLDPE), and mixture thereof. In yet another embodiment of the present invention, the sealant composition polymer is linear low density polyethylene (LLDPE).
[0024] In one embodiment of the present invention, the sealant composition contains from about 50 to about 99 weight percent diorganopolysiloxane polymer and from about 1 to about 50 weight percent polymer (b). In another embodiment of the present invention, the sealant composition contains from about 60 to about 95 weight percent diorganopolysiloxane polymer and from about 5 to about 40 weight percent polymer (b). In yet another embodiment of the present invention, the sealant composition contains from about 65 to about 95 weight percent diorganopolysiloxane polymer and from about 5 to about 35 weight percent polymer (b).
[0025] The blending method of diorganopolysiloxane polymer (a) with polymer (b) may be performed by those methods know in the art, for example, melt blending, solution blending or mixing of polymer powder component (b) in diorganopolysiloxane polymer (a).
[0026] Suitable cross-linkers (c) for the siloxanes of the sealant composition may include an alkylsilicate of the general formula:
(R 14 O)(R 15 O)(R 16 O)(R 17 O)Si
where R 14 , R 15 , R 16 and R 17 are independently chosen monovalent C 1 to C 60 hydrocarbon radicals.
[0027] Crosslinkers useful herein include, but are not limited to, tetra-N-propylsilicate (NPS), tetraethylortho silicate and methyltrimethoxysilane and similar alkyl substituted alkoxysilane compositions, and the like.
[0028] In one embodiment of the present invention, the level of incorporation of the alkylsilicate (crosslinker) ranges from about 0.1 weight percent to about 10 weight percent. In another embodiment of the invention, the level of incorporation of the alkylsilicate (crosslinker) ranges from about 0.3 weight percent to about 5 weight percent. In yet another embodiment of the present invention, the level of incorporation of the alkylsilicate (crosslinker) ranges from about 0.5 weight percent to about 1.5 weight percent of the total composition.
[0029] Suitable catalysts (d) can be any of those known to be useful for facilitating crosslinking in silicone sealant compositions. The catalyst may include metal and non-metal catalysts. Examples of the metal portion of the metal condensation catalysts useful in the present invention include tin, titanium, zirconium, lead, iron cobalt, antimony, manganese, bismuth and zinc compounds.
[0030] In one embodiment of the present invention, tin compounds useful for facilitating crosslinking in silicone sealant compositions include: tin compounds such as dibutyltindilaurate, dibutyltindiacetate, dibutyltindimethoxide, tinoctoate, isobutyltintriceroate, dibutyltinoxide, solubilized dibutyl tin oxide, dibutyltin bis-diisooctylphthalate, bis-tripropoxysilyl dioctyltin, dibutyltin bis-acetylacetone, silylated dibutyltin dioxide, carbomethoxyphenyl tin tris-uberate, isobutyltin triceroate, dimethyltin dibutyrate, dimethyltin di-neodecanoate, triethyltin tartarate, dibutyltin dibenzoate, tin oleate, tin naphthenate, butyltintri-2-ethylhexylhexoate, and tinbutyrate, and the like. In still another embodiment, tin compounds useful for facilitating crosslinking in silicone sealant compositions are chelated titanium compounds, for example, 1,3-propanedioxytitanium bis(ethylacetoacetate); di-isopropoxytitanium bis(ethylacetoacetate); and tetra-alkyl titanates, for example, tetra n-butyl titanate and tetra-isopropyl titanate. In yet another embodiment of the present invention, diorganotin bis β-diketonates is used for facilitating crosslinking in silicone sealant composition.
[0031] In one aspect of the present invention, the catalyst is a metal catalyst. In another aspect of the present invention, the metal catalyst is selected from the group consisting of tin compounds, and in yet another aspect of the invention, the metal catalyst is solubilized dibutyl tin oxide.
[0032] In one embodiment of the present invention, the level of incorporation of the catalyst, ranges from about 0.001 weight percent to about 1 weight percent of the total composition. In another embodiment off the invention, the level of incorporation of the catalyst, ranges from about 0.003 weight percent to about 0.5 weight percent of the total composition. In yet another embodiment of the present invention, the level of incorporation of the catalyst, ranges from about 0.005 weight percent to about 0.2 weight percent of the total composition.
[0033] The silicone compositions of the present invention further comprise an alkoxysilane or blend of alkoxysilanes as an adhesion promoter. In one embodiment, the adhesion promoter may be a combination blend of n-2-aminoethyl-3-aminopropyltrimethoxysilane and 1,3,5-tris(trimethoxysilylpropyl)isocyanurate. Other adhesion promoters useful in the present invention include but are not limited to n-2-aminoethyl-3-aminopropyltriethoxysilane, γ-aminopropyltriethoxysilane, γ-aminopropyltrimethoxysilane, aminopropyltrimethoxysilane, bis-γ-trimethoxysilypropyl)amine, N-Phenyl-γ-aminopropyltrimethoxysilane, triaminofinctionaltrimethoxysilane, γ-aminopropylmethyldiethoxysilane, γ-aminopropylmethyldiethoxysilane, methacryloxypropyltrimethoxysilane, methylaminopropyltrimethoxysilane, γ-glycidoxypropylethyldimethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxyethyltrimethoxysilane, β-(3,4-epoxycyclohexyl)propyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethylmethyldimethoxysilane, isocyanatopropyltriethoxysilane, isocyanatopropylmethyldimethoxysilane, β-cyanoethyltrimethoxysilane, γ-acryloxypropyltrimethoxysilane, γ-methacryloxypropylmethyldimethoxysilane, 4-amino-3,3,-dimethylbutyltrimethoxysilane, and n-ethyl-3-trimethoxysilyl-2-methylpropanamine, and the like.
[0034] The level of incorporation of the alkoxysilane (adhesion promoter) ranges from about 0.1 weight percent to about 20 weight percent. In one embodiment of the invention, the adhesion promoter ranges from about 0.3 weight percent to about 10 weight percent of the total composition. In another embodiment of the invention, the adhesion promoter ranges from about 0.5 weight percent to about 2 weight percent of the total composition.
[0035] The silicone compositions of the present invention may also comprise a filler. Suitable fillers of the present invention include, but are not limited to, ground, precipitated and colloidal calcium carbonates which is treated with compounds such as stearate or stearic acid, reinforcing silicas such as fumed silicas, precipitated silicas, silica gels and hydrophobized silicas and silica gels; crushed and ground quartz, alumina, aluminum hydroxide, titanium hydroxide, diatomaceous earth, iron oxide, carbon black and graphite or clays such as kaolin, bentonite or montmorillonite, talc, mica, and the like.
[0036] In one embodiment of the present invention, the filler is a calcium carbonate filler, silica filler or a mixture thereof. The type and amount of filler added depends upon the desired physical properties for the cured silicone composition. In another embodiment of the invention, the amount of filler is from 0 weight percent to about 80 weight percent of the total composition. In yet another embodiment of the invention, the amount of filler is from about 10 weight percent to about 60 weight percent of the total composition. In still another embodiment of the invention, the amount of filler is from about 30 weight percent to about 55 weight percent of the total composition. The filler may be a single species or a mixture of two or more species.
[0037] In a further embodiment of the present invention, the sealant composition contains an inorganic substance from the general class of so called “clays” or “nano-clays.” “Organo-clays” are clays or other layered materials that have been treated with organic molecules (also called exfoliating agents or surface modifiers) capable of undergoing ion exchange reactions with the cations present at the interlayer surfaces of the layers.
[0038] In one embodiment of the invention, the clay materials used herein include natural or synthetic phyllosilicates, particularly smectic clays such as montmorillonite, sodium montmorillonite, calcium montmorillonite, magnesium montmorillonite, nontronite, beidellite, volkonskoite, laponite, hectorite, saponite, sauconite, magadite, kenyaite, sobockite, svindordite, stevensite, talc, mica, kaolinite, as well as vermiculite, halloysite, aluminate oxides, or hydrotalcite, and the like and mixtures thereof. In another embodiment, other useful layered materials include micaceous minerals, such as illite and mixed layered illite/smectite minerals, such as rectorite, tarosovite, ledikite and admixtures of illites with the clay minerals named above. Any swellable layered material that sufficiently sorbs the organic molecules to increase the interlayer spacing between adjacent phyllosilicate platelets to at least 5 angstroms, or to at least 10 angstroms, (when the phyllosilicate is measured dry) may be used in the practice of this invention.
[0039] The aforementioned particles can be natural or synthetic such as smectite clay. This distinction can influence the particle size and for this invention, the particles should have a lateral dimension of between 0.01 μm and 5 μm, and preferably between 0.05 μm and 2 μm, and more preferably between 0.1 μm and 1 μm. The thickness or the vertical dimension of the particles can vary between 0.5 nm and 10 nm, and preferably between 1 nm and 5 nm.
[0040] In still another embodiment of the present invention, organic and inorganic compounds useful for treating or modifying the clays and layered materials include cationic surfactants such as ammonium, ammonium chloride, alkylammonium (primary, secondary, tertiary and quaternary), phosphonium or sulfonium derivatives of aliphatic, aromatic or arylaliphatic amines, phosphines or sulfides. Such organic molecules are among the “surface modifiers” or “exfoliating agents” discussed herein. Additional organic or inorganic molecules useful for treating the clays and layered materials include amine compounds (or the corresponding ammonium ion) with the structure R 3 R 4 R 5 N, wherein R 3 , R 4 , and R 5 are C 1 to C 30 alkyls or alkenes in one embodiment, C 1 to C 20 alkyls or alkenes in another embodiment, which may be the same or different. In one embodiment, the organic molecule is a long chain tertiary amine where R 3 is a C 14 to C 20 alkyl or alkene. In another embodiment, R 4 and or R 5 may also be a C 14 to C 20 alkyl or alkene. In yet another embodiment of the present invention, the modifier can be an amine with the structure R 6 R 7 R 8 N, wherein R 6 , R 7 , and R 8 are Cl to C 30 alkoxy silanes or combination of C 1 to C 30 alkyls or alkenes and alkoxy silanes.
[0041] Suitable clays that are treated or modified to form organo-clays include, but are not limited to, montmorillonite, sodium montmorillonite, calcium montmorillonite, magnesium montmorillonite, nontronite, beidellite, volkonskoite, laponite, hectorite, saponite, sauconite, magadite, kenyaite, sobockite, svindordite, stevensite, vermiculite, halloysite, aluminate oxides, hydrotalcite, illite, rectorite, tarosovite, ledikite, and mixtures thereof. The organo-clays of the present invention may further comprise one or more of ammonium, primary alkylammonium, secondary alkylammonium, tertiary alkylammonium quaternary alkylammonium, phosphonium derivatives of aliphatic, aromatic or arylaliphatic amines, phosphines or sulfides or sulfonium derivatives of aliphatic, aromatic or arylaliphatic amines, phosphines or sulfides. In one embodiment of the present invention, the organo-clay is an alkyl ammonium modified montmorillonite.
[0042] The amount of clay incorporated in the sealant composition of the present invention in accordance with embodiments of the invention, is preferably an effective amount to provide decrease the sealant's permeability to gas. In one embodiment of the present invention, the sealant composition of the present invention contains from 0 to about 50 weight percent nano-clay. In another embodiment, the compositions of the present invention have from about 1 to about 20 weight percent nano-clay.
[0043] The compositions of the present invention may optionally comprise non-ionic surfactant compound selected from the group of surfactants consisting of polyethylene glycol, polypropylene glycol, ethoxylated castor oil, oleic acid ethoxylate, alkylphenol ethoxylates, copolymers of ethylene oxide (EO) and propylene oxide (PO) and copolymers of silicones and polyethers (silicone polyether copolymers), copolymers of silicones and copolymers of ethylene oxide and propylene oxide and mixtures thereof in an amount ranging from slightly above 0 weight percent to about 10 weight percent, more preferably from about 0.1 weight percent to about 5 weight percent, and most preferably from about 0.5 weight percent to about 0.75 weight percent of the total composition.
[0044] The compositions of the present invention may be prepared using other ingredients that are conventionally employed in room temperature vulcanizing (RTV) silicone compositions such as colorants, pigments and plasticizers, as long as they do not interfere with the desired properties.
[0045] Furthermore, these compositions can be prepared using melt, solvent and in-situ polymerization of siloxane polymers as known in the art.
[0046] Preferably, the methods of blending the diorganopolysiloxane polymers with polymers may be accomplished by contacting the components in a tumbler or other physical blending means, followed by melt blending in an extruder. Alternatively, the components can be melt blended directly in an extruder, Brabender or any other melt blending means.
[0047] The invention is illustrated by the following non-limiting examples: Polydimethyl Siloxane (PDMS) mixture (Silanol 5000 and silanol 50000, Gelest), was melt blended with LLDPE (melt flow index (MFI) 20, from Sabic) by Hake internal mixer at 150° C., 200RPM, for total mixing time of 12 minutes. Three (3) such blends were prepared with weight percent LLDPE of 10, 20 and 30, (see Example 1, 2 and 3, respectively, listed below), by the following procedure:
1. Mix silanols 5000 cPs and 50000 cPs in 1:1 ratio. 2. Add 70 percent of silanol mixture into the Hake mixer ( 150° C. 3. Start the experiment using program window. 4. Add LLDPE to the mixer in small amounts. Time of addition 1-2 minutes. 5. Add remaining mixture 30 percent of silanol into the mixer. 6. Continue mixing for total of 12 minutes. 7. At the end of 12 th minute the rotation stops automatically, collect the blended material into a glass petridish.
[0055] The following Examples were prepared from the batches obtained using above procedure:
Example 1=52 grams mix silanol (5000 and 50000 @ 50:50)+6 grams LLDPE Example 2=48 grams mix silanol (5000 and 50000 @ 50:50)+12 grams LLDPE Example 3=42 grams mix silanol (5000 and 50000 @ 50:50)+18 grams LLDPE
[0059] Example 1, 2 and 3, were then used to make cured sheets as follows: PDMS-LLDPE blends were mixed with n-propyl silicate (cross-linker, obtained from Gelest Chemicals, USA) and solubilized dibutyl tin oxide (DBTO)(catalyst, obtained from GE silicones, Waterford, USA), in amounts as shown in Table 1, using a hand blender for 5-7 minutes. Air bubbles were removed by vacuum and the mixture was poured in Teflon mould and kept for 24 hrs under ambient conditions (25° C. and 50 percent humidity). The cured sheets were removed from mould after 24 hours and kept at ambient temperature for seven days for complete curing.
TABLE 1 Amount nPs DBTO Examples (Grams) ml ml Comparative Example 1 50 1 0.06 Silanol Mixture Example 1 50 0.9 0.05 Silanol with 10 wt. % LLDPE Example 2 50 0.72 0.04 Silanol with 20 wt. % LLDPE Example 3 50 0.5 0.03 Silanol with 30 wt. % LLDPE
[0060] The Argon permeability of Examples 1-3 and Comparative Example 1 was measured using a gas permeability set-up. The measurements were based on the variable-volume method at 100 PSI pressure and temperature of 25° C. Measurements were repeated under identical conditions for 2-3 times in order to ensure their reproducibility. The results of the permeability data are graphically displayed in FIG. 1 .
[0061] The variable-volume method as displayed in FIG. 1 measures Argon (Ar) permeability in “barrer” units (0.0 to 1200.0). As shown in FIG. 1 , Examples 1-3 displayed lowered Ar permeability relative to the Comparative Example 1.
[0062] Examples 5, 6 and 7 were prepared as follows: Polydimethyl Siloxane (PDMS) mixture (Silanol 3000 and silanol 30000, GE silicones), was melt blended with LLDPE (melt flow index (MFI) 20, from Sabic) in an extruder at 150° C., along with the mixture of Hakenuka TDD CaCO 3 and Omya FT CaCO 3 . The temperature settings of the barrel are given below in Table 2:
[0063] Comparative Example 4 was prepared as follows:
[0064] Polydimethyl Siloxane (PDMS) mixture (Silanol 3000 and silanol 30000, GE silicones), was melt blended in an extruder at 150° C., along with the mixture of Hakenuka TDD CaCO 3 and Omya FT CaCO 3 . The temperature settings of the barrel are given below in Table 2:
TABLE 2 Temp settings: Barrel 1-2 75° C. Barrel 3-10 150° C. Barrel 11-15 cooling to 45° C.
[0065] The feed rate was set at 50lbs/hr. The formulations of Comparative Example 4 and Examples 5, 6 and 7 are displayed in Table 3 and were produced in an extruder at 150° C.:
TABLE 3 CaCO 3 (50:50 mixture Silanol Silanol of Hakenuka Sabic Examples 3000 cps 30000 cps TDD and Omya FT LLDPE Talc Comparative Example 4 25.0 25.0 50.0 — — Example 5 22.7 22.7 50.0 4.7 — Example 6 20.0 20.0 50.0 10.0 — Example 7 20.0 20.0 25.0 10.0 25
The extruded material was collected in 6-ounce semco cartridges.
[0066] Comparative Example 4, and Examples 5, 6, and 7 were then used to make cured sheets as follows:
[0067] The PDMS-LLDPE blends of Examples 5-7 and Comparative Example 4 were mixed with Part B (catalyst mixture consists of solubilized dibutyl tin oxide, n-propyl silicate, aminopropyl triethoxysilane, carbon black and silicone oil ) in 12.5:1 ratio in semkit mixer for 6 minutes. The mixture was then poured in Teflon mould and kept for 24 hours under ambient conditions (25° C. and 50 percent humidity). The cured sheets were removed from mould after 24 hours and kept at ambient temperature for seven days for complete curing.
[0068] The permeability data of Comparative Example 4, and Examples 5, 6, and 7 with LLDPE and fillers is displayed in FIGS. 2 and 3 .
[0069] As shown in FIGS. 2 and 3 , Examples 5-7 displayed lowered Ar permeability relative to Comparative Example 4.
[0070] While the preferred embodiment of the present invention has been illustrated and described in detail, various modifications of, for example, components, materials and parameters, will become apparent to those skilled in the art, and it is intended to cover in the appended claims all such modifications and changes which come within the scope of this invention.
|
The present invention provides for a room temperature cured silicone thermoplastic resin sealant composition with reduced gas permeability useful in the manufacture of glazing such as windows and doors.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of my copending application Ser. No. 09/780,302, filed Feb. 9, 2001; which was a division of my earlier application No. Ser. No. 09/503,665, filed Feb. 14, 2000, now U.S. Pat. No. 6,257,195. The contents of my earlier documents are herein incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0002] The invention relates to a fluid pump for pumping liquid and/or gas phase materials. The fluid pump is useful, as described in my earlier applications, in the context of an output system of an internal combustion engine or a turbine engine and an input system for injecting fluid into the combustion process. The input system, in that case, includes a displacement pump, specifically for use with air and water, which can be utilized as a gas compression pump in the internal combustion engine and the turbine.
[0003] Fluid displacement pumps are subject to a variety of applications in engineering. For instance, such pumps are utilized in compression systems such as air compressors and as fluid pumps. For example, British Patent Specification 265,659 to Bernhard discloses an internal combustion engine with fuel pressurization separate from the combustion chamber. There, fuel is pressurized in a compressor and the pressurized fuel is fed from the pump to the engine through a port assembly.
[0004] U.S. Pat. No. 1,287,268 to Edwards discloses a propulsion system for a motor vehicle. There, a compressor formed with mutually interengaging helical impellers pumps to an internal combustion engine which is also formed with mutually interengaging helical impellers. The internal combustion engine drives a generator, which pumps hydraulic fluid to individual hydraulic motors that are disposed at each of the wheels. The impellers of Edwards are formed with “flat” blades of a constant thickness from the axle radially outward to their outermost tip.
[0005] The efficiency of fluid pumps with interengaging impeller blades is dependent on the seal that is in effect formed between the blades. While the outer seal is relatively easily obtained with a corresponding housing wall, the inner seal between the blades, i.e., at the location where the blades overlap is rather difficult to obtain. In the prior art system of Edwards, for example, the flat blades do not sufficiently seal against one another and the corresponding efficiency of the double impeller pump is therefore relatively low. Certain applications of the fluid pump require a better seal and better backflow prevention.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide a fluid displacement pump, which overcomes the disadvantages of the heretofore-known devices and methods of this general type and which is further improved in terms of efficiency and backflow prevention, and which allows essentially continuous pumping output with negligible backflow.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a fluid displacement pump, comprising:
[0008] a housing formed with a chamber having a wall defined by two parallel, mutually intersecting cylindrical openings defining respective cylinder axes; and
[0009] two axles respectively disposed at and rotatably mounted about respective axes coaxial with said cylinder axes, said axles each carrying a helically rising blade sealing against said wall of said housing and engaging into one another so as to form a substantially completely closed wall within said chamber during a rotation of said axles;
[0010] said blades having a decreasing thickness from said axles to an outer periphery thereof.
[0011] In an alternative embodiment of the invention, the blades increase in thickness from the axle outward. Details of the alternative embodiment will emerge from the following description of the figures.
[0012] In accordance with an added feature of the invention, said blades have a rounded surface extending from said axle to an outer periphery thereof.
[0013] In accordance with an additional feature of the invention, said rounded surface is defined by a radius of curvature in a radial section of said blades, said radius being greater than a diameter of said blades. Preferably, the radius of curvature is approximately three times the diameter of said blades.
[0014] In accordance with another feature of the invention, said blades are conical as seen in axial section, with mutually opposite surfaces steadily merging towards one another from said axle to the outer periphery.
[0015] With the above and other objects in view there is also provided, in accordance with the invention, a fluid displacement pump, comprising:
[0016] a housing formed with a chamber having a wall defined by two parallel, mutually intersecting cylindrical openings defining respective cylinder axes; and
[0017] two axles respectively disposed at and rotatably mounted about respective axes coaxial with said cylinder axes, said axles each carrying a helically rising blade sealing against said wall of said housing and engaging into one another so as to form a substantially completely closed wall within said chamber during a rotation of said axles;
[0018] said blades having a given thickness and helically rising along said axle with a given lead substantially greater than the given thickness of said blades.
[0019] In a preferred embodiment, the ratio of the spacing between the blade turns (the lead minus the blade thickness) to the thickness of the blades lies between 5/4 and 2.
[0020] The axles are preferably cylindrical, i.e., their peripheral wall is defined by mutually parallel lines.
[0021] In accordance with an added feature of the invention, the rounded surface is defined by a radius of curvature in a radial section of the blades, the radius being greater than a diameter of the blades. In a preferred embodiment, the radius of curvature is approximately three times the diameter of the blades.
[0022] In accordance with another feature of the invention, the blade on each of the axles has a helical rise of approximately 7° and the blades are substantially conical in radial section from the axle to a periphery thereof.
[0023] In accordance with again an added feature of the invention, the blade of one helix of the double helix are spaced apart by a distance defined by the blades of the other helix of the double helix.
[0024] In accordance with a concomitant feature of the invention, the blades enclose an angle of between approximately 45° and almost 90° with the cylinder axes.
[0025] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0026] Although the invention is illustrated and described herein as embodied in a fluid displacement pump with backflow stop, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0027] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] [0028]FIG. 1 is a partial sectional and side-elevational view of a fluid displacement pump according to the invention;
[0029] [0029]FIG. 2 is a top plan view onto the impeller blades and the housing of FIG. 1;
[0030] [0030]FIG. 3 is a plan view of the housing;
[0031] [0031]FIG. 4 is a plan view onto the impeller blades;
[0032] [0032]FIG. 5 is a side view of two mutually interengaging blade structures;
[0033] [0033]FIG. 6 is an enlarged view of the detail indicated in FIG. 5;
[0034] [0034]FIG. 7 is an axial section through the axle and a blade of a preferred embodiment of the invention;
[0035] [0035]FIG. 8 is a diagrammatic sectional view of an alternative embodiment of the blade structure;
[0036] [0036]FIG. 9 is a diagrammatic sectional view of a further alternative embodiment of the blade structure;
[0037] [0037]FIG. 10 is a diagrammatic section view of yet another alternative embodiment of the blade structure;
[0038] [0038]FIG. 11 is a diagrammatic sectional view of another alternative embodiment of the blade structure;
[0039] [0039]FIG. 12 is a diagrammatic sectional view of yet another alternative embodiment of the blade structure;
[0040] [0040]FIG. 13 is a diagrammatic sectional view of an alternative orientation of the blade structure;
[0041] [0041]FIG. 14 is an elevational view of two equal orientation impeller blades prior to interengagement; and
[0042] [0042]FIG. 15 is an elevational view thereof, after the two blades have been inserted into one another.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is seen an elevational view of two interengaging impellers with a section outline of the sidewalls of a housing and a diagrammatic view of a drive system. The fluid pump is a double impeller system, with a first impeller 9 A driven by a first gear 14 A and a second impeller 9 B driven by a second gear 14 B. The impeller embodiment is a positive displacement system and, at the same time, a back-pressure membrane. As the ribbed impellers rotate, the fluid flow 11 (e.g., air, liquid, hydraulic fluid) is “packaged” into chamber 30 formed between a cylindrical impeller axle 31 , a housing wall 20 , and a blade 9 B. Each impeller has a respective blade 9 A and 9 B.
[0044] Following the helical path of the chamber 30 , each chamber formed between the turns of the blade 9 B is closed off by the blade 9 A of the adjacent impeller structure. Depending on the rotational speed of the impeller system and the size of the chambers 30 , the impellers 9 A and 9 B form a pressure pump with positive displacement towards a high-pressure chamber. The fluid flow 11 is at a lesser pressure than in the high-pressure chamber, located above the housing in FIG. 1. As the blades 9 A and 9 B of the impeller rotate, various vertically stacked chambers are opened and closed so that it will result in a positive flow from the bottom to the high-pressure side at the top. At the same time, any pulsations and explosions due, for example, to a combustion of fuel in a chamber on the high-pressure side or any other backpressure will be prevented from flowing back past the blades 9 A and 9 B. In other words, the impeller pump is always closed with regard to a direct backflow of the fluid out from the high-pressure side.
[0045] The impellers 9 A and 9 B may be driven at variable speed. In order to synchronize the blades 9 A and 9 B, they are connected via gear wheels 14 A and 14 B, respectively, connected to their axles 31 . A drive 26 is diagrammatically illustrated towards the left of the gear 14 A. The drive 26 may be, for example, a gear of a toothed rack, an electrical motor, a feedback system driven by the output of the axles 31 , or any similar controlled drive. Any type of speed control may be implemented for the impeller system. It is also possible, of course, the drive the shafts 31 directly with direct drive motors. The two spindles are engaged with the meshing gear wheels 14 A and 14 B.
[0046] [0046]FIG. 2 is an axial plan view of the impeller system showing the engagement or meshing of the two blades 9 A and 9 B and the tight placement of the impeller blades inside the walls 20 . The positive displacement force of the impeller system is thus only slightly impaired by backflow and leakage between the impeller blades 9 A, 9 B and the walls 20 and, negligibly, between the axle 31 and the adjacent blade 9 A or 9 B. The blades 9 A and 9 B seal tightly against the housing wall 20 . In an exemplary embodiment of the novel fluid pump, the spacing between the outer periphery of the blades and the inner surface of the wall is in the range of a few mils, for example 0.1-0.4 mm. Depending on its use, the fluid pump may be additionally sealed with a silicon sealing layer provided on the inside of the housing wall and/or on the periphery of the blades 9 A and 9 B.
[0047] With reference to FIGS. 2 and 3, the housing of the positive displacement system is defined by walls 20 with rotationally symmetrical portions. In the illustrated embodiment with the two interengaging impellers, the housing has two intersecting circular arches that essentially correspond to the periphery of the blades 9 A and 9 B in their engagement position. A width D of the housing opening in which the impeller spindles are rotatably disposed corresponds to a sum of the diameters of the impeller blades 9 A, 9 B minus the overlap O. The overlap O, in turn, corresponds essentially to the rifling depth of the impellers, i.e., the difference in the radius of the blades 9 A, 9 B and the radius of the shaft 31 . The width D may also be expressed as the sum of two times the diameter d of the shaft 31 plus two times the rifling depth of the impellers.
[0048] As seen in FIGS. 4 and 5, the blades or helical rifling of the blades is offset by approximately 180° so as to distribute the pumping discharge of each of the chambers 30 into the high-pressure side. In other words, it is advantageous for the chambers 30 to reach the top position at which they empty into the high-pressure side alternatingly. In the case of two blades, the offset should thereby be in the neighborhood of 180°.
[0049] If three or more impeller spindles are used, the housing 20 requires a corresponding modification and, advantageously, the rotary offset of the impeller rifling may be distributed accordingly by 360°/n, where n is the number of impeller spindles.
[0050] The volume of the chambers 30 and the rotational speed of the impellers defines the pump pressure and the volume displacement per time of the impeller injection. With reference to FIG. 6, the volume of each chamber 30 corresponds approximately to the double integral of the differential rotary angle dθ taken through 360° and the differential radius dr taken from the radius r of the shaft 30 to the radius R of the impeller blade 9 A, 9 B, multiplied with the blade spacing z, minus the volume portion of the adjacent blade that engages into the space in the center between the two spindles.
[0051] In order to maximize the seal between the blades, and thus the seal of the backflow-preventing wall, the blades 9 A and 9 B are modified in terms of their curvature. In that regard, the illustration in FIGS. 1, 5, and 6 is simplified to show the blades with a constant thickness from the axle 31 to their peripheries. With reference to FIG. 7, which is a sectional view taken diagonally through the center of the axle 31 of one of the impellers, the blades are curved from the axle outward with regard to their thickness. The measurements and relationships among the various dimensions are best illustrated with reference to a specific example.
[0052] In the exemplary embodiment, the blades 9 have a diameter D=125 mm (5 in). The axle 31 has a diameter d=25 mm (1 in). The radius r of the blades, therefore, is r=50 mm (2 in), measured from the periphery of the axle 31 to their outer periphery. The rise angle of the helically winding blades 9 is about 7°. As an intermediate production step, the blades may be tapered by a taper angle φ=3°. That is, the angle α formed between the peripheral wall of the axle 31 and the blade 9 is α=90°+φ=93° at the top and at the bottom. Furthermore, the blades 9 are curved from the inside out with a radius of curvature R=400 mm (16 in). The position of the origin of the radius R (i.e., the center of the arc) is defined by the angle φ. For instance, if φ=0, then the blades are not tapered, and the origin of R lies on the peripheral wall of the axle 31 . If the blades are tapered with φ=0, then the origin of R is moved into the axle 31 by the appropriate amount defined by the angle φ. By modeling the novel shape of the blades, the inventor has been able to confirm that a proper and superior seal is created between the interengaging impellers.
[0053] [0053]FIG. 8 illustrates an alternative in which the blades 9 are only tapered with the angle φ. The surfaces are not rounded. In a preferred embodiment of this alternative, the angle φ=3°.
[0054] [0054]FIG. 9 illustrates yet another alternative. Here, the blades are not tapered, but only curved. Again, the radius R=400 mm (16 in) and the origin of the arc lies on the peripheral wall of the axle 31 . Accordingly, the intersection angle α between the blade 9 and the axle 31 is α=90°.
[0055] [0055]FIG. 10 illustrates a further variation. Here, the inventor recognized that certain fluids (usually lower viscosity fluids) require a less proper seal between the blades. Accordingly, here, a spacing L between the blade windings which defines the lead of the impeller, is less than a thickness H of the blade 9 (note that the distance L is not the lead of the helical winding, the lead would be defined by the spacing L plus the height of the blade, i.e., L+H). Here, the difference is ΔD=L−H. The reduction from the spacing L to the thickness H may be from 80% to as much as 50%. In other words, a ratio L/H may range from 5/4 to 2. In the embodiments with the blade taper and/or the curvature defined by the radius R, the parameters L and H must be defined in dependence on the distance r from the axle 31 . That is, in that case, ΔD=L(r)−H(r) and the spacing L and the height H of the blade 9 is preferably chosen such that ΔD is constant.
[0056] [0056]FIGS. 11 and 12 illustrate yet a further variation of the inventive concept. In FIG. 11, the blades 9 have a bulge in section. That is, the height H of the blade varies from H 1 at the axle 31 to H 2 at approximately half its radial extent, and then returns to the height H 1 at its outer periphery. The embodiment of FIG. 12 is similar, except the blade 9 thins considerably at its outer periphery, to a height H 3 <H 1 <H 2 .
[0057] The embodiment illustrated in FIG. 13 provides for an attack angle θ between the blade 9 and the axle which is different from 90°. In a preferred embodiment, the angle θ=70°. It should be understood that the embodiment with the non-orthogonal orientation of the blades, i.e., the angle θ≠90°, is not exclusive of the rounded and/or tapered variations that are illustrated in FIGS. 8, 9, 11 and 12 . Further, the increased spacing ΔD illustrated in FIG. 10 may be utilized in this embodiment as well.
[0058] It will be understood that, of a pair of blades, one may be right-wound and the other may be left-wound. In that case, a counter-rotation of the two blades leads to a rise of both of the spaces 30 . If the two blades are wound in the same sense, then the blades will be rotated in the same direction. In the former case, however, a substantially reduced amount of friction will result between the two sets of blades. Also, if the adjacent blades rise in the same sense, the axes must be offset from parallel by twice their lead angle. This illustrated diagrammatically in FIGS. 14 and 15.
|
The fluid displacement pump enables substantially continuous pumping from a low-pressure side to a high-pressure side substantially without any backflow or backpressure pulsations. Liquid or gas is injected to the high-pressure side by way of mutually intertwined worm spindles that form a fluidtight displacement system. The blades of the impeller system are slightly curved from the inside out, i.e., from their axles to their periphery, so as to ensure a tight seal between adjacent blades. The orientation of the blades is almost flat, i.e., their attack angle relative to backpressure is close to perpendicular so that they will turn quite freely in the forward direction, but will not be turned backwards by a pressurized backflow. The impeller rotation that is introduced via the spindle shafts nevertheless leads to a volume displacement towards the high-pressure side, for instance, towards a chamber to be pressurized or to be subjected to equal pressure.
| 5
|
BACKGROUND
[0001] 1. Field
[0002] Curable compositions such as adhesive compositions for bonding polymeric substrates to hydroxylated surfaces are disclosed. In particular, adhesive compositions suitable for use in polymer-to-glass, for example elastomer-to-glass such as rubber-to-glass, bonding applications are provided. One aspect of the invention provides novel compounds suitable for use in adhesive compositions suitable for rubber to glass bonding applications.
[0003] 2. Brief Description of Related Technology
[0004] Reinforced composite materials play a critical role in the manufacture of high-performance products that need to be lightweight, yet strong enough to take harsh loading and operating conditions. Popular reinforcing materials included wood, glass, metals, quartz and carbon fibres. Composites reinforced with such materials may find utility in the manufacture of a number of structural materials such as aerospace components and racing car bodies.
[0005] Per unit weight glass represents one of the strongest structural materials around, and, for example, is stronger than steel on a weight per weight basis. Furthermore, glass exhibits improved stress and strain resistance compared to many other common reinforcement media. For example, glass cord may be utilised to exploit the unique properties of glass fibres to impart strength and dimensional stability to polymeric products.
[0006] Glass fibre reinforced composite materials consist of high strength glass fibres embedded in a matrix. For example, Glass Fibre Reinforced Concrete comprises glass fibres embedded in cement-based matrix and may find utility in buildings and other structural edifices. Similarly, Glass Reinforced Plastic comprises glass fibres embedded in a plastic material. Glass Reinforced Plastics are immensely versatile materials which combine to provide lightweight materials with high strength performance. Glass reinforced plastics find utility in a number of different areas from structural engineering to telecommunications.
[0007] Elastomer to glass bonding provides an attractive means by which the structural strength of glass can be combined with the elastomeric properties of the elastomer/rubber. Reinforcing fibres such as glass fibres have been used as a reinforcing material for rubber articles such as in rubber belts, tyres and hoses. In particular, glass fibres have been employed to reinforce automotive timing belts, where there is a need for synchronous transfer of power from crankshaft to overhead camshaft without loss of inertia.
[0008] In general, rubber articles are repeatedly subjected to a flexing stress resulting in flex fatigue. This can lead to reduced performance, a peel-off between the reinforcing fibre and a rubber matrix and a wearing of the reinforcing fibre. Accordingly, adhesives for rubber to glass bonding should be capable of enduring such stresses.
[0009] Traditionally, such glass cord composites are manufactured by coating individual filaments of glass yarn with specialised coatings, such as resorcinol formaldehyde latex (RFL) formulations. Conventional rubber to metal bonding products are then employed to bond the RFL latex to the rubber via a vulcanisation step.
[0010] Traditional rubber to metal bonding technology, incorporates a two-step system, where in a first step a primer is applied and thereafter in a second step an adhesive is applied. The primer ordinarily consists of solutions or suspensions of chlorinated rubber and phenolic resins containing reactive groups, and also pigments such as titanium dioxide, zinc oxide, carbon black, etc. The primer is generally applied as a thin layer onto a treated (cleaned) surface of a metallic component such as treated steel component for example a component that has been grit blasted or chemically treated. The adhesive ordinarily consists of a large range of rubber materials and cross-linkers. These include, but are not restricted to, chlorinated and bromochlorinated rubbers, aromatic nitrosobenzene compounds and bismaleimide as cross-linkers, xylene, perchloroethylene and ethylbenzene as solvents, and also some lead or zinc salts. The adhesive layer is generally the link between the primed metal and the rubber.
[0011] Generally, it is desirable that bonding to the target substrate is achieved during a vulcanisation step like compression moulding, transfer moulding, injection moulding and autoclave heating, for example with steam or hot air. For example, semi-solid rubber can be injected into a mould. The semi-solid rubber is then cross-linked into a fully cured rubber and the bond with the substrate is formed at the same time.
[0012] Certain requirements of the curing system are desirable. This includes, ease of processing, stability (for example avoiding sedimentation), ease of application, fast drying (to allow handling without fouling), good wetting properties, and good curing strengths. Curing should be achieved independently of the type of elastomer (rubber) employed and also independently of the type of substrate. It will be appreciated that some rubbers are blended materials and accordingly it is desirable that good curing is achieved with such blended materials. Suitably consistent curing is achieved under various process parameters. Durability is also desirable.
[0013] Notwithstanding the state of the art it would be desirable to provide compounds and compositions to bond polymeric substrates (for example elastomers) to hydroxylated substrates such as glass.
SUMMARY
[0014] The present invention provides for a method of bonding polymers to hydroxylated surfaces. Polymer to glass bonding, such as elastomer to glass bonding, for example rubber to glass bonding may be beneficial in applications wherein the properties of metals, such as high molecular weights, susceptibility to corrosion, durability and cost detracts from their suitability in particular applications.
[0015] In a first aspect, the present invention provides for a method for bonding a polymer to a hydroxylated surface, the method comprising:
[0016] applying a compound comprising;
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof,
[0019] to at least one of the surface or the polymer and bringing the surface and polymer together. The compound may be applied to the hydroxylated surface.
[0020] The method may further comprise the step of heating subsequent to bringing the substrates together. Advantageously, heating may increase the rate of bond formation. Heating may improve bond strength.
[0021] As used herein the term hydroxylated surface refers to any substrate with a surface comprising an atom bonded to a hydroxy group. Suitable non-limiting examples include a hydrous metal oxide, glass substrates comprising surface Si—OH bonds or clay substrates comprising surface Al—OH bonds. Suitable hydroxylated surfaces include those of silicates, aluminates, germanates and combinations thereof The hydroxylated surface may be a silicate, an aluminate or combinations thereof. As used herein, the term silicate refers to substrates comprising Si—OH bonds. The term aluminate refers to substrates having Al—OH bonds and the term germinate refers to substrates having Ge—OH bonds.
[0022] For example, the hydroxylated surface may be one of glass such as glass fibres, quartz, clays, talcs, zeolites, porcelains, ceramics, silicon substrates such as silicon wafers and combinations thereof.
[0023] The polymer may comprise alkene and/or allylic functionality within the polymer chain. For example, diene and/or allylic functionality may be present within the polymer chain. Suitably, the polymer may comprise allylic functionality. Suitable polymers may include elastomers. Suitable elastomers may comprise natural or synthetic rubbers. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be a hydrogenated nitrile butadiene rubber (HNBR). The polymer may be a C 2 -C 1,000,000 polymer, such as a C 2 -C 10,000 polymer.
[0024] The at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor may be a nitrosobenzene or a nitrosobenzene precursor and combinations thereof
[0025] The method of the present invention may additionally comprise the step of cleaning, for example abrasively cleaning, such as blasting, for example grit-blasting the hydroxylated surface prior to application of the compound thereto. Cleaning may reveal nascent hydroxyl groups on the surface, thereby greatly enhancing the ability of the adhesive to bond the hydroxylated surface and the polymer, such as an elastomer, for example a rubber together.
[0026] Within the context of this specification the term aromatic nitroso moiety refers to an aromatic moiety having at least one nitroso group. Similarly, the term aromatic nitroso precursor moiety refers to any compound that is capable of being transformed into an aromatic nitroso moiety with at least one nitroso group. The term aromatic comprises both fused and non-fused aromatic rings.
[0027] For example, a non-limiting selection of fused and non-fused aromatic nitroso moieties embraced by the present invention are detailed below:
[0000]
[0028] As will be appreciated by a person skilled in the art, the nitroso structures disclosed above may optionally be substituted one or more times, for example with at least one of C 1 -C 20 alkyl, C 1 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 6 -C 20 aralkyl, C 6 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of a composition comprising the compound.
[0029] The compounds used in the method of the present invention may assist in the formation of polymer to glass bonds, such as elastomer to glass bonds, for example rubber to glass bonds. They can be easily applied at the interface between the rubber and the glass and assist in developing strong and durable bonds during the curing process.
[0030] Within the method of the present invention, and in contrast to conventional systems, the compound utilised in the method of the present invention can be applied (as part of an adhesive composition) to unvulcanised rubber (as distinct from a non-elastomeric substrate) prior to vulcanisation and bond formation, and upon subsequent vulcanization a bond results. This means that the compound/adhesive system may be applied to a rubber or a glass substrate. The compound may be applied to a glass substrate.
[0031] The aromatic nitroso precursor moiety may comprise an oxime, a dioxime and combinations thereof. For example, the aromatic nitroso precursor moiety may be the mono- or dioxime of a compound selected from the group consisting of:
[0000]
[0032] As will be appreciated by a person skilled in the art, the diketone structures disclosed above may optionally be substituted one or more times, for example with at least one of C 1 -C 20 alkyl, C 1 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 6 -C 20 aralkyl, C 6 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of a composition comprising the precursor compound, for example, provided there is no interference with the generation of an aromatic nitroso compound in-situ.
[0033] The aromatic nitroso moiety of the compound utilised in the method of the present invention may comprise a nitrosobenzene moiety. The nitrosobenzene moiety may be a mononitrosobenzene, a dinitrosobenzene, or combinations thereof. Similarly, the aromatic nitroso precursor moiety of the composition of the present invention may comprise a nitrosobenzene moiety precursor. The nitrosobenzene precursor may be a mononitrosobenzene precursor, a dinitrosobenzene precursor, or combinations thereof. It will be appreciated that the nitrosobenzene precursor may form one of a nitrosobenzene structure, a dinitrosobenzene structure or apara-nitrosophenol structure in-situ. The nitrosobenzene precursor may be at least one of a quinone dioxime or a quinone oxime. It has been found that such structures assist in the formation of desirable bonds.
[0034] As will be appreciated by a person skilled in the art, references to nitrosobenzene and nitrosobenzene precursor moieties include nitrosobenzene and nitrosobenzene precursor moieties that may optionally be substituted one or more times with at least one of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 6 -C 20 aralkyl, C 6 -C 20 alkaryl, C 6 -C 20 arylamine, C 6 -C 20 arylnitroso, cyano, amino, hydroxy, halogen and combinations thereof. Such substitutions are possible provided there is no interference with effective bonding or curing of a composition comprising these compounds. For example, provided there is no interference with the generation of a nitrosobenzene moiety in-situ.
[0035] The silane moiety of the compound utilised in the method of the present invention may be of the structure:
[0000]
where ‘a’ can be 1-3 and ‘b’ can be 0-2, wherein a+b=3 and at least one alkoxy group is present;
R 1 can be selected from H, C 1 -C 24 alkyl, C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl;
wherein when a≧1 at least one R 1 is not hydrogen; and
R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl.
[0040] In one embodiment, a is 3 and R 1 is C 1 -C 24 alkyl. R 1 may be C 1 -C 4 alkyl and a may be 3.
[0041] The compounds may be reaction products derived from an isocyanate or isothiocyanate and an active hydrogen compound, such as —NH x (where x=1 or 2), —SH, or —OH. In this manner the so-described compounds should contain at least one linkage described by:
[0000]
[0042] where X can be S or O, and Y includes -NH x (where x=1 or 2), —S, or —O.
[0043] The general structure for these compounds is shown below:
[0000]
[0044] where ‘a’ can be 1-3 and ‘b’ can be 0-2; wherein a+b=3 and at least one alkoxy group is present;
R 1 can be selected from H, C 1 -C 24 alkyl or C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl, and where when a≧1 at least one R 1 is not hydrogen; and R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl; n can be 1-10; X can be O or S; Y can be —O, —S, or —NH x (where x=1 or 2); and R 3 may be a moiety comprising nitrosoaromatic, or a nitrosoaromatic precursor as defined herein.
[0050] R 3 may be a moiety comprising nitrosobenzene, quinone dioxime or quinone oxime.
[0051] R 1 may be selected from C 1 -C 24 alkyl or C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl or C 3 -C 24 acyl and ‘a’ may be 3. X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. R 1 may be selected from C 1 -C 4 alkyl, X may be O and ‘a’ is 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be NH x (where x=1) and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, ‘a’ may be 3 and R 3 may be a moiety comprising nitrosobenzene.
[0052] Structures for R 3 , showing the linkage through ‘Y’, can include:
[0000]
[0053] where R 4 can be C 1 to C 10 ; and
[0054] Z indicates that the rings of the above structures can optionally be mono-, di-, tri- or tetrasubstituted with the group consisting of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 6 -C 20 aralkyl, C 6 -C 20 alkaryl, C 5 -C 20 arylamine, C 5 -C 20 arylnitroso, amino, hydroxy, halogen and combinations thereof, and further where the substituents can either be the same or different on each carbon atom of the ring. Such substitutions may be possible provided there is no interference with effective bonding or curing of the compositions. For example, provided there is no interference with the generation of a nitrosobenzene compound in-situ.
[0055] In a related embodiment, the compound utilised in the method of the present invention may have the general structure:
[0000]
[0000] where n can be 1-10;
‘a’ can be 1-3 and ‘b’ can be 0-2; wherein a+b=3 and at least one alkoxy group is present; c can be ‘a’ or 1 to 3; d can be ‘b’ or 1 to 3; R 1 can be selected from H, C 1 -C 24 alkyl or C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and where when a≧1 at least one R 1 is not hydrogen; R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl; X can be O or S; and Y can be —O, —S, or —NH x (where x=1 or 2).
[0062] R 1 may be selected from C 1 -C 24 alkyl or C 3 -C 24 acyl. R 1 may be selected from C 1 -C2 24 alkyl or C 3 -C 24 acyl and ‘a’ may be 3. X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. R 1 may be selected from C 1 -C 4 alkyl, X may be O and ‘a’ is 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be —NH x (where x=1) and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3 and ‘a’ may be 3.
[0063] In a further embodiment, the compound utilised in the method of the present invention may be an oligomeric or co-oligomeric compound of the general structure:
[0000]
[0000] where m can be 1-100; n can be 1-10; p can be 1-10; q can be 0-50; and if q=0, m≧2;
R 1 can be selected from H, C 1 -C 24 alkyl or C 3 -C 24 acyl, and preferably from C 1 -C 4 alkyl; R 2 can be selected from OR 1 , C 1 -C 24 alkyl or C 3 -C 24 acyl, and where when R 2 ═OR 1 R 1 is not hydrogen; R 4 can be selected from acrylate, aldehyde, amino, anhydride, azide, maleimide, carboxylate, sulphonate, epoxide, ester functional, halogens, hydroxyl, isocyanate or blocked isocyanate, sulfur functional, vinyl and olefin functional, or polymeric structures; X can be O or S; Y can be —O, —S, or —NH x (where x=1 or 2); and R 3 may be a moiety comprising nitrosoaromatic, or a nitrosoaromatic precursor as defined herein.
[0070] R 3 may be a moiety comprising nitrosobenzene, quinone dioxime or quinone oxime.
[0071] R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl and R 2 may be OR 1 . X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. R 1 may be selected from C 1 -C 4 alkyl, X may be O and R 2 may be OR 1 . R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and R 2 may be OR 1 . R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be —NH x (where x=1) and R 2 may be OR 1 . R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3, R 2 may be OR 1 and R 3 may be a moiety comprising nitrosobenzene. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3, R 2 may be OR 1 , R 3 may be a moiety comprising nitrosobenzene, q may be 0, and m may be ≧2. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, n may be 3, R 2 may be OR 1 , R 3 may be a moiety comprising nitrosobenzene, q may be 0, m may be ≧2, and R 4 may be vinyl or ester.
[0072] Specific examples of compounds utilised in the method of the present invention may include the following:
[0000]
[0073] It will be appreciated that the compounds utilised in the method of the present invention may be formulated as part of a composition.
[0074] The so-described compounds and formulations may result in a number of advantages. For example, a one-part adhesive system may be formulated. Such systems are readily applied to substrates in a single step using convenient and conventional techniques, for example spraying or dipping. Compounds and formulations as so provided may have reduced toxicity as compared to conventional dinitrosobenzene formulations. Compounds and formulations as so provided can also achieve excellent bond strengths. In addition, cured compositions of the present invention exhibit hot water and solvent resistance.
[0075] Accordingly, the method of the present invention for bonding a polymer to a hydroxylated surface may comprise applying a composition (according to the present invention) to at least one of the polymer or surface, and mating the polymer and surface so as to form a bond, wherein the composition comprises:
[0076] (i) at least one compound comprising;
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof; and
[0079] (ii) a suitable carrier vehicle for the compound.
[0000] It will be appreciated that any suitable carrier vehicle may be utilised. It is desirable that the carrier vehicle should be environmentally friendly. Such compositions may find utility in bonding a substrate such as a glass substrate to a natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be a hydrogenated nitrile butadiene rubber (“HNBR”).
[0080] The compound comprising the at least one alkoxy silane moiety and the at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor (also known as a nitrososilane) may be present in an amount of 1 to 20% w/w of the total composition. Suitably, the nitrososilane may be present in an amount of 1 to 15% w/w, for example 4 to 12% w/w. The nitrososilane may be present in 6% w/w of the total composition.
[0081] Compositions utilised in the method of the present invention may find utility in any application where it is desirable to form an aromatic nitroso moiety in-situ. Similarly, compositions of the present invention may find utility in any application where it is desirable to form an aromatic dinitroso moiety in-situ. It will be appreciated that within these compositions the compound can react in-situ to form a nitrosobenzene moiety. It is also contemplated that the compound can react in-situ to form a dinitrosobenzene moiety. For example, for particularly good bonding it may be desirable for the compound to react in-situ to form apara-nitrosophenol moiety.
[0082] Compositions utilised in the method of the present invention may be one-part compositions. Compositions of the present invention may be two-part compositions.
[0083] Combinations of silanes (i.e. nitrososilanes and other silanes) may be employed in a composition utilised in the method of the present invention. For example, one or more silanes may be included within compositions utilised in method of the present invention. These silanes are generally of the formula:
[0000]
[0000] where:
n is either 1 or 2; y=(2-n) each R 1 can be selected from C 1 -C 24 alkyl or C 2 -C 24 acyl; each R 2 can be selected from C 1 -C 30 aliphatic groups, substituted C 6 -C 30 aromatic groups, or unsubstituted C 6 -C 30 aromatic groups; R 5 can be selected from hydrogen, C 1 -C 10 alkylene,
C 1 -C 10 alkylene substituted with one or more amino groups, C 2 -C 10 alkenylene substituted with one or more amino groups, C 6 -C 10 arylene, or C 7 -C 20 alkylarlyene;
X—R 5 is optional and X is either:
[0000]
[0000] where each R 3 can be selected from hydrogen, C 1 -C 30 aliphatic groups, or C 6 -C 30 aromatic groups; and
R 4 can be selected from C 1 -C 30 aliphatic groups, or C 6 -C 30 aromatic groups; and wherein when n=1, at least one of the R 3 and the R 5 is not hydrogen.
[0093] In one embodiment, X—R 5 is present. In this embodiment R 1 can be selected from C 1 -C 24 alkyl, R 2 can be selected from C 1 -C 30 aliphatic groups, X can be N—R 3 and R 5 can be selected from hydrogen or C 1 -C 10 alkylene. As will be appreciated, when X—R 5 is absent the silane may be of the general formula (where R 1 and R 2 are as defined above):
[0000]
[0094] Preferred silanes include bis-silyl silanes such as those having two trisubstituted silyl groups. The substituents may be individually chosen from C 1 -C 20 alkoxy, C 6 -C 30 aryloxy and C 2 -C 30 aryloxy. Suitable bis-silyl silanes for use within the present invention include:
[0000]
[0000] where:
each R 1 can be selected from C 1 -C 24 alkyl or C 2 -C 24 acyl; each R 2 can be selected from C 1 -C 20 aliphatic groups or C 6 -C 30 aromatic groups; X is optional and is either:
[0000]
[0000] where each R 3 can be selected from hydrogen, C 1 -C 20 aliphatic groups, or C 6 -C 30 aromatic groups; and
R 4 can be selected from C 1 -C 20 aliphatic groups or C 6 -C 30 aromatic groups.
[0099] In one embodiment, X is present. R 1 can be selected from C 1 -C 24 alkyl, R 2 can be selected from C 1 -C 30 aliphatic groups, and X can be N—R 3 . As will be appreciated, when X is absent the bis-silane may be of the general formula (where R 1 and R 2 are as defined above):
[0000]
[0100] Examples of some bis-silyl aminosilanes formulated in compositions for use in the method of the present invention include: bis-(trimethoxysilylpropyl)amine, bis-(triethoxysilylpropyl)amine, bis-(triethoxysilylpropyl) ethylene diamine, N-[2-(vinylbenzylamino)ethyl]-3-aminopropyltrimethoxy silane, and aminoethyl-aminopropyltrimethoxy silane.
[0101] Such silanes (as described in the preceding paragraphs) may be included in the range of about 1:3 to about 3:1 (stoichiometrically) relative to the aromatic nitrososilane (or the aromatic nitrosoprecursor silane). Mixing of the aromatic nitrososilane and/or the aromatic nitrosoprecursor silane and the silanes described by the structural formulae in the preceding paragraphs may result in excellent rubber-to-glass bonding. In particular, the inclusion of the amino bis(propyltrimethoxysilane) in addition to the aromatic nitroso silane and/or the aromatic nitroso precursor silane may enhance rubber to glass bond strength significantly.
[0102] The silane may be present in an amount of 1 to 10% w/w of the total composition. Suitably, the silane may be present in an amount of 1 to 5% w/w, for example 1 to 3% w/w. The silane may be present in 3% w/w of the total composition.
[0103] Generally, the final solution applied to the target substrate may vary in the total silane concentration and ratio (silane to nitrososilane) over a wide range and still provide beneficial results. The final solution should contain a total silane concentration of at least approximately 0.1% by volume, i.e., the concentration of the combination of silanes and nitrososilanes in the final solution. Solutions having a total silane concentration of between about 0.1% and about 10% by volume generally provide strong bonding without waste of valuable silanes.
[0104] Excellent adhesion between elastomeric materials, such as rubber compositions, and surfaces comprising hydroxyl groups (e.g., glass and zeolites), with minimal waste of silane solution may be realized through the use of the compositions as so described.
[0105] For example, a first substrate may be constructed from a natural or synthetic rubber to be bonded to another substrate comprising surface hydroxyl groups. The second substrate comprising surface hydroxyl groups may be a glass substrate. Generally, the alkoxy silane moiety of the compound will anchor to a surface with hydroxyl groups. The moiety selected from an aromatic nitroso or an aromatic nitroso precursor will generally become anchored to the rubber. Accordingly, each end of the molecule is functionalised and assists in bonding the materials together with a strong and durable bond.
[0106] Thus, a glass substrate coated with an adhesive composition as so described may be adhered to a polymer such as an elastomeric material, for example a rubber composition, by applying the elastomer material in an uncured state onto the glass coated with the adhesive composition and curing the elastomeric material thereon to bond it to the glass. In the case of a rubber polymeric material the uncured rubber may be vulcanized in-situ to cure the rubber, resulting in further bonding of the rubber to the glass.
[0107] Such bonding to glass is achieved through the nitroso groups which are capable of reacting with polymers, in particular a polymer with alkene/allylic functionality within the polymer chain. For example, a polymer with diene or allylic functionality. Suitably, the polymer may comprise allylic functionality.
[0108] Alternatively, suitable polymers are those capable of reacting with nitroso groups so as to provide cross-links therebetween. Such a reaction produces a variety of cross-links for example between the nitroso group and a rubber material. The materials utilised in the method of the present invention are thought to reduce free nitroso groups as the nitroso group is within a molecular structure. In the reaction of the aromatic nitroso silane and/or the aromatic nitroso precursor silane and a glass substrate, the nitroso may react with alkene/allylic functionality within the natural rubber while the silane forms the bond with the glass.
[0109] In a further aspect the invention extends to a compound of the following general structure:
[0000]
[0000] where ‘a’ can be 1-3 and ‘b’ can be 0-2; wherein a+b=3 and at least one alkoxy group is present;
R 1 can be selected from H, C 1 -C 24 alkyl, C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and where when a≧1 at least one R 1 is not hydrogen; R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl; m and n can be the same or different and can be 1-10; X can be O or S; Y can be —O, —S, or —NH x (where x=1 or 2); R 4 can be C 1 to C 10 ; and Z indicates that the rings of the above structures can optionally be mono-, di-, tri- or tetrasubstituted with the group consisting of C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 3 -C 20 aralkyl, C 3 -C 20 alkaryl, C 5 -C 20 arylamine, C 5 -C 20 arylnitroso, amino, hydroxy, halogen and combinations thereof, and further where the substituents can either be the same or different on each carbon atom of the ring. Such substitutions may be possible provided there is no interference with effective bonding or curing of a bonding composition comprising the compound.
[0117] R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl. R 1 may be selected from C 1 -C 24 alkyl, C 3 -C 24 acyl and ‘a’ may be 3. X may be O. Y may be O or —NH x (where x=1). Y may be O. X and Y may be O. n may be C 2 -C 5 alkyl. m may be C 2 -C 5 alkyl. R 1 may be selected from C 1 -C 4 alkyl, X may be O and ‘a’ is 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be —NH x (where x=1) and ‘a’ may be 3. R 1 may be selected from C 1 -C 4 alkyl, X may be O, Y may be O, ‘a’ may be 3 and R 4 may be C 1 to C 10 .
[0118] The compound may be:
[0000]
[0119] In a further aspect, the present invention extends to an adhesive composition comprising a compound of the present invention. The composition may further comprise a suitable carrier vehicle for the compound. The composition may additionally comprise a silane (as described above), such as an aminosilane.
[0120] The composition of the present invention may find utility in bonding polymeric substrates, for example, elastomeric substrates to non-elastomeric substrates. One example is rubber (natural or synthetic) to non-rubber substrates, for example in bonding glass to natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be a HNBR.
[0121] The invention further extends to a cured residue between a hydroxylated surface and a polymeric substrate having diene and or allylic functionality within the polymer chain (such as an elastomer, for example a natural or synthetic rubber), the residue comprising a silane anchored to the hydroxylated surface and the cycloaddition reaction product of a nitroso group and a diene or allyl group of the polymeric substrate. The hydroxylated surface and the polymer substrate are not part of the residue.
[0122] For example, when the polymeric substrate comprises allylic functionality with the polymer chain (for example in a natural or synthetic rubber), the residue may be of the following general structure (wherein the hydroxylated surface and the polymer substrate are not part of the residue):
[0000]
[0000] where ‘a’ can be 0-2 , ‘b’ can be 0-2 and c can be 1 to 3, such that a+b+c=3;
R 1 can be selected from H, C 1 -C 24 alkyl, C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl and where when a≧1 at least one R 1 is not hydrogen; and R 2 can be selected from C 1 -C 24 alkyl and C 3 -C 24 acyl, preferably from C 1 -C 4 alkyl; m and n can be the same or different and can be 1-10; X can be O or S; Y can be —O, —S, or —NH x (where x=1 or 2); R 4 can be C 1 to C 10 ; and Z indicates that the rings of the above structures can optionally be mono-, di-, tri- or tetrasubstituted with C 1 -C 20 alkyl, C 3 -C 20 cycloalkyl, C 1 -C 20 alkoxy, C 7 -C 20 aralkyl, C 7 -C 20 alkaryl, C 5 -C 20 arylamine, C 5 -C 20 arylnitroso, amino, hydroxy, halogen and combinations thereof, and further where the substituents can either be the same or different on each carbon atom of the ring. Such substitutions may be possible provided there is no interference with effective bonding or curing of a bonding composition comprising the compound.
[0130] In a further aspect, the invention extends to a cure product comprising a substrate and a composition according to the present invention. The invention further extends to an assembly comprising at least two substrates bonded together by an adhesive composition according to the present invention.
[0131] In yet a further aspect the present invention provides a process for bonding two substrates together comprising the steps of:
(i) applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof to at least one substrate; (ii) applying a compound comprising;
a) at least one alkoxy silane moiety; and b) at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof;
to at least one substrate, and (iii) mating the first and second substrates so as to form a bond with the composition.
[0138] As used herein, the term “applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof” refers to applying an amount of a silicate, an aluminate, a germanate or combinations thereof to a surface for subsequent application of a compound comprising at least one alkoxy silane moiety and at least one aromatic nitroso (precursor) moiety. For example, the primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied as a deposit, monolayer, thin film, layer, etc. Suitably, a primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied to the surface of a first substrate for the purpose of priming said first substrate for subsequent bonding to a second substrate. The primer may comprise a silicate, an aluminate or combinations thereof. The second substrate may be an elastomer, for example a natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be HNBR.
[0139] The primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied to one substrate or both substrates. Advantageously, applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof to substrates may result in improved cure strength, particularly in production and automated processes.
[0140] The primer comprising a silicate, an aluminate, a germanate or combinations thereof may be applied to the at least one substrate in a suitable carrier. For example, the carrier may be a solvent, a wetting agent or a dispersing medium.
[0141] The primer may comprise a component selected from the group comprising glass such as glass fibres, quartz, clays, talcs, zeolites, porcelains, ceramics, silicon substrates and combinations thereof. The primer may comprise a silicate.
[0142] The compound comprising at least one alkoxy silane moiety; and at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof may comprise a compound according to any of the generic formulae or specific formulae as disclosed herein.
[0143] A first substrate may be a polymer. The polymer may comprise diene or allylic functionality within the polymer chain. For example, the polymer may be an elastomer, such as natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be a hydrogenated nitrile butadiene rubber (HNBR). The primer may be applied to the polymeric substrate. The primer may be applied to the other substrates which do not have any or sufficient diene and or allylic functionality.
[0144] At least one of the substrates may be a natural or synthetic rubber. The process may further comprise the step of vulcanising or crosslinking the rubber. One desirable process involves vulcanisation of the rubber and bonding to the second substrate at the same time.
[0145] The inventive primers and compounds (and compositions) utilised in the method of the present invention may be used in a pre-applied format. As used herein, the term pre-applied indicates that the primer or compound or compositions of the present invention may be applied to a substrate such that it remains secured thereto, and the resulting pre-treated substrate is suitable for storage. The primer or compound of composition should retain its efficacy over time. The pre-treated substrate may be stored for subsequent bonding to a second substrate.
[0146] For example, this may involve pre-applying a primer comprising a silicate, an aluminate, a germanate or combinations thereof to a first substrate, such that it remains secured thereto. Advantageously, substrates can be primed in a pre-treatment process, optionally stored, and subsequently utilised in (automated) manufacturing processes.
[0147] Accordingly, the invention further provides for a substrate having a primer comprising a silicate, an aluminate, a germanate or combinations thereof applied thereto for the purpose of priming said substrate for subsequent bonding to a second substrate using a compound comprising at least one alkoxy silane moiety; and at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof. At least one of the substrates may comprise a polymer comprising diene or allylic functionality within the polymer chain, for example, the polymer may be an elastomer, such as natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be HNBR.
[0148] The invention further provides for a substrate having a compound comprising at least one alkoxy silane moiety; and at least one moiety selected from an aromatic nitroso or an aromatic nitroso precursor and combinations thereof pre-applied thereto for subsequent bonding to a second substrate. A first substrate may comprise a hydroxylated surface as defined herein. A second substrate may comprise a polymer. The polymer may comprise diene or allylic functionality within the polymer chain, for example, the polymer may be an elastomer, such as natural or synthetic rubber. The synthetic rubber may be a nitrile butadiene rubber. The synthetic rubber may be HNBR. Advantageously, substrates can be pre-treated and subsequently utilised in (automated) manufacturing processes.
[0149] The primer or compound or composition of the present invention may be pre-applied to the polymeric substrate (such as an elastomer, for example a natural or synthetic rubber), or the hydroxylated surface. The composition may be pre-applied to the hydroxylated surface.
[0150] The inventive methods, compounds and compositions of the present invention may find utility in the following non-limiting applications: manufacture of automotive timing belts, bonding to glass/glass fibre reinforced plastic and composite parts, manufacture of reinforced rubbers, tyre manufacture, conveyor belt manufacture and the manufacture of woven materials such as clothing, for example protective clothing.
[0151] It will be appreciated by a person skilled in the art that the compositions of the present invention may additionally comprises conventional additives such as fillers, pigments, stabilisers, and/or moisture scavengers, subject to said additives not interfering with effective curing of the compositions.
[0152] Where suitable, it will be appreciated that all optional and/or preferred features of one embodiment of the invention may be combined with optional and/or preferred features of another/other embodiment(s) of the invention.
DETAILED DESCRIPTION
[0153] The rubber compositions utilised in bonding according to the method of the present invention may further include known additives common to rubber compositions. These include reinforcing carbon blacks; inactive fillers such as calcium carbonates, chalks, talcs, or metal oxides; accelerator systems; vulcanization retarders; promoters such as zinc oxide or stearic acid; plasticizers such as aromatic, paraffinic, naphthenic and synthetic mineral oils; ageing, light-protecting ozone-protecting, fatigue, coloration, and processing auxiliaries; and sulfur. Commonly these additives may be present at a quantity of about 0.1 parts to about 80 parts per 100 parts by weight of the rubber composition.
[0154] Prior to application of the silane solution, the surface to be coated with the adhesive composition may be cleaned to allow better adhesion. For example, cleaning with solvent or alkaline material or cleaning with an abrasive agent. Application can then be conducted by a variety of methods, including dipping, spraying, brushing or wiping the solution onto the substrate. It has been suggested that for improving rubber adhesion the coating remain partially cross-linked prior to vulcanisation. For this reason, the coating is usually air dried at room temperature as heat drying can cause a higher degree of cross-linking that will result in poorer adhesion.
[0155] Compounds of the invention were made as set out below.
EXAMPLES
[0156] Compounds A, B, C, D and E (supra) were synthesised according to the following experimental procedures and as illustrated in the reaction schemes below.
Nitrosylation Reaction (1): (infra) was carried out as outlined in J. J. D'Amico, C. C. Tung and L. A. Walker, J. Am. Chem. Soc., 5957 (1959):
[0000]
Reaction (2): γ-Isocyantopropyltriethoxysilane (GE Bayer Silicones A-1310) (2.35 g, 9 5 mmol) was solvated in 10 mL of anhydrous THF in a 50 mL round bottom flask. The reaction flask was flushed with nitrogen and charged with N,N-bis-(2-hydroxyethyl)-4-nitroso-aniline (2 g, 9.5 mmol), followed by a catalytic quantity of dibutyltin dilaurate (1.5 μmol). The reaction was refluxed for an additional 2 hours under nitrogen. Consumption of the isocyanate (2275 cm −1 ) was monitored using infrared spectroscopy. The solvents were removed under reduced pressure to give the product in a quantitative yield.
[0000]
Reaction (3): γ-Isocyantopropyltrimethoxysilane (ABCR GmbH) (1.5 g, 7.3 mmol) was solvated in 8 mL of anhydrous THF in a 50 mL round bottom flask. The reaction flask was flushed with nitrogen and charged with N,N-bis-(2-hydroxyethyl)-4-nitroso-aniline (1.53 g, 7.3 mmol), followed by a catalytic quantity of dibutyltin dilaurate (1 μmol). The reaction was refluxed for an additional 2 hours under nitrogen. Consumption of the isocyanate (2275 cm −1 ) was monitored using infrared spectroscopy. The solvents were removed under reduced pressure to give the product in a quantitative yield.
[0000]
Reaction (4): γ-Isocyantopropyltriethoxysilane (GE Bayer Silicones A-1310) (2.35 g, 9.5 mmol) was solvated in 10 mL of anhydrous THF in a 50 mL round bottom flask. The reaction flask was flushed with nitrogen and charged with N,N-bis-(2-hydroxyethyl)-4-nitroso-aniline (1 g, 4.75 mmol), followed by a catalytic quantity of dibutyltin dilaurate (1.5 μmol). The reaction was refluxed for an additional 5 hours under nitrogen. Consumption of the isocyanate (2275 cm −1 ) was monitored using infrared spectroscopy. The solvents were removed under reduced pressure to give the product in a quantitative yield.
[0000]
[0000]
Reaction (5): γ-Isocyantopropyltriethoxysilane (GE Bayer Silicones A-1310) (10.68 g, 43.18 mmol) was solvated in 30 mL of anhydrous THF in a 100 mL round bottom flask. The reaction flask was flushed with nitrogen and charged with p-benzoquinone dioxime (Sigma-Aldrich) (3 g, 21.72 mmol), followed by a catalytic quantity of dibutyltin dilaurate (1.5 μmol). The reaction was refluxed for an additional 5 hours under nitrogen. Consumption of the isocyanate (2275 cm −1 ) was monitored using infrared spectroscopy. The solvents were removed under reduced pressure to give the product in a quantitative yield.
Reaction (6): γ-Isocyantopropyltriethoxysilane (GE Bayer Silicones A-1310) (2.35 g, 9.5 mmol) was solvated in 10 mL of anhydrous THF in a 50 mL round bottom flask. The reaction flask was flushed with nitrogen and charged with 2-(N-ethylanilino)ethanol (0.78 g, 4.75 mmol), followed by a catalytic quantity of dibutyltin dilaurate (1.5 μmol). The reaction was refluxed for an additional 5 hours under nitrogen. Consumption of the isocyanate (2275 cm −1 ) was monitored using infrared spectroscopy. The solvents were removed under reduced pressure to give the product in a quantitative yield.
[0000]
[0000]
[0163] Formulations comprising the compounds of the invention were prepared as set out below. Bis(trimethoxysilylpropyl)amine is commercially available from Sigma Aldrich and is of the formula:
[0000]
(E)
Compositions Used in Natural Rubber Bonding
Ingredient
Level (Weight %)
Compound E
6.4
Bis(triethoxysilylpropyl) amine
1.3
Superchlon HE1200
8.9
Isopropanol
8.4
MEK
29.0
Xylene
46.0
Natural Rubber Composition—Available From Merl Ltd. (Merl Sulfur Cured NR60)
[0000]
Tests were carried out using natural rubber of the following composition:
[0000]
Ingredient
Parts by weight
Natural Rubber (a)
100
Zinc Oxide
3.5
Stearic Acid
2
Carbon Black (b)
40
Naphthenic Oil (low viscosity) (c)
5
1,2-Dihydro-2,2,4-Trimethylquinoline (d)
2
N-(1,3-dimethylbutyl)-N′-phenyl-p-phenylenediamine (e)
1
Hydrocarbon Waxes (f)
2
CBS (g)
0.7
Sulphur
2.5
(a) NR SMR CV 60;
(b) SRF N762 black;
(c) Oil Strukthene 410;
(d) Flectol H;
(e) Santoflex 13 (HPPD);
(f) Sunproof Improved Wax;
(g) Vulcanisation accelerator, N-Cyclohexyl-2-benzothiazole.
Testing
[0165] To assess the efficacy of the adhesive systems of the present invention in bonding rubbers to a number of substrates, a series of tests were performed according to the ASTM 429-B standard adjusted to a 45° angle. The substrates (2.54 cm (1 inch) wide, 10.16 cm (4 inch) long panels or coupons) were coated with the adhesive and adhered to natural rubber in a vulcanisation process. The natural rubber compositions were sulfur-cured compositions as set out in the Formulation table supra.
[0166] Typically the substrates were wiped with a dry cloth. The substrates were also subjected to grit-blasting, followed by a second wiping with a dry cloth. Before application of the adhesive, 2.54 cm (1 inch) of length and 2.54 cm wide (1 inch) on both ends of the substrate/coupon was masked to prevent that region.
[0167] Typically the substrates were wiped with a dry cloth. The substrates were also subjected to grit-blasting, followed by a second wiping with a dry cloth. Before application of the adhesive, 2.54 cm (1 inch) of length and 2.54 cm wide (1 inch) on both ends of the substrate/coupon was masked to prevent that region being available for bonding to the rubber, leaving a central area of 2.54 cm (1 inch) in width and 5.08 cm (2 inches) in length available to bond to the rubber.
[0168] In the bonding operation of the present invention, the compositions are applied to the substrates by either a dipping, spraying or brush method to ensure an even coverage, preferably after the substrate has been cleaned.
[0169] Drying may be carried out under ambient room temperature conditions. Solvent evaporation rate can be increased by heat, forced air or both.
[0170] A layer of uncured rubber was then placed on each coupon and cured in a standard hydraulic vulcanisation press for a period of time specified by the rubber's cure profile. In the case of the natural rubber used in the bonding process in the present invention, the rubber was cured for 20 minutes at 150° C. under a pressure of 20-30 Tonnes, to ensure intimate contact of the surfaces being bonded and the adhesive.
[0171] After curing the bonded samples were aged for 24 hours at room temperature before being subjected to testing and the tear pattern noted. Each sample was tested by the 45° angle modified ASTM 429-B standard using Instron equipment (Instron tester, Model No. 5500R) at a load rate of 50 mm per minute until separation is complete.
RESULTS
[0172] A number of different substrates were tested as set out below in Table 1.
[0000]
TABLE 1
Grit-blasted
Non Grit-blasted
Entry
Substrate
(N/mm)
(N/mm)
1
Glass lap (Control) a
Strong Bond,
Strong Bond,
resulting in 100%
resulting in 100%
rubber failure
rubber failure
2
Polypropylene b
No bond
No bond
3
FR4 Epoxy Glass—epoxy
14.690
17.804
resin reinforced with
woven fibre glass mat c
4
Polypropylene 30%
8.686*
No Bond
reinforced with
Glass fibre d
5
Nylon 66 containing
11.467
No Bond
20% Talc b
6
Polypropylene containing
10.059*
No Bond
20% Talc d
*Significant substrate deformation observed.
a available from Ideal Glass Ltd;
b available from William Cox Ltd. (Also Goodfellow);
c GSPK Circuits Ltd.
d available from Rocholl GmbH.
[0173] Entry 1, the glass slide substrate, represents the control reaction. Very strong bonds were observed, typically resulting in rubber failure prior to bond failure. Rubber coverage is the percentage of rubber remaining on the bonded substrate after peel testing. 100% Rubber failure means that the rubber completely failed with no portion of the rubber peeling away from the surface of the substrate (and equates to 100% rubber failure). Generally, it is desirable that the rubber substrate fails before the substrate to rubber bond fails. Entry 2, i.e. a polypropylene substrate, is the second control reaction. No bond is formed between the rubber composition and this substrate.
[0174] Entries 1 and 3 in Table 1 exhibit good bond strengths to rubber irrespective of whether the substrate was grit-blasted prior to cure. However, entries 4 to 6 show strong dependence on whether the substrate has been grit-blasted. Grit-blasted substrates exhibit good bond strengths. However, absent a pre-treatment grit-blasting step, the same substrates failed to show any bonding to the rubber substrate. One possible suggestion for this observation is that grit-blasting reveals nascent hydroxyl groups in the substrates, thereby greatly enhancing the ability of the adhesive to bond the substrate and rubber together.
[0175] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.
|
Methods for bonding polymeric substrates to hydroxylated surfaces such as glass are disclosed. The polymeric substrates may be elastomeric substrates such as a natural Or synthetic rubber. The method may comprise applying a compound comprising at least one alkoxy silane moiety and at least one moiety selected from a nitrosoaromatic or a nitrosoaromatic precursor to one of the substrates. The nitrosoaromatic moiety may be a nitrosobenzene. The nitrosoaromatic precursor may be a nitrosobenzene precursor, such as at least one of a quinone dioxime or a quinone oxime. Novel primers and compounds suitable for use in the bonding process are also disclosed.
| 8
|
TECHNICAL FIELD
[0001] The invention relates generally to Common Public Radio Interface/Open Base Station Architecture Initiative (CPRI/OBSAI) systems and, more particularly, to performing latency measurements for CPRI/OBSAI systems.
BACKGROUND
[0002] Referring to FIG. 1 of the drawings, the reference numeral 100 generally designates a portion of a convention communications system. As shown, a base station system 102 operates to provide communications between a network interface 106 and an air interface, which is typically used for wireless communications. The base station system 102 generally comprises radio equipment 108 and a radio equipment controller 110 , which each have a physical layer (PHY) 112 and 114 that communicate with each other over a CPRI/OBSAI link 113 . As part of the protocol for a CPRI/OBSAI system, PHY 114 generally includes a timing circuit 116 that operates to calculate the “round trip” latency between the radio equipment 108 and radio equipment controller 110 .
[0003] Turning to FIG. 2 , an example of a conventional PHY 114 can be seen in greater detail. Within PHY 114 , there is a transmit path 118 and a receive path 120 that serially communicate data to PHY 112 over link 113 and that communicate (in parallel) data to/from the network interface 106 . When performing latency calculation, the stop/start counter 126 measures the elapsed time between commas (either encoded or unencoded) detected by the comma detect circuits 122 and 124 . Typically, counter 126 measures the time between a comma detected from the parallel transmit data (or transmit comma) by comma detect circuit 122 and a comma detected from the parallel receive data (or receive comma) by comma detect circuit 124 . The resolution of this latency measurement is a factor in evaluating the system 100 .
[0004] As a result, it is desirable to have the latency measurement be as high a resolution as possible. However, for timing circuit 116 , there are drawbacks. For example, the logic for the timing circuit 116 operates in a high speed clock domain (compared to the clock domain used for the transmit and receive paths 118 and 120 ). This high speed configuration results in significant power consumption as well as increased risk of a false comma detection when the parallel data containing a comma is presented to the high speed clock domain from the lower speed clock domains. Therefore, there is a need for a timing circuit with improved performance.
[0005] Another example of a conventional is European Patent No. EP1814341.
SUMMARY
[0006] A preferred embodiment of the present invention, accordingly, provides an apparatus. The apparatus comprises a transmit comma detect circuit that is clocked by first clock signal; a receive comma detect circuit that is clocked by the first clock signal; and a stopwatch counter having: a transmit latching circuit having: a first transmit latching path that is clocked by negative edges of a second clock signal and that is coupled to the transmit comma detect circuit, wherein the frequency of the second clock signal is greater than the frequency of the first clock signal; a second transmit latching path that is clocked by positive edges of the second clock signal and that is coupled to the transmit comma detect circuit; and a first flip-flop having an input terminal, a clock terminal, and an output terminal, wherein the input terminal of the first flip-flop is coupled to the first transmit latching path, and wherein the clock terminal of the first flip-flop is coupled to the second transmit latching path; a receive latching circuit having: a first receive latching path that is clocked by the negative edges of the second clock signal and that is coupled to the receive comma detect circuit; a second receive latching path that is clocked by the positive edges of the second clock signal and that is coupled to the receive comma detect circuit; and a second flip-flop having an input terminal, a clock terminal, and an output terminal, wherein the input terminal of the first flip-flop is coupled to the first receive latching path, and wherein the clock terminal of the first flip-flop is coupled to the second receive latching path; and a counter state machine that is coupled to the second transmit latching path, the second receive latching path, the first flip-flop, and the second flip-flop.
[0007] In accordance with a preferred embodiment of the present invention, the first transmit latching path and the first receive latching path each further comprises: a plurality of input negative edge triggering flip-flops coupled in series with one another; a first logic circuit that is coupled to at least one of the input negative edge triggering flip-flops; and an output negative edge triggering flip-flop that is coupled to the first logic circuit and the first flip flop for the first transmit latching path and the second flip-flop for the first receive latching path.
[0008] In accordance with a preferred embodiment of the present invention, the first logic circuit further comprises: a first AND gate that is coupled to at least two of the input negative edge triggering flip-flops; and a second AND gate that is coupled to the first AND gate and the counter state machine.
[0009] In accordance with a preferred embodiment of the present invention, the second transmit latching path and the second receive latching path each further comprises: a plurality of input positive edge triggering flip-flops coupled in series with one another; a first logic circuit that is coupled to at least one of the input positive edge triggering flip-flops; and an output positive edge triggering flip-flop that is coupled to the fourth AND gate and the first flip flop for the second transmit latching path and the second flip-flop for the second receive latching path.
[0010] In accordance with a preferred embodiment of the present invention, the first logic circuit further comprises: a first AND gate that is coupled to at least two of the input positive edge triggering flip-flops; and a second AND gate that is coupled to the first AND gate and the counter state machine.
[0011] In accordance with a preferred embodiment of the present invention, the counter state machine further comprises: a count enable generator that is coupled to the output positive edge triggering flip-flop from each of the second transmit latching path and the second receive latching path; a post processing circuit that is coupled to the count enable generator; a counter that is coupled to the count enable generator; a validation circuit count enable generator; an output circuit that is coupled to the counter and the validation circuit; and a gating circuit that is coupled to the output positive edge triggering flip-flop from each of the second transmit latching path and the second receive latching path and the count enable generator.
[0012] In accordance with a preferred embodiment of the present invention, the post processing circuit and counter further comprises: a first OR gate that is coupled to the first flip-flop and the second flip-flop; an XOR gate that is coupled to the first flip-flop and the second flip-flop; an AND gate that is coupled to the first OR gate and the count enable generator; a third flip-flop that is coupled to the AND gate; a second OR gate that is coupled to the count enable generator and the third flip-flop; an incrementer that is coupled to the second OR gate and the count enable generator; a fourth flip-flop that is couple to the XOR gate; and a fifth flip-flop that is coupled to the fourth flip-flop and the count enable generator.
[0013] In accordance with a preferred embodiment of the present invention, the transmit comma detect circuit and the receive comma detect circuit each has a plurality of channels, and wherein the first clock signal further comprises a transmit clock signal for clocking the transmit comma detect circuit and a receive clock signal for clocking the receive comma detect circuit, and wherein the apparatus further comprises: a first multiplexer that is coupled between the transmit comma detect circuit and the stopwatch counter; and a second multiplexer that is coupled between the receive detect circuit and the stopwatch circuit.
[0014] In accordance with a preferred embodiment of the present invention, an apparatus is provided. The apparatus comprises a physical layer (PHY) transmit path; a PHY receive path; a transmit comma detect circuit that is clocked by first clock signal and that is coupled to the PHY transmit path; a receive comma detect circuit that is clocked by the first clock signal and that is coupled to the PHY receive path; and a stopwatch counter having: a transmit latching circuit having: a first transmit latching path that is clocked by negative edges of a second clock signal and that is coupled to the transmit comma detect circuit, wherein the frequency of the second clock signal is greater than the frequency of the first clock signal; a second transmit latching path that is clocked by positive edges of the second clock signal and that is coupled to the transmit comma detect circuit; and a first flip-flop having an input terminal, a clock terminal, and an output terminal, wherein the input terminal of the first flip-flop is coupled to the first transmit latching path, and wherein the clock terminal of the first flip-flop is coupled to the second transmit latching path; a receive latching circuit having: a first receive latching path that is clocked by the negative edges of the second clock signal and that is coupled to the receive comma detect circuit; a second receive latching path that is clocked by the positive edges of the second clock signal and that is coupled to the receive comma detect circuit; and a second flip-flop having an input terminal, a clock terminal, and an output terminal, wherein the input terminal of the second flip-flop is coupled to the first receive latching path, and wherein the clock terminal of the first flip-flop is coupled to the second receive latching path; and a counter state machine that is coupled to the second transmit latching path, the second receive latching path, the first flip-flop, and the second flip-flop.
[0015] In accordance with a preferred embodiment of the present invention, method for measuring latency in a Common Public Radio Interface/Open Base Station Architecture Initiative (CPRI/OBSAI) system is provided. The method comprises performing transmit comma detection so as to generate a transmit comma detection scalar; generating a start signal from the transmit detection scalar based on positive edge triggering of a clock signal; generating a first data signal from the transmit detection scalar based on negative edge triggering of the clock signal; latching the first data signal so as to generate a transmit signal, wherein the start signal is used as a transmit clocking signal for the step of latching the first data signal; performing receive comma detection so as to generate a receive comma detection scalar; generating a stop signal from the receive detection scalar based on positive edge triggering of the clock signal; generating a second data signal from the receive detection scalar based on negative edge triggering of the clock signal; latching the second data signal so as to generate a receive signal, wherein the stop signal is used as a receive clocking signal for the step of latching the second data signal; and calculating the latency based at least in part on receive signal, transmit signal, stop signal, and start signal.
[0016] In accordance with a preferred embodiment of the present invention, the method step of calculating further comprises: counting between assertion of the start signal and assertion of the stop signal; and performing a correction calculation after assertion of the stop signal.
[0017] In accordance with a preferred embodiment of the present invention, the step of performing a correction calculation further comprises: XORing the transmit and receive signals; latching the XORed the transmit and receive signals to generate a first latched signal; ORing the transmit signal and an inverse of the receive signal; latching the ORed transmit signal and inverse of the receive signal to generate a second latched signal; ORing with second latched signal and an enable signal to generate an increment signal; and incrementing based at least in part on the increment signal.
[0018] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
[0020] FIG. 1 is a block diagram of an example of a conventional communications system;
[0021] FIG. 2 is a block diagram of an example of the PHY of FIG. 1 used with a CPRI/OBSAI link;
[0022] FIG. 3 is a block diagram of a timing circuit in accordance with a preferred embodiment of the present invention;
[0023] FIG. 4A is a block diagram of an example of the transmit latching circuit of FIG. 3 ;
[0024] FIG. 4B is a block diagram of an example of the receive latching circuit of FIG. 3 ;
[0025] FIG. 5 is a block diagram of an example of the counter state machine of FIG. 3 ; and
[0026] FIG. 6 is an example of the post processing circuit and counter of FIG. 5 .
DETAILED DESCRIPTION
[0027] Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views.
[0028] Turning to FIG. 3 of the drawings, an example of a timing circuit 300 in accordance with a preferred embodiment of the present invention can be seen. Timing circuit 300 generally comprises a transmit comma detect circuit 302 , a receive comma detect circuit 314 , multiplexers 304 and 312 , a stopwatch counter 316 , and a Management Data Input/Output circuit (MDIO) 318 . The stopwatch counter 316 generally comprises a transmit latching circuit 306 , a counter state machine 308 , and a receive latching circuit 310 .
[0029] In operation, the transmit comma detect circuit 302 performs comma detection for PHY transmit path 118 , while the receive comma detect circuit 314 performs comma detection for PHY receive path 120 . Each of these circuits 302 and 314 is clocked by clock signal CLK 1 (which is typically has a frequency between about 61.4 MHz and about 614.4 MHz). It is possible however, for each of circuits 302 and 314 to be clocked by different clock signals (i.e., a receive clock signal and a transmit clock signal) which may or may not have the same frequencies, but for the sake of simplicity, only clock signal CLK 1 is shown. Each of circuits 302 and 314 can also have multiple channels, but, for the sake of simplicity, two channels are shown. Multiplexers 304 and 312 (which can be, for example, instantiated 2-to-1 multiplexer cells and which can be controlled by select signal SELSYNC from MDIO 318 ) can then multiplex the channels from circuits 302 and 314 for the stopwatch counter 316 . Typically, the detection of a transmit comma or a receive comma is reflected by the transmission of a single bit from the circuits 302 and 314 to the stopwatch counter 316 .
[0030] Based on the comma detection from circuits 302 and 314 , the stopwatch counter 316 is able to calculate the latency using “mixed” timings with the same clock signal CLK 2 . Generally, the transmit latching circuit 306 and the receive latching circuit 310 operate at twice the speed of the counter state machine 308 by using double edge latching. Initially, the counter state machine 308 asserts a gating signal TGATE to transmit latching circuit 306 to look for a transmit comma from the transmit comma detect circuit 302 . Upon detection of a transmit comma from the transmit comma detect circuit 302 (and multiplexer 304 , if applicable), the transmit latching circuit 306 asserts a start signal START to the counter state machine 308 and provides a count signal T to the counter state machine 308 . Following the assertion of the start signal START, the counter state machine 308 asserts gating signal RGATE to the receive latching circuit 310 so as to eventually receive a stop signal STOP and a count signal R. Once the receive comma detect circuit 314 detects a receive comma (which is provided to the receive latching circuit 310 through multiplexer 312 , if applicable), the receive latching circuit 310 asserts the stop signal STOP to the counter state machine 308 . Based on the start signal START, the stop signal STOP, and the count signals T and R, the counter state machine 308 can issue a count output signal CNTOUT[ 0 :N] (which can be about 20 bits long) to MDIO 318 . Additionally, the MDIO 318 can assert a done signal DONE (which is typically active high) to the stopwatch counter 316 if the count output signal CNTOUT[ 0 :N] is valid, and the stopwatch counter 316 can be reset through assertion of the reset signal RESET (which is typically active low).
[0031] Turning to FIGS. 4A and 4B , examples of the transmit latching circuit 306 and receive latching circuit 310 can be seen in greater detail. Each of circuits 306 and 310 have a latching path that is clocked on the positive edge or rising edge of clock signal CLK 2 (which generally has a frequency of about 1.5625 GHz) and a latching path that is clocked on the negative edge or falling edge of clock signal CLK 2 . The negative edge triggering paths include negative edge triggering D flip-flops 402 - 1 to 402 - 4 (for circuits 306 ) and 452 - 1 to 452 - 4 (for circuits 310 ), AND gates 408 / 410 (for circuits 306 ) and 458 / 460 (for circuits 310 ). The positive edge triggering paths include positive edge triggering D flip-flops 404 - 1 to 404 - 4 (for circuits 306 ) and 454 - 1 to 454 - 4 (for circuits 310 ), AND gates 414 / 416 (for circuits 306 ) and 464 / 466 (for circuits 310 ). The outputs from the negative edge triggering paths are then provided as the input signal for D flip-flops 406 (for circuit 306 ) and 456 (for circuit 310 ), while outputs from the positive edge triggering paths (which also operates as the start signal START and stop signal STOP) are then provided as the clock signal for D flip-flops 406 (for circuit 306 ) and 456 (for circuit 310 ).
[0032] In operation, circuits 306 and 310 are able to perform latching operations at twice the speed of clock signal CLK 2 (typically about 3.125 GHz). When gated (the respective gate signal TGATE or RGATE is asserted), D flip-flops 406 (for circuit 306 ) and 456 (for circuit 310 ) register a high or low logic value from its respective negative edge triggered path based on clocking from its respective positive edge triggered path as count signals T and R. Typically, D flip-flops 406 and 456 operate at twice the speed of clock signal CLK 2 in the circuits 306 and 312 , and the “D” input logic for D flip-flops 406 and 456 is generally reduced to a single wire to enable fastest timing closure for a given technology. Additionally, the D flip-flops 406 (for circuit 306 ) and 456 (for circuit 310 ) can also be reset (respectively) by AND gates 418 and 468 when either the done signal DONE is asserted high or the reset signal RESET is asserted low. The other parts of the circuits 306 and 310 can also be reset by the reset signal RESET.
[0033] Turning now to FIG. 5 , an example of the counter state machine 308 can be seen in more detail. Counter state machine 308 generally comprises post processing circuit 502 , gating circuit 504 , count enable generator 506 , counter 508 , output circuit 510 , and validation circuit 512 . Counter state machine 508 typically operates on the rising edge of the clock signal CLK 2 , but because of post processing circuit 502 , the resolution of the counter state machine 308 is about twice the rate of the clock signal CLK 2 . Preferably, based on the logic states of count signals T and R, the counter state machine 308 operates on one of four counting modes (shown in Table 1 below) to adjust the count output signal CNTOUT[ 0 :N].
[0000]
TABLE 1
T
0
0
1
1
R
0
1
0
1
Count Mode
+0
−1
+1
+0
[0034] In operation, the count enable generator 506 , counter 508 , validation circuit 512 , post processing circuit 502 , and output circuit 510 operate together to generate the count output signal CNTOUT[ 0 :N]. When the start signal START is asserted (indicating the detection of a transmit comma) and the done signal DONE is not asserted, the count enable signal generator 506 issues an enable signal CNTEN to counter 508 , which begins incrementing based on the rising edge of clock signal CLK 2 . Typically, counter 508 is a 19-bit counter which stops when a predetermined maximum value is reached and can be reset when the done signal DONE (which is associated with the read synchronization signal RDSYNC) is asserted. Once the stop signal STOP is asserted (indicating the detection of a receive comma), the post processing circuit 502 and validation circuit 512 are enabled and the counter 508 is disabled. The validation circuit 512 issues a valid signal VALID to the output circuit 510 , which enables the output circuit 510 to store count values received from the counter 508 and post processing circuit 502 . The post processing circuit 502 provides the first or bit CNT[ 0 ] to the output circuit 510 and an adjustment signal ADJ to counter 508 . With the adjustment from the post processing circuit 502 , the counter 508 can issue a count signal CNT[ 1 :N] (which is typically 19 bits) to the output circuit 510 . Based on the 0 th bit CNT[ 0 ] and the count signal CNT[ 1 :N], the output circuit 510 can provide the count output signal CNTOUT[ 0 :N] to MDIO 318 . Also, counter state machine 308 generally provides a feedback system for gating the transmit latching circuit 306 and the receive latching circuit 310 by employing gating circuit 504 to generate gating signals TGATE and RGATE based on the start signal START and stop signal STOP.
[0035] Turning now to FIG. 6 , an example of the counter 508 and post processing circuit 502 can be seen in greater detail. The post processing circuit 502 generally comprises OR gate 602 , XOR gate 606 , D flip-flops 608 , 610 , and 612 , and AND gate 604 . Counter 508 generally comprises OR gate 614 and incrementer 616 .
[0036] In operation, the post processing circuit 502 is able to generate the adjustment signal ADJ and the 0 th bit CNT[ 0 ] based on the count signals T and R. Because the post processing circuit 502 operates at very high speed, complex logic is not desirable, so use of subtraction (as one of the count modes shown in Table 1 above for the counter state machine 308 ) is not desirable. As a substitute, the counter 508 is delayed by one cycle (for example, about 0.64 ns) so that the offset allows the post processing arithmetic or count modes to be +1, +2, and +3 instead of −1, 0, and +1 (respectively), which is shown in Table 2 below.
[0000] TABLE 2 T 0 0 1 1 R 0 1 0 1 Count Mode +2 +1 +3 +2
For count mode of +2, the OR gate 602 outputs a logic high signal (through AND gate 604 ) to D flip-flop 608 , which then outputs the ADJ signal to the OR gate 614 of counter 508 . As a result, incrementer 616 of counter 508 is able to increment for one additional cycle. For the count mode of +1, the XOR gate outputs a logic high signal to flip-flops 610 and 612 to reflect a “1” in the 0 th bit CNT[ 0 ]. Finally, for a count mode of +3, the incrementer 616 increments for an additional cycle and a “1” is indicated in the O th bit CNT[ 0 ].
[0037] As a result of using timing circuit 300 , several advantages can be realized. For example, a latency measurement accuracy of 651 ps (which is 20 times better than current CPRI/OBSAI systems). Additionally, because the amount of high speed circuit has been reduced, the overall power consumption can be reduced. Also, because there can be a single bit data transfer from a low speed clock domain to a high speed clock domain, the likelihood of detecting a false comma can be greatly reduced.
[0038] Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
|
As part of the protocol for Common Public Radio Interface/Open Base Station Architecture Initiative (CPRI/OBSAI) systems, timing circuits are used to calculate the “round trip” latency across CPRI/OBSAI links. Traditionally, these timing circuits have been plagued with numerous problems. Here, however, a timing circuit is provided that has improved latency measurement accuracy, reduced power consumption, and a reduced likelihood of detecting a false comma. This is generally accomplished through the use of double edge latching in combination with post processing circuit and single bit transmission between low and high speed clock domains.
| 8
|
RELATED U.S. APPLICATIONS
[0001] This application is a divisional application of application Ser. No. 12/334,086, filed Dec. 12, 2008, which is a continuation of application Ser. No. 11/327,906, filed Jan. 9, 2006, now U.S. Pat. No. 7,498,234, which is a continuation of prior U.S. application Ser. No. 10/784,601, now U.S. Pat. No. 7,067,396, which is a continuation of U.S. application Ser. No. 09/777,516, filed Feb. 6, 2001, now U.S. Pat. No. 6,809,009, which in turn is a continuation of prior U.S. application Ser. No. 09/299,683, filed Apr. 26, 1999, now U.S. Pat. No. 6,225,192 granted May 1, 2001, which in turn is a continuation of U.S. application Ser. No. 08/856,275, filed May 14, 1997, now U.S. Pat. No. 6,020,252, all of which are incorporated by reference herein.
TECHNICAL FIELD
[0002] This invention relates to a method of producing a thin layer of semiconductor material. The thin layer produced can possibly be provided with electronic components.
[0003] The invention permits the production of thin layers of either monocrystalline or polycrystalline or even amorphous semiconductor and, for example the production of substrates of the Silicon on Insulator type or the production of self-supporting thin layers of monocrystalline semiconductor. Electronic circuits and/or microstructures can be either completely or in part created in these layers or in these substrates.
BACKGROUND
[0004] It is known that implanting ions of a rare gas or of hydrogen in a semiconductor material induces the formation of microcavities at a depth proximate to the mean penetration depth of the ions. French Patent Application No. FR-A-2 681 472 discloses a method which uses this property in order to obtain a thin film of semiconductor. This method consists of subjecting a wafer of the desired semiconductor material that includes a flat face, to the following steps a first implantation step by bombarding the flat face of the wafer with ions creating, within the volume of the wafer and at a depth proximate to the penetration depth of the ions, a layer of microcavities separating the wafer into a lower region constituting the mass of the substrate and an upper region constituting the thin film, the ions being chosen from among the ions of rare gases or of hydrogen gas and the temperature of the wafer being maintained below the temperature at which the implanted ions can escape from the semiconductor by diffusion.
[0005] a second step of bringing the flat face of the wafer into close contact with a support made up of at least one layer of rigid material. This close contact may be created, for example using an adhesive substance, or by the effect of a preliminary preparation of the surfaces and possibly a thermal and/or electrostatic treatment in order to promote interatomic bonding between the support and the wafer;
[0006] a third step of thermal treatment of the wafer-support assembly at a temperature greater than the temperature at which the implantation was carried out and sufficient to create, through a crystal rearrangement effect in the wafer and through the pressure of the microcavities, a separation between the thin film and the mass of the substrate. This temperature is, for example 500° C. for silicon.
[0007] This implantation is capable of creating a layer of gaseous microbubbles. This layer of microbubbles thus created within the volume of the wafer; at a depth proximate to the mean penetration depth of the ions demarcates, within the volume of the wafer, two regions separated by this layer: one region intended to constitute the thin film and one region forming the rest of the substrate.
[0008] According to the implantation conditions, after implantation of a gas, such as, for example hydrogen, cavities or microbubbles may or may not be observable by transmission electronic microscopy. In the case of silicon, it can be obtained microcavities, the size of which can vary from a few nm to several hundreds of nm. Hence, particularly when the implantation temperature is low, these cavities are only observable during the thermal treatment stage, a step during which nucleation is brought about in order to end up with the coalescence of the microcavities at the end of the thermal treatment.
[0009] The method described in French Patent Application No. FR-A-2 681 472 does not allow the production of electronic circuits in or at the surface of the flat face of the wafer after the ion implantation step. Indeed, the creation of such circuits implies the carrying out of certain classic micro-electronics operations (diffusion annealing, deposition etc.) that require thermal treatment stages (typically from 40° C. to 700° C.) according to the steps for silicon. At these temperatures, blisters form on the surface of the flat face of the implanted wafer. By way of example, for an implantation of hydrogen ions at a dose of 5.10 16 protons/cm 2 and at 100 keV energy in a silicon wafer, a thermal treatment carried out at 500° C. for 30 min. leads to degradation of 50% of the surface of the flat face of the wafer, this degradation resulting in the appearance of blisters and to their bursting. It is then no longer possible to properly ensure that the flat face of the wafer is brought into close contact with the support (which will be called the applicator in the subsequent description) so as to detach the semiconductor layer from the rest of the wafer.
[0010] This phenomenon of the formation of blisters and craters in the surface of a silicon wafer implanted with hydrogen ions after annealing has been discussed in the article “Investigation of the bubble formation mechanism in a-Si:H films by Fourier-transform infrared microspectroscopy” by Y. Mishima and T. Yagishita, that appeared in the J. Appl. Phys. 64 (8), 15th Oct. 1988, pages 3972-3974.
SUMMARY
[0011] This invention has been conceived in order to improve the method described in French Patent Application No. FR-A-2 681 472. After a step of ion implantation within a range of appropriate doses and before the separation step, it allows to carry out a thermal treatment of the part of the wafer corresponding to the future thin layer, in particular between 400° C. and 700° C. for silicon, without degrading the surface condition of the flat face of the wafer and without separation of the thin layer. This intermediate thermal treatment can form part of the operations for developing electronic components or can be applied for other reasons.
[0012] The invention is also applicable in the case where the thickness of the thin layer is sufficient to confer good mechanical characteristics on it, in which case it is not necessary to use an applicator in order to achieve the separation of the thin layer from the rest of the wafer, but where it is desired, despite everything, to avoid surface defects in the flat face.
[0013] Therefore an objective of the invention is a method of production of a thin layer of semiconductor material from a wafer of said material having a flat face, including an ion implantation step consisting of bombarding said flat face with ions chosen from among the ions of rare gases or of hydrogen, at a specific temperature and a specific dose in order to create, in a plane called a reference plane and situated at a depth proximate to the mean depth of penetration of the ions, microcavities, the method also including a subsequent thermal treatment step at a temperature sufficient to achieve separation of the wafer into two parts, across the reference plane, the part situated on the side of the flat face constituting the thin layer, characterised in that:
[0014] the ion implantation step is carried out with an ion dose between a minimum dose and a maximum dose, the minimum dose being that from which there will be sufficient creation of microcavities to obtain the embrittlement of the wafer along the reference plane, the maximum dose, or critical dose being that above which, during the thermal treatment step, there is separation of the wafer,
[0015] a separation step of separating the wafer into two parts, across the reference plane, is provided after or during the thermal treatment step, this separation step comprising the application of mechanical forces between the two parts of the wafer.
[0016] These mechanical forces can be tensile forces, shear forces or bending forces applied alone or in combination.
[0017] In the application, by microcavities, one understands cavities that can be of any form; for example, the cavities can be of a flat shape, that is to say of small height (a few interatomic distances) or of substantially spherical shape or any other different shape. These cavities can contain a free gaseous phase and/or atoms of gas arising from the implanted ions fixed to atoms of the material forming the walls of the cavities. In Anglo-Saxon terminology, these cavities are generally called “platelets”, “microblisters” or even “bubbles”.
[0018] The thermal treatment carried out with the purpose of achieving separation of the thin layer from the rest of the wafer, allows the microcavities to be brought to a stable state. Indeed, under the effect of temperature, the microcavities coalesce to reach a final definitive condition. Hence, the temperature is chosen in such a way that this condition is obtained.
[0019] According to French Patent Application No. FR-A-2 681 472, the doses implanted are such that, under the effect of the thermal treatment, a layer of microcavities is obtained that allows the separation to be achieved directly.
[0020] According to this invention, the doses implanted are insufficient to achieve a separation during the thermal treatment, the doses implanted only allow an embrittlement of the wafer at the reference plane, the separation requires an extra step of applying mechanical forces. Furthermore, the critical dose, as defined in the invention, is less than the dose at which during the ion implantation and thermal treatment steps, there is blister formation on the flat face of the wafer. The problem of blisters does not therefore arise in the invention.
[0021] The method according to the invention can include, between the thermal treatment step and the separation step, a step consisting of producing all or part of at least one electronic component in the part of the wafer before forming the thin layer.
[0022] If the production of this electronic component requires phases of heat treatment, these are preferably carried out at a temperature below that of the thermal treatment.
[0023] If needed, just before the separation step, an extra step is provided, consisting of bringing said wafer, on the side of said flat face, into close contact with and rigidly fixing it to a support through which mechanical forces such as tensile and/or shearing forces will be applied.
[0024] This support can be a flexible support, for example a sheet of Kapton®. It can also be a rigid support such as a wafer of oxidised silicon.
BRIEF DESCRIPTION OF THE DRAWING
[0025] The invention will be better understood and other advantages and features will become apparent on reading the description that follows, giving by way of a non-limitative example, in which:
[0026] FIG. 1 represents diagrammatically a wafer of semiconductor material, one face of which is being subjected to ion bombardment in application of the method according to this invention,
[0027] FIG. 2 represents diagrammatically the preceding wafer, at the end of the thermal treatment step intended to cause the microcavities to coalesce, according to this invention,
[0028] FIG. 3 represents diagrammatically the preceding wafer, after formation of electronic components in the part corresponding to the desired thin layer,
[0029] FIG. 4 represents diagrammatically the step of separating the preceding wafer into two parts, in accordance with this invention.
DETAILED DESCRIPTION
[0030] An important feature of this invention lies in the implantation of hydrogen or rare gas ions at a dose less than or equal to the dose above which there would be separation during the thermal treatment. The dose used is such that it permits embrittlement of the material at a depth R.sub.p corresponding to the mean distance travelled by the ions in the material, but the wafer remains sufficiently mechanically resistant to support all the thermal treatment steps necessary to produce the electronic circuits. In other terms, the implanted wafer has, in the area of the microcavities, solid bridges linking the part of the wafer designed to form the thin layer and the remaining part of the wafer.
[0031] The description is now going to be directed to the production of a thin layer of semiconductor material from a thick substrate having a flat face. The starting substrate may or may not be covered on this flat face with one or several layers of materials, such as, for example, encapsulating materials such as a dielectric.
[0032] FIG. 1 illustrates the ion implantation step of a wafer 1 of semiconductor material. The flat face 2 of the wafer receives the ionic bombardment represented by arrows. In the case where the flat face 2 of the wafer is covered with one or several non-semiconductor materials, the energy of the ions is chosen to be sufficient for them to penetrate into the mass of semiconductor material.
[0033] If the case arises, the thickness of the implanted semiconductor material must be such that all or part of electronic components and/or microstructures can be produced in the thin layer. By way of example, the mean penetration of hydrogen ions is 2.mu.m at 200 keV in silicon.
[0034] The ion implantation of these types of ions into the semiconductor substrate creates, at a depth proximate to the depth corresponding to the mean distance R.sub.p travelled by the ions along a perpendicular to the flat face, an area 3 with a high concentration of atoms giving rise to microcavities. For example, the maximum concentration of hydrogen is 10 21 H + /cm 3 for an implantation dose of 2.10 16 H + /cm 2 at 100 keV. This ion implantation step must be carried out at a temperature such that the implanted gas ions do not diffuse any great distance as the implantation step goes along. This would interfere with or ruin the formation of microcavities. For example, in the case of an implantation of hydrogen ions in silicon, the implantation will be carried out at a temperature below 350° C.
[0035] The implantation dose (number of ions received per unit surface area during the implantation period) is chosen in such a way that the dose is less than or equal to a dose, called the critical dose, such that, above this critical dose, during the subsequent thermal treatment step, there is separation of the thin layer from the rest of the wafer. In the case of implantation of hydrogen ions, this critical dose is of the order of 4.10 16 H + /cm 2 for an energy of 160 keV.
[0036] The implantation dose is also chosen to be greater than a minimum dose from which during the subsequent thermal treatment step, the formation of microcavities and the interaction between them is sufficient, that is to say it permits the embrittlement of the implanted material in the area of the microcavities 3 . This means that solid bridges of semiconductor material still exist between the microcavities. In the case of an implantation of ions of hydrogen gas into a silicon substrate, this minimum dose is of the order of 1.10 16 /cm 2 at an energy of 100 keV.
[0037] The following step of the method according to the invention consists of a thermal treatment of the wafer at a temperature that is sufficient to allow coalescence of the microcavities along the reference plane. In the case of an implantation, at a temperature below 350° C., of ions of hydrogen gas into a silicon substrate and a dose of 3.10 16 H + /cm 2 at an energy of 100 keV, after a thermal treatment of thirty minutes at 550° C., it is observed by transmission electronic microscopy in section, cavities of height equal to a few fractions of nanometers and with an extension, along the reference plane of several nanometers or indeed several tens of nanometers. This thermal treatment permits, at the same time, the precipitation and then stabilisation of the atoms of implanted gas in the form of microcavities.
[0038] The microcavities 4 (see FIG. 2 ) occupy, along the reference plane, a surface area approximately equal to the surface area implanted. The cavities are not situated exactly in the same plane. They are in planes parallel to the reference plane, some nanometers or tens of nanometers from this reference plane. For this reason, the upper part of the substrate situated between the reference plane and the flat face 2 is not totally separated from the body of the substrate, the body of the substrate being defined as the rest of the substrate between the reference plane and the faces of the substrate other than the flat face. The remaining bonds are sufficiently strong to support the steps of manipulation and of annealing brought about by the technological steps taken in the creation of the integrated circuits. However, the bond between the upper part and the mass of the substrate is very much weakened since this bond is only made through bridges of semiconductor material situated between the cavities.
[0039] All or a part of electronic components, circuits and microstructures can then be created on the flat face 2 (at the surface or under the surface).
[0040] The ion implantation energy of the hydrogen or rare gas ions in the first step has been chosen in such a way that the depth of the area of microcavities is sufficient for it not to be disturbed by the creation of components, electronic circuits and/or microstructures during this step. Furthermore, the whole of the thermal annealing operations that the development of electronic circuits or microstructures requires, is chosen in such a way that possible diffusion of the implanted ions is minimised. For example, in the case of a wafer of monocrystalline silicon, the maximum temperature of the various phases of the method will be limited to 900° C.
[0041] FIG. 3 illustrates the case where several electronic components, reference number 5 , have been developed on the flat face 2 and in the part of the wafer intended to form the thin layer.
[0042] The separation step then follows. It consists of applying separating mechanical forces, for example, tensile forces between the parts of the wafer or substrate situated on each side of the reference plane in a manner that fractures the remaining solid bridges. This operation allows to obtain the thin layer of semiconductor material fitted with electronic components in the case described. FIG. 4 illustrates this separation step in the course of which the thin layer 6 is separated from the remaining mass 7 of the substrate by the action of forces acting in the opposite direction and represented by the arrows.
[0043] Experience shows that the tensile stress necessary to separate the upper part of the body of the substrate is low particularly when a shearing stress is applied between the upper part and the body of the substrate, that is to say when the stresses applied have a component applied along the reference plane. This is simply explained by the fact that the shear stress promotes the propagation of fractures and cavities within the reference plane.
[0044] The upper part of the substrate, being by nature thin, the tensile stress and/or the shear stress cannot in most cases be comfortably applied directly to it. It is then preferable, before the separation step, to make the wafer, via its flat face 2 , integral with a support or applicator through which the mechanical forces will be applied to the upper part of the wafer. This applicator is represented in FIG. 4 under reference number 8 .
[0045] The applicator can be a rigid or a flexible support. By the term rigidly fixing the applicator onto the wafer, one understands here any sticking operation or operation of preparing the surfaces and bringing them into contact that allows sufficient bonding energy to be provided between the applicator and the flat face of the wafer to resist the tensile and/or shear and/or bending process(es) of the separation step.
[0046] The applicator can be, for example, a sheet of plastic material such as Kapton® which has been made adherent to the flat face of the substrate. In this example, after application of the method according to the invention, a thin layer of monocrystalline semiconductor on a sheet of Kapton® is obtained.
[0047] So as to properly transmit the stresses to the whole of the upper thin layer, the circuits created in and at the surface of the upper layer can have been covered with a protective layer, possibly making it flat, during the step of developing the electronic components. The applicator is then rigidly fixed to the upper thin layer of the wafer through this protective layer.
[0048] The applicator may also be a rigid support, for example a silicon wafer, the surface of which has been covered with a dielectric layer. An appropriate physico-chemical treatment is, for example, carried out on the flat face of the wafer and/or the surface of the applicator (carrying a dielectric layer or not) so that bringing them into contact, possibly associated with a heat treatment, rigidly fixes the flat face of the wafer and the applicator together.
[0049] In the case mentioned as an example where the applicator is a silicon wafer carrying a layer of oxide on its surface and where the semiconductor substrate is a wafer of monocrystalline silicon, after application of the method according to the invention, a wafer of silicon on insulator is obtained where the surface layer of silicon is the fine layer provided by the upper part of the substrate.
[0050] Furthermore, after separation of the thin layer from the rest of the wafer, the free face of this layer can allow the further repeat use of a substrate that can be fitted with electronic components produced completely or partially on the substrate. Such a stacking allows a “three dimensional” assembly of electronic circuits, the stiffener itself possibly including electronic components.
|
A semiconductor structure includes a thin semiconductor layer fixed on an applicator or flexible support, the thin layer having an exposed surface characterized by fractured solid bridges spaced apart by cavities. A method of producing the thin layer of semiconductor material includes implanting ions into the semiconductor wafer to define a reference plane, where the ion dose is above a minimum dose, but below a critical dose so as to avoid degrading the wafer surface. The method further includes applying a thermal treatment to define a layer of microcavities and applying stress to free the thin layer from the wafer.
| 8
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the method and structure for installing sheet metal roofing shingle arrays, and more particularly to the method and structure of mounting stamped sheet metal roof covering pieces conformed to interlock into exterior shapes reproducing the shape of oriental roofing tile and fastened onto reinforcing ribs.
[0003] 2. Description of the Prior Art
[0004] Over long historic periods a roofing system has been practiced in China in which fired clay or ceramic valley pans are bridged at their adjacent edges by semicircular caps, resulting in a very distinct appearance. This roofing process, with some minor variations, has been adopted in the neighboring areas and is therefore now known by the familiar expression ‘Oriental Roof’. With some frequency this oriental roof styling covers distinctly appearing building structures and it is therefore associated with distinct architectural motifs. The pleasing, well appreciated oriental styling motif obtains its visual underpinnings from the ribbed skeletal structure originally used to support the tile and the convolved shape is particularly useful in creating visual interest and distinctiveness in commonly designed building tracts. When implemented in traditional fired clay or ceramic tile, however, structures that have been appropriately ribbed and reinforced would be needed to accommodate this roofing weight and the ribbed roof exterior therefore suggests some structural efficacy. Recently, however, the construction techniques of frame housing prefer light weight over structural bulk and the interesting ornamental variety of this venerable roofing method has not had appropriate adaptation to our mode of life.
[0005] One constant process of life is the wear and damage that is universally sustained with time, including the wear and deterioration of the roofing shingles covering our buildings. As result a variety of roof coverings have been devised in the past that can be applied directly onto the most common roof covering, i.e., asphalt shingle, and these replacement roof coverings are now widely used. These, however, do little to improve the structure supporting the roof which very often also suffers some deterioration as the original roof covering fails. Amongst these are various forms of sheet metal shingle, also frequently applied directly on top of the existing asphalt tile, the substantially more rigid and durable aspects of a metal stamping being used to advantage to bridge and cover the deteriorating structure of the asphalt tile and also of its underlayment. Examples of stamped sheet metal roofing tile can be found in the teachings of U.S. Pat. Nos. 5,613,337 to Plath et al, 4,185,436 and 4,218,857 to Vallee, 6,298,625 to Sweet, 5,442,888 to Ilnyckyj and others. While suitable for the purposes intended, each of the foregoing examples describes a generally flat shingle structure which obtains structural stiffness only within the individual stamping itself and therefore lends little support over greater spans. For those instances where longer bridging spans are required, as in roof structures that show some deflection in the joists and beams themselves, little is available in the marketplace.
[0006] A convenient roof covering technique that includes structural reinforcement is extensively desired and it is one such technique that is described herein utilizing to advantage oriental roofing to accomodate reinforcement of structural beams.
SUMMARY OF THE INVENTION
[0007] Accordingly, it is the general purpose and object of the present invention to provide an assembly of sheet metal roof covering pieces which are useful with stiffening ribs applied in a novel process of recovering a roof.
[0008] Other objects of the invention are to provide a roof recovering method and structure in which the new roofing tile is installed in conjunction with stiffening ribs.
[0009] Yet additional objects of the invention are to provide a novel process for recovering roofs in which the roof covering includes reinforcing ribs.
[0010] Further objects of the invention are to utilize the ornamental aspects of an oriental roof covering to provide stiffening structure in the course of roof repair.
[0011] Briefly, these and other objects are accomplished within the present invention by providing a stamped sheet metal array of roof covering pieces which are affixed to a roof along with a set of generally parallel wood ribs, selected ones of which being aligned over the roof joists and rafters supporting the roof to provide stiffening thereto. The valleys between these ribs are then covered by stamped pans included in the inventive roofing array and the adjacent edges of the pans are bridged by semicircular caps arched over the subjacent ribs, thus replicating the exterior shape of an oriental roof Additional pieces of the array are then useful as end plugs closing the open cap ends, shaped blocks to cover the voids defined by each pan and other stampings for any necessary ridge covering and ridge connections. This assortment of pieces may be formed from relatively thin sheet metal such as galvanized sheet, aluminium or copper sheeting and may be coated, painted or otherwise colored to reproduce the color scheme of oriental roofing tile.
[0012] Preferably this combination of sheet metal pieces and the stiffening ribs is laid on top of a surface of roofing felt that is first positioned to cover the old roofing. Thus the ribs provide the further advantage of enhanced attachment of the roofing layers, reducing the incidents of peeling and tearing caused by weather and wind. In addition, the inventive recovering process entails bending of interlocking folds in the course of fastening thereof to the stiffening ribs, this bending process further improving structural integrity.
[0013] It will be appreciated that the ultimate shape of each cap and valley tile will be determined by the curling and bending thereof in the course of installation. The inventive process, therefore, is particularly suitable for existing structures that have distorted or settled with time effected by reproductions of old roof coverings which themselves varied in the course of their fabrication. Accordingly, the instant process is particularly suitable for the do-it-yourself practitioner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a perspective illustration, separated by parts, of the inventive roofing combination aligned to recover a previously covered roof;
[0015] [0015]FIG. 2 is a further perspective illustration of the inventive roofing combination in its installed form;
[0016] [0016]FIG. 3 is a sectional view of the inventive roofing combination taken along line 3 - 3 of FIG. 2;
[0017] [0017]FIG. 4 is yet another sectional view of the inventive roofing combination taken along line 4 - 4 of FIG. 2;
[0018] [0018]FIG. 5 is a detail illustration, in perspective and in partial section, of the end structure useful with the inventive roofing combination;
[0019] [0019]FIG. 6 is a further detail illustration, in perspective, of the ridge piece structure useful with the inventive roofing combination;
[0020] [0020]FIG. 7 is a sectional view taken along line 7 - 7 of FIG. 6 of the ridge piece useful with the inventive roofing combination;
[0021] [0021]FIG. 8 is yet a further detail illustration, in perspective, of a ridge fairing useful with the inventive roofing combination; and
[0022] [0022]FIG. 9 is a sequence diagram of the steps comprising the inventive roofing process described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] As shown in FIGS. 1 - 8 the inventive sheet metal roofing array, collectively designated by the numeral 20 , includes a plurality of formed sheet metal valley pans 21 , a further plurality of sheet metal cover caps 31 and also a plurality of stamped ridge caps 41 . Included further in the array are stamped, circular cover cap lids 51 together with semicircular versions thereof 51 a and also semicircular ridge cap lids 61 for finishing off respectively the exposed ends of cover caps 31 and ridge caps 41 . Provided further is an assortment of fairings, flashings and stops including ridge flashing 72 , bird stops 73 and 74 and apex covers 75 a and b and 76 a and b . This complement of parts and components is useful with a vertically aligned set of stiffening ribs 111 in the form of conventional 2″ by 4″ nominal construction lumber that may be laid on top of a layer of roofing felt 112 rolled onto the existing roof covering ERC that, because of its wear, is to be recovered. To obtain the maximum structural benefit selected ones of the stiffening ribs 111 are aligned directly over the subjacent existing roof beams or rafters RJ and fastened thereto by way of long fasteners 113 extending all the way through the stiffener, the felt layer, the exising roof covering and then into the beam. Depending on the spacing of the roofing framework one or more additional ribs 111 of similar construction lumber may be fastened to the roof between those fastened to the framework and each of the valley pans 21 are therefore dimensioned to accomodate an integer division of typical framework spacing.
[0024] Those in the art will appreciate that under current practice the roof beam spacing is typically 16 inch or 24 inch center to center. Each of the valley pans 21 , therefore, is sized in width to about a 7 inch planform, allowing for an overlay of its lateral edges 22 and 23 onto the corresponding vertical surfaces 111 a and b of the adjacent ribs 111 , to be fastened thereto by nails or other fasteners 115 . Longitudinally each valley pan 21 is dimensioned to a net dimension once again in integer units (e.g., two feet) defined two transverse edges 24 and 25 each including a corresponding fold 26 and 27 over the opposite pan surfaces for effecting a stepped interlock between the pans as they are fitted in a column up the valley covering the space between adjacent ribs. In each instance the lower edge of the upper pan that is interlocked with the one below it is forced down against the felt layer 112 and as so held the bent upwardly lateral edges 22 and 23 adjacent the interlock are nailed to the side surfaces 111 a and b of the ribs 111 , the overlying alignmend resulting from the dimensional excess in the pan width. The fastened edges 22 and 23 on either side of each rib 111 are then covered and bridged by the arched caps 31 , each cap again being defined by lateral edges 32 and 33 extending between transverse edges 34 and 35 formed by opposed folds 36 and 37 that are, once more, interlocked for a stepwise progression over each rib in a manner similar to the pans.
[0025] It will be appreciated that the foregoing installation process distorts in bending the folded transverse edges that are interlocked with the next valley pan or cap in each instance. Thus the installation sequence assists structural integrity by further crimping the interlock, thereby assuring better resistance to wind damage. Moreover, as each cap and valey pan is fastened to the ribs small adjustments can be effected in the curvature or edge bending to accomodate any settling and other distortion that is usually found in all existing structures. The inventive process, therefore, enhances both the resulting strength of sheet metal roof covering and the stiffness of the whole roof structure while also providing an interesting architectural variant of the finished roof covering.
[0026] To further enhance both the structural integrity and the visual appearance the lower ends of each of the ribs 111 may be covered by the circular lids 51 fitted subjacent the transverse edges of caps 31 , each lid including a cylindrical skirt 52 formed in the course of its stamping. The sheet metal structure of the skirt is then trimmed and shaped to conform with any roof edge treatment ET and once so shaped may be affixed directly to the rib end by one or more nails 115 . At the top end ridge boards 121 may be affixed on top of the felt 112 on both sides of each roof ridge RR to which the flashing 72 may be affixed and which thereafter may be covered an bridged by ridge caps 41 , again defined by longitudinal edges 42 and 43 extending between transverse edges 44 and 45 formed by opposite side folds 46 and 47 for interlocked engagement. As with caps 31 this interlocked row of ridge caps is curled to a tighter bend in the course of fastening to the ridge boards 121 by nails 115 , thereby crimping the interlocked folds 76 and 77 for better structural engagement. The ends of these ridge cap rows may then be finished off by one of the several apex covers 75 a , 75 b , 76 a or 76 b depending on the roof configuration Bird stops 73 and 74 , each in the form of an L-sectioned sheet metal strip provided with semicircular cut-outs 73 a or 74 a in one leg thereof, can then be applied to cover any voids and overhangs formed by the ridge caps, the bird stops being formed to include cutouts 73 a or 74 a at various densities to accomodate various ridge alignments. Any open end voids in the cover caps 31 or ridge caps 41 can then be filled by the semicircular caps 51 a or 61 .
[0027] It will be appreciated that this inventive process and structure for effecting a sheet metal roof cover is particularly suited for those homeowners that would like to do it themselves. The process permits one to retain the integrity of the old roof covering, thereby permitting a piece-wise construction that creates little disruption in the use of the home being covered. Moreover, the process lends itself to all sorts decorative options and color schemes allowing the home owner the desired freedom of personal taste expression.
[0028] In each instance the inventive process 200 commences with the original roof covering that may be left in place, or may be removed in those sections that require repair, followed by a covering of a layer of roofing felt in step 201 . The ridges RR are then trimmed with the ridge boards 121 in step 202 and thereafter the vertical stiffeners 111 are fastened to the roof in step 203 with those aligned over the original rafters fastened thereto. This skeletal structure both reinforces the original roof and also provides the attachments and alignment for the installation of the interlocked valley pan 21 in columns between the adjacent stiffeners, in step 204 , which are then bridged by the cover caps 31 in step 205 . In both the steps 204 and 205 substantial manual flexure of the individual pieces while such are fastened both assures a positive structural interlock and also accomodates structural distortions. Once this is done the remaining openiongs and gaps are then trimmed out in step 207 . In this manner a conveniently effected covering technique is devised which replicates the distinct architectural motifs of oriental roofing.
[0029] Obviously many modifications and variations can be effected without departing from the spirit of the invention instantly disclosed. It is therefore intended that the scope of the invention be determined solely by the claims appended hereto.
|
An assemblage of sheet metal roof covering pieces is utilized in a novel process to recover and stiffen a deteriorated roof without the necessity for extensive removal of the original roof covering, the deteriorated roof structure further stiffened by spaced stiffening ribs that also serve to fix in interlocked engagement the sheet metal roof covering pieces. Included in the assemblage are interlocking valey pans that are sequentially compressed between the ribs and then fastened with the valley pans then bridged by curved sheet metal caps that are also interlocked. The resulting structure has the pleasing appearance of an Oriental tile roof.
| 4
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/524376, filed Aug. 17, 2011, the disclosure of which is hereby incorporated in its entirety by reference herein.
BACKGROUND OF THE INVENTION
[0002] The technology described herein relates generally restoration of grooves used in conjunction with seal wire, particularly to methods of restoring the profile of such grooves, and more particularly, to thermal spray techniques for such restorations.
[0003] Many gas turbine engine assemblies include a seal between adjacent surfaces of moving and non-moving parts, such as a rotating disk and a stationary structure, or between parts which have clearances between their mating surfaces. One common construction for such seals utilizes a seal wire formed of one or more segments which is inserted into a groove in one part and biased against the opposing part in sealing engagement.
[0004] During operation, the constant contact between the seal wire and the mating surface results in wear of the seal wire and/or movement of the seal wire within its groove. Since the seal wires are typically fashioned from one or more segments, with abutting ends located at one or more locations around their circumference. movement of the seal wire within the groove may result in fretting and/or other wear of the groove resulting from the motion of the seal wire ends. Over time this fretting or wear of the groove enlarges the groove and reduces the effectiveness of the seal wire arrangement,
[0005] During repair and overhaul operations it is desirable to restore the seal wire and groove assembly to original or other suitable dimensions and tolerances. However, due to limitations of current repair methods it is frequently necessary to scrap and replace the rotor assembly with a new one having the proper groove dimensions. There remains a need for a repair method which will restore the groove geometry in a durable and economical fashion.
BRIEF SUMMARY OF THE INVENTION
[0006] In one aspect, a method of repairing a seal wire groove, the groove forming an annular structure having an outer surface and an inner surface and defining an original profile when new, comprising the steps of: removing a less-than-annular portion of the original profile of the groove to remove damaged portions of at least one of the inner and outer surfaces thereby forming a void; adding new material to the void; and shaping the new material to form a new profile of the groove.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a cross-sectional illustration of an exemplary gas turbine engine assembly; and
[0008] FIG. 2 is a cross-sectional elevational illustration of an exemplary compressor spool depicting a representative location for remaining illustrations;
[0009] FIG. 3 is an enlarged partial elevational sectional illustration of a compressor blade mounted on a compressor spool;
[0010] FIG. 4 is a more enlarged partial elevational sectional illustration depicting and defining relevant dimensions;
[0011] FIG. 5 is a cross-sectional illustration of a complete revolution of the compressor spool including seal wire sections installed;
[0012] FIG. 6 is a view similar to FIG. 4 depicting fretting wear due to motion of the seal wire in service;
[0013] FIG. 7 is a view similar to FIG. 6 depicting a portion of the compressor spool after material removal of the damaged portion;
[0014] FIG. 8 is a perspective view of the portion of the compressor spool of FIG. 7 taken through an intermediate station of the material removal to illustrate the end of the removal;
[0015] FIG. 9 is a view similar to FIG. 7 after new repair material has been added; and
[0016] FIG. 10 is a view similar to FIG. 9 after the new repair material of FIG. 9 has been machined to the correct profile.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 is a cross-sectional schematic illustration of an exemplary gas turbine engine assembly 10 having a longitudinal axis 11 . Gas turbine engine assembly 10 includes a fan assembly 12 and a core gas turbine engine 13 . Core gas turbine engine 13 includes a high pressure compressor 14 , a combustor 16 , and a high pressure turbine 18 . In the exemplary embodiment, gas turbine engine assembly 10 also includes a low pressure turbine 20 , and a multi-stage booster compressor 32 , and a splitter 34 that substantially circumscribes booster 32 .
[0018] Fan assembly 12 includes an array of fan blades 24 extending radially outward from a rotor disk 26 , the forward portion of which is enclosed by a streamlined spinner 25 . Gas turbine engine assembly 10 has an intake side 28 and an exhaust side 30 . Fan assembly 12 , booster 22 , and turbine 20 are coupled together by a first rotor shaft 11 , and compressor 14 and turbine 18 are coupled together by a second rotor shaft 22 .
[0019] In operation, air flows through fan assembly 12 and a first portion 50 of the airflow is channeled through booster 32 . The compressed air that is discharged from booster 32 is channeled through compressor 14 wherein the airflow is further compressed and delivered to combustor 16 . Hot products of combustion (not shown in FIG. 1 ) from combustor 16 are utilized to drive turbines 18 and 20 , and turbine 20 is utilized to drive fan assembly 12 and booster 32 by way of shaft 21 . Gas turbine engine assembly 10 is operable at a range of operating conditions between design operating conditions and off-design operating conditions.
[0020] A second portion 52 of the airflow discharged from fan assembly 12 is channeled through a bypass duct 40 to bypass a portion of the airflow from fan assembly 12 around core gas turbine engine 13 . More specifically, bypass duct 40 extends between a fan casing or shroud 36 and splitter 34 . Accordingly, a first portion 50 of the airflow from fan assembly 12 is channeled through booster 32 and then into compressor 14 as described above, and a second portion 52 of the airflow from fan assembly 12 is channeled through bypass duct 40 to provide thrust for an aircraft, for example. Splitter 34 divides the incoming airflow into first and second portions 50 and 52 , respectively. Gas turbine engine assembly 10 also includes a fan frame assembly 60 to provide structural support for fan assembly 12 and is also utilized to couple fan assembly 12 to core gas turbine engine 13 .
[0021] Fan frame assembly 60 includes a plurality of outlet guide vanes 70 that extend substantially radially between a radially outer mounting flange and a radially inner mounting flange and are circumferentially-spaced within bypass duct 40 . Fan frame assembly 60 may also include a plurality of struts that are coupled between a radially outer mounting flange and a radially inner mounting flange. In one embodiment, fan frame assembly 60 is fabricated in arcuate segments in which flanges are coupled to outlet guide vanes 70 and struts. In one embodiment, outlet guide vanes and struts are coupled coaxially within bypass duct 40 . Optionally, outlet guide vanes 70 may be coupled downstream from struts within bypass duct 40 .
[0022] Fan frame assembly 60 is one of various frame and support assemblies of gas turbine engine assembly 10 that are used to facilitate maintaining an orientation of various components within gas turbine engine assembly 10 . More specifically, such frame and support assemblies interconnect stationary components and provide rotor bearing supports. Fan frame assembly 60 is coupled downstream from fan assembly 12 within bypass duct 40 such that outlet guide vanes 70 and struts are circumferentially-spaced around the outlet of fan assembly 12 and extend across the airflow path discharged from fan assembly 12 .
[0023] FIG. 2 is a cross-sectional elevational illustration of an exemplary compressor spool 90 forming a part of the compressor 14 of FIG. 1 , depicting a representative location identified with the circle and numeral 3 for the more detailed illustrations which follow.
[0024] FIG. 3 is an enlarged partial elevational sectional illustration of a compressor blade 91 mounted on a compressor spool 90 . As shown in FIG. 3 , the compressor blade 91 includes several elements such as an airfoil 92 , a dovetail 93 , and a platform 95 between the airfoil 92 and the dovetail 93 . The dovetail 93 is sized and shaped to fit in dovetail slot 97 of compressor spool 90 to secure the blade 91 to the spool 90 . The spool 90 and dovetail slot 97 are annular structures and a plurality of blades 91 are secured to the spool 90 around their circumference, though only a single blade 91 is illustrated for clarity. Also shown in FIG. 3 is a seal wire groove 94 for containing a seal wire 96 to form a seal between the platform 95 and the spool 90 to enhance efficiency of the compressor 14 in operation and thereby improve fuel consumption of the gas turbine engine assembly 10 .
[0025] FIG. 4 is a more enlarged partial elevational sectional illustration of the elements of FIG. 3 . As shown in FIG. 4 , the seal wire groove 94 is spaced inwardly from the edge of the disk portion 98 of the compressor spool 90 by a dimension A which forms a shoulder 99 and a dimension B which forms a horizontal surface on the outer side of the groove 94 . These shapes and dimensions are sized, shaped, and configured for the specific gas turbine engine assembly 10 for which they are intended, so the illustrations herein are intended to be illustrative and not limiting in terms of geometry. The platform 94 typically has a complementary shape to the radially-outer surfaces of the disk portion 98 . As shown in FIG. 4 , the seal wire 96 is located in the seal wire groove 94 and typically biased radially outwardly against the underside of the platform 94 . The disk portion 98 may be formed from a metallic material, in which case the inner and outer surfaces of the groove 94 are formed of a metallic material. The seal wire 96 may also be formed of a metallic material and may be generally rectangular in cross section.
[0026] FIG. 5 is a cross-sectional illustration of a complete revolution of the compressor spool 90 including sections of seal wire 96 installed in groove 94 . The seal wire 96 will typically comprise multiple (more than one) pieces of material and thus have at least two ends 100 , In the exemplary embodiment shown in FIG. 5 , the seal wire 96 is formed in three (3) sections having six (6) ends labeled 100 . Each of the ends 100 is a potential source for wear of the seal wire groove 94 .
[0027] In service, the vibrations, pressures, and thermal effects experienced by the seal wire 96 often result in “fretting” wear to the surfaces of the groove 94 in the vicinity of the ends 100 due to their movement in various directions. This wear results in removal of material from the surfaces of the groove 94 such as depicted in wear zones 101 in FIG. 5 , such that the grove 94 is enlarged in cross section and deviates from the original profile of the groove 94 When in a new condition. Wear may occur to the outer surface (proximal to the shoulder 99 ), to the opposing inner surface, or both. This results in a reduced sealing capability of the seal wire 96 and may also accelerate wear as the ends 100 of the seal wire have more freedom of movement as the degree of wear increases.
[0028] FIG. 6 is a view similar to FIG. 4 depicting fretting wear 101 due to motion of the ends 100 of the seal wire 96 in service. In contrast to the condition of the surfaces and elements depicted in FIG. 4 , as shown in FIG. 6 portions of the groove 94 are worn away and enlarged such that the surfaces of the groove 94 are no longer consistent with the original profile of the groove 94 when it was in a like-new, as-manufactured condition. Surfaces of the seal wire 96 in this illustration are also shown as irregular and worn. Typically the condition of the seal wire 96 is of less concern than the condition of the groove 94 as the seal wire 96 is typically replaced with a new seal wire during repair while for economic reasons it is desirable to repair and restore the profile of the groove 94 and retain the disk portion 98 of the spool 90 for continued service.
[0029] FIG. 7 is a view similar to FIG. 6 depicting a portion of the compressor spool 90 after material removal of the damaged portion in the wear zone 101 . Material removal of the worn, irregular, soiled, or otherwise deteriorated portion of the surfaces groove 94 is the first step in the method of repairing the groove 94 . This removal results in a void having a new profile 102 which differs from the original profile 103 (shown in dotted line in FIG. 7 ), and has surfaces which are relatively solid, smooth, and of uniform character. In the exemplary embodiment shown, the repair method is being accomplished on the outer surface (proximal to shoulder 99 ) of the groove 94 , although it could be equally applied to the opposing inner surface, or to both surfaces. Material removal to generate the new profile 102 may be accomplished by mechanical means, such as machining by rotary tools such as a saw blade or abrasive disk, or other means such as chemical or electrical machining processes, and may be done in one pass or in multiple steps or stages. A tool with an appropriate profile may be used, or a tool with a generic profile which is controlled in such a manner as to generate the proper profile may be used.
[0030] FIG. 8 is a perspective view of the portion of the disk portion 98 of the compressor spool 90 of FIG. 7 taken through an intermediate station of the material removal section (new profile 102 ) to illustrate the end 104 of the removal. Because the material removal occurs over a less-than-annular portion or segment of the annular disk 98 , it by definition forms a void having at least two ends 104 for each material removal and defines a localized repair area. It is believed that these ends 104 , being defined by remaining portions of original material of the disk 98 , provide stability and support for the new material to be added to restore the original profile 103 of the groove 94 . The lead in angle and radius characteristics of the ends 104 , such as an exit radius, may be determined with both the tooling and techniques used for the material removal, as well as the adhesion and minimum thickness requirements for the new material to be added. Repairs made with new material which is too thin in cross section or comparatively lower adhesion characteristics may tend to spall during engine operation.
[0031] FIG. 9 is a view similar to FIG. 7 after new repair material 104 has been added to build back material equal to or greater than the original profile 103 of the groove 94 . Said differently, new material is added in excess of the volume of the void. The addition of new material can be accomplished by any suitable method or apparatus depending upon the quantity and type of material to be added and upon the size, shape, and material from which the disk 98 is constructed.
[0032] Metal Thermal Spray is one category of suitable material addition processes. In an exemplary embodiment, the material addition may be Inco 718 material being sprayed using the Hyper-Velocity Oxy-Fuel (HVOF) process, Various metals can be applied using this method, not just Inco 718 . Other metal spray processes such as Plasma spray may also be utilized. Representative processes involve spraying molten metal through a nozzle at the target area of the part being repaired and building up the material in the seal wire groove 94 to achieve a condition such as shown in FIG. 9 . The HVOF process has been found to exhibit a lesser amount of voiding and is easier to machine to the desired finished profile than some other potential processes. It has also been found to do a minimal amount of parent material damage (i.e., to the disk material at or below the removal profile 102 ) because it maintains the repair area parent material temperatures below solution or melting. With certain other processes such as a typical weld process, it could heat the area to a point that could alter the metal grain structure or cause micro cracking.
[0033] FIG. 10 is a view similar to FIG. 9 of the disk 98 after the new repair material 104 of FIG. 9 has been shaped, such as by machining, to the proper finished profile 105 . The new finished profile 105 will typically be the same as or substantially similar to the original as-manufactured profile 103 shown in FIGS. 7 and 8 . However, under certain circumstances the new profile 105 could differ particularly if a replacement seal wire 96 having a different geometry were to be used. In such a scenario, the remaining portions of the circumference of the seal wire groove 94 may or may not be machined to match the new profile 105 .
[0034] Material removal or shaping of the newly-added repair material to generate the finished profile 105 may be accomplished by mechanical means, such as machining by rotary tools such as a saw blade or abrasive disk, or other means such as chemical or electrical machining processes, and may be done in one pass or in multiple steps or stages. A tool with an appropriate profile may be used, or a tool with a generic profile which is controlled in such a manner as to generate the proper profile may be used.
[0035] The steps described above may be repeated multiple times at different annular stations around the groove, and performed either simultaneously or sequentially.
[0036] While much of the discussion has focused on an aviation gas turbine engine as the context for this repair, it is foreseeable that such methods may be suitable for use in other environments wherein a wire-type seal is used with a complementary groove and rejuvenation is required, such as steam turbines or other turbomachinery.
[0037] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
|
A method of repairing a seal wire groove is disclosed, the groove forming an annular structure having an outer surface and an inner surface and defining an original profile when new, comprising the steps of: removing a less-than-annular portion of the original profile of the groove to remove damaged portions of at least one of the inner and outer surfaces thereby forming a void; adding new material to the void; and shaping the new material to form a new profile of the groove.
| 8
|
TECHNICAL FIELD
This invention relates to solenoid controlled pilot operated hydraulic valves.
BACKGROUND OF THE INVENTION
Conventional solenoid controlled hydraulic valves have solenoid coils mounted externally of the valve body. The solenoid is connected with the internal parts of a valve by two distinctive methods:
air gap solenoids have an armature working against a pushpin which is dynamically sealed against leakage of fluid from the valve body;
wet pin solenoids have a coil encircling non-magnetic tubing with a slidably disposed armature, the tubing being internally exposed to system pressure.
There are well recognized disadvantages in both structures. The dynamic seals of the air gap solenoids are not reliable, create substantial friction forces, and limit the valve operating pressure. The non-magnetic tubing of wet pin solenoids creates substantial resistance to magnetic flux and also limits the valve operating pressure. In both configurations the solenoid coils are located on the exterior of the valve body and dissipate heat to the surrounding environment. As a result, solenoid coils of conventional valves have a winding of excessive size and are costly when compared with other valve components.
Consider, in particular, the poppet type solenoid controlled hydraulic valves. The limitations of these type valves can be outlined as follows. Poppets slide within a valve body. Their position is controlled by either internal or external pilot pressure. Valves with internal pilot lines can operate only if the clearance between the slidable poppet and the adjacent valve member is extremely small. This relationship is required in order to control the differential pressure on opposite sides of the poppet. Such closeness of clearance requires very fine machining tolerances and surface finishes of the poppets and adjacent components. These requirements also limit the size of poppet valves having internal piloting since leakage across the poppet becomes uncontrollable with increasing by larger dimensions. One can conclude (with poppet valves having external piloting) that because of the leakage across the poppet body from the pressure line to the pilot line, that these valves cannot be used for applications where internal leakage is not allowed. Further, external pilot sections are actually additional valves with all their complexity and cost.
It is, therefore, an object of the present invention to provide a valve structure where the pilot controlling section is disposed within the valve body immediately adjacent to the main section of the valve and thus, providing a compact structure with a minimum for potential external leakage points and a faster response time.
Another object of the present invention is to provide a solenoid hydraulic valve structure where the solenoid coil is fully integrated with other valve components, by positioning the solenoid coil inside the valve body and exposing the coil to the pressurized fluid. This integration of the electromagnetic coil within the valve body, as disclosed in the present invention, permits construction of the magnetic circuit with practically no detrimental gaps. This construction utilizes the coil electromagnetic forces to their greatest potential.
Another object of the present invention is to provide a solenoid valve structure where the solenoid coil is positioned within the valve body in such a way that the coil contact with the surrounding atmosphere is eliminated making valves constructed in accordance with the present invention capable of operating in hazardous environments.
Another object of the present invention is to provide a solenoid controlled pilot operated valve structure which consists of a main section and a number of pilot sections located closely adjacent the main section in a common valve body constructed in such manner that the main valve section may accomplish different functions according to the pilot section which is actuated. For example the function may be: normally-open or normally-closed directional control, pressure relief, flow check, etc.
Another object of the present invention is to provide a solenoid controlled, pilot operated, poppet type valve structure where the main valve member is slidably sealed by a novel adjustable seal-bearing comprising a deformable plastic sleeve circumferentially mounted over a tapered portion of the main valve member abutting an adjusting nut. Under pressure from the adjusting nut the plastic sleeve moves along the tapered portion expanding to such degree that it fills the clearance between the main valve member and the mating body component of the valve. This creates a minimum friction seal and plain bearing, simultaneously, with leakage reduced to nothing. This greatly reduces requirements for machined finishes and tolerances of principal valve components.
Another object of the present invention is to provide a solenoid controlled valve structure where the solenoid coil is positioned within the valve body chamber and integrated with other valve components in a manner which allows the coil to be cooled by circulating hydraulic system fluid about the coil. Direct contact of coil with system circulating fluid radically improves heat dissipation efficiency.
Other objects and advantages of the present invention will become apparent from the following detailed description.
SUMMARY OF THE INVENTION
The present invention is an improved hydraulic solenoid controlled pilot operated valve structure eliminating the disadvantage of prior art structures, as discussed above, in a novel manner. The present invention includes both normally-open and normally-closed configurations of such solenoid controlled hydraulic valves.
In the disclosed embodiments the valves are configured with a valve body having inlet and outlet connections, a valve chamber and pilot lines. All of the valve parts are disposed within the valve body and generally grouped in two sections, main and pilot sections. The main and pilot sections are sealably separated by a disk shaped member with an axially positioned pilot flow orifice. This orifice is controlled by the movement of the solenoid armature as a result of the excitation of an electromagnetic coil.
The first embodiment of the present invention comprises a solenoid controlled hydraulic valve of normally-closed configuration includes in combination a valve housing, main and pilot sections, inlet and outlet connections, and pilot flow passages. The main section includes a sleeve, a main valve member, an adjustable seal and bearing, and a main valve chamber formed within said sleeve in which said main valve member reciprocates. The sleeve, interposed between said inlet and outlet connections, forms the main passage therebetween and provides a seat closure for the main valve member. The adjustable seal-bearing means surrounds a distally disposed inwardly tapering portion of said main valve member and simultaneously engages the exterior surface of the main valve member and the interior surface of the sleeve creating a leak resistant separation between the main flow passage and the main valve chamber.
A metering orifice provides a connection between the main flow passage and the main valve chamber through the sidewall of the main valve member. This provides a flow path permitting differential pressures to be created between the main flow passage and the main valve chamber to operate the main valve member when a pilot flow is applied. A first spring means is disposed within an annulus in the main valve member and opposed against said disk member for assisting in the operation of the main valve member.
The pilot section includes a solenoid coil and housing, an armature responsive to magnetic forces, a pilot valve member, and a pilot valve chamber formed within a cylindrical extension of the disk member and extending within the solenoid coil in which said pilot valve member and said armature reciprocate. The disk member has an aperture therethrough to provide a pilot flow orifice which may be opened and closed by said pilot valve member in accordance with the energizing and de-energizing of the solenoid coil. A second spring means disposed within an annulus in said armature and opposed against said solenoid housing urges said armature and pilot valve member to attain a position closing the pilot flow orifice. The solenoid coil is disposed within the solenoid housing, which is integrated within the valve housing, and has its curvilinear external surfaces simultaneously exposed to equal fluid pressure of the pilot flow.
Upon energizing the solenoid coil, the armature and pilot valve member are pulled toward a magnetic pole in the solenoid housing, opening the pilot flow orifice, causing a pilot flow to begin which causes a decrease in pressure in the main valve chamber and, in turn, the unseating of the main valve member in response to the decrease in pressure in the main valve chamber. Upon de-energizing the solenoid coil, the armature and pilot valve member are again urged by said second spring means toward the pilot flow orifice, closing the pilot flow orifice, causing the pilot flow to cease which causes an increase in pressure in the main valve chamber and, in turn, the seating of the main valve member in response to the increase of pressure in the main valve chamber.
A second embodiment of the present invention comprises a solenoid controlled hydraulic valve of normally-open configuration includes in combination a valve housing, main and pilot sections, inlet and outlet connections, and pilot flow passages. The main section includes a sleeve, a main valve member, an adjustable seal-bearing means, and a main valve chamber formed within said sleeve in which said main valve member reciprocates. The sleeve, which is interposed between said inlet and outlet connections, forms the main passage therebetween and provides a seat closure for the main valve member. The adjustable seal-bearing means surrounds a distally disposed inwardly tapering portion of said main valve member and simultaneously engages the exterior surface of the main valve member and the interior surface of the sleeve creating a link resistant separation between the main flow passage and the main valve chamber.
A metering orifice provides a connection between the main flow passage and the main valve chamber through the sidewall of the main valve member. This, again, provides a flow path permitting differential pressures to be created between the main flow passage and the main valve chamber to operate the main valve member when a pilot flow is applied. A first spring means is disposed within an annulus in the main valve member and opposed against said disk member for assisting in the operation of the main valve member.
The pilot section includes a solenoid coil and housing, an armature responsive to magnetic forces, a pilot valve member, a first pilot valve chamber formed within a cylindrical extension of the disk member in which said pilot valve member reciprocates, and a second pilot valve chamber formed within the solenoid housing and extending within the solenoid coil in which said armature reciprocates. The disk member has an aperture therethrough to provide a pilot flow orifice which may be opened and closed by said pilot valve member in accordance with the energizing and de-energizing of the solenoid coil. A second spring means is disposed about said pilot valve member and opposed against said disk member for urging said pilot valve member and said armature to attain a position opening the pilot flow orifice. The solenoid coil is disposed within the solenoid housing, which is integrated within the valve housing, and has its curvilinear external surfaces simultaneously exposed to equal fluid pressure of the pilot flow.
Upon energizing the solenoid coil, the armature and pilot valve member are pulled toward a magnetic pole in the cylindrical extension of the disk member, closing the pilot flow orifice, causing a pilot flow to cease which causes an increase in pressure in the main valve chamber and, in turn, the seating of the main valve member in response to the increase of pressure in the main valve chamber. Upon de-energizing the solenoid coil, the armature and pilot valve member are again urged by said second spring means away from the pilot flow orifice, opening the pilot flow orifice, causing the pilot flow to begin which causes a decrease in pressure in the main valve chamber and, in turn, the unseating of the main valve member in response to the decrease in pressure in the main valve chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there are shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangement and instrumentalities shown.
FIG. 1 is a cross-sectional view of the normally closed configuration of the solenoid controlled hydraulic valve with integrated solenoid of the present invention.
FIG. 2 is a cross-sectional view of the normally-open configuration of the solenoid controlled hydraulic valve with an integrated solenoid of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not intended in a limiting sense, but is made solely for the purpose of illustrating the general principles of the invention.
Referring now to the drawings in detail, where like numerals represent like elements, there is shown in FIG. 1 a hydraulic valve structure generally designated 10 comprising a valve body 12 having a longitudinally positioned valve sleeve 14 within which annulus the main valve member 16 reciprocates. The valve sleeve 14 has a number of circumferentially located apertures 18 for connecting with the main valve inlet connection 20 and the main valve outlet connection 22. The sleeve 14 also serves as the main valve seat 24 through which there is a central bore, the main valve passage 26. The main valve body 12 also includes a pilot flow passage 28 connecting the outlet connection 22 with the pilot valve chamber 30 through a pilot flow connecting passage 32.
Positioned concentrically along the longitudinal axis within a bore into the main valve member 16 is a biasing spring 34 which urges the main valve member 16 toward the main valve seat 24. The spring 34 abuts against a disk 36 situated in juxtaposition against the sleeve 14.
The main valve member 16 is substantially cylindrical in structure and toward the distal end, through which the spring 34 enters, tapers inward. Annularly disposed about this outer surface taper of the main valve member 16 is an adjustable seal 38 held in place by a nut 40 which circumferentially surrounds the distal end of the main valve member 16 and the spring 34 and applies pressure against the seal 38 as the nut 40 is tightened. Under tightening pressure from the nut 40, which is threadedly connected about the distal end of the main valve member 16, the seal 38 is pushed further upward along the taper formed on the exterior surface of the main valve member 16 expanding and forming a seal with and a bearing against the sleeve 14, simultaneously. This adjustment of the seal 38 reduces any leakage around the main valve member 16 to substantially zero. The adjustable seal 38 can be made of any deformable thermoplastic material, for example PTFE.
A metering orifice 42 is drilled into the main valve member 16 to connect the chamber 44 with the inlet connection 20 through the valve sleeve apertures 18. The chamber 44 includes an axially aligned central bore in the main valve member 16 in which the biasing spring 34 is partially housed. The metering orifice 42 provides for a fluid pressure connection through the main valve member 16 to the pilot orifice 46.
The main section of the valve is separated from the pilot valve section by the disk 36. A pilot orifice sleeve 48 is permanently attached within a central bore in disk 36. A tapered or stepped central bore in pilot sleeve 48 forms the pilot orifice 46. A pilot valve member 50 contacts and forms a closure with the pilot section side of the pilot orifice 46 to be described more fully hereinafter.
The disk 36 has an extended cylindrical section which extends away from the main valve section and serves to form the pilot valve chamber 30. Within the hollowed out cylindrical portion of the extended part of disk 36, i.e. the pilot valve chamber 30, an armature 52 is slidably disposed. Fixedly mounted to one end of the armature 52 is the pilot valve member 50. At the opposite end of the armature 52 and into a central bore of the armature is located a pilot section biasing spring 54 which urges the armature 52 toward the pilot orifice 46. The biasing spring 54 abuts or rests against the internal surface of the solenoid housing 56 which surrounds the cylindrical extension portion of the disk 36 and forms the rear wall of the pilot chamber 30. The armature 52 with its attached pilot valve member 50 can be pulled away from the pilot orifice 46 by the magnetic attraction of a solenoid coil 58. In order that the armature 52 depend solely for its motion on the biasing spring 54 and the magnetic attraction of the solenoid coil 58, a small longitudinal passage 60 extends from one end of the armature 52 to the other to connect the pilot valve chamber 30 with the pilot valve extension chamber 62. In this manner the armature 52 is pressure balanced so as to be unaffected in its movement by changes in fluid pressures within the valve.
The integrated solenoid of the present invention comprises the solenoid coil 58, the solenoid housing 56, the extended cylindrical portion of disk 36, and the armature 52. The integrated solenoid is constructed in such a manner that the slidable armature 52 is guided by the annulus of the extended cylindrical portion of the disk 36 which prevents the armature 52 from coming into proximate contact with the solenoid coil 58. In this manner the solenoid coil 58 is protected from wear or other damage which might result from direct contact between the solenoid coil 58 and the moving metallic body of the slidable armature 52. The solenoid coil 58 is fitted between the end of the extended cylindrical portion of disk 36 and the solenoid housing 56. The individual windings of the solenoid coil 58 are electrically insulated from the fluid within the valve, however, the solenoid coil 58, as a whole, is exposed to the fluid. The solenoid coil 58 receives its electrical energy from an external source by means of electrical conducting wires sealed within the conduit 64.
The solenoid coil 58 is pressure balanced in similar fashion to the armature 52. A connecting channel 68 provides for a fluid pressure connection between the pilot chamber 30 and a solenoid pressure balance chamber 70. With fluid of equal pressure surrounding the solenoid coil 58, there is no chance of deformation, distortion, or collapse of the coil causing a failure of the pilot section of the valve 10.
The magnetic relationship, within the pilot section among the extended cylindrical portion of disk 36, the solenoid coil 58, and the solenoid housing 56, creates a magnetic pole in the solenoid housing 56 aligned with the point at which the biasing spring 54 abuts the solenoid housing. This magnetic relationship causes the armature 52 to be attracted to or repelled from the solenoid housing 56. Each of these elements is made from metallic substance which conducts magnetic flux.
When the solenoid coil 58 is de-energized, the pilot section biasing spring 54 urges the armature 52 and its attached pilot valve member 50 in the direction of the pilot orifice 46. The pilot valve member 50 closes the pilot orifice 46 interrupting the pilot flow. When the pilot flow is interrupted, the pressures outside the main valve member 16 and inside the chamber 44 become equal. Thus, since the pressure force within the chamber 44 (having an area defined by the exposed surface of the disk 36 facing into the chamber 44) is greater than the pressure force outside the main valve member 16 (having an area defined by the surface between the main valve passage 26 and the annulus of the sleeve 14) the main valve member 16 responds to the urging of the biasing spring 34 and contacts the valve seat 24 blocking the main valve passage 26.
When the solenoid coil 58 is energized, the armature 52 with its attached pilot valve member 50 is electromagnetically attracted toward the solenoid housing 56. As the armature 52 is drawn the by magnetic force of the solenoid coil 58 toward the pole in the solenoid housing 56, the pilot valve member 50 is drawn out of the pilot orifice 46 opening the orifice and allowing the pilot flow to begin. The pilot flow begins at the inlet connection 20 flowing through the metering orifice 42, the chamber 44, the pilot orifice 46, the connecting passage 32, the pilot flow passage 28 and, finally, to the outlet connection 22. The flow of fluid through the metering orifice 42 creates a pressure loss in the chamber 44 so that the pressure therein becomes substantially lower than the pressure external to the main valve member 16. This differential in pressure causes the fluid pressure forces outside the main valve member 16 to overcome the force in the biasing spring 34 and push the main valve member 16 away from the valve seat 24 opening the main valve passage 42 between the inlet connection 20 and the outlet connection 22. For as long a period as the solenoid coil 58 is energized, the main valve passage 26 will remain open.
Referring to the second embodiment of the present invention as shown in FIG. 2, the normally-open configuration of a hydraulic valve, generally designated 110, includes many structural and operating elements substantially identical to those of the normally-closed hydraulic valve 10 shown in FIG. 1. The normally-open hydraulic valve 110 comprises a valve body 112 having a longitudinally positioned valve sleeve 114 within which annulus the main valve member 116 reciprocates. The valve sleeve 114 has a number of circumferentially located apertures 118 for connection with the main valve inlet connection 120 and the main valve outlet connection 122. The sleeve 114 serves at the main valve seat 124 through which there is a central bore, the main valve passage 126. The main valve body 112 also includes a pilot flow passage 128 connecting the outlet port 122 with the pilot valve chamber 130 through a pilot flow connecting passage 132.
The normally-open hydraulic valve 110 also has positioned concentrically along the longitudinal axis within a bore into the main valve member 116 a biasing spring 134 which urges the main valve member 116 toward the main valve seat 124. The spring 134 abuts against a disk 136 situated in juxtaposition against the sleeve 114.
The main valve member 116 is substantially cylindrical in structure and toward the distal end, through which the spring 134 enters, tapers inward. Annularly disposed about this outer surface taper of the main valve member 116 is an adjustable seal 138 held in place by a nut 140 which circumferentially surrounds the distal end of the main valve member 116 and the spring 134 and applies pressure against the seal 138 as the nut 140 is tightened. Under tightening pressure from the nut 140, which is threadedly connected about the distal end of the main valve member 116, the seal 138 is pushed further upward along the taper formed on the exterior surface of the main valve member 116 expanding and forming a seal with and a bearing against the sleeve 114, simultaneously. This adjustment of the seal 138 reduces any leakage around the main valve member 116 to substantially zero. The adjustable seal 138 can be made of any deformable thermoplastic material, for example, PTFE.
As in the first embodiment of the present invention, a metering orifice 142 is drilled into the main valve member 116 to connect the chamber 144 with the inlet port 120 through the valve chamber sleeve apertures 118. The chamber 144 includes an axially aligned central bore in the main valve member 116 in which the biasing spring 134 is housed. The metering orifice 142 provides for a fluid pressure connection through the main valve member 116 to the pilot orifice 146.
The main section of the valve is separated from the pilot section by the disk 136. A pilot orifice sleeve 148 forms the pilot orifice 146. A pilot valve member 150 contacts and forms a closure with the pilot section side of the pilot orifice 146 to be described more fully hereinafter.
The disk 136 has an extended cylindrical section which extends away from the main section and serves to form a first pilot section chamber 130. At the distal end of the extended cylindrical portion of the disk 136 there is an axially aligned bore 166 through which the pilot valve member 150 reciprocates. The machining and tolerances of the bore 166 are such that the shaft of the pilot valve member 150 closely fits therewithin. The bore 166 acts as a guide means so that the pilot valve member 150 remains in axial alignment with the pilot orifice 146.
Within a second pilot section chamber 162, located immediately adjacent and outside the distal end of the extended cylindrical portion of the disk 136, surrounded by the solenoid coil 158 and fitting within a bore in the solenoid housing 156, is a magnetically controlled reciprocating armature 152. The armature 152 is able to freely slide in a reciprocating manner within the second pilot section chamber 162. At the furthest extent of its travel away from the pilot orifice 146, the armature 152 contacts a stop means 172 which restrains the armature 152 from coming into contact with the solenoid housing 156.
The pilot valve member 150 is kept in proximate contact with the proximal end of the armature 152 by the pilot chamber biasing spring 154. The proximal end of the biasing spring 154 abuts against the pilot sleeve 148 at a location surrounding the pilot orifice 146 and, at its distal end, contacts an enlarged shaft section of the pilot valve member 150. The biasing spring 154 urges the pilot valve member 150 against the proximal surface of the armature 152 (located in the second pilot section chamber 162) which, in turn, urges the armature 152 against the armature stop 172 preventing further travel by the armature 152 and the pilot valve member 150, although the biasing spring 154 will not be in full extension.
The armature 152, along with the pilot valve member 150, can be pushed toward the pilot orifice 146 by the magnetic forces occurring when the solenoid coil 158 is energized. In order that the armature 152 depends solely for its motion upon the biasing spring 154 and the magnetic forces of the solenoid coil 158, a small longitudinal passage 160 extends from one end of the armature 152 to the other to connect, and to permit fluid to flow between, the second pilot section chamber 162 and the pilot section extension chamber 174. In this manner the armature 152 is pressure balanced so as to be unaffected in its movement by changes in fluid pressures within the valve.
The integrated solenoid of the present invention comprises the solenoid coil 158, the solenoid housing 156, the extended cylindrical portion of disk 136, and the armature 152. The integrated solenoid is constructed in such a manner that the slidable armature 152 is guided by the annulus of a cylindrical bore in the solenoid housing 156 which prevents the armature 152 from coming into proximate contact with the solenoid coil 158. In this manner the solenoid coil 158 is protected from wear or other damage which might result from direct contact between the solenoid coil 158 and the moving metallic body of the slidable armature 152. The solenoid coil 158 is fitted between the extended cylindrical portion of disk 136 and the solenoid housing 156. The individual windings of the solenoid coil 158 are electrically insulated from the fluid within the valve, however, the solenoid coil 158, as a whole, is exposed to the fluid. The solenoid coil 158 receives its electrical energy from an external source by means of electrical conducting wires sealed within the electrical conduit 164.
The solenoid coil 158 is pressure balanced in similar fashion to the armature 152. The connecting channel 168 provides for a fluid pressure connection between the second pilot section chamber 162 and a solenoid pressure balance chamber 170. With fluid of equal pressure surrounding the solenoid coil 158, there is no chance of deformation, distortion, or collapse of the coil causing a failure of the pilot section of the valve 110.
The magnetic relationship within the pilot valve section of the normally-open hydraulic valve 110 among the extended cylindrical portion of the disk 136, the solenoid coil 158, and the solenoid housing 156, creates a magnetic pole in the extended cylindrical portion of disk 136 aligned with the point at which the shaft of the pilot valve member passes through the extended cylindrical portion of disk 136. This magnetic relationship causes the armature 152 to be attracted to or repelled from the extended cylindrical portion of disk 136. Each of these elements is made from a metallic substance which conducts magnetic flux.
Returning for the moment to the pilot valve member 150 and its extension shaft, the unit reciprocates through the bore 166 of the extended cylindrical portion of disk 136 to make proximate contact with the armature 152. The passage through which the pilot valve member passes, the bore 166, is a smooth, circular hole in the extended cylindrical portion of disk 136. The extension shaft of the pilot valve member 150 has at least one longitudinal slot which serves as a fluid pressure connecting means or passage 176 between the first pilot section chamber 130 and the second pilot section chamber 162 in which the armature 152 is housed. In order that the pilot valve member 150 remain in its axially aligned position, it is preferred, although not absolutely necessary if close machining tolerances are obtainable, that two slots be cut into the extension shaft of the pilot valve member 150. These slots should be 180° apart such that the pilot valve member 150 be slidable in reciprocating fashion through the bore 166 and remain properly aligned with the pilot orifice 146.
When a solenoid coil 158 is de-energized, the pilot section biasing spring 154 urges the armature 152 and the pilot valve member 150 in the direction of the solenoid housing 156. As the armature 152 is urged toward the solenoid housing 156, the pilot valve member 150 is drawn out of the pilot orifice 146 opening the orifice and allowing the pilot flow to begin. The pilot flow begins at the inlet connection 120 flowing through the metering orifice 142, the chamber 144, the pilot orifice 146, the connecting passage 132, the pilot flow passage 128 and, finally, to the outlet connection 122. The flow of fluid through the metering orifice 142 creates a pressure loss in the chamber 144 so that the pressure therein becomes substantially lower than the pressure external to the main valve member 116. This differential in pressure causes the fluid pressure force outside the main valve member 116 to overcome the force in the biasing spring 134 and push the main valve member 116 away from the valve seat 124 opening the main valve passage 142 between the inlet connection 120 and the outlet connection 122. For as long a period as a solenoid coil 158 remains de-energized, the main valve passage 126 will remain open.
When the solenoid coil 158 is energized, the armature 152 is magnetically attracted toward the extended cylindrical portion of disk 136. The armature 152 is pushing the pilot valve member 150 against the urging of the biasing spring 154 and will cause the pilot valve member 150 to close the pilot orifice 146 interrupting the pilot flow. When the pilot flow is interrupted, the pressure outside the main valve member 116 and inside the chamber 144 become equal. Thus, since the pressure force within the chamber 144 (having an area defined by the exposed surface of the disk 136 facing into the chamber 144) is greater than the pressure force outside the main valve member 116 (having an area defined by the surface between the main valve passage 126 and the annulus of the sleeve 114) the main valve member 116 responds to the urging of the biasing spring 134 and contacts the valve seat 124 blocking the main valve passage 126.
From the description of the two foregoing preferred embodiments of the present invention, it is apparent that a poppet valve can be constructed with its solenoid pilot control mechanism located within the main valve housing. This structure is achieved without the limitation of prior valves of this type restricting the fluid pressure without incurring substantially increased costs in constructing and operating such valves. Further, the novel configuration of the solenoid controlled pilot section of the valves of the present invention permit controlling flows of fluids having substantially increased pressures in solenoid controlled poppet-type valves. Also, the novel structure of a deformable plastic seal-bearing mounted over a distally located tapered portion of main valve member, creating not only a seal between the main valve member and the valve sleeve but also a bearing upon which the main valve member moves, eliminates leakage along the bearing surface between the sleeve and the main valve member resulting in a simpler structural relationship. Hence, poppet valves of larger dimensions for controlling flows having substantially higher fluid pressures is made possible.
The structural interrelationship of both the bearing and seal in the main valve chamber and of the pressure balanced armature and solenoid coil provide a greater efficiency in handling more accurately flows of fluid having increased pressures without the need to resort to external pilot valves of greatly increased size to handle the higher pressure fluids. Further, because the solenoid coil is integrated within the valve housing, a coil of relatively smaller size can be utilized because the magnetic flow path is not disrupted by detrimental gaps. The smaller size of the coil, or compactness, allows the coil to be placed within the valve housing and reduces the amount of conductor needed to achieve the magnetic force required to control the valve. There is, overall, a significant cost savings in placing the solenoid coil within the housing.
In regard to the second embodiment of the invention, the normally-open valve, the reversal of the structural arrangement of the elements in the pilot section of the valve significantly reduced the area available to apply the magnetic attraction to the armature. The magnetic pole, in this instance, resides in the disk on the proximal side of the armature, in distinction from the normally-closed valve where the pole resides on the distal side of the armature in the solenoid housing. In order to optimize the surface area of the pole to achieve the maximum attractive forces, it was necessary to create the two chambers. At the same time the alignment of the pilot valve member remains critical. A trade-off was necessitated between maximizing the surface area of the disk facing the armature and the size of the bore through which the pilot valve member reciprocates to open and close the pilot orifice. It was determined that in order to obtain maximum control over the pilot section that the pilot valve member would be demounted from the armature, as in prior valve of this type, but remain governed by the motion of the armature as assured by the biasing spring. In this manner, the maximizing of the surface area of the pole was accomplished in order to meet and overcome the requirements of the hydraulic control over the fluid flows governed by the valve.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
|
A solenoid controlled pilot operated valve in which the valve elements are grouped into main and pilot sections including a combined seal-bearing means surrounding the main valve member and a solenoid coil integrated into the pilot control section of either a normally-open or normally-closed configuration of said valve in which the solenoid coil and armature are exposed to pressurized fluid.
| 5
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 61/573,966, filed on Sep. 15, 2011, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Embodiments of the present subject matter relate to electronic document and file management systems and methods.
[0003] Electronic data and content capturing systems enable enhanced accessibility and reduced complexity for clients managing large volumes of data files. Content capturing systems generally increase the flexibility and usability of information while reducing client costs. For example, electronic content capturing systems are generally capable of understanding the information that is located on a client's enterprise servers. This enables, for example, access to the information to appropriate individuals while ensuring that important information is properly classified, retained, and preserved. Content capturing systems may also enable archiving of data from different sources on the client's enterprise servers.
SUMMARY
[0004] According to one aspect, a method of validating an electronic content collection task is disclosed. The method includes scanning a designated electronic memory location, detecting a control file, the control file including content control information and having a corresponding index file, verifying the accuracy of the content control information, and modifying at least one parameter of the corresponding index file such that it can be recognized for inclusion within a content collection task if the content control information is accurate.
[0005] According to another aspect, a method of validating an electronic content collection task is disclosed which includes scanning a document file extension of at least one document file, the document file having been subject to a content collection task that modifies the document file extension, reading the document file extension, and logging an error in an event log if the document file extension indicates an error in the content collection task.
[0006] According to another aspect, a method is disclosed which includes retrieving task-specific content control information from a validation database, the task-specific content control information including information indicative of the status of an electronic content collection task, displaying the task-specific content control information through an electronic interface, receiving an input through the electronic interface, and modifying the status of the content collection task in the validation database based on the received input.
[0007] According to another aspect, an apparatus for validating an electronic content collection task is disclosed. The apparatus includes a memory, and a processor operatively coupled to the memory and configured to scan a designated electronic memory location, detect a control file, the control file including content control information and having a corresponding index file, verify the accuracy of the content control information, and modify at least one parameter of the corresponding index file such that it can be recognized for inclusion within a content collection task if the content control information is accurate.
[0008] According to another aspect, an apparatus is disclosed which includes a memory, and a processor operatively coupled to the memory and configured to retrieve task-specific content control information from a validation database, the task-specific content control information including information indicative of the status of an electronic content collection task, display the task-specific content control information through an electronic interface, receive an input through the electronic interface, and modify the status of the content collection task in the validation database based on the received input.
[0009] According to another aspect, an apparatus for validating an electronic content collection task which includes a memory, and a processor operatively coupled to the memory and configured to scan a document file extension of at least one document file, the document file having been subject to a content collection task that modifies the document file extension, read the document file extension, and log an error in an event log if the document file extension indicates an error in the content collection task.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a flowchart of a content collection method including validation according to some embodiments.
[0011] FIG. 2 illustrates a functional block diagram of a validation and content collection system according to some embodiments.
[0012] FIGS. 3A-3C illustrate examples of index file relationships that may be simultaneously supported by a validation processor according to some embodiments.
[0013] FIG. 4A is a flowchart of a pre-validation method according to some embodiments.
[0014] FIG. 4B is a flowchart of a content collection method according to some embodiments.
[0015] FIG. 4C is a flowchart of a post-validation method according to some embodiments.
[0016] FIGS. 5A-5C illustrate examples of notifications which can be sent to a client workstation or support team according to some embodiments.
[0017] FIGS. 6A-6B illustrate examples of a dashboard according to some embodiments.
DETAILED DESCRIPTION OF EMBODIMENTS
[0018] In some embodiments, an electronic content capturing system is capable of monitoring content sources, such as electronic feeds from client enterprise systems (e.g., client mainframe, outlook servers, in-house applications) via fileshares. As referred to herein, the term client refers to individuals or entities that are owners or custodians of content that is to be collected. In some applications, each document or file relates to (e.g., is critical to) a client's business. As a result, it is important to account for all documents that are processed using the electronic capturing system.
[0019] Conventional content capturing systems generally lack validation capabilities that are capable of monitoring the collection of each document that is collected, logging errors at different stages of the collection procedure, and interfacing with client systems and support capabilities to correct errors. These validation functions are important for supporting critical content collection in which documents and indices (e.g., all documents and indices) should be accounted for.
[0020] In some embodiments, a validation system is configured to interface with an electronic content capturing system to validate one or more content capturing tasks. The validation system is configured to, for example, confirm that the content capturing system has received the entire task, that the metadata associated with the document and files to be captured is complete and/or is formatted correctly, and/or that all of the documents or files have been collected (e.g., “ingested”) by the content collection system within an expected duration. In some embodiments, the validation system is configured to maintain and update a status of each content collection task as well as maintain an error report or log regarding errors that relate to the document or file to be collected or that were encountered during an attempt to collect a document or file.
[0021] In some embodiments, the validation system is structured as a Control—Index—Document paradigm, such that document collection is managed and monitored appropriately. The validation system, according to some embodiments, may also be capable of use with index files and schema that are associated with various formats, such as XML index files and XML schema. In some embodiments, the validation system functions include verification that documents that are to be collected actually exist, and/or verification that the documents were successfully collected or ingested by the content collection system.
[0022] In some embodiments, the validation system is configured to log and track each collection task in a database. In the event of an error, the validation system may be configured to notify client or enterprise content management (ECM) support staff. In some embodiments, the validation system includes an interface that allows ECM support staff to monitor the content collection process, and configure each process by project or task route.
[0023] FIG. 1 is a flowchart of a content collection method 100 including validation according to some embodiments. As shown in FIG. 1 , the method 100 includes a pre-validation sub-process as shown in block 102 . As will be described in greater detail with reference to FIG. 2 below, client data that is to be collected may be stored in fileshare memory location that is monitored by a content collection and validation system. The pre-validation sub-process may include validation of document counts, index file layouts, and metadata that is included in the fileshare memory. In some embodiments, the pre-validation sub-process logs information and pre-validation errors in a validation database. The method 100 also includes a content collection sub-process as shown in block 104 . The content collection sub-process includes collection or ingestion of documents or other electronic content, and modification of file extensions to index files to reflect a successful or unsuccessful collection routine. The method 100 also includes a post-validation sub-process as shown in block 106 . The post-validation sub-process includes validation of successful document or file collection routines, generation of logs corresponding to post-validation and content collection errors encountered, and notification to clients of pre-validation errors that were previously encountered. The method 100 also includes an interface processing sub-routine as shown in block 108 . The interface processing sub-routine includes displaying task status, support notes, and links to support documentation as well as allowing support staff to edit individual content collection tasks. The interface processing sub-routine may also generate content collection statistics related to any number or subset of content collection tasks. Examples of the pre-validation sub-process, the content collection sub-process, the post-validation sub-process and the interface processing sub-routine will be described with reference to FIGS. 4A-4C , 5 A- 5 C, and 6 A- 6 B below.
[0024] FIG. 2 illustrates a functional block diagram of a validation and content collection system 200 according to some embodiments. As shown in FIG. 2 , the system 200 includes a client server 202 in communication with a fileshare memory 204 . For example, the client server may include one or more client fileshares. While shown separately, the fileshare memory 204 may also be located within the client server 202 . The fileshare memory 204 includes folders for control files 206 , indexes/content files 208 , and success files 210 , which are accessible by a content collection processor 212 and a validation processor 214 . The control files 206 and index files 208 are populated by the client server 202 and correspond to electronic content, such as documents 216 , that is to be collected by the content collection processor 212 . As will be described in greater detail below with reference to FIG. 4A , the success folders 210 include control files that are associated with content that has been successfully pre-validated by the validation processor 214 .
[0025] The validation processor 214 includes a pre-validation module 218 , a post-validation module 220 , an event log module 222 , and a dashboard/interface control module 224 . The operation of each of the modules 218 , 220 , 222 , and 224 will be described in greater detail with reference to FIGS. 4A-4C below. The validation processor 214 is configured to communicate with and modify a validation database 226 which maintains a current status of each content collection task. The validation processor 214 is also in communication with a support terminal 230 , a log monitoring module 232 , and a client workstation 234 in order to communicate results of the validation process and to efficiently handle error occurrences.
[0026] While shown as separate processors in FIG. 2 , in some embodiments, the content collection processor 212 and the validation processor 214 may be incorporated in a single processor. Other variations and implementations of the processing architecture may also be used.
[0027] The validation processor 214 may be configured to support a variety of platforms and file types. For example, in some embodiments, the validation processor 214 is configured to support multiple index file relationships. FIGS. 3A-3C illustrate examples of index file relationships that may be simultaneously supported by a validation processor 214 according to some embodiments. The file types supported by the validation processor 214 may include a one-to-one client generated index file (xml) to validation index file (idx) relationship as shown in FIG. 3A , a one-to-many client generated index file (xml) to validation index file (idx) relationship as shown in FIG. 3B , or an all in one client generated control file (ctl) that is split into multiple validation index files (idx) as shown in FIG. 3C . In some embodiments, the validation processor 214 is configured to process project specific configurations of index files that are generated by the client server which may include, for example, particular XML coded index files. Table 1 below illustrates some examples of various fields and their associated descriptions which may be varied according to project specific configurations.
[0000]
TABLE 1
Field
Description
IndexWithEmbeddedControlFile
May be used for “All in One” control files.
If not specified, the default may be set to “False.”
“True” if the control and index files are combined. “False”
otherwise.
TriggerFileExtension
Indicates the extension of the control file.
If not specified, the default may be set to “ctl.”
May be used when IndexWithEmbeddedControlFile is set to
“True.”
List the extension of the combined control and index file name.
Example: “xml”
OneToManyIndexes
May be used for “One to Many” index files.
If not specified, the default may be set to “False.”
May be set to “True” for passing a single index file for a list of
documents in a single trigger/control file (as opposed to a separate
index file for each document).
IndexFileSplitTag
May be used when value for OneToManyIndexes tag is set to
“True.”
Enter the xml tag value to use when splitting a single index file
with a list of tags per document into individual xml files for each
document.
Example: <Doc>
DirToMonitorForCtl
Universal Naming Convention (UNC) path
Specifies where the Pre-Validation program should monitor for the
trigger/control file.
ConsecutiveCtlErr
If not specified, a default number may be set (e.g., “5”).
Specifies the number of control file(s) that can encounter an error
in a run before stopping the program from processing any new
control files for this task.
To stop the program on a first encountered error, set the value to
“0.”,
IndexFile_Xpath
Specifies the XML Xpath where the index file location will be
found in the control file.
Example: /Control/IndexFiles/File/Path.
RecordCount_Xpath
Specifies the XML Xpath where the record count for the number
of indexes will be found in the control file.
Example: /Control/IndexFiles/File/RecordCount.
ContentFile_Xpath
Specifies the XML Xpath where the content file location will be
found in the index file.
Example: /FILETAG/DOC/ImagePath.
ContinueOnCtlOutOfBalanceFlag
If not specified, the default may be set to “False.”
Set to “True” to continue processing the control file even if the
index file count from the control file does not match the count of
index files in the index directory.
Set to “False” to stop processing the control file if the index file
count from control file does not match the count of index files in
the index directory.
MissingContentFilesLimit
If not specified, a default may be set (e.g., “0”).
Specifies the limit for number of missing content file(s) before
stopping the control file from processing further.
To stop the program on first missing content set the value to “0.”
ctl_Success
Specifies the UNC path to which the Post-Validation process will
move the control file upon successful processing
ctl_Failed
Specifies the UNC path where the Post-Validation process will
create the IngestionProcessInDisableMode.txt file when the
process needs to be put in disabled mode.
Disabled mode applies to that task route/task only.
May be set to the same path as DirToMonitorForCtl.
DisableProcessFile
If not specified, a default may be set
(e.g., “IngestionProcessInDisableMode.txt”).
Name of the file that will be created to disable the process from
running again when the count of error control files reaches the
limit set in the configuration file.
The process will not restart for the task until the file is manually
deleted.
PreValidationIdxFileExt
If not specified, a default may be set (e.g., “xml”).
Specifies the index file extension that will be provided by
Business System Area.
PostValidationIdxFileExt
If not specified, a default may be set (e.g., “idx”).
Specifies the index file extension that should be applied once the
Pre-Validation process has successfully completed validating the
index file(s).
Set to the same extension for which Document Collection Tool
(e.g., ICC) monitors.
EmailTo
If not specified, a default may be set.
List the Microsoft Exchange Mlist of the Business System Area
that will be providing the data.
Additional e-mail addresses can be added separated by commas.
EmailFrom
LogsLocation
Specifies the UNC path where the error and status logs are located.
ErrLogName
StatusLogName
If not specified, a default may be set (e.g., “StatusLog.txt.”)
Name for the status log, where for each control file processed
system may log 1) the date/time, 2) name of the control file, 3) if
the control file processing was a success or a failure, 4) the
number of index file(s) from control file(s), and/or 5) the number
of index file(s) from the index directory.
The date will may be appended to the name to create a new log for
each day.
ValidateXml
If not specified, the default may be set to “True.”
If OneToManyIndexes = “False”:
Set to “True” to validate the index file against an associated XML
xsd schema validation file.
Set to “False” to not validate the index file against an associated
XML xsd schema validation file.
If OneToManyIndexes = “True”:
When index file is One to Many, the index file is validated against
the XML xsd schema validation file before index file is split into
individual index files. Therefore, set to “False” to not validate the
index file again after the split of the index files.
ValidateAllIndexFiles
If not specified, the default may be set to “False.”
False = Stop validating the index files once the
InvalidIndexFilesLimit is reached.
True = Continue validating the index files even if the
InvalidIndexFilesLimit is reached. However, if the invalid index
file limit is reached then do not rename the index file success, for
example, do not rename .xml to .idx.
ValidateXmlAfterSplit
If not specified, the default may be set to “False.”
For one to many and combined control/index file:
False = Validate the XML file before split them into individual
index file.
True = Split the index file into individual index file without
validating.
If this tag is set to True then set the ValidateXml to True to
validate the index file after the split.
InvalidIndexFilesLimit
If not specified, the default may be set to “0.”
Specifies the limit for count of invalid index file(s) before
stopping the control file from processing further.
To stop the program on first invalid index file put the value “0.”
xsdFile
Used if ValidateXml = “True” Or OneToManyIndexes = “True”
Specifies the path where the XML xsd schema validation file for
this ingestion is located.
RetryLimit
If not specified, a default may be set (e.g., 5).
Specifies the maximum number of times the Post-Validation
process will check to see if the document collection tool is finished
before flagging the ingestion as an error.
WaitTime
If not specified, a default value may be set (e.g., “250”).
Specifies time in millisecond used to calculate the time Post-
Validation should wait before checking if the ingestion is
complete.
Multiplied times the number of documents (e.g., for 100
documents and a WaitTime = 250, a total wait time of 25 seconds
is used).
Value may be set to any integer.
ObjectStore
Name of the Object Store in which document collection tool will
store the ingested content.
DocClass
Name of the Document Class in which document collection tool
will store the ingested content.
RCServer
Name of the document collection tool server that will process the
tasks.
ECMErrorResolutionLimit
If not specified, a default may be set (e.g., “7200” or 2 hours)
Maximum time in seconds the Support Staff has to update the
status of a task having an error in the Pre-Validation database, or
fix the error, before an error notification email is sent.
Hours
Seconds
2
7200
4
14400
8
28800
12
43200
24
86400
36
129600
48
172800
72
259200
BusSpecificRootTag_Xpath
If the business area has information sent in the control file which
they want to be returned in the log file generated by
Post-Validation process, then that information is enclosed inside a
tag. For example:.
<BusinessTag>
<BusTag1>BusTag1Test1</BusTag1>
<BusTag2>BusTag2Test1</BusTag2>
</BusinessTag>
The Pre-Validation process may extract the information from the
control file, writes it to the database, then the Post-Validation
process includes it in the log file.
ErrorIDPrefix
Indicates the criticality of the ingestion tasks.
If not specified, a default value may be set (e.g., “7.”)
Value specified is used as a prefix for the error number.
For example, use 6 for non-critical ingestions where error
notification should be sent by e-mail to local client support (e.g.,
IT).
Use 7 for critical ingestions where error notification by pager is
sent to Support Staff/System Administrator.
RootPathToArchiveFldr
If data should be archived to another folder then the root location
of the archived folder may be provided.
IngestionIdentifier_Xpath
Xpath to where the Ingestion Run Identifier value is passed in the
index file.
IgnoreZeroRecordCountControlFile
Set to “False” if the Pre-Validation process should error when a
control file has a record count of zero.
Set to “True” if the Pre-Validation process should ignore control
files with a record count of zero and not throw an error.
StaticIndexFilePath
To be used for “One to Many” or combined index/control index
file type only.
Pass the path that needs to be appended to the file name for
where index file is located.
StaticContentFilePath
To be used for “One to Many” or combined index/control index
file type only.
Pass the path that needs to be appended to the file name for
where index file is located.
[0028] Some examples of the functionality of the validation processor 214 and the content collection processor 212 are shown in FIGS. 4A-4C . FIG. 4A is a flowchart of a pre-validation method 400 according to some embodiments. The pre-validation process 400 may be performed by the pre-validation module 218 discussed above with reference to FIG. 2 .
[0029] As shown in FIG. 4A , the pre-validation process 400 includes scanning fileshares for control files as shown in block 402 . For example, as discussed above with reference to FIG. 2 , the client server 202 may be configured to write content, index, and control files to monitored fileshares which are located in fileshare memory 204 . The validation processor 214 , through operation of the pre-validation module 218 , is configured to monitor, for example, control files 206 located in fileshare memory 204 . The detection of a control file in the fileshare memory 204 triggers other operations of the pre-validation process 400 .
[0030] The pre-validation process 400 generates a database entry as shown in block 404 in order to track and update the status of a content collection task. For example, as shown in FIG. 2 , the pre-validation module 218 is configured to communicate with the validation database 228 in order to add an entry related to a content collection task. At block 406 , the pre-validation process 400 validates the number of files or documents (counts) associated with the content. For example, the pre-validation module 218 may be configured to compare the number of indexes noted in the control file 206 associated with the content against the actual number of indexes and documents that are located in the corresponding index/content file 208 .
[0031] As shown in decision block 408 , the pre-validation process 400 may determine whether a document/index count error has been detected during pre-validation. If an error has not been detected, the process may also validate metadata integrity by confirming that each index file points to a document, that the index file properties exist, contain values, and follow the proper format (e.g., date format) as shown in block 409 .
[0032] As shown in decision block 410 , the pre-validation process 400 may determine whether an error has been detected with metadata integrity during pre-validation. If an error has not been detected, the control file/index file is split into individual index files (if configured) as shown in block 411 . For example, as discussed above with reference to FIG. 3C , if a client server 202 generates an all-in-one index file, the pre-validation module 218 may split the all-in-one client generated index file to generate multiple index files that are to be recognized by the content collection processor 212 . In some embodiments, the content collection tool is configured to recognize specified index file extensions (e.g., “.idx”). These index file extensions may be set based on task specific configurations as indicated above in Table 1. Following a successful pre-validation, the file extensions are changed to index extensions (e.g., from “.xml” to “.idx”) as shown in block 412 in order to allow recognition of content by the content collection tool. In addition, the associated control file is moved from the control files 206 to the success files 210 within the fileshare memory 204 as shown in block 414 . Further, the database entry in validation database 228 corresponding to the task is updated to reflect a successful pre-validation procedure as shown in block 416 .
[0033] The pre-validation tool advantageously maintains compatibility with conventional content collection file formatting. For example, for a conventional content collection system in which clients provide index files having a “.xml” extension, the pre-validation tool can be configured to recognize the “.xml” and trigger a pre-validation process. Configuration of the content collection tool can also be changed such that the “.xml” format does not trigger a content collection operation by the content collection tool. Rather, the content collection tool can be configured to search for an index file extension that is set by the pre-validation tool (e.g., “.idx”), which reflects a pre-validated index file that relates to a content collection task.
[0034] With reference to FIG. 4A , if an error has been detected by the pre-validation process in decision block 410 (e.g., corrupt index file, missing values, etc.), the extension of one of the control file and/or one or more of the index files associated with the content is changed (e.g., to a “.err” extension) as shown in block 418 in order to alert the post-validation process of the error as will be discussed in greater detail with reference to FIG. 4C . The type of error encountered may dictate which of the control file and/or the one or more index file extensions are to be changed to reflect the error. For example, if an error relates to the number of documents that are provided relative to the number of documents referenced in the control file, the control file extension may be changed to reflect that a control file error was encountered. Following detection of an error, the database entry status of the validation database 228 is updated to reflect the error that is encountered during pre-validation as shown in block 420 .
[0035] FIG. 4B is a flowchart of a content collection method 420 according to some embodiments. The content collection method 420 may be performed by the content collection processor 212 discussed above with reference to FIG. 2 . The content collection method 420 includes detecting and collecting content files as shown in block 422 . For example, the content collection processor 212 is configured to detect index files in the fileshare memory 204 having the “.idx” extension which is set by the pre-validation process, and is configured to collect the corresponding content, such as documents 216 . The collected content, may be, for example, archived in order to conserve client resources and/or automatically distributed to particular users. Content collection method 420 also includes a determination of whether an error was encountered for a particular content collection task as shown in decision block 424 . Examples of content collection errors may include errors that are encountered as a result of validating the content of each index file. For example, an index file may generally include a particular task route (e.g., content storage location) and/or data type (e.g., letter, email, or the like). If the task route is invalid and/or the referenced document data type does not match the actual document data type, an error is detected by the content collection tool.
[0036] As shown in FIG. 4B , if an error is not encountered during content collection, an extension is added to the document 216 (e.g., “.SUCCESS”) indicating successful content collection as shown in block 426 . If an error is encountered during content collection, an extension reflecting an error (e.g., “.ERROR”) is added to the document 216 as shown in block 428 .
[0037] FIG. 4C is a flowchart of a post-validation method 430 according to some embodiments. The post-validation method 430 may be performed by the post-validation module 220 discussed above with reference to FIG. 2 . As shown in block 432 , the method includes scanning the unprocessed job or task status entries in the validation database 228 .
[0038] If the post-validation module 220 detects that a database entry in validation database 228 is set to an error status, the post-validation module 220 determines that the corresponding task encountered an error during pre-validation. As shown in decision block 434 , the method includes determining whether one of these pre-validation errors has been detected. If an error has been detected, a notification is sent to the client to correct the error as shown in block 436 . Examples of client notifications will be described in greater detail with reference to FIGS. 5A-5C below. With reference to FIG. 2 , the post-validation module 220 is configured to communicate with a designated client workstation 234 (e.g., IT department, designated email address, or the like). The client workstation 234 is enabled to correct the errors and remove the “.err” extension from the corresponding control file. Following removal of the “.err” extension, the pre-validation module 220 is re-triggered to pre-validate the content and change the index file extension for recognition by the content collection processor 212 . The process may then proceed normally through content collection and post-validation.
[0039] Detection of a pre-validation error also results in a pre-validation error being logged in a task-specific log file in the task fileshare as shown in block 438 . For example, the post-validation module 220 may write a task-specific log file to fileshare memory 204 in order to log the error event. Further, if the corresponding database entry in the validation database 228 does not already reflect an error status, the corresponding database entry is updated to reflect the error status as shown in block 440 .
[0040] If an error is not detected at decision block 434 (e.g., the task status indicates that the Pre-Validation process was successful), the extensions of the collected documents are detected to determine whether an error was encountered during document collection, as shown in block 442 . For example, the post-validation module 220 is configured to check whether a collected document has a “.ERROR” extension, or whether all collected documents have a “.SUCCESS” extension. If a collected document includes neither extension, the post-validation module 220 may determine that content collection is still pending and may continue to periodically check the document's extension.
[0041] At decision block 444 , the method determines whether an error extension is detected or whether a predetermined number of checks have been exceeded. If neither event occurs, and if the extension of the collected document reflects a successful document collection, the status in the validation database 228 is updated to reflect a successful content collection process as shown in block 448 . Furthermore, a successful status is logged in a task-specific log file in the task fileshare as shown in block 448 . For example, the post-validation module 220 may write a task-specific log file to fileshare memory 204 in order to log the error event. However, if an error extension is detected or the number of checks is exceeded, a post-validation error is logged in the event log as shown in block 446 . For example, as discussed above, the pre-validation module 220 may communicate with the event log module 222 in order to log the error event. Detection of a post-validation error also results in a post-validation error being logged in a job-specific log file in the job fileshare as shown in block 438 . For example, the post-validation module 220 may write a job-specific log file to fileshare memory block 204 in order to log the error event. Further, if the corresponding database entry in the validation database 228 does not already reflect an error status, the corresponding database entry is updated to reflect the error status as shown in block 440 .
[0042] With reference to FIG. 2 , the event log module 222 may be continuously monitored by the log monitoring module 232 . As the log monitoring module 232 encounters error events that are logged in the event log module, the log monitoring module 232 is configured to communicate with system support 230 (e.g., ECM support) in order to correct the errors. System support 230 may then troubleshoot and/or correct errors through communication with the dashboard/interface control module 226 that is incorporated in the validation processor 214 . Following correction, system support 230 may also be enabled to remove the “.ERROR” extensions from document files, triggering the content collection processor 212 to ingest or collect the documents as a new task. As discussed above, successful collection of the documents results in the addition of the “.SUCCESS” extension by the content collection processor 212 , which can then be validated by the post-validation module 220 .
[0043] In some embodiments, the Validation Processor 214 can be configured at the project level to prepend various error prefixes to the error codes in the event log module 222 . For example, an error with a prefix of “6” could indicate a non-critical error, whereas an error with a prefix of “7” could indicate a critical error. External monitoring tools are used to monitor the logs for these prefixes and notify support staff in the event of errors
[0044] FIGS. 5A-5C illustrate examples of notifications which can be sent to a client workstation or support team according to some embodiments. As shown in FIG. 5A , an email may be generated to notify designated recipients when pre-validation errors occur. The email notification 500 A can include interface tools 502 (e.g., reply, replay all, forward, etc.), and an addressing field 504 which identifies the source address, recipient address and subject of the email. In the example shown in FIG. 5A , an email is sent to a to indicate a pre-validation error. The email may be sent to a client's designated recipient email address (e.g., a client IT support email address corresponding to client workstation 232 ). The email body 506 indicates the details of the error that was encountered and includes a link 508 to troubleshoot information that can be of assistance to the recipient for resolving the error. The email may also include support services contact information, which may be classified by error criticality. The email body 506 also includes task information 510 , such as the control file name, pre-run database ID, post-run database ID, record count (e.g., number of documents in task), pre-validation success count, pre-validation error count, post-validation success count, post-validation error count, and a configuration file name. The email body 506 also includes an error list 512 which includes separate error entries that reflect the specific errors that were encountered for the associated task. Each error entry may include information identifying the error, such as error number, the date and time the error was encountered, the file name that encountered the error, the location of the file in the fileshare, and a description of the error including any actions which occurred as a result of encountering the error.
[0045] FIG. 5B illustrates an example of an email notification 500 B which can be sent when a post-validation error has been encountered. In some embodiments, the email notification 500 B shown in FIG. 5B may be sent automatically to content collection support personnel (e.g., System Support 230 ) through monitoring of the event log module 222 by the log monitoring module 232 . The email notification 500 B includes email interface tools 502 and addressing fields 504 as discussed above with reference to FIG. 5A . The email body 520 may indicate the severity or type of notification (e.g., Error), the status of the error, the source of the error (e.g., post-validation), and an indication of the code-range of the post-validation error. As discussed above, a pre-fix of the code-range may indicate the criticality of the type of error that was encountered. The email body 520 also includes an error specific description 522 which can indicate the date/time of the error, an identifying error-code, an error type, and a detailed description of the error. The email body 520 can also include a source description field 524 which identifies the source domain of the error, the agent (e.g., server) that encountered the error, the time and date the error was encountered, and owner (e.g., repository) of the error which may be in the form of a link to a particular task-route that is affiliated with the document that encountered the error.
[0046] FIG. 5C is an example of an email notification 500 C which may be sent to a designated recipient when a post-validation error has occurred and has not been resolved within a predetermined time by content collection system support personnel. Similar to the email notification 500 A of FIG. 5A , the email notification 500 C includes email interface tools 502 and addressing field 504 . The email body 530 also includes task information 510 which is similar to that described above with reference to FIG. 5A . The email notification 500 C informs the recipient that an error was encountered and is in the process of being resolved. Contact information, which may be specific to the criticality of the error, may also be provided as shown in FIG. 5C .
[0047] FIGS. 6A-6B illustrate examples of a dashboard 602 A, 602 B according to some embodiments. As shown in FIG. 6A , the dashboard 602 A can display the status and statistics related to all content collection tasks together, and may classify each status by customizable groups such as in-process 606 , non-critical 608 , critical 610 , and all errors 612 . The dashboard 602 A can include a filterable document search field 604 , and can also include linked fields within each error entry that provide access to additional information about content collection tasks. Accessing one of the task entries through dashboard 602 A and/or searching for particular tasks may link to a corresponding task specific dashboard 602 B as shown in FIG. 6B . The task specific dashboard 602 B can include information regarding the status of each document within the corresponding task. For example, error entries 612 identify error information pertaining to individual content collection tasks. Within each error entry 612 , additional information regarding each error by accessing a designated link associated with the number of errors for the entry. Additional support notes may also be accessed through a designated link corresponding to each entry. The status of the errors may be editable by accessing corresponding editing links following correction by support staff.
[0048] While not shown in FIG. 6B , the dashboard 602 B can also include tallies including information regarding all content collection tasks. In some embodiments, support personnel may also bulk modify the error status of jobs in the database when a large number of jobs have the same error.
[0049] The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0050] In one or more example embodiments, the functions and methods described may be implemented in hardware, software, or firmware executed on a processor, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium or memory. Computer-readable media include both non-transitory computer storage media and communication media including any medium that facilitates transfer of a computer program. A storage medium may be any available media that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can include non-transitory computer-readable media including RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer. A computer-readable medium can include a communication signal path. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium.
[0051] The system may include various modules as discussed above. As can be appreciated by one of ordinary skill in the art, each of the modules may include one or more of a variety of sub routines, procedures, definitional statements and macros. Each of the modules may be separately compiled and linked into a single executable program. Therefore, the description of each of the modules is used for convenience to describe the functionality of the disclosed embodiments. Thus, the processes that are undergone by each of the modules may be redistributed to one of the other modules, combined together in a single module, or made available in, for example, a shareable dynamic link library.
[0052] The system may be used in connection with various operating systems such as Linux®, UNIX® or Microsoft Windows®. The system may be written in any conventional programming language such as C, C++, BASIC, Pascal, or Java, and ran under a conventional operating system. The system may also be written using interpreted languages such as Visual Basic (VB.NET), Perl, Python or Ruby.
[0053] It will be appreciated by those skilled in the art that various modifications and changes may be made without departing from the scope of the described technology. Such modifications and changes are intended to fall within the scope of the embodiments that are described. It will also be appreciated by those of skill in the art that features included in one embodiment are interchangeable with other embodiments; and that one or more features from a depicted embodiment can be included with other depicted embodiments in any combination. For example, any of the various components described herein and/or depicted in the figures may be combined, interchanged, or excluded from other embodiments.
|
Electronic data file and content capturing systems and methods enable enhanced accessibility and reduced complexity for clients managing large volumes of digital data files. According to one aspect, a system and method provided for validation and tracking of content collection tasks. According to another aspect, systems and methods are disclosed for error management through integrated interfaces that are capable of interacting with and correcting the results of content collection tasks.
| 6
|
BACKGROUND OF THE INVENTION
This invention relates to an expansion device for a heat pump.
Heat pumps employ a compressor, an indoor heat exchanger, an outdoor heat exchanger, an expansion device and 4-way reversing valve, to switch operation between cooling and heating modes. Heat pumps utilize an expansion device through which the refrigerant flow expands from high pressure and temperature to low pressure and temperature. Different size restriction of the expansion device is required for proper system operation depending upon whether the heat pump is in a cooling or heating mode of operation. Obviously, when the system is operating in cooling or in heating mode, the direction of the refrigerant flow through the expansion device is reversed.
Prior art heat pump systems with single expansion devices use a moveable piston that moves in a first direction in which its flow resistance is substantially higher than when it is moved in an opposite second direction. The first direction corresponds to the heating mode and second direction corresponds the cooling mode. The piston is prone to wear, which adversely effects the operation and reliability of the system due to undesirably large tolerances and contamination. Furthermore, modern heat pump systems are incorporating alternate refrigerants, such as R410A, and POE oils. The system utilizing R410A refrigerant operate at much higher pressure differentials than more common R22 and R134A refrigerants employed in the past within the system. This adversely impacts the expansion device wear, lubrication and results in higher loads during transient conditions of operation.
Therefore, there is a need for a single reliable, inexpensive expansion device for the heat pump systems that is not as prone to wear and reliability problems.
SUMMARY OF THE INVENTION
The inventive heat pump expansion device consists of a flow resistance device that has a different resistance to flow depending on the flow direction through this device. The flow resistance device is fixed or rigidly mounted relative to first and second fluid passages so that it avoids the wear problems of the moveable piston in the prior art. The fluid flow resistance device in several examples of the invention is a fixed obstruction about which the refrigerant must flow when traveling through the expansion device. The flow resistance device has features on one side that create a low drag coefficient when the refrigerant flows in one direction but a high drag coefficient when the refrigerant flows in the opposing direction.
Accordingly, the present invention provides a reliable, inexpensive expansion device that is not as prone to wear and reduces reliability problems.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a heat pump having the inventive expansion device.
FIG. 2 to a cross-sectional view of a first example of the inventive expansion device.
FIG. 3 is a cross-sectional view of second example of the inventive expansion device.
FIG. 4 is a cross-sectional view of a third example of the inventive expansion device.
FIG. 5 is a cross-sectional view of a fourth exampled of the inventive expansion device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A heat pump 10 utilizing the present invention and capable of operating in both cooling and heating modes is shown schematically in FIG. 1 . The heat pump 10 includes a compressor 12 . The compressor 12 delivers refrigerant through a discharge port 14 that is returned back to the compressor through a suction port 16 .
Refrigerant moves through a four-way valve 18 that can be switched between heating and cooling positions to direct the refrigerant flow in a desired manner (indicated by the arrows associated with valve 18 in FIG. 1 ) depending upon the requested mode of operation, as is well known in the art. When the valve 18 is positioned in the cooling position, refrigerant flows from the discharge port 14 through the valve 18 to an outdoor heat exchanger 20 where heat from the compressed refrigerant is rejected to a secondary fluid, such as air. The refrigerant flows from the outdoor heat exchanger 20 through a first fluid passage 26 of the inventive expansion device 22 . The refrigerant when flowing in this forward direction expands as it moves from the first fluid passage to a second fluid passage 28 thereby reducing its pressure and temperature. The expanded refrigerant flows through an indoor heat exchanger 24 to accept heat from another secondary fluid and supply cold air indoors. The refrigerant returns from the indoor exchanger 24 to the suction port 16 through the valve 18 .
When the valve 18 is in the heating position, refrigerant flows from the discharge port 14 through the valve 18 to the indoor heat exchanger 24 where heat is rejected to the indoors. The refrigerant flows from the indoor heat exchanger 24 through second fluid passage 28 to the expansion device 22 . As the refrigerant flows in this reverse direction from the second fluid passage 28 through the expansion device 22 to the first fluid passage 26 , the refrigerant flow is more restricted in this direction as compared to the forward direction. The refrigerant flows from the first fluid passage 26 through the outdoor heat exchanger 20 , four-way valve 18 and back to the suction port 16 through the valve 18 .
Several examples of the inventive expansion device are shown in FIGS. 2–6 . The inventive expansion device 22 includes a flow resistance device 30 that is arranged between the first 26 and second 28 fluid passages. Unlike the prior art moveable piston, the flow resistance device 30 is fixed relative to the fluid passages 26 and 28 so that it does not have any features that are subject to damage, wear or contamination. The flow resistance device 30 is shown schematically supported by a pin. The flow resistance device 30 has lower fluid resistance when the refrigerant is flowing in the forward or cooling direction than when refrigerant is flowing in the reverse or heating direction, acting as a fluid diode. This variable fluid resistance is achieved by providing different features on either side of the flow resistance device 30 that increases the fluid resistance in one direction and provides lower fluid resistance in the other direction.
Referring to FIG. 2 , the flow resistance device 30 includes a barbed end 32 facing the second fluid passage 28 . When the refrigerant is flowing in the forward or cooling direction, the refrigerant flows about smooth surfaces of the flow resistance device 30 so that the arrangement of the flow resistance device 30 between the passages 26 and 28 creates relatively little resistance. However, when the refrigerant flows in the reverse order or heating direction, the refrigerant flows into the barbed end 32 creating a very high drag or resistance to the fluid flow.
Another example of the invention is shown in FIG. 3 , which utilizes an angled fluid passage 34 as the flow resistance device 30 . The angled fluid passage 34 is arranged such that refrigerant flowing in the cooling direction generally bypasses the angled fluid passage 34 flowing more directly through to the second fluid passage 28 . However, when the refrigerant flows in the heating direction the refrigerant more easily flows into the angled fluid passage 34 due to its orientation relative to the second fluid passage 28 . Fluid flow from the second fluid passage 28 into the entry of the angled fluid passage 34 is better maintained due to the shallow angle of the wall between the second fluid passage 28 and the wall at the opening of the angled fluid passage 34 . The refrigerant exits the angled fluid passage 34 in such a manner that it is directed back into the flow of refrigerant flowing from the second fluid passage 28 to the first fluid passage 26 creating turbulence and generating an increased flow resistance as compared to refrigerant flowing in the cooling direction.
Referring to FIGS. 4 and 5 , the flow resistance device 30 is arranged between the fluid passages 26 and 28 in a similar manner to that shown in FIG. 2 . As shown in FIG. 4 , the flow resistance device 30 is an open faced hemisphere 38 , and the flow resistance device 30 shown in FIG. 5 is a C-shaped channel 40 arranged between the fluid passages 26 and 28 . As the refrigerant flows in the cooling direction, the smooth rounded surface of the flow resistance devices 30 have a relatively low drag coefficient. However, when the refrigerant flows in the heating direction into the cupped area of the flow resistance devices 30 , a relatively high drag coefficient is experienced increasing the flow resistance in the heating direction.
It should be appreciated that the flow resistances can be expressed using various terminology. For example, the flow resistances can be expressed as drag coefficients. The flow resistances can also be expressed as relative degrees of turbulent or laminar flows. In any event, the change in flow resistance based upon the direction of refrigerant flow is achieved by utilizing a fixed flow resistance device.
Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
|
An expansion device for the heat pump applications consists of a flow resistance device that has a different resistance to refrigerant flow depending on the flow direction through this device. The flow resistance device has no moving parts so that it avoids the damage, wear and contamination problems of the moveable piston in the prior art. The flow resistance device is a fixed obstruction about which the fluid must flow when traveling through the expansion device.
| 5
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
Generally, this invention relates to downhole tools for use in a well. In particular, but not by way of limitation, this invention relates to those tools utilizing a bypass to allow well fluids located below the tool to bypass the main fluid passages of the tool as the tool string is being stung into, or out of, a production packer.
2. Description of Prior Art
During the course of drilling an oil or gas well, one operation which is often performed is to lower a testing string into the well to test the production capabilities of the hydrocarbon producing underground formations intersected by the well. This testing is accomplished by lowering a string of pipe, commonly referred to as the drill pipe, into the well with a formation tester valve attached. Another tool typically run into the well is known as a Tubing String Testing Valve (TST), which is a full opening test valve that allows the drill stem test string to be pressure tested while running in the hole. The TST contains a flapper type valve which acts somewhat similar to a check valve. As the tool string is being run into the hole, the test string annulus can fill with fluid. However, if pressure is placed on the tubing string, the TST flapper valve will seat and seal, thereby allowing the string to be pressure tested. The pressure testing of the drill string can be accomplished as many times as desired.
Once the test string is run to its desired depth, it is then necessary to sting, via a set of seals located on the bottom of the test string, into the production packer. However, if it is necessary to pull the test string up, the TST flapper valve will act as a check valve, thereby causing a pressure decrease due to a increase in volume in the annulus below the TST flapper valve. This decrease in pressure can operate to affect the seals on the bottom of the test string, as well as the seals on the production packer itself.
Furthermore, if one of the other tester valves located in the test string have been closed for testing reasons, the pulling in and out of the seals can act to destroy the seal integrity on the stinger of the test string as well as effecting the seals in the production packer, by causing a piston effect due to the closed annulus area.
Several types of bypasses have been employed with use in drill stem testing. U.S. Pat. No. 2,740,479 to Schwegman provided a bypass which allowed fluid from below the formation tester to flow upward through the packer mandrel and through the lower end of the tester valve, then outward through a bypass port so that it could flow upward in the annulus between the tester valve and the wellbore in order to bypass the piston effect of the larger packer located below the tester valve.
Another example of such a bypass is seen in U.S. Pat. No. 4,582,140 to Barrington, assigned to Halliburton, assignee of the present invention. The Barrington device allowed a choice of several possible functions of that bypass tool In a first arrangement, a bypass is run into the wellbore in an open position and is then latched closed upon operation of the tool by setting down weight. In the second arrangement, the open bypass is run into the well, the bypass is closed by setting down weight; however, the bypass could reopen when the weight was picked up. Finally, the Barrington invention allowed the bypass port to be completely eliminated when it was desired to run the tool without bypass.
However, the bypass valves of the prior art do not deal with the bypass in which a TST valve has been utilized. Therefore, in reference to the present invention, there are several features not possible with the prior art bypass valves. One feature includes the fact that a rupture disk is utilized, said rupture disk being operable by transmitting pressure via an oil chamber to rupture the disk. Also, as an added feature there is included two sets of shear pins provided in the tool. One set of shear pins allows the activation of the time delay function of the present invention; the second set allows for the floating piston to begin its travel, and move the operating mandrel after a predetermined amount of oil has been metered out of the second oil chamber.
Another feature of the present invention utilizes a metering cartridge in order to implement its time delay. The metering cartridge utilizes a restriction, and the restriction size can be varied, hence directly effecting the amount of time necessary to meter the oil.
Also there is contained a recess neck on the operating mandrel, thereby effectively allowing the metering cartridge to be bypassed. When the recess neck of the operating mandrel reaches the metering cartridge, the flow of oil can bypass the metering cartridge, and allow rapid movement of the operating mandrel to import a jarring effect in the tool. Once this jarring effect is accomplished, the ported mandrel will effectively seal off the bypass ports. Furthermore, another feature of the invention is that once the bypass ports have been closed, hydrostatic pressure from within the tubing string will keep the ported mandrel in a closed position alleviating the need for a locking mechanism.
Another feature of the invention allows for pressure testing the seal of the ported mandrel before the test tool is run into the hole. Yet another feature includes having the oil in the second chamber as well as air in a separate chamber under atmospheric pressure, thereby allowing a differential pressure which the floating pistons can act against.
SUMMARY
The present well tool provides for a fluid bypass in a drill stem testing string. The well tool comprises a mandrel which is capable of transmitting force, such as weight, to an internal oil chamber. This force is then transmitted by means of a passage within the well tool to a rupture disk. The rupture disk can be set at varied rupture pressures, at the option of the operator.
Once the desired pressure has ruptured the disk, the mandrel will move up and jar a ported operating mandrel, exposing the port to hydrostatic tubing pressure. This hydrostatic tubing pressure will act on a floating piston contained within a second oil chamber which will force oil to an atmospheric air chamber; however, the flow of oil is delayed by means of a metering cartridge. This provides for a time delay.
After a predetermined amount of oil has been metered, the flow will become unrestricted, allowing for the jarring between the inner operating mandrel and the bypass ported mandrel, thereby effectively closing the bypass ports. Once in the closed position, there is no need for a locking mechanism because the tubing hydrostatic pressure will act to keep the ported mandrel in a closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the present invention will be more fully understood from the following description and drawings wherein:
FIG. 1 provides a schematic vertically sectioned view of a representative offshore installation which may be employed for testing purposes and illustrates a formation testing "string" or tool assembly and position in a submerged wellbore and extending upwardly to a floating operating and testing station.
FIGS. 2A-2E comprise a vertical quarter-section elevation of the production packer bypass valve of the present invention, with bypass ports in the open position.
FIG. 3 comprises a sectional elevation of the rupture disk assembly.
FIG. 4 comprises a sectional elevation of the splined upper mandrel.
FIGS. 5A-5E comprise a vertical quarter-section elevation of the production bypass valve after the bypass ports have been closed.
FIG. 6 comprises a section elevation taken along line 6--6 of FIG. 2.
OVERALL WELL TESTING ENVIRONMENT
Referring to FIG. 1 of the present invention, a testing string for use in an offshore oil or gas well is schematically illustrated.
In FIG. 1 a floating work station 1 is centered over a submerged oil or gas well located in the sea floor 2 having a wellbore 3 which extends from the sea floor 2 to a submerged formation 5 to be tested. The wellbore 3 is typically lined by steel casing 4 cemented into place. A subsea conduit 6 extends from the deck 7 of the floating work station 1 into a wellhead installation 10. The floating work station 1 has a derrick 8 and a hoisting apparatus 9 for raising and lowering tools to drill, test, and complete the oil or gas well.
A testing string 14 is being lowered in the wellbore 3 of the oil or gas well. The testing string includes such tools as one or more pressure balanced slip joints 15 to compensate for the wave action of the floating work station 1 as the testing string is being lowered into place, a circulation valve 16, a tester valve 17 and the bypass valve of the present invention 19.
The slip joint 15 may be similar to that described in U.S. Pat. No. 3,354,950 to Hyde. The circulation valve 16 is preferably of the annulus pressure responsive type and may be as described in U.S. Patent Nos. 3,850,250 or 3,970,147. The circulation valve 16 may also be the reclosable type as described in U.S. Pat. No. 4,113,012 to Evans et. al.
The tester valve 17 is preferably the type disclosed in U.S. Pat. No. 4,429,748, although other annulus pressure responsive tester valves as known in the art may be employed.
A tubing string tester (TST) valve 18 as described in U.S. Pat. No. 4,328,866 which is annulus pressure responsive is located in the testing string above the by-pass valve 19 of the present invention.
The tester valve 17, circulation valve 16 and TST valve 18 are operated by fluid annulus pressure exerted by a pump 11 on the deck of the floating work station 1. Pressure changes are transmitted by a pipe 12 to the well annulus 13 between the casing 4 and the testing string 14. Well annulus pressure is isolated from the formation 5 to be tested by a packer 21 set in the well casing 4 just above the formation 5. The packer 21 may be a Baker Oil Tools Model D packer, the Otis type W packer, the Halliburton Services EZ Drill® SV packer or other packers well known in the well testing art.
The testing string 14 includes a tubing seal assembly 20 at the lower end of the testing string which "stings" into or stabs through a passageway through the production packer 21 for forming a seal isolating the well annulus 13 above the packer 21 from an interior bore portion 22 of the well immediately adjacent the formation 5 and below the packer 21.
By-pass valve 19 relieves pressure built up in testing string 14 below tester valve 17 as seal assembly 20 stabs into packer 21.
A perforating gun 24 may be run via wireline to or may be disposed on a tubing string at the lower end of testing string 14 to form perforations 23 in casing 4, thereby allowing formation fluids to flow from the formation 5 into the flow passage of the testing string 14 via perforations 23. Alternatively, the casing 4 may have been perforated prior to running testing string 14 into the wellbore 3.
A formation test controlling the flow of fluid from the formation 5 through the flow channel in the testing string 14 by applying and releasing fluid annulus pressure to the well annulus 13 by pump 11 to Operate circulation valve 16, tester valve 17, and check valve 18 and measuring of the pressure build up curves and fluid temperature curves with appropriate pressure and temperature sensors in the testing string 14 is fully described in the aforementioned patents.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the description which follows, like parts are generally marked throughout the specification and drawing with the same reference numerals, respectively.
The production packer bypass valve generally comprises a tubular housing member, first power mandrel, a second operating mandrel, means for jarring the first mandrel, means for restricting the flow of oil to an atmospheric chamber, an inner operating mandrel, a ported bypass mandrel, and means for impacting the ported bypass mandrel.
Referring to FIG. 2E, the power mandrel 100 is comprised of a bottom adapter, 101. The bottom adapter has an external thread connection means 102 at its bottom end, while at its opposite end there is provided an internal thread connection means 103, with seal means 104 directly above the internal thread connection means. Both the threaded connections and seals in this portion of the tool, as well as all other threaded connection and seals are those commonly used by the industry as will be appreciated by those skilled in the art.
The power mandrel 100 also contains an inner splined power mandrel 108 with an external thread connection means 106 on the lower end to be threaded with the internal thread end means 103 of the bottom adapter 101. The seal means 104 of the power mandrel will surround the inner splined power mandrel 108 around the outer sealing diameter 109 so that the annulus well bore fluids will be prevented from entering the tubing annulus at this point.
The remaining inner power mandrel 108 has an inner shoulder 110 and disposed on its upper end is an elastomeric member commonly referred to as an O-ring 111. Adjacent to the O-ring 111 and mounted on the top portion of the inner power mandrel is floating piston 112. The floating piston is slidably disposed in oil chamber 113, said oil chamber 113 being formed from the differential area of the outer diameter of the tubular housing 114 and the inner splined power mandrel member 108. This oil chamber is filled with oil at atmospheric pressure before the tool is run in the hole. The floating piston 112 has an elastomeric member placed in the top and bottom grooves 115 and 116, respectively.
The tubular housing member 114 generally consists of a first splined tubular member 117, which will match the grooves of the inner spline power mandrel 101. Referring to FIG. 4, the first spline tubular member 117 will have a plurality of shoulders 118 with an inner diameter smooth bore 187. Referring again to FIG. 2D, at its upper end, the tubular housing member 114 will have an internal threading connection means 120, to which tubular housing nipple member 121 will be threadily connected. The tubular housing nipple member 121 has bored there through a vertical passage 122 from its bottom, such that there is communication between the first oil chamber 113 to a communication port 123 drilled through the tubular member, at a skewed angle, which is also known as a first pressure passage means.
Referring now to FIG. 3, intersecting the vertical passage 122 is a hole 124 drilled at an oblique angle to the outer tubular member. A rupture disk 125 is placed in the bore thereof. At the end of the oblique hole 124, a plug 126 is placed which will effectively seal off the annulus fluids. The vertical passage 122 enters the oblique hole 124 at a position between the plug 126 and the rupture disk 125. As shown in FIG. 2D, the tubular housing nipple 121 has an increased inner diameter at position 127, which defines a shoulder. Also, the tubular housing nipple member at its upper end has elastomeric seal means 128.
An inner operating mandrel, shown generally as 129, is longitudinally disposed above the tubular housing nipple member 121 and with a first defined shoulder 130 resting on shoulder 131 of the tubular housing nipple. The inner operating mandrel 129 also has a bored through port 132 through which the hydrostatic pressure of the tubing will be communicated.
Also contained on the inner operating mandrel 129 is a first recess 133 for inclusion of a plurality of shear pins 134. A second elongated slot 135 is provided for a second set of shear pins 136. The cut-out section 188 of the inner operating mandrel 129 terminates at shoulder 190. Referring to FIG. 2C, the inner operating mandrel 129 will also have an indented groove machined thereon, at 137, which will allow for placement of a ring 138 about the inner operating mandrel 129, or as commonly known by those skilled in the art, a "snap ring" 138. The snap ring 138 is placed around the inner operating mandrel 129 in this groove 137. The inner operating mandrel will have a recessed neck 139 formed from chamfered surfaces 140 and 141.
The outer tubular housing 114 will have a third member 143 threadily connected to the tubular nipple member 121. This third member 143 forms a chamber 144, known as the second oil chamber 144, which is disposed between the third tubular member 143 and the inner operating mandrel 129. Also, bored through the third member 143 are two ports, 145 and 146, which will allow placement of a fluid, such as hydraulic oil, into the chamber 144. This forms the second oil chamber 144. Ports 145 & 146 have contained therein fluid plugs 147 and 148 threadily engaged to prevent oil removal. Port 145 is known as the vent port and port 146 is known as the fill port.
Referring to FIG. 2D, slidably disposed in the second oil chamber 144, is a floating piston 149. A recess 196 is defined on floating piston 149. About both recesses 150 and 151 are placed seals 152 and 153. Before activation of the tool, the floating piston 149 rest against the outer ledge 154 of the tubular nipple member 121. The outer ledge 154 of the tubular nipple 121 has elastomeric sealing means on both the upper and lower sides 155, 156, respectfully.
Referring to FIG. 2C, at the top end of the second oil chamber 144, there is placed a metering cartridge 157 which comprises an annular collar having cylindrical interior and exterior edges 158 and 159, respectfully. Exterior surfaces 159 accommodates annular recess 160 therein, in which is disposed seal means 161.
A plurality of longitudinally oriented metering bores 164 extend partially through metering device 157 from the bottom thereof upwardly. A fluid metering device 157 such as is disclosed in U.S. Pat. No. 3,323,550, and is sold under the trade name of Lee Visco Jet, is disposed in each metering bore 160 at the lower end thereof.
As seen in FIG. 2B, threadily connected to the metering cartridge will be the air chamber case 165. The air chamber case has on its top side internal thread connection means 166 for make-up with the outer ported housing member 167. The air chamber 168 is formed between the air chamber case 165 and the inner operating mandrel housing 129. Since the tool is dressed at the surface, under surface conditions, air in chamber 168 is at atmospheric pressure.
The outer ported nipple 167 contains bypass port 169 bored therethrough. The outer ported nipple 167 has a ledge 170 which has placed about it a set of elastomeric seals, 171 and 172, which seals the air chamber case 165. Referring to FIG. 2A, also provided on the outer ported nipple 167, is a top adapter sub 175, on which first 173 and second 174 auxiliary ports are disposed. The neck of the top adapter sub 175 contains internal threading connection means 176 and a shoulder 177 upon which the ported mandrel can abut.
Referring to FIGS. 2A and 2B, the inner ported mandrel 178 comprises at least one bypass port 179, about which are two sets of elastomeric seals, 180 and 181, respectively and terminates with and shoulder 200. Also, at each end of the inner ported mandrel 178 are seals 182 and 183 respectively. A shoulder 185 of greater outer diameter relative to the inner ported mandrel 178 is provided. Seal means 188 are also provided. Terminating shoulder 200 will abut shoulder 177 after the inner ported mandrel has been jarred.
OPERATION OF THE PREFERRED EMBODIMENT
Returning to figure 1 of the drawings, it will be assumed that a drill stem test string is being, or has been run in the hole in a manner well known in the art; once the test string has been run to the depth of the production packer, the test string can be pressure tested. This is accomplished by utilizing the TST valve. After a successful test, the test string can be stung into the packer seal bore. Also, it may be desirable to sting into the packer bore first, and thereafter testing the test string.
At the point of stinging into the packer, the piston effect contained within the area below the production packer is eliminated because of the bypass ports contained on the present tool. In other words, as the tool string is stung into the packer bore, the excess fluid can be circulated through the bypass ports 169. On the other hand, if for some reason it becomes necessary to pick up the test string, the fluid in the casing annulus can circulate back down the annulus to below the production packer via the bypass ports 169.
Once it is time to begin testing the well, the bypass port 169 will need to be closed. Thus, weight is transmitted from the tool string, by setting down weight, to the first mandrel bottom adapter 101, which in turns transmits weight to the first inner splined power mandrel 108. This power mandrel is slidably mounted in the outer tubular housing 114.
As weight is being applied to the first power mandrel 108, the shoulder 110 of the first power mandrel 10B is urged upward against seal 111 and floating piston 112. As more weight is set down on the first inner splined power mandrel 108, the greater the amount of force is being transmitted to first oil chamber 113. The oil acts through the vertical cut through passage means section 122 of tubular nipple member 121 and is transmitted to the rupture disk 125 via the pressure passage means 122. The rupture disk 125 has a predetermined bursting strength; hence, after the predetermined amount of force transmitted via the oil chamber 113 against the rupture disk 125 has been exerted, the disk will rupture and the oil previously in the first oil chamber 113 will be emptied via an annulus port 125A out into the casing annulus.
Thus, oil has been vented out of the first oil chamber 113 and since there is no longer any resistance, the first inner splined power mandrel 108 will move up rapidly, and strike the inner operating mandrel 129 at shoulder 190. This force will act to jar the inner operating mandrel 129 and will shear pin 134. The port 132 on inner operating mandrel 129 will then be allowed to move up relative to the floating piston 149. The port 132 will then transmit the hydrostatic pressure of the tubing to the floating piston 149, an area represented by numeral 192.
Floating piston 149, being forced upward by the hydrostatic pressure of the tubing acting on the area 192, tends upward against the oil in the second oil chamber 144. The oil in the second oil chamber 144 has been placed in the tool at the surface under atmospheric pressure.
Thus, the oil is being urged out of the chamber 144 due to the difference between the tubing hydrostatic pressure and atmospheric pressure; however, the oil must flow through the metering cartridge 157. The oil enters through the flow device 164, and through annulus 158. The metering cartridge 157 causes a restriction; thus, there is a delay of several minutes from the point where the floating piston 149 begins its upward push and until the recess 139 disposed on the inner operating mandrel, and in particular the chamfered surfaces 141, reaches the metering cartridge 157. The oil is flowing into the air chamber 168 via the annular space between the air chamber case 165 and the inner operating mandrel 129, annular space shown generally at 189 via aperture 194.
Floating piston 149 will slidably travel until floating piston 149 engages snap ring 138 at recess 196. Afterwards, the inner operating mandrel 129 will move relative to the third outer tubular member 143.
In the preferred embodiment, once the recessed neck 139 reaches the metering cartridge, the oil heretofore prevented from circulating around the metering cartridge by seals 161, will in fact bypass the metering cartridge. Therefore, since there is no longer a restriction (the oil is entering into the atmospheric air chamber) the inner operating mandrel 129 will be urged up axially, contacting the inner ported mandrel 178, shown in FIG. 5D, at shoulder 198. Alternatively, the inner operating mandrel 129 can contain a smooth outer diameter (i.e. there is no recessed neck) which will still allow for mandrel 129 to be urged up axially, contacting the inner ported mandrel 178.
When the tool is run in the hole, the bypass ports 169 and 179 of the outer ported nipple 167 and inner ported mandrel 178 are aligned. Thus, by the jarring of the inner operating mandrel 129 and inner ported mandrel 178, the inner ported mandrel 178 will be forced into the neck of the top adapter 175, such that the shoulder 177 of the adapter will abut the shoulder 200 of the inner ported mandrel 178. Referring to FIG. 5A and 5B, with the ported mandrel 178 being in this position, elastomeric seals 180 and 182 are now aligned on either side of port 169 thereby effectively sealing the casing annulus fluid from the internal diameter of the tool and the remainder of the internal diameter of the test string.
Referring to FIG. 2A, also disclosed is a method of testing the seals 180 and 181 before the tool is run in the hole. In order to test the seals 180 and 181, the design of the present invention allows for an auxiliary pump to be hooked up to external auxiliary port 173. Pressure can then be applied to the auxiliary port 173, with pressure being transmitted to the shoulder 185 of the inner ported mandrel 178 as the shoulder rests against the edge of the ported nipple 186.
The pressure applied will tend to make the shoulder 185 travel longitudinally up, relative to the outer ported housing 167 and top adapter 175, thereby closing the bypass ports 169. At this point, seal 180 and 182 will traverse bypass port 169, as shown in figure 5B. Thus, pressure can now be applied to bypass port 169 and an effective test of seals 180 and 182 can be performed. After the test, the inner ported mandrel 178 can be longitudinally moved down so that port 179 of the inner ported mandrel 178 is aligned with a bypass port 169 of the outer ported housing member 167, and the tool can be run into the hole, as shown in FIG. 2A and 2B. Thus, it is apparent that the apparatus of the present invention readily achieves the advantages mentioned as well as those inherent therein. While certain preferred embodiments of the invention have been illustrated for the purpose of this disclosure, numerous changes in the arrangement and construction of parts may be made by those skilled in the art, which changes are embodied within the scope and spirit of the present invention as defined by the appended claims.
|
A bypass valve for bypassing well fluids, and method of use thereof. The valve comprises a tubular housing defining a bypass port therethrough with an inner sleeve mandrel defining a bypass port initially aligned with the bypass port in the housing. The valve also comprises a power mandrel slidably disposed within the housing such that, as weight is set down on the power mandrel, pressure is increased in a first oil chamber which has a rupture disc in communiction therewith. When the pressure reaches a predetermined level, the rupture disc ruptures so that the oil chamber is emptied into the well annulus. This allows the power mandrel to move and strike an operating mandrel which is also slidably disposed in the housing. The jarring force shears a shear pin which allows the operating mandrel to move a floating piston disposed in a second oil chamber. A metering cartridge restricts flow of fluid out of the second metering chamber, thereby providing a time delay for movement of the operating mandrel. The operating mandrel eventually contacts the sleeve mandrel and moves it with respect to the housing so that the bypass ports are no longer aligned, thereby closing the valve.
| 4
|
RELATED APPLICATIONS
[0001] This application is a continuation of allowed U.S. application Ser. No. 11/198,149, filed Aug. 8, 2005, which is herein incorporated by reference.
BACKGROUND
[0002] The present invention is directed to a method and a system for managing collections of data. More specifically the present invention is directed to a method and a system for managing a hierarchy of subsets of data.
[0003] There are many environments in which it is desirable to monitor system operations and/or collect sets of data over certain time periods or in connection with the occurrence of certain events. These sets of data can be considered to be samples of data for a given time interval or in regards to the occurrence of some event or state transaction. One environment in which this periodic sampling is done is in the communications network arena. For example, it may be desirable to collect netflow data from routers in a wide area network (WAN) or local area network (LAN). In this arrangement the netflow information can be gathered by dedicated servers referred to as “collectors”. It is known that it may be appropriate to take samples of the collected data rather than to store all of the raw data in a database. The sampling may be made up of collection of the relevant data that corresponds to a predetermined time interval or corresponds to the occurrence of a particular event. The time interval or event occurrence selected defines a sampling “granularity”. One such data sampling technique is referred to as smart sampling. An example of an algorithm for smart sampling is:
Smart sampling algorithm int smartSample (DataType data, int z) { static int count = 0; if (data.x>z) data.samplingFactor = 1.0; else{ count+=data.x; if (count < z) return 0;//drop else { data.samplingFactor = ((double)z) / data.x; count - count % z; } } return 1; //sample }
[0004] For the ease of description, the remainder of this example will focus on a sampling algorithm which samples data over a given time interval, such as every five minutes. One of skill in the art will recognize, though that the duration of the time interval is variable, as is the decision to use time intervals to define sampling intervals.
[0005] Once the raw data is sampled it can be ingested into a database. The initial sampling interval is taken to be the initial, and smallest, sampling granularity. The size of the granularity, that is the sampling interval, in this example can be set by the data collector.
[0006] In the desired working environment it may be helpful to look at samples of data over larger granularities or time intervals. For example it may be desirable to know what the samples of data are for a one hour period, or a one day period rather than the five minute interval of the smallest granularity. Using a composable sampling algorithm, that is an algorithm that can successively sample, with increasing granularity, the resulting set from each previous round of sampling, a system can derive data for a larger sampling granularity from the set of data collected at the smaller granularity. The derived data set would be equivalent to a data set that could have been collected if the larger granularity had been used at the collection stage.
[0007] In the example given above each sample set for each five minute interval could be considered a separate bin of data. To derive data for a one hour time interval the sampling algorithm would be run over twelve “bins” of data corresponding to the smallest granular level. The derived data would be equivalent to data that would have been collected if the original granularity or time interval had been set for one hour. This derived data set is smaller than the data set in the twelve bins from which it was derived, but there is a corresponding loss of detail.
[0008] The derived data set for hour long intervals could be sampled again to create a data set for a higher level of granularity, for example a day. Thus 24 “one hour” bins of data would be sampled to create another data set, even further reduced. This set would be equivalent to the data that would have been collected if the original granularity bad been selected to be a 24 hour interval rather than the original 5 minute interval.
[0009] One problem that arises in this repeated smart sampling of the data is the problem of making sure that the sampled data are appropriately associated with the respective defined levels of granularity.
[0010] A couple of solutions have been proposed to this problem, but they each have drawbacks.
[0011] One solution involves replicating, within the database, the data that corresponds to each of the granularity levels. In this arrangement any data record that appears in each granularity level actually appears multiple times in the database, each instantiation having associated with it a key or code or identifier that indicates the particular granularity level that instantiation is associated with. While this solution arguably simplifies the process of sorting through the database for records for each granularity level, the replication and duplication increases the storage requirements of the database arrangement.
[0012] In a second proposed solution the data records are not replicated. Instead, each data record receives a separate identifier or key in connection with each granularity that is introduced into the system. As an example, consider bins of 5 minute time intervals sampled and re-sampled so as to create granularities of 1 hour, 24 hours, and seven days. Thus three additional levels of granularity will have been introduced. All of the data records get examined when one conducts a search or query at the smallest or finest level of granularity; a first subset of data records, something less than all of the data records, are in the next level of granularity, the one-hour bins; second subset, something less than the data records of the first subset are in the third granular level and so on. In the second proposed solution a flag for each granularity level is associated with each data record. If “0” indicates that the record is not contained at a particular granularity level and “1” indicates that it is, then if a data record has a key of 0011 this indicates the record is in the five minute interval set and the one hour subset, but not the one day or one week subsets (the flags in this example are arranged with smallest granularity on the right and increasing granularity going from right-to-left; alternative arrangements for the flags may be possible). This arrangement eliminates the need to replicate the data base. However, this arrangement requires that a new key or identifier or code for every data record must be added every time a new level of granularity is created. That is, a new flag must be added to each data record with each sampling of the data so as to accurately and completely reflect those granularity levels with which the data records are associated.
[0013] It is desirable to have a data records management arrangement that avoids the need for duplication of records while avoiding having to introduce multiple keys or flags or identifiers for each data records.
SUMMARY OF THE INVENTION
[0014] The present invention provides an arrangement by which data can be managed even where differing levels of granularity are being considered without undue replication of data or undue expansion of the number of keys or codes or identifiers for each data record.
[0015] In one embodiment a method provides for each data record, collected at a first granularity level, to have associated with it a single key or identifier. As the collected records are re-sampled to provide for higher granularity views of the data, the single key or identifier may be changed to a different identifier to reflect the coarsest or highest level of granularity with which the record is associated. Thus each record may have a single identifier and yet not need to be replicated. When a search is to be done at a given granularity level, the system can query all of the data records having the code for that granularity level and all of the data records having codes of any of the granularity levels that are higher (or coarser) than the given granularity level. This will capture all of the pertinent data records.
[0016] In this arrangement two or more granularity level codes can be processed in parallel to perform a given query.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention is described with reference to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements.
[0018] FIG. 1 is a block diagram illustrating a system in which an embodiment of the present invention may be used.
[0019] FIG. 2 is a flow diagram to illustrate an example of data collection in the system of FIG. 1 .
[0020] FIG. 3 is an alternative presentation of the data collection and sampling shown in FIG. 2 .
[0021] FIG. 4 is a Venn diagram to illustrate a relationship between data sets collected in the system of FIG. 1 .
[0022] FIG. 5 is a flow chart describing a process flow for implementing an embodiment of the present invention.
DETAILED DESCRIPTION
[0000] Overview
[0023] In accordance with an embodiment of the present invention, each data record in a first granularity level is assigned a granularity identifier when the records in a compilation are sampled to create that first granularity level. When the data records corresponding to the first granularity level are sampled to create a second granularity level, those data records that appear in the second granularity level have their granularity level identifier replaced so that their new identifier corresponds to the second granularity level. The process is repeated for each successive sampling process and generation of granularity levels such that when sampling is completed, each data record in granularity level one to X has a single granularity level identifier indicative of the highest, most coarse, granularity level with which the data record is associated.
[0024] FIG. 1 illustrates a system in which data records are gathered, sampled and re-sampled. In this arrangement routers in a wide area network (WAN) or local area network (LAN), network characteristics, such as Cisco Netflow data can be collected by a collector, not shown. This collection of data corresponds to the pre-sampled network data in FIG. 1 . This collection of data is sampled by a smart sampling machine.
[0025] An example of a sampling algorithm for use in the smart sampling machine is a composable sampling process, meaning it can successively sample (with increasing value of z) the resulting set from each previous stage and the final set (e.g. at stage J) would be equivalent in terms of expected number of elements and variance to a single sampling of the original set using the threshold at stage J. For example, if S z referred to a set of sizes sampled by the optimal sampling function using a threshold of z, then:
S z 1 =P z 1 ( S original ) S z 2 =P z 2 ( S z 1 ) S z j =P z j ( S z j-1 )
Since the expected number of elements and variance of the sampled set depend on p(x) and r(x) (i.e., the optimal sampling and renormalization functions), we need to show:
r z 1 , … , z j ( x ) = r z j ( x ) since - r ( x ) = x p ( x ) or max ( x , z ) , then r z 1 , … , z j ( x ) = max ( ( z 1 , … , z j ) , x ) = max ( z j , x ) = r z j ( x ) ( proven !! ! ) ( 1 ) p z 1 , … , z j ( x ) = p z j ( x ) - defining p z 1 , … , z j ( x ) recursively as p z 1 , … , z j - 1 ( x ) p z j ( r z 1 , … , z j ( x ) ) results in p z , j ( r z 1 , … , z j ( x ) ) equaling min ( 1 , max ( z j - 1 , x ) z j ) . Combining the previous equality with the property that any element in a sampled set S z is ≥ z causes p z j - 1 ( x ) p z j ( x ) ( or min ( 1 , x z j - 1 ) min ( 1 , max ( z j - 1 , x ) z j ) ) to equal p z j ( x ) ( p z j - 1 ( x ) ) when z j - 1 ≤ z j ≤ z j + 1 . ( 2 )
[0026] The sampling technique reduces the collection of data creating “bins” of data records, each bin corresponding to “N” minutes of network traffic. These N bins of data records are shared in the database machine, with each “N” minute sample stored in its own file/bin in the database. It may be desirable in the given system to create an artificial sampling window having an interval that is some multiple of the initial sampling interval. For example the original interval N may be 5 minutes while it might be desirable to consider data over a 20 minute interval. The smart sampling machine can be used to group 4 “bins” of records and create a new sample set for the one hour interval. The new sample set would have a higher, coarser, granularity and presumably fewer data records.
[0027] FIG. 2 illustrates conceptually how the data records wind up being associated with difference sampling subsets as sampling is performed one or more times.
[0028] Element 201 , referred to as the parent contains 4 time-continuous post-sampled bins starting at time T and ending at time T+3N, that is, data records for four time intervals at the finest level of granularity (5 minutes per interval in the above example).
[0029] The second level, the children ( 202 A and 202 B) are separate subsets derived by sampling the records of the parent over two consecutive, 2N intervals. That is, element 202 A represents the set of data records created by a sampling of intervals T and T+N (or the first two intervals of the 4 intervals is the parent; the first ten minutes in the example). The element 202 B represents the set derived by sampling the third and fourth intervals of the point, the second ten minutes in the example.
[0030] Further sampling can yield data over an even longer time interval, for example 20 minutes, by sampling the data records of element 202 A and data records of element 202 B.
[0031] The higher the level of granularity the fewer the data records corresponding to the set. All of the records at a given granularity level appear not only in that subset, but in the subset of each granularity level that is lower or finer than that given granularity level. In the illustrated example every data record in the grandchild subset appears in the children level and in the parent level.
[0032] The present invention provides a technique for assigning a single identifier to each data record so that efficient storage can be effected while still facilitating database queries at differing levels of granularity. For example, if a query is desirable across all of the data records at the finest granularity, all of the bins of records at the parent level are examined. If, however, the query is to be conducted at the child level it is desirable to examine all of the records that were part of the subset created by that first level of sampling. The subset of data records includes data records that are also found in one or more higher granularity levels. In the present invention the data records receive a granularity level identifier that identifies the highest granularity level of which the record is a member. This means that any data records that are at the child level, but not the grandchild level, have a child level identifier. Any of the data records for the child level that are in the grandchild level as well, but not a great-grandchild level (should such a sampling granularity exist) has a grandchild level identifier. When a query is to be done at the child level the query is applied to less than all of the parent records. Instead it is applied to the records having the child level identifier, records having the grandchild level identifier and each level identifier up to the coarsest granularity level. This will ultimately capture each of the data records initially identified when the sampling operation created the “child level” of granularity.
[0033] In connection with this embodiment of the invention, because the query is made to one or more granularity level identifier at a time, the query can be processed in parallel across the data records corresponding to the respective granularity level identifiers. This will actually provide the benefit of a more efficient query processing. Thus the present invention not only enhances the efficiency of the storage of the data records, it can be used to enhance the efficiency of querying the database.
[0034] FIG. 3 is alternative presentation of the information illustrated in FIG. 2 . For example level 301 correspond to the parent level of FIG. 2 wherein there are M contiguous intervals of N time, where M=8 and N=five minutes. Thus there are 8 bins of data records covering a 40 minute interval. Level 302 corresponds to the child level of FIG. 2 wherein M/4=2, that is groups of 2 bins are sampled to create a first subset of data over four virtual bins, each corresponding to a 10 minutes window. Level 303 corresponds to the grandchild level of FIG. 2 where M/2=4, that is a second subset of data records is identified, associated with two “virtual bins” each having a 20 minute interval. Finally, a last level 304 is a great grandchild level (not shown in FIG. 2 ) wherein a third subset of data records is identified, associated with a virtual bin having a 40 minute interval.
[0035] FIG. 4 is a diagram provided to help illustrate a relationship between the records in the various granularity levels. As the granularity becomes more coarse the number of records in a level becomes smaller. However, every record at a given granularity was taken as a sample from a finer level of granularity. Thus each record at a given granularity level is inherently a member of the granularity subset for each preceding, finer level of granularity. The present invention takes advantage of this fact by assigning to each data record an identifier associated with the highest, coarsest, granularity level in which the data record appears and then generates search queries using multiple identifiers to capture a universe of data records that matches all of the records that were within a given granularity irrespective of how many coarser levels the record may also appear in due to re-sampling.
[0000] The Process
[0036] FIG. 5 illustrates a flow chart for executing a process according to an embodiment of the present invention.
[0037] According to an embodiment of a process, data records are collected corresponding to a given time interval are stored in files or bins on an interval by interval basis, 501 . The set of data records are sampled over some second interval, typically a multiple of the given time interval to identify a first subset of the data records as being part of a first sampling granularity level, 505 . All of the records identified as being members of this first subset are provided a unique identifier corresponding to the first granularity level, e.g. 001 , 510 .
[0038] The subset of data records of said first granularity level are sampled over a third time interval, typically a multiple of the second time interval, to identify a second subset of the data records as being part of a second sampling granularity level, 515 . All of the records identified as being members of this second subset have their unique identifier replaced to show that the record is a member of this second subset, 520 . The unique identifier for those records which are part of the first subset, but not the second subset, remains unchanged. If a third granularity level is to be created the process of sampling and replacing unique identifiers is repeated. The result is that each record has a unique granularity level identifier that indicates the highest (coarsest) granularity level subset with which the record is associated.
[0039] In the three level example of FIG. 3 the unique identifiers could be 001 for the first granularity level (M/4), 011 for the second granularity level (M/2) and 111 for the third granularity level. In this example, a query directed to the coarsest granularity level, the third level, would only be directed to those data records in the database with the identifier 111 . If a query is directed to the second granularity level, the process is directed to all of the records with identifier 011 and those records with identifier 111 , the latter because the records at that higher granularity were samples taken from the second level of granularity. If a query is directed to the first granularity level the process is directed to all of the records with the identifier 001 and those records with identifiers 011 and 111 , the latter two identifiers because all of the data records in these granularity levels were samples originally appearing in the first subset, that is the first granularity level.
[0040] When multiple identifiers are used to respond to or perform a query the search or query mechanism can process the identifiers in parallel, as described above, thereby enhancing the processing operation.
CONCLUSION
[0041] While various embodiments of the invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. For example, the above example described data collections based on data sampled from a communications network. The invention is also usable in other environments where data is to be collected and grouped and then sampled to create information sets that reflect different granular views of the collected data. For example, this could be applied to any data collection/reporting system where the data collected is selected by a composable sampling algorithm. In addition, the recited examples refer to collections of data based on sampling intervals that are defined in relation to time intervals. The invention is also applicable where the sampling is to be event-driven rather than length-of-elapsed-time driven. Examples of such event-driven data collection arrangements include resampling the data collected for a particular duration to further reduce its volume when the duration exceeds a predetermined threshold. The disclosed embodiments illustrated up to three additional levels of sampling granularity. One of skill in the art would recognize that the present invention is applicable across more or fewer levels of granularity. The invention provides an identification that captures a highest, coarsest granularity level for a given record and then makes sure that all appropriate identifiers are employed to adequately respond to any query. Thus, the breadth and scope of the invention should not be limited by any of the above-described embodiments, but should be defined only in accordance with the following claims and their equivalents. While the invention has been particularly shown and described with reference to specific embodiments thereof, it will be understood that various changes in form and details may be made.
|
A method and system provide for management of a collection of data records. The data records have associated therewith an identifier or code that indicates the most coarse level of granularity with which the data record is associated in a hierarchy of sampling subsets created across a range of granularity levels.
| 8
|
[0001] The present invention is a result of a research and development project sponsored by the US National Science Foundation Small Business Technology Transfer (STTR) Program.
FIELD OF THE INVENTION
[0002] The present invention relates generally to the field of nano graphene, often referred to as nano graphene platelets (NGPs), nano graphene sheets, or nano graphene ribbons (NGRs).
BACKGROUND OF THE INVENTION
[0003] Nanocomposites containing nano-scaled fillers possess unique features and functions unavailable in conventional fiber-reinforced polymers. One major filler development in the past two decades is the carbon nanotube (CNT), which has a broad range of nanotechnology applications. However, attempts to produce CNT in large quantities have been fraught with overwhelming challenges due to poor yield and costly fabrication and purification processes. Hence, even the moderately priced multi-walled CNTs remain too expensive to be used in high volume polymer composite and other functional or structural applications. Further, for many applications, processing of nanocomposites with high CNT concentrations has been difficult due to the high melt viscosity.
[0004] Instead of trying to develop lower-cost processes for CNTs, the applicants sought to develop an alternative nanoscale carbon material with comparable properties that can be produced much more cost-effectively and in larger quantities. This development work led to the discovery of processes and compositions for a new class of nano material now commonly referred to as nano graphene platelets (NGPs), graphene nano sheets, or graphene nano ribbons [e.g., B. Z. Jang and W. C. Huang, “Nano-scaled graphene plates,” U.S. Pat. No. 7,071,258, Jul. 4, 2006].
[0005] An NGP is a platelet, sheet, or ribbon composed of one or multiple layers of graphene plane, with a thickness as small as 0.34 nm (one carbon atom thick). A single-layer graphene is composed of carbon atoms forming a 2-D hexagonal lattice through strong in-plane covalent bonds. In a multi-layer NGP, several graphene planes are weakly bonded together through van der Waals forces in the thickness-direction. Multi-layer NGPs can have a thickness up to 100 nm. Conceptually, an NGP may be viewed as a flattened sheet of a carbon nano-tube (CNT), with a single-layer graphene corresponding to a single-wall CNT and a multi-layer graphene corresponding to a multi-wall CNT. However, this very difference in geometry also makes electronic structure and related physical and chemical properties very different between NGP and CNT. It is now commonly recognized in the field of nanotechnology that NGP and CNT are two different and distinct classes of materials.
[0006] NGPs are predicted to have a range of unusual physical, chemical, and mechanical properties and several unique properties have been observed. For instance, single-layer graphene (also referred to as single-sheet NGP) was found to exhibit the highest intrinsic strength and highest thermal conductivity of all existing materials [C. Lee, et al., “Measurement of the Elastic Properties and Intrinsic Strength of Monolayer Graphene,” Science, 321 (July 2008) 385-388; A. Balandin, et al. “Superior Thermal Conductivity of Single-Layer Graphene,” Nano Lett., 8 (3) (2008) 902-907]. Single-sheet NGPs possess twice the specific surface areas compared with single-walled CNTs. In addition to single-layer graphene, multiple-layer graphene platelets also exhibit unique and useful behaviors. Single-layer and multiple-layer graphene are herein collectively referred to as NGPs. Graphene platelets may be oxidized to various extents during their preparation, resulting in graphite oxide or graphene oxide (GO) platelets. In the present context, NGPs refer to both “pristine graphene” containing no oxygen and “GO nano platelets” of various oxygen contents. It is helpful to herein describe how NGPs are produced.
[0007] The processes that have been used to prepare NGPs were recently reviewed by the applicants [Bor Z. Jang and A Zhamu, “Processing of Nano Graphene Platelets (NGPs) and NGP Nanocomposites: A Review,” J Materials Sci. 43 (2008) 5092-5101]. As illustrated in FIG. 1 , the most commonly used process entails treating a natural graphite powder (referred to as Product (A) in FIG. 1 ) with an intercalant and an oxidant (e.g., concentrated sulfuric acid and nitric acid, respectively) to obtain a graphite intercalation compound (GIC) or, actually, graphite oxide (GO) (referred to as Product (B) in FIG. 1 ). Prior to intercalation or oxidation, graphite has an inter-graphene plane spacing of approximately 0.335 nm (L d =½d 002 =0.335 nm or 3.35 Å, based on X-ray diffraction data readily available in open literature). There is a misconception in the scientific community that van der Waals forces are weak forces, which needs some qualifications. It is well-known that van der Waals forces are short range forces, but can be extremely strong in magnitude if the separation between two objects (e.g., two atoms or molecules) is very small, say <0.4 nm. However, the magnitude of van der Waals forces drops precipitously when the separation increases just slightly. Since the inter-graphene plane distance in un-intercalated and un-oxidized graphite crystal is small (<0.34 nm), the inter-graphene bonds (van der Waals forces) are actually very strong.
[0008] With an intercalation or oxidation treatment, the inter-graphene spacing is increased to a value typically greater than 0.55-0.65 nm. This is the first expansion stage experienced by the graphite material. The van der Waals forces are now significantly weakened due to the increased spacing. It is important to note that, in most cases, some of the graphene layers in a GIC are intercalated (with inter-graphene spacing increased to 0.55-0.65 nm and van der Waals forces weakened), but other layers could remain un-intercalated or incompletely intercalated (with inter-graphene spacing remaining approximately 0.34 nm and van der Waals forces staying strong).
[0009] In the conventional processes, the obtained GIC or GO, dispersed in the intercalant solution, will need to be rinsed for several cycles and then dried to obtain GIC or GO powders. These dried powders, commonly referred to as expandable graphite, are then subjected to further expansion or second expansion (often referred to as exfoliation) typically using a thermal shock exposure approach (at a temperature from 650° C. to 1,100° C.). The acid molecules residing in the inter-graphene spacing are decomposed at such a high temperature, generating volatile gas molecules that could push apart graphene planes. The inter-flake distance between two loosely connected flakes or platelets is now increased to the range of typically >20 nm to several μm (hence, very weak van der Waals forces).
[0010] Unfortunately, typically a significant portion of the gaseous molecules escape without contributing to exfoliation of graphite flakes. Further, those un-intercalated and incompletely intercalated graphite layers remain intact (still having an inter-graphene spacing of approximately <0.34 nm). Additionally, many of the exfoliated flakes re-stack together by re-forming van der Waals forces if they could not be properly separated in time. These effects during this exfoliation step led to the formation of exfoliated graphite (referred to as Product (C) in FIG. 1 ), which is commonly referred to as “graphite worm” in the industry.
[0011] The exfoliated graphite or graphite worm is characterized by having networks of interconnected (un-separated) flakes which are typically >50 nm thick (often >100 nm thick). These individual flakes are each composed of hundreds of layers with inter-layer spacing of approximately 0.34 nm (not 0.6 nm), as evidenced by the X-ray diffraction data readily available in the open literature. In other words, these flakes, if separated, are individual graphite particles, rather than graphite intercalation compound (GIC) particles. This thermal shock procedure can produce some separated graphite flakes or graphene sheets, but normally the majority of graphite flakes remain interconnected. Again, the inter-flake distance between two loosely connected flakes or platelets is now increased to from 20 nm to several μm and, hence, the ven der Waals forces that hold them together are now very weak, enabling easy separation by mechanical shearing or ultrasonication.
[0012] Typically, the exfoliated graphite or graphite worm is then subjected to a sheet or flake separation treatment using air milling, mechanical shearing, or ultrasonication in a liquid (e.g., water). Hence, a conventional process basically entails three distinct procedures: first expansion (oxidation or intercalation), further expansion (so called “exfoliation”), and separation. The resulting NGPs are graphene oxide (GO), rather than pristine graphene.
[0013] It is important to note that the separation treatment (e.g. using ultrasonication or shearing) is to separate those thick flakes from one another (breaking up the graphite worm or sever those weak interconnections), and it is not intended for further peeling off individual graphene planes. In the prior art, a person of ordinary skill would believe that ultrasonication is incapable of peeling off non-intercalated/un-oxidized graphene layers. In other words, in the conventional processes, the post-exfoliation ultrasonication procedure was meant to break up graphite worms (i.e., to separate those already largely expanded/exfoliated flakes that are only loosely connected). Specifically, it is important to further emphasize the fact that, in the prior art processes, ultrasonification is used after intercalation and oxidation of graphite (i.e., after first expansion) and most typically after thermal shock exposure of the resulting GIC or GO (i.e., after second expansion or exfoliation) to aid in breaking up those graphite worms. There are already much larger spacings between flakes after intercalation and/or after exfoliation (hence, making it possible to easily separate flakes by ultrasonic waves). This ultrasonication was not perceived to be capable of separating those un-intercalated/un-oxidized layers where the inter-graphene spacing remains <0.34 nm and the van der Waals forces remain strong.
[0014] To the best of our knowledge, the applicant's research group was the very first in the world to surprisingly observe that, under proper conditions (e.g., with the assistance of a surfactant), ultrasonication can be used to produce ultra-thin graphene directly from graphite, without having to go through chemical intercalation or oxidation. This invention was reported in a patent application [A. Zhamu, J. Shi, J. Guo, and Bor Z. Jang, “Method of Producing Exfoliated Graphite, Flexible Graphite, and Nano Graphene Plates,” US patent Ser. No. Pending, 11/800,728 (May 8, 2007)]. Schematically shown in FIG. 2 are the essential procedures used to produce single-layer or few-layer graphene using this direct ultrasonication process. This innovative process involves simply dispersing pristine graphite powder particles in a liquid medium (e.g., water, alcohol, or acetone) containing a dispersing agent or surfactant to obtain a suspension. The suspension is then subjected to an ultrasonication treatment, typically at a temperature between 0° C. and 100° C. for 10-120 minutes. No chemical intercalation or oxidation is required. The graphite material has never been exposed to any obnoxious chemical. This process combines expansion, exfoliation, and separation into one step. Hence, this simple yet elegant method obviates the need to expose graphite to a high-temperature, or chemical oxidizing environment. The resulting NGPs are essentially pristine graphene, which is highly conductive both electrically and thermally.
[0015] This direct ultrasonication process may be considered as peeling off graphene layers at a rate of 20,000 attempts per second (if the ultrasonic frequency is 20 kHz) or higher (if higher frequency) per each suspended graphite particle. The resulting NGPs are pristine graphene without any intentionally added or bonded oxygen. This is a powerful approach to the large-scale preparation of pristine NGPs.
[0016] After additional research and development work, we have further discovered that a surfactant is not needed if the graphite particles are mixed with a certain liquid or solvent that meets a specific surface energy requirement. The resulting surfactant-free mixture of pristine graphitic particles (non-preintercalated, un-oxidized, un-fluorinated, etc) and solvent is then subjected to direct ultrasonication. This improvement is significant since it eliminates the need to remove a surfactant from this liquid or solvent. In certain applications, the surfactant removal procedure could be challenging, tedious, or expensive, particularly where the NGP-liquid suspension is intended for use directly as a product (e.g., as a conductive ink, coating, or paint) and the presence of a surfactant is undesirable.
[0017] The presently invented process is fast and environmentally benign. It can be easily scaled-up for mass production of highly conducting graphene. Again, it is important to emphasize that, in all prior art processes, ultrasonification was used after intercalation and oxidation of graphite (i.e., after first expansion) and, in most cases, after thermal shock exposure of the resulting GIC or GO (after second expansion). In contrast, the presently invented process does not involve pre-oxidizing or pre-intercalating the starting graphite particles.
[0018] It may be noted that a few other approaches to producing graphene materials also involve the use of pristine graphite as starting material. The fundamental value of such an approach lies in its avoidance of graphite oxidation and subsequent reduction (typically incomplete reduction only), thereby preserving the desirable electronic properties of graphene. There is precedent for exfoliation of pristine graphite in neat organic solvents without oxidation or surfactants. Hernandez et al reported dispersion of natural graphite using N-methylpyrrolidone (NMP), resulting in individual sheets of graphene at a concentration of ≦0.01 mg/mL [Y. Hernandez, et al, “High-yield production of graphene by liquid phase exfoliation of graphite,” Nature Nanotechnology, 2008, 3, 563]. This is possible because the energy required to exfoliate graphene is balanced by the solvent-graphene interaction for solvents whose surface energies match that of graphene, resulting in a minimal enthalpy of mixing and possibly negative Gibbs free energy of mixing. This is a liquid phase “dissolution” approach. NMP is a highly polar solvent, and not ideal in cases where reaction chemistry requires a nonpolar medium. Further, it is hygroscopic, making its use problematic when water must be excluded from reaction mixtures.
[0019] Hence, it was an object of the present invention to provide a method of mass-producing a pristine nano graphene material that has good electrical conductivity.
[0020] It was another object of the present invention to provide a process for mass-producing pristine NGPs without involving the use of any undesirable acid, oxidizing agent, chemical reducing agent, or a surfactant.
[0021] It was a further object of the present invention to provide a process for producing ultra-thin NGPs (e.g., those with a thickness less than 1 nm).
[0022] Another object of the present invention was to provide a process capable of directly producing a dispersion product containing pristine NGPs and a liquid medium, without having to remove a surfactant or any other chemical from the dispersion.
[0023] Still another object of the present invention was to provide a process capable of directly producing a precursor to a composite product, wherein the precursor contains pristine NGPs dispersed in a surfactant-free liquid medium (e.g., a solvent) and a monomer or polymer dissolved therein. This process does not require removal of a surfactant or any other chemical from the solvent. When the solvent is vaporized and monomer cured or synthesized, an NGP-reinforced polymer composite is produced.
[0024] A further object of the invention was to provide a versatile process for mass-producing pristine NGPs from a broad range of pristine graphitic materials (e.g. natural graphite, artificial graphite, MCMBs, carbon or graphite fibers, carbon or graphite nano-fibers, graphitic cokes, meso-phase carbon, soft carbon, hard carbon, graphitized pitch, and combinations thereof).
SUMMARY OF THE INVENTION
[0025] The present invention provides a method of exfoliating a graphitic material to produce nano-scaled graphene platelets having a thickness smaller than 100 nm, typically smaller than 10 nm, and most typically smaller than 1 nm. The method comprises (a) dispersing particles of a graphitic material in a liquid medium containing no surfactant to obtain a suspension wherein the liquid medium has a low surface tension, characterized as having a contact angle on the graphene plane smaller than 90° (preferably <75°, more preferably <60°, further preferably <45°, and most preferably <30°); and (b) exposing the suspension to ultrasonic waves (a process commonly referred to as ultrasonication) at an energy or power level for a sufficient length of time to produce the separated nano-scaled platelets. This contact angle is measured on the graphene plane, not on the graphene edge surface. The suspension typically has a graphitic material content much greater than 0.1 mg/mL, more typically >1 mg/mL, most typically >10 mg/mL (hence, affording a truly high production yield). The power level is typically above 80 watts, but more typically above 150 watts and, in many cases, above 200 watts.
[0026] In the presently invented method, the contact angle between the liquid (e.g., solvent) and the graphene plane (not the edge surface of a graphite crystallite) is the most critical parameter that dictates if direct ultrasonication can produce NGPs directly from a pristine graphitic material without prior intercalation, oxidation, fluorination, or any other chemical treatment.
[0027] Using natural graphite as an example, a graphite powder typically contains graphite particles that are 10-500 μm in diameter. Each particle is composed of multiple crystallites demarcated by defected or amorphous carbon boundaries. Each crystallite is basically a stack of typically hundreds of graphene layers bonded together by van der Waals forces in a direction normal to the graphene plane (or basal plane), as schematically shown in FIG. 3(A) . The length and width of a crystallite are typically in the range of 100 nm to 10 μm, but can be larger or smaller depending upon the sources of materials or how the graphitic materials were made.
[0028] Direct ultrasonication as herein disclosed serves to not only break up the graphite particles into individual crystallites, but also expand, exfoliate, and separate individual graphene planes (or a small stack of graphene planes) from each crystallite to produce ultra-thin, pristine NGPs. Preferably, the ultrasonication step is conducted at a temperature lower than 100° C. The energy (power) level is typically greater than 80 watts, preferably greater than 150 watts. The graphitic material could be natural graphite, synthetic graphite, highly oriented pyrolytic graphite, meso-carbon mcro-bead (MCMB), partially graphitized pitch, graphite fiber, graphite nano-fiber, soft carbon, hard carbon, pyrolitic coke, or a combination thereof.
[0029] This invented method could involve adding a monomer or polymer into the resulting suspension of nano graphene in solvent. The resulting suspension comprises NGPs dispersed in a monomer- or polymer-containing solvent to form a nanocomposite precursor suspension. This suspension can be converted to a mat or paper (e.g., by following a paper-making process). The nanocomposite precursor suspension may be converted to a nanocomposite solid by removing the solvent or polymerizing the monomer.
[0030] It may be noted that ultrasonication was used to separate graphite flakes after exfoliation of pre-intercalated or pre-oxidized natural graphite. Examples are given in Sakawaki, et al. (“Foliated Fine Graphite Particles and Method for Preparing Same,” U.S. Pat. No. 5,330,680, Jul. 19, 1994); and Chen, et al. (“Preparation and Characterization of Graphite Nanosheets from Ultrasonic Powdering Technique,” Carbon, Vol. 42, 2004, 753-759). However, there has been no report on the utilization of high-power ultrasonic waves in directly exfoliating graphite (without acid intercalation, oxidation, or solvating/dissolving by a solvent) and, concurrently, separating exfoliated particles into isolated or separated graphite flakes or platelets with a thickness less than 10 nm.
[0031] Those who are skilled in the art of expandable graphite, graphite exfoliation, and flexible graphite would believe that graphite must be intercalated or oxidized first to obtain a stable intercalation compound or graphite oxide before it could be exfoliated. It is extremely surprising for us to observe that prior intercalation or oxidation is not required of graphite for expansion and exfoliation, and that exfoliation can be achieved by using ultrasonic waves at relatively low temperatures (e.g., room temperature).
[0032] Most of the prior art methods of producing NGPs began with natural graphite as the starting material. In the instant application, the graphitic material is not limited to natural graphite; it may be selected from the group consisting of natural graphite, artificial graphite, graphite oxide, graphite fluoride, graphite fiber, carbon fiber, carbon nano-fiber, carbon nano-tube, mesophase carbon micro-bead (MCMB), soft carbon, hard carbon, and combinations thereof. This is not a trivial or obvious extension of the work on natural graphite since these materials have very different surface morphology and other characteristics that could prevent liquid wetting or interaction. Technically, MCMBs are usually obtained from a petroleum heavy oil or pitch, coal tar pitch, or polynuclear hydrocarbon material (highly aromatic molecules). When such a precursor pitch material is carbonized by heat treatment at 400° to 550° C., micro-crystals called mesophase micro-spheres are formed in a non-crystalline pitch matrix. These mesophase micro-spheres, after being isolated from the pitch matrix (which is typically soluble in selected solvents), are often referred to as meso-carbon micro-beads (MCMB). The MCMBs commercially available are those that have been subjected to a further heat treatment at a temperature in the range of 2,000° C. and 3,000° C. Some of the carbonized pitch is not spherical in shape and can be partially graphitized to generate graphene sheets dispersed in an amorphous carbon matrix.
[0033] In many cases, the NGPs produced in our studies have a specific surface area in the range of approximately 300 m 2 /g to 2,600 m 2 /g. The NGPs obtained with the presently invented process tend to contain a significant proportion of single-layer graphene (with a thickness of approximately 0.34 nm) or graphene of few layers (<2 nm). The NGP material obtained with this process, when formed into a thin film with a thickness no greater than 100 nm, exhibits an electrical conductivity of typically at least 100 S/cm and quite often higher than 1,000 S/cm.
[0034] The presently invented process is superior to many prior art processes in several aspects:
(1) For instance, Aksay, McAllister, and co-workers used thermal exfoliation of completely oxidized graphite (GO) to obtain exfoliated graphite oxide platelets [McAllister, M. J., et al., “Single sheet functionalized graphene by oxidation and thermal expansion of graphite,” Chem. Materials 19(18), 4396-4404 (2007)]. The process involved exposing the GO to a gas environment at 1,050° C. for 30 seconds or in a propane torch for less than 15 seconds. Such a thermal shock exposure typically produces graphite oxide platelets (rather than nano graphene) that are typically not electrically conducting. (2) In another commonly used prior art approach, as practiced by Stankovich et al. [S. Stankovich, “Stable aqueous dispersions of graphitic nanoplatelets via the reduction of exfoliated graphite oxide in the presence of poly(sodium 4-styrenesulfonate),” J. Mater. Chem. 16, 155-158 (2006)], graphite was heavily oxidized to obtain graphite oxide, which was then mixed with water. The resulting suspension was then subjected to ultrasonication for an extended period of time to produce colloidal dispersions of GO platelets. The graphite oxide dispersion was then reduced with hydrazine, in the presence of poly (sodium 4-styrenesulfonate). This process led to the formation of a stable aqueous dispersion of polymer-coated graphene platelets. However, the reducing agent, hydrazine, is a toxic substance. (3) Becerril, et al [H. A. Becerril, et al., “Evaluation of Solution-Processed Reduced Graphene Oxide Films as Transparent Conductors,” ACS Nano, 2 (2008) 463-470] developed a process for producing transparent, yet conducting electrode. The electrode was made by following a very tedious process that involves oxidation of natural graphite to form GO, repeated washing, ultrasonication, and 15 cycles of impurity removal steps that include centrifugation, discarding supernatant liquid, and re-suspending the solid in an aqueous mixture of sulfuric acid and hydrogen peroxide. The suspension was eventually spin-coated on a solid substrate to form a GO thin film, which was then partially reduced by heating the film in a high vacuum at a high temperature for a long period of time. Such a long process does not appear to be amenable to mass production of conducting nano graphene platelets. (4) Another unexpected benefit of the presently invented process is the observation that the pristine NGPs produced are relatively defect-free, exhibiting an exceptionally high conductivity. In contrast, the heavily oxidized GO platelets are typically highly defected and could not fully recover the perfect graphene structure even after chemical reduction. Therefore, the resulting platelets exhibit a conductivity value lower than that of a more perfect NGP obtained with the presently invented process. (5) The presently invented process, if desirable, allows for the mixing and dispersion of a wide range of ingredients in the liquid medium (in addition to the produced NGPs) for the purpose of imparting other desirable functionalities to the dispersion. For instance, those ingredients commonly used in a paint or coating formulation may be easily added into the dispersion. (6) For nanocomposite applications, a resin component (e.g., monomer, oligomer, and polymer) and/or curing agent may be easily added to the suspension to form a precursor solution to a composite. Subsequently, the liquid medium (e.g., solvent) may be removed and the resulting mixture solidified.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 Conventional, most commonly used chemical processes for producing oxidized NGPs or GO platelets.
[0042] FIG. 2 A surfactant-assisted direct ultrasonication method disclosed earlier by the instant applicants.
[0043] FIG. 3 (A) Schematic of graphite crystallites in a graphitic material; each crystallite is a stack of graphene planes bonded together along the crystallographic c-direction; (B) An isolated NGP having two graphene planes and four edge surfaces.
[0044] FIG. 4 Graphene plane contact angle values of various liquids plotted as a function of liquid surface tension.
[0045] FIG. 5 Graphene edge surface contact angle values of various liquids plotted as a function of liquid surface tension.
[0046] FIG. 6 Average thickness of NGPs obtained by direct ultrasonication in various liquids, platted as a function of graphene plane contact angle values.
[0047] FIG. 7 A perceived view of how low surface tension solvent-assisted direct ultrasonication works to produce ultra-thin graphene sheets.
[0048] FIG. 8 The graphene surface contact angle data for those liquids considered “good solvents” for solvating or dissolving graphene molecules according to the approach of Hernandez, et al. These data indicate that these good solvents exhibit too high a contact angle to be useful or effective for the solvent-assisted direct ultrasonication of the instant application.
[0049] FIG. 9 The electrical conductivity data of three series of NGP-epoxy composites, one featuring pristine graphene as a reinforcement, the second chemically reduced graphite oxide, and the third graphite oxide platelets.
[0050] FIG. 10 Transmission electron micrograph of select NGP.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0051] Carbon materials can assume an essentially amorphous structure (glassy carbon), a highly organized crystal (graphite), or a whole range of intermediate structures that are characterized in that various proportions and sizes of graphite crystallites and defects are dispersed in an amorphous matrix. Typically, a graphite crystallite is composed of a number of graphene sheets or basal planes that are bonded together through van der Waals forces in the c-axis direction, the direction perpendicular to the basal plane. These graphite crystallites are typically of micron- or nanometer sizes. The graphite crystallites are dispersed in or connected by crystal defects or an amorphous phase in a graphite particle, which can be a graphite flake, carbon/graphite fiber segment, carbon/graphite whisker, or carbon/graphite nano-fiber.
[0052] One preferred specific embodiment of the present invention is a method of producing a nano graphene platelet (NGP) material that is essentially composed of a sheet of graphene plane or multiple sheets of graphene plane stacked and bonded together. Each graphene plane, also referred to as a graphene sheet or basal plane, comprises a two-dimensional hexagonal structure of carbon atoms. Each platelet has a length and a width parallel to the graphene plane and a thickness orthogonal to the graphite plane. The thickness of an NGP is 100 nanometers (nm) or smaller and more typically thinner than 10 nm with a single-sheet NGP being as thin as 0.34 nm. The length and width of a NGP are typically between 1 μm and 10 μm, but could be longer or shorter. For certain applications, both length and width are smaller than 1 μm.
[0053] The method is capable of concurrently exfoliating and separating a graphitic material to produce pristine. The method comprises no pre-intercalation or pre-oxidation step since the starting material is a pristine graphitic material. The method comprises: (a) providing a pristine graphitic material comprising at least a graphite crystallite having a graphene plane and an edge surface; (b) dispersing multiple particles of said graphitic material in a liquid medium containing therein no surfactant to produce a suspension, wherein the liquid medium is characterized by having a surface free energy that enables wetting of the liquid on a graphene plane; and (c) exposing the suspension to direct ultrasonication at an energy or intensity level (e.g. >150 watts) for a sufficient length of time to produce the nano graphene platelets. The concentration of the starting material in the solvent is typically much higher than 0.1 mg/mL, and more typically higher than 1 mg/mL, and most typically higher than 10 mg/mL, implying that this is a truly high production yield process.
[0054] The first step may involve preparing a graphitic material powder, such as fine graphite particulates, short segments of carbon fiber or graphite fiber, carbon or graphite whiskers, carbon or graphitic nano-fibers, MCMBs, pyrolitic cokes, or their mixtures. The length and/or diameter of these graphite particles are preferably less than 0.2 mm (200 μm), further preferably less than 0.01 mm (10 μm). They can be smaller than 1 μm. The graphite particles are known to typically contain micron- and/or nanometer-scaled graphite crystallites with each crystallite being composed of multiple graphene sheets bonded by van der Waals forces.
[0055] The second step of the presently invented method comprises dispersing a pristine graphitic material in a liquid medium (e.g., a low surface tension solvent) to obtain a suspension with the particles being suspended in the liquid medium. The suspension is then subjected to high-power ultrasonication (e.g., typically >>80 watts, but more typically >150 watts) typically at 0-100° C. (more typically at approximately 20° C.) for 30 minutes (can be longer or shorter). Typically, the starting pristine graphite material is in the concentration of >1-10 mg/mL. Typically, 30 minutes were all that was needed to create ultra-thin NGPs well-dispersed in the solvent. When a proper solvent was used, essentially no large graphite particle (e.g. >100 nm) was found after ultrasonication for 30 minutes. No centrifuging step was required to remove excessively large graphite particles. In other words, essentially >99% of the graphite particles was effectively exfoliated for most of the samples. For some graphite fibers, less than 99% but greater than 95% was exfoliated to become NGPs. This is in sharp contrast to the typically less than 10% of effectiveness in other processes (e.g., Hernandez, et al, to be further discussed later)
[0056] Most importantly, we have surprisingly found that the low surface tension solvent and high-power ultrasonic waves work in concert to facilitate the expansion, exfoliation and separation of graphene planes from the graphitic material. In order to understand why low surface tension solvents work well to assist ultrasonic waves in producing ultra-thin graphene, we conducted a very extensive surface tension and contact angle measurement study. More than 50 solvents or liquid media were investigated. The contact angle measurements began with the preparation of several “graphene blocks.” A sufficient quantity of ultra-thin, pristine graphene platelets, upon solvent removal, was compressed in a steel mould using a hydraulic hot press. The mould cavity was approximately 2 cm×2 cm×2 cm in dimensions. The pressing procedure was carried out in such a manner that a majority of the platelets are more or less parallel to one another, as confirmed by scanning electron microscopy. After washing with acetone, each resulting block has two “graphene planes” and four “edge surfaces” for use in the contact angle measurement using a horizontal optical microscope.
[0057] Contact angle is a convenient measure of wettability because it is sensitive to the variation of surface properties. A low contact angle (θ) indicates a good wetting. In an ideal gas-liquid-solid system, where the solid is smooth, homogeneous planar and non-deformable, the contact angle θ is related to the surface tension and to the interfacial energies by the well-known Young's equation, Eq. (1):
[0000] cos θ 0 =(γ sg −γ sl )/γ lg (1)
[0000] where θ 0 is the Young's angle or the intrinsic contact angle, γ sg is the surface energy of the solid in the presence of the vapor of the liquid, γ lg is the surface tension or surface free energy of the liquid and γ sl is the interfacial solid-liquid energy. Re-arranging Eq. (1), we have γ lg cos θ 0 =(γ sg −γ sl ). For wetting of a liquid on a surface to occur, one must have 0≦θ 0 ≦90° and 1≧ cos θ≧0. With those parameters, a parameter S l was defined:
[0000] S l =γ sg −γ sl −γ lg cos θ 0 (2)
[0000] At a critical condition, θ 0 =0°, S l becomes the spreading coefficient S=γ sg −γ sl —γ lg . If S>0, the wetting is complete and if S<0, there is partial wetting.
[0058] We measured the contact angles of more than 50 solvents on both the graphene plane and the edge surface of a graphene block. The data are summarized in FIGS. 4 and 5 , respectively. FIG. 4 demonstrates that the solvent contact angle on a graphene plane scales with the surface tension of the solvent. Although not shown in FIG. 4 , the raw data indicated that the solvents with a contact angle higher than 90 degrees (e.g., glycerol) were ineffective in helping high-power ultrasonication to produce NGPs from a pristine graphitic material. Some of the solvents with a contact angle between 75 and 90 degrees were effective (e.g., N,N-dimethyl formamide, DMF), but others were not (e.g., N,N-dimethyl acetamide, DMA). All the solvents with a contact angle lower than 75 degrees were found to be effective in promoting the production of NGPs using direct ultrasonication.
[0059] The much higher degree of data scattering in FIG. 5 indicates that the contact angle on the edge surface is not an effective or reliable criterion with which one can determine if a given solvent is an effective solvent in the process of direct ultrasonication. We proceeded to measure the average thickness of NGPs in 30 samples. The results are summarized in FIG. 6 and Table 1 below:
[0000]
TABLE 1
Surface tension of selected solvents, their graphene plane
contact angles, and the average thickness of the NGPs
produced by direct ultrasonication.
Surface
Graphene
Platelet
tension
plane
thickness
Liquid
γ (mN/m)
Contact angle
(nm)
Acetic acid
27.6
54
32
Formic acid
37.58
77
36
Acetone
23.7
42
1.4
Diethyl ether
17
25
0.8
Ethanol
22.27
39
7.8
Ethanol (40%) + Water
29.63
62
56
Ethanol (11.1%) + Water
46.03
92
310
Glycerol
63
125
325
n-Hexane
18.4
26
0.85
Isopropanol
21.7
29
6.7
Methanol
22.6
38
3.2
n-Octane
21.8
44
14.6
Benzene
28.88
32
6.2
Methyl ethyl ketone (MEK)
24.6
56
35
N,N-dimethyl acetamide (DMA)
36.7
82
287
N,N-dimethyl formamide (DMF)
37.1
78
32
N-methyl-2-pyrrolidone, NMP
40.79
77
11.6
n-Heptane
20.14
32
2.3
Perfluoroheptane
12.85
25
0.67
Perfluorohexane
11.91
23
0.61
Perfluorooctane
14
30
0.72
Polyethylen glycol 200 (PEG)
43.5
87
315
Polydimethyl siloxane
19
58
33
Pyridine
38
76
37
Tetrahydrofuran (THF)
26.4
57
26
Toluene
28.4
45
23
o-Xylene
30.1
77
18
[0060] These data demonstrate that the average NGP thickness obtained by the instant direct ultrasonication approach is closely related to the contact angle of the solvent used. In general, a smaller contact angle on the graphene plane leads to thinner NGPs. With a contact angle <45 degrees, the NGP average thickness is <20 nm. A contact angle <30 degrees leads to NGPs with an average thickness <10 nm and, in many cases, <1 nm (with a significant portion being single-layer graphene).
[0061] Not wishing to be bound by any theory, but the applicants speculate that a solvent with a low surface tension value and providing a graphene plane contact angle <75 degrees is particularly effective in helping ultrasonic waves to exfoliate and separate graphene planes from graphite crystallites in the following ways:
[0062] This direct ultrasonication process may be considered as opening up graphene planes or peeling off graphene layers at a rate of 20,000 attempts per second (if the ultrasonic frequency is 20 kHz) or higher (if higher frequency) per each suspended graphite particle. Ultrasonic waves can generate tensile, compressive, and (locally) shear stresses to graphite particles. In a given cycle, using tensile and compressive stresses as an example, the first half of a cycle may be a positive stress half-cycle (hence possibly acting to open up the edge of a graphene plane relative to its neighboring graphene plane). However, during the next half-cycle, the same graphene plane may be subjected to a compressive stress (possibly acting to close up the opening). If a solvent with a low surface tension is present, the solvent molecules could quickly spread onto the freshly created graphene plane (during the positive-stress half cycle), preventing the expanded or opened-up graphene planes from completely re-tacking due to van der Waals forces. Since the ultrasonic wave frequencies are high, the positive and negative half cycles alternate very rapidly and the solvent must be capable of wetting and spreading at a high rate. Solvents with a high surface tension would unlikely have such ability. The contact angle is a good way to gauge the ability of a solvent to undergo rapid spreading. This concept may be illustrated in FIG. 7 .
[0063] Typically, the starting pristine graphite material is in the concentration of 1-50 mg/mL. As high as 100 mg/mL has been used, and this is not an upper bound. The resulting NGPs are pristine graphene without any intentionally added or bonded oxygen. This is a powerful approach to the large-scale preparation of pristine NGPs directly from pristine graphitic materials.
[0064] As indicated earlier, Hernandez et al disclosed that graphite could be dispersed in some solvents. In particular, the graphite was partially exfoliated to multilayer structures in N-methylpyrrolidone (NMP), γ-butyrolactone (GBL) and 1,3-dimethyl-2-imidazolidinone (DMEU) [Y. Hernandez, et al, Nature Nanotechnology, 2008, 3, 563]. The question was what solvent properties led to this exfoliation of graphite and why? According to Hernandez et al, such exfoliation could only occur if the net energetic cost is very small. In thermodynamics, this energy balance is expressed as the enthalpy of mixing (per unit volume), which may be given as:
[0000]
Δ
H
mix
V
min
≈
2
T
flake
(
δ
G
-
δ
sol
)
2
φ
(
3
)
[0000] where δ i =(E sur i ) 1/2 is the square root of the surface energy of phase i, T flake is the thickness of a graphene flake, and φ is the graphene volume fraction. This equation shows the enthalpy of mixing is dependent on the balance of graphene and solvent surface energies. For graphite, the surface energy is defined as the energy per unit area required to overcome the van der Waals forces when peeling two sheets apart. Since the entropy of mixing between a large molecule (graphene) and a solvent is very small, the goal was to find solvents that lead to a minimal ΔH mix /V mix so that the Gibbs free energy of mixing, ΔG mix /V mix =(ΔH mix /V mix )−T ΔS mix /V mix , can be negative and graphene can be at least partially dissolved (mixed) in the solvent.
[0065] Fernandez et al suggested that, based on equation (3), a minimal energy cost of exfoliation is expected for solvents whose surface energy matches that of graphite. To test this, Fernandez et al dispersed graphite in a range of solvents. By measuring the optical absorbance after mild centrifugation and using the absorption coefficient (660 nm) to transform absorbance into concentration, they could quantify the amount of graphite flakes dispersed as a function of solvent surface energy (calculated from surface tension). The dispersed concentration shows a strong peak for solvents with a surface energy very close to the literature values of the nanotube/graphite surface energy (i.e. ˜70-80 mN/m or mJ/m 2 ). Coupled with equation (3), this seems to suggest that not only is the enthalpy of mixing for graphite dispersed in good solvents very close to zero, but the solvent-graphite interaction is van der Waals rather than covalent. In addition and most importantly, Hernandez et al predicted that good solvents are characterized by surface tensions in the region of 40-50 mN/m.
[0066] It may be noted that the approach of Hernandez et al relies on matching the surface tension of a solvent to that of graphite so that the solvent can make its way into the inter-graphene spacings. In other words, the favorable solvent-graphite interaction is sufficient to overcome the graphene-graphene bonds (which are van der Waals forces) to “solvate” or dissolute graphene sheets (molecules). In actuality, these “good” solvents serve as an intercalant that penetrates into some of the inter-graphene spacings, thereby expanding the graphene-graphene separations and significantly weakening the graphene-graphene bonds in some regions. Subsequently, low-intensity ultrasonication (in a laboratory sonic cleaning bath) was used to help separate and disperse these expanded graphene layers from other non-solvated or non-intercalated portions (the non-solvated portions were typically >>90% in all cases, resulting in less than 10% yield).
[0067] Thermodynamically, these good solvents should be capable of “dissolving” graphite given a sufficient length of solvent immersion time, and ultrasonication is not really required. Specifically, the “good solvent” acts to solvate or dissolve individual graphene sheets, which are aromatic molecules in a hexagon structure. The good solvent has a surface tension in the range of 40-50 mN/m, not above and not below these values; otherwise, the enthalpy of mixing would not be close to zero and this approach would not work. This is fundamentally different from the discovery of the instant application in that, in general, the lower the solvent surface tension (and the lower the graphene plane contact angle), the more effective the solvents are in rapidly spreading on the graphene plane (which is opened up by ultrasonic waves). Our solvents of low surface tension do not have to play the role of “opening up,” “solvating,” or “dissolving” graphene sheets. The high-power ultrasonic waves do just that. By contrast, Henandez et al did not use high-power ultrasonic waves to open up graphene planes to facilitate dissolution of graphite in a solvent (the good solvent does that job). Instead, they used low-power sonic waves to separate those limited amounts of solvated graphene planes or stacks of graphene planes from the un-solvated portions.
[0068] Furthermore, Hernandez et al meticulously suggested that high power ultrasonication must not be used to avoid destruction of the graphene sheets. Further, in a typical solvent dissolution experiment, as disclosed by Hernandez et al, a maximum graphite concentration of 0.1 mg per mL of solvent was used and typically only 2.5-8.3% of the graphite was exfoliated to become multi-layer graphene. This implies that as small as 0.00025 mg-0.00083 mg is produced per 1 mL of solvent. This is really a poor production yield and not suitable for large-scale production of ultra-thin graphene. By contrast, given the same ultrasonication time (30 minutes), we were able to produce more than 10 mg of graphene per mL of low surface tension solvent, which are more than four (4) orders of magnitude higher. In general, in our cases, more than 99% of the graphitic material particles present in the suspension were effectively exfoliated to become NGPs.
[0069] FIG. 8 shows the graphene plane contact angles of 11 liquids that have a surface tension in the best range (40-50 mN/m) for good solvents as specified by Hernandez et al. It is clear that most of the contact angles are much higher than 80 degrees. Clearly, these solvents are not effective liquids in helping out on our direct ultrasonication processes. What Hernandez et al considered the best solvent, benzyl benzoate (BNBZ, with a perfect surface tension value of 45.97 mN/m), actually fairs very poorly in terms of the graphene plane contact angle (98 degrees) and the effectiveness in helping out the ultrasonic waves for producing NGPs (average graphite crystallite size of 285 nm, although a very small amount of NGPs was recovered). These observations further validate the assertion that the low surface tension liquid approach of the instant application is fundamentally different and patently distinct from the “good” solvent dissolution or solvating approach of Hernandez et al. one skilled in the art would not and could not anticipate the surprising discovery of the instant application based on the teaching Hernandez, et al. or a combination of the teachings by Hernandez et al and others in the art.
[0070] Conventional exfoliation processes for producing graphite worms from a graphite material normally include exposing a graphite intercalation compound (GIC) to a high temperature environment, most typically between 850 and 1,050° C. These high temperatures were utilized with the purpose of maximizing the expansion of graphite crystallites along the c-axis direction. Unfortunately, graphite is known to be subject to oxidation at 350° C. or higher, and severe oxidation can occur at a temperature higher than 650° C. even just for a short duration of time. Upon oxidation, graphite would suffer from a dramatic loss in electrical and thermal conductivity. These are energy-intensive processes. In contrast, the presently invented method makes use of an ultrasonication temperature typically lying between 0° C. and 100° C. Hence, this method obviates the need or possibility to expose the graphitic material to a high-temperature, oxidizing environment.
[0071] Ultrasonic energy also enables the resulting platelets to be well dispersed in the very liquid medium, producing a homogeneous suspension. One major advantage of this approach is that exfoliation, separation, and dispersion are achieved in a single step. A monomer, oligomer, or polymer may be added to this suspension to form a suspension that is a precursor to a nanocomposite structure. In some cases, the dispersing medium may contain the monomer or polymer even before ultrasonication process begins. The process may include a further step of converting the suspension to a mat or paper (e.g., using any well-known paper-making process), or converting the nanocomposite precursor suspension to a nanocomposite solid. Alternatively, the resulting platelets, after drying to become a solid powder, may be mixed with a monomer to form a mixture, which can be polymerized to obtain a nanocomposite solid. The platelets can be mixed with a polymer melt to form a mixture that is subsequently solidified to become a nanocomposite solid.
[0072] The following examples serve to provide the best modes of practice for the present invention and should not be construed as limiting the scope of the invention:
Example 1
Nano-Scaled Graphene Platelets (NGPs) from Natural Graphite
[0073] Five grams of natural graphite, ground to approximately 20 μm or less in sizes, were dispersed in 1,000 mL of n-Heptane. An ultrasonic energy level of 200 W (Branson S450 Ultrasonicator) was used for exfoliation and separation of graphene planes for a period of ½ hours. The average thickness of the resulting NGPs was 2.1 nm.
Example 2
Ultrasonication of Natural Graphite Using a Solvent of High Surface Tension
[0074] Five grams of natural graphite, ground to approximately 20 μm or less in sizes, were dispersed in 1,000 mL of glycerol (surface tension=63 mN/m and graphene surface contact angle=125 degrees) to obtain a suspension. An ultrasonic energy level of 150 W (Branson S450 Ultrasonicator) was used for a period of 1 hour. Graphite particles were broken down to approximately 300 nm in thickness. Very few NGPs were recovered from the suspension after one hour.
Example 3
NGPs from MCMBs
[0075] Five grams of MCMBs (supplied from Shanghai Shan Shan Tech Co.) with an average particle size of approximately 18 μm, were dispersed in 1,000 mL of benzene. An ultrasonic energy level of 250 W (Branson S450 Ultrasonicator) was used for the exfoliation and separation of graphene planes for a period of ½ hours. The average thickness of the resulting NGPs was 6.2 nm. When a lower surface tension liquid (Perfluorohexane, surface tension of 11.91 mN/m and contact angle of 23 degrees) was used, the average NGP thickness was 0.61 nm, indicating that most of the NGPs were single-layer graphene.
Example 4
Thermal Exfoliation and Separation of Graphite Oxide
[0076] Graphite oxide was prepared by oxidation of graphite flakes with sulfuric acid, nitrate, and permanganate according to the method of Hummers [U.S. Pat. No. 2,798,878, Jul. 9, 1957]. Upon completion of the reaction, the mixture was poured into deionized water and filtered. The graphite oxide was repeatedly washed in a 5% solution of HCl to remove most of the sulphate ions. The sample was then washed repeatedly with deionized water until the pH of the filtrate was neutral. The slurry was spray-dried and stored in a vacuum oven at 60° C. for 24 hours. The interlayer spacing of the resulting laminar graphite oxide was determined by the Debye-Scherrer X-ray technique to be approximately 0.73 nm (7.3 Å).
[0077] Dried graphite oxide powder was then placed in a tube furnace pre-set at a temperature of 1,050° C. for 60 minutes. The resulting exfoliated graphite was subjected to low-power ultrasonication (60 watts) for 10 minutes to break up the graphite worms and separate graphene layers. Several batches of graphite oxide (GO) platelets were produced under identical conditions to obtain approximately 2.4 Kg of oxidized NGPs or GO platelets (Sample 4 a ).
[0078] A similar amount of GO platelets was obtained and then subjected to chemical reduction by hydrazine at 140° C. for 24 hours. The GO-to-hydrazine molecular ratio was one-to-five. The chemically reduced GO platelets are referred to as Sample 4 b.
[0079] A similar amount of pristine NGPs was prepared under conditions identical to Example 1. These pristine NGPs are herein referred to as Sample 4 c.
[0080] Samples 4 a , 4 b , and 4 c were then mixed with epoxy resin (Epon 862 and Epikure W) at various NGP proportions to obtain three series of NGP-epoxy composite materials for electrical conductivity measurements. The four-point probe method was used to measure the electrical conductivity of all composite samples each of approximately 2.5 cm×2.5 cm×0.5 cm. The in-plane conductivity data of the three series of NGP nanocomposites are summarized in FIG. 9 .
[0081] These data clearly show that the electrical conductivity of pristine NGP composites is typically several orders of magnitude higher than that of GO platelet composites. Even after some lengthy chemical reduction of GO, the conductivity of reduced GO platelet-epoxy composites is still much lower than that of pristine NGP composites.
[0082] Furthermore, the percolation threshold (the critical weight percentage of NGPs or GO platelets) above which platelets overlap to form a network of electron-conducting paths in a polymer matrix for pristine NGPs, was approximately 0.03% while that for GO platelets was 0.5%. These impressive results demonstrate the outstanding properties of pristine graphene obtained by the processes of the instant application.
Example 5
NGPs from Short Carbon Fiber Segments
[0083] The procedure was similar to that used in Example 1, but the starting material was graphite fibers chopped into segments with 0.2 mm or smaller in length prior to dispersion in water. The diameter of carbon fibers was approximately 12 μm. After ultrasonication for 2 hours at 160 W, the platelets exhibit an average thickness of 4.8 nm.
Example 7
NGPs from Carbon Nano-Fibers (CNFs)
[0084] A powder sample of graphitic nano-fibers was prepared by introducing an ethylene gas through a quartz tube pre-set at a temperature of approximately 800° C. Also contained in the tube was a small amount of nano-scaled Cu—Ni powder supported on a crucible to serve as a catalyst, which promoted the decomposition of the hydrocarbon gas and growth of CNFs. Approximately 2.5 grams of CNFs (diameter of 10 to 80 nm) were dispersed in methanol. The sample was then subjected to ultrasonication at 20° C. for two hours to effect exfoliation and separation. Fine NGPs with an average thickness of 2.5 nm were obtained.
Examples 8-33
NGPs from Various Solvents
[0085] Solvents listed in Table 1 were used respectively to assist in the production of NGPs from natural graphite using the direct ultrasonication approach. All samples were obtained at approximately 20-25° C. for 30 minutes at a power of 200 watts.
[0086] In conclusion, the presently invented method has many advantages over prior art methods of exfoliating graphite materials for producing nano graphene platelets. Summarized below are some of the more salient features or advantages:
(1) The present method is versatile and applicable to essentially all graphitic materials including, but not limited to, natural graphite, artificial graphite (e.g., highly oriented pyrolytic graphite, HOPG), graphite fluoride, graphite fiber, carbon fiber, carbon nano-fiber, carbon nano-tube, mesophase carbon micro-bead (MCMB), graphitized soft carbon, hard carbon, and graphitic coke. (2) A large concentration of starting graphitic material can be ultrasonicated with an efficiency typically >99%. This is an extraordinarily high production yield process. (3) The method does not involve a high exfoliation temperature (e.g., typically below 100° C.) and, hence, avoids undesirable high-temperature chemical reactions (e.g., avoids oxidation of graphite). The resulting NGPs exhibit excellent conductivity. (4) The method makes use of a pristine graphitic material. The prior art step of intercalation, which typically involves using an undesirable acid such as sulfuric and nitric acid, can be avoided in the presently invented method. Hence, this is a much more environmentally benign process. This method is applicable to a wide range of liquid media. Expansion, exfoliation, separation, and dispersion are essentially combined into one step. (5) A large number of solvents with a low surface tension can be chosen. Depending upon a specific end use, there is always a suitable liquid medium that can be selected. No other prior art approach is nearly as versatile as this approach. (6) This method is amenable to the preparation of various precursor forms (e.g., suspension, paper, mat, thin film, and lamina) to nanocomposites.
|
The present invention provides a method of producing pristine or non-oxidized nano graphene platelets (NGPs) that are highly conductive. The method comprises: (a) providing a pristine graphitic material comprising at least a graphite crystallite having at least a graphene plane and an edge surface; (b) dispersing multiple particles of the pristine graphitic material in a liquid medium containing therein no surfactant to produce a suspension, wherein the multiple particles in the liquid have a concentration greater than 0.1 mg/mL and the liquid medium is characterized by having a surface tension that enables wetting of the liquid on a graphene plane exhibiting a contact angle less than 90 degrees; and (c) exposing the suspension to direct ultrasonication at a sufficient energy or intensity level for a sufficient length of time to produce the NGPs. Pristine NGPs can be used as a conductive additive in transparent electrodes for solar cells or flat panel displays (e.g., to replace expensive indium-tin oxide), battery and supercapacitor electrodes, and nanocomposites for electromagnetic wave interference (EMI) shielding, static charge dissipation, and fuel cell bipolar plate applications.
| 1
|
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This U.S. non-provisional patent application is a divisional of U.S. patent application Ser. No. 13/412,760, filed Mar. 6, 2012, which claims benefit under 35 U.S.C. §119 to Korean Patent Application No. 10-2011-0058623 filed on Jun. 16, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] Embodiments of the inventive concepts relate to semiconductor devices having a vertical transistor and a non-vertical transistor and methods of forming the same.
[0004] 2. Description of Related Art
[0005] A vast amount of research has been conducted on various methods for embodying low-power semiconductor devices. With the growing tendency for MOSFETs to have channel lengths of about 100 nm or less, the fabrication of semiconductor devices having both a high driving current and a low off-leakage current has become increasingly difficult due to a phenomenon known in the industry as the short-channel effect. To overcome these limitations, fabrication techniques have been employed whereby devices having different threshold voltages are formed on the same semiconductor substrate by controlling the doping profile of a channel region. However, as the operating voltage of devices becomes about 1 V or lower, the leakage current of a low threshold voltage (V T ) device may greatly increase, leading to unreliable and inefficient operation.
SUMMARY
[0006] Embodiments of the inventive concepts provide semiconductor devices suitable for increasing integration density and reducing power consumption, and methods of forming the same.
[0007] Other embodiments of the inventive concepts provide a static random access memory (SRAM) cell, suitable for increased integration density and reduced power consumption.
[0008] Aspects of the inventive concepts are not limited by the above description, and other unmentioned aspects will be clearly understood by one of ordinary skill in the art from example embodiments described herein.
[0009] In one aspect, a semiconductor device comprises: a substrate extending in a horizontal direction; a vertical transistor on the substrate, the vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the channel region; and a gate electrode at a sidewall of, and insulated from, the channel region; and a horizontal transistor on the substrate, the horizontal transistor comprising: a first diffusion region and a second diffusion region on the substrate and spaced apart from each other; a channel region on the substrate between the first diffusion region and the second diffusion region; and a gate electrode on the channel region and isolated from the channel region; wherein a portion of a gate electrode of the vertical transistor and a portion of the gate electrode of the horizontal transistor are at a same vertical position in the vertical direction relative to the substrate.
[0010] In one embodiment, the semiconductor device further comprises a layer of material on the horizontal transistor and the vertical transistor, the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor both in direct contact with the layer of material.
[0011] In one embodiment, the layer of material comprises an etch stop layer.
[0012] In one embodiment, the layer of material comprises an insulating layer.
[0013] In one embodiment, the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor comprise portions of a same layer of material.
[0014] In one embodiment, the first diffusion region of the horizontal transistor is contiguous with the first diffusion region of the vertical transistor.
[0015] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that is higher in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0016] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that is lower in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0017] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that has a same vertical position as a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0018] In one embodiment, the first diffusion region of the vertical transistor comprises a drain of the vertical transistor; the second diffusion region of the vertical transistor comprises a source of the vertical transistor; the first diffusion region of the horizontal transistor comprises one of a drain and source of the horizontal transistor; the second diffusion region of the horizontal transistor comprises the other of the drain and source of the horizontal transistor.
[0019] In one embodiment, the first diffusion region of the vertical transistor and the first diffusion region and second diffusion region of the horizontal transistor lie at a same vertical position relative to the substrate.
[0020] In one embodiment, the first diffusion region of the vertical transistor includes a vertical protrusion extending in the vertical direction, and wherein the vertical channel region is on the vertical protrusion.
[0021] In one embodiment, the vertical transistor further comprises a silicide region on the second diffusion region.
[0022] In one embodiment, the vertical transistor further comprises a metal pattern on the silicide region.
[0023] In one embodiment, the second diffusion region of the vertical transistor comprises a silicide region in direct contact with the vertical channel region of the vertical transistor.
[0024] In one embodiment, the first diffusion region of the horizontal transistor and the first diffusion region of the vertical transistors both have a silicide region thereon.
[0025] In one embodiment, the semiconductor device further comprises an insulating spacer on sidewalls of the gate electrode of the vertical transistor and on sidewalls of the gate electrode of the horizontal transistor.
[0026] In one embodiment, the semiconductor device further comprises a silicide region on the gate electrode of the vertical transistor and on the gate electrode of the horizontal transistor.
[0027] In one embodiment, the second diffusion region of the vertical transistor has a width in the horizontal direction that is greater than a width of the channel region of the vertical transistor in the horizontal direction.
[0028] In one embodiment, the gate electrode of the horizontal transistor has a bottom that is at a position that is lower than a lower boundary of the first and second diffusion regions of the horizontal transistor.
[0029] In one embodiment, the semiconductor device further comprises an interlayer via in direct contact with a top of the second diffusion region of the vertical transistor.
[0030] In one embodiment, the semiconductor device further comprises a buried oxide layer on the substrate and wherein the vertical transistor and the horizontal transistor are on the buried oxide layer.
[0031] In one embodiment, the channel region of the vertical transistor comprises single-crystal material.
[0032] In one embodiment, the vertical transistor comprises a first vertical transistor, and further comprising: a second vertical transistor on the substrate, the second vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the first vertical channel region; and a gate electrode at a sidewall of, and insulated from, the vertical channel region.
[0033] In one embodiment, the first vertical transistor and second vertical transistor comprise an inverter pair.
[0034] In one embodiment, the first vertical transistor comprises one of a p-channel and re-channel transistor and wherein the second vertical transistor comprise the other of a p-channel and n-channel transistor.
[0035] In one embodiment, the substrate comprises one of a bulk substrate and a silicon-on-insulator (SOI) substrate.
[0036] In another aspect, a semiconductor device comprises: a substrate extending in a horizontal direction; a vertical transistor on the substrate, the vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the channel region; and a gate electrode at a sidewall of, and insulated from, the channel region; a horizontal transistor on the substrate, the horizontal transistor comprising: a first diffusion region and a second diffusion region on the substrate and spaced apart from each other; a channel region on the substrate between the first diffusion region and the second diffusion region; and a gate electrode on the channel region and isolated from the channel region; and a layer of material on the horizontal transistor and the vertical transistor, the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor both in direct contact with the layer of material.
[0037] In one embodiment, the layer of material comprises an etch stop layer
[0038] In one embodiment, the layer of material comprises an insulating layer.
[0039] In one embodiment, a portion of a gate electrode of the vertical transistor and a portion of the gate electrode of the horizontal transistor are at a same vertical position in the vertical direction relative to the substrate.
[0040] In one embodiment, the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor comprise portions of a same layer of material.
[0041] In one embodiment, the first diffusion region of the horizontal transistor is contiguous with the first diffusion region of the vertical transistor.
[0042] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that is higher in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0043] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that is lower in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0044] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that has a same vertical position as a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0045] In one embodiment, the first diffusion region of the vertical transistor comprises a drain of the vertical transistor; the second diffusion region of the vertical transistor comprises a source of the vertical transistor; the first diffusion region of the horizontal transistor comprises one of a drain and source of the horizontal transistor; the second diffusion region of the horizontal transistor comprises the other of the drain and source of the horizontal transistor.
[0046] In one embodiment, the first diffusion region of the vertical transistor and the first diffusion region and second diffusion region of the horizontal transistor lie at a same vertical position relative to the substrate.
[0047] In one embodiment, the first diffusion region of the vertical transistor includes a vertical protrusion extending in the vertical direction, and wherein the vertical channel region is on the vertical protrusion.
[0048] In one embodiment, the vertical transistor further comprises a silicide region on the second diffusion region.
[0049] In one embodiment, the vertical transistor further comprises a metal pattern on the silicide region.
[0050] In one embodiment, the second diffusion region of the vertical transistor comprises a silicide region in direct contact with the vertical channel region of the vertical transistor.
[0051] In one embodiment, the first diffusion region of the horizontal transistor and the first diffusion region of the vertical transistors both have a silicide region thereon.
[0052] In one embodiment, the semiconductor device further comprises an insulating spacer on sidewalls of the gate electrode of the vertical transistor and on sidewalls of the gate electrode of the horizontal transistor.
[0053] In one embodiment, the semiconductor device further comprises a silicide region on the gate electrode of the vertical transistor and on the gate electrode of the horizontal transistor.
[0054] In one embodiment, the second diffusion region of the vertical transistor has a width in the horizontal direction that is greater than a width of the channel region of the vertical transistor in the horizontal direction.
[0055] In one embodiment, the gate electrode of the horizontal transistor has a bottom that is at a position that is lower than a lower boundary of the first and second diffusion regions of the horizontal transistor.
[0056] In one embodiment, the semiconductor device further comprises an interlayer via in direct contact with a top of the second diffusion region of the vertical transistor.
[0057] In one embodiment, the semiconductor device further comprises a buried oxide layer on the substrate and wherein the vertical transistor and the horizontal transistor are on the buried oxide layer.
[0058] In one embodiment, the channel region of the vertical transistor comprises single-crystal material.
[0059] In one embodiment, the vertical transistor comprises a first vertical transistor, and further comprising: a second vertical transistor on the substrate, the second vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the first vertical channel region; and a gate electrode at a sidewall of, and insulated from, the vertical channel region.
[0060] In one embodiment, the first vertical transistor and second vertical transistor comprise an inverter pair.
[0061] In one embodiment, the first vertical transistor comprises one of a p-channel and re-channel transistor and wherein the second vertical transistor comprise the other of a p-channel and n-channel transistor.
[0062] In one embodiment, the substrate comprises one of a bulk substrate and a silicon-on-insulator (SOI) substrate.
[0063] In another aspect, a semiconductor device comprises: a substrate extending in a horizontal direction; a vertical transistor on the substrate, the vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the channel region; and a gate electrode at a sidewall of, and insulated from, the channel region; and a horizontal transistor on the substrate, the horizontal transistor comprising: a first diffusion region and a second diffusion region on the substrate and spaced apart from each other; a channel region on the substrate between the first diffusion region and the second diffusion region; and a gate electrode on the channel region and isolated from the channel region, wherein the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor comprise portions of a same layer of material.
[0064] In one embodiment, a portion of a gate electrode of the vertical transistor and a portion of the gate electrode of the horizontal transistor are at a same vertical position in the vertical direction relative to the substrate.
[0065] In one embodiment, the semiconductor device further comprises a layer of material on the horizontal transistor and the vertical transistor, the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor both in direct contact with the layer of material.
[0066] In one embodiment, the layer of material comprises an etch stop layer
[0067] In one embodiment, the layer of material comprises an insulating layer
[0068] In one embodiment, the first diffusion region of the horizontal transistor is contiguous with the first diffusion region of the vertical transistor.
[0069] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that is higher in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0070] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that is lower in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0071] In one embodiment, the first diffusion region of the horizontal transistor that is contiguous with the first diffusion region of the vertical transistor has a lower boundary that has a same vertical position as a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0072] In one embodiment, the first diffusion region of the vertical transistor comprises a drain of the vertical transistor; the second diffusion region of the vertical transistor comprises a source of the vertical transistor; the first diffusion region of the horizontal transistor comprises one of a drain and source of the horizontal transistor; the second diffusion region of the horizontal transistor comprises the other of the drain and source of the horizontal transistor.
[0073] In one embodiment, the first diffusion region of the vertical transistor and the first diffusion region and second diffusion region of the horizontal transistor lie at a same vertical position relative to the substrate.
[0074] In one embodiment, the first diffusion region of the vertical transistor includes a vertical protrusion extending in the vertical direction, and wherein the vertical channel region is on the vertical protrusion.
[0075] In one embodiment, the vertical transistor further comprises a silicide region on the second diffusion region.
[0076] In one embodiment, the vertical transistor further comprises a metal pattern on the silicide region.
[0077] In one embodiment, the second diffusion region of the vertical transistor comprises a silicide region in direct contact with the vertical channel region of the vertical transistor.
[0078] In one embodiment, first diffusion region of the horizontal transistor and the first diffusion region of the vertical transistors both have a silicide region thereon.
[0079] In one embodiment, the semiconductor device further comprises an insulating spacer on sidewalls of the gate electrode of the vertical transistor and on sidewalls of the gate electrode of the horizontal transistor.
[0080] In one embodiment, the semiconductor device further comprises a silicide region on the gate electrode of the vertical transistor and on the gate electrode of the horizontal transistor.
[0081] In one embodiment, the second diffusion region of the vertical transistor has a width in the horizontal direction that is greater than a width of the channel region of the vertical transistor in the horizontal direction.
[0082] In one embodiment, the gate electrode of the horizontal transistor has a bottom that is at a position that is lower than a lower boundary of the first and second diffusion regions of the horizontal transistor.
[0083] In one embodiment, the semiconductor device further comprises an interlayer via in direct contact with a top of the second diffusion region of the vertical transistor.
[0084] In one embodiment, the semiconductor device further comprises a buried oxide layer on the substrate and wherein the vertical transistor and the horizontal transistor are on the buried oxide layer.
[0085] In one embodiment, the channel region of the vertical transistor comprises single-crystal material.
[0086] In one embodiment, the vertical transistor comprises a first vertical transistor, and further comprising: a second vertical transistor on the substrate, the second vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the first vertical channel region; and a gate electrode at a sidewall of, and insulated from, the vertical channel region.
[0087] In one embodiment, the first vertical transistor and second vertical transistor comprise an inverter pair.
[0088] In one embodiment, the first vertical transistor comprises one of a p-channel and re-channel transistor and wherein the second vertical transistor comprise the other of a p-channel and n-channel transistor.
[0089] In one embodiment, the substrate comprises one of a bulk substrate and a silicon-on-insulator (SOI) substrate.
[0090] In another aspect, a memory cell of a memory device comprises: a first pull-up transistor and a first pull-down transistor coupled at a first node and connected in series between a first voltage source and a second voltage source, gates of the first pull-up transistor and the first pull-down transistor coupled at a second node; a first access transistor coupled between the first node and a first bit line of the memory device, a gate of the first access transistor coupled to a word line of the memory device; a second pull-up transistor and a second pull-down transistor coupled at the second node and connected in series between the first voltage source and the second voltage source, gates of the second pull-up transistor and the second pull-down transistor coupled to the first node; a second access transistor coupled between the second node and a second bit line of the memory device, a gate of the second access transistor coupled to the word line of the memory device; wherein the first pull-up transistor, the first pull-down transistor, the second pull-up transistor and the second pull-down transistor each comprise vertical channel transistors having channel regions that extend in a vertical direction relative to a substrate of the memory device, and each comprise gate electrodes at sidewalls of the vertically extending channel regions; wherein the first access transistor and the second access transistor each comprise horizontal channel transistors having channel regions that extend in a horizontal direction of the substrate, and each comprise gate electrodes on the channel regions; and wherein the gate electrodes of the first pull-up transistor, the first pull-down transistor, the second pull-up transistor and the second pull-down transistor and the gate electrodes of the first access transistor and the second access transistor comprise portions of a same layer of material.
[0091] In one embodiment, the vertical channel transistors each comprise: a first diffusion region on the substrate; the channel region on the first diffusion region and extending in the vertical direction relative to the horizontal direction of extension of the substrate; a second diffusion region on the channel region; and the gate electrode at a sidewall of, and insulated from, the channel region; and wherein the horizontal channel transistors each comprise: a first diffusion region and a second diffusion region on the substrate and spaced apart from each other; the channel region on the substrate between the first diffusion region and the second diffusion region; and the gate electrode on the channel region and isolated from the channel region.
[0092] In one embodiment, the first diffusion region of each of the horizontal channel transistors is contiguous with the first diffusion region of one of the vertical channel transistors.
[0093] In one embodiment, the first diffusion region of each of the horizontal transistors that is contiguous with the first diffusion region of one of the vertical transistors has a lower boundary that is higher in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0094] In one embodiment, the first diffusion region of each of the horizontal transistors that is contiguous with the first diffusion region of one of the vertical transistors has a lower boundary that is lower in vertical position than a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0095] In one embodiment, the first diffusion region of each of the horizontal transistors that is contiguous with the first diffusion region of one of the vertical transistors has a lower boundary that has a same vertical position as a lower boundary of the first diffusion region of the vertical transistor, relative to an upper surface of the substrate.
[0096] In one embodiment, the first diffusion region of each vertical transistor comprises a drain of the vertical transistor; the second diffusion region of each vertical transistor comprises a source of the vertical transistor; the first diffusion region of each horizontal transistor comprises one of a drain and source of the horizontal transistor; the second diffusion region of each horizontal transistor comprises the other of the drain and source of the horizontal transistor.
[0097] In one embodiment, the first diffusion region of the vertical transistors and the first diffusion region and second diffusion regions of the horizontal transistors lie at a same vertical position relative to the substrate.
[0098] In one embodiment, the first diffusion regions of the vertical transistors each includes a vertical protrusion extending in the vertical direction, and wherein the vertical channel region is on the vertical protrusion.
[0099] In one embodiment, the vertical transistors each further comprise a silicide region on the second diffusion region.
[0100] In one embodiment, the vertical transistors each further comprise a metal pattern on the silicide region.
[0101] In one embodiment, the second diffusion region of each vertical transistor comprises a silicide region in direct contact with the vertical channel region of the vertical transistor.
[0102] In one embodiment, the first diffusion region of the horizontal transistors and the first diffusion region of the vertical transistors both have a silicide region thereon.
[0103] In one embodiment, the second diffusion region of the vertical transistors has a width in the horizontal direction that is greater than a width of the channel region of the vertical transistors in the horizontal direction.
[0104] In one embodiment, the gate electrodes of the horizontal transistors have a bottom that is at a position that is lower than a lower boundary of the first and second diffusion regions of the horizontal transistors.
[0105] In one embodiment, the memory cell further comprises an interlayer via in direct contact with a top of the second diffusion region of the vertical transistors.
[0106] In one embodiment, a portion of the gate electrodes of the first pull-up transistor, the first pull-down transistor, the second pull-up transistor and the second pull-down transistor and a portion of the gate electrodes of the first access transistor and the second access transistor are at a same vertical position in the vertical direction relative to the substrate.
[0107] In one embodiment, the memory cell further comprises a layer of material on the horizontal transistor and the vertical transistor, the gate electrodes of the first pull-up transistor, the first pull-down transistor, the second pull-up transistor and the second pull-down transistor and the gate electrodes of the first access transistor and the second access transistor both in direct contact with the layer of material.
[0108] In one embodiment, the layer of material comprises an etch stop layer.
[0109] In one embodiment, the layer of material comprises an insulating layer
[0110] In one embodiment, the memory cell further comprises a buried oxide layer on the substrate and wherein the vertical transistor and the horizontal transistor are on the buried oxide layer.
[0111] In one embodiment, the channel region of the vertical transistor comprises single-crystal material.
[0112] In one embodiment, the substrate comprises one of a bulk substrate and a silicon-on-insulator (SOI) substrate.
[0113] In another aspect, a method of forming a semiconductor device comprising: forming a first diffusion region on a substrate; forming a channel region for a vertical transistor on the first diffusion region that extends in a vertical direction relative to the substrate; and providing a vertical transistor gate electrode at sidewalls of the vertical transistor channel region and simultaneously providing a horizontal transistor gate electrode on the substrate at a position that is spaced apart from the vertical transistor.
[0114] In one embodiment, forming the channel region for the vertical transistor comprises: forming a first well in the substrate; forming the first diffusion region in a portion of the first well by doping the first diffusion region with a doping element of a first polarity; epitaxially growing a first channel layer on the first diffusion region; doping an upper portion of the first channel layer with a doping element of a second polarity; patterning the first channel layer to form the channel region for the vertical transistor, the channel region extending between the first diffusion region and a second diffusion region comprising the patterned upper portion of the first channel layer.
[0115] In one embodiment, providing a vertical transistor gate electrode at sidewalls of the vertical transistor channel region and simultaneously providing a horizontal transistor gate electrode on the substrate at a position that is spaced apart from the vertical transistor comprises: providing a gate insulating layer on the channel region of the vertical transistor and on the first well; providing a gate electrode layer on the gate insulating layer; patterning the gate electrode layer to form the vertical transistor gate electrode and to form the horizontal transistor gate electrode on a portion of the first well spaced apart from the first diffusion region
[0116] In one embodiment, the method further comprises forming a third diffusion region and a fourth diffusion region for a horizontal transistor in the substrate at sidewalls of the horizontal transistor gate electrode.
[0117] In one embodiment, the fourth diffusion region of the horizontal transistor is contiguous with the first diffusion region of the vertical transistor.
[0118] In one embodiment, providing the vertical transistor gate electrode and simultaneously providing a horizontal gate electrode comprises: providing a gate insulating layer on sidewalls of the vertical transistor channel region and on the substrate; providing a gate electrode layer to cover the gate insulating layer; patterning the gate electrode layer to form the vertical transistor gate electrode and simultaneously form the horizontal gate electrode.
[0119] In one embodiment, the method further comprises: forming a second diffusion region on the vertical transistor channel region; fainting a third diffusion region in the substrate at a side of the horizontal gate electrode opposite the vertical transistor channel region; forming a fourth diffusion region in the substrate at a side of the horizontal gate electrode opposite the third diffusion region, wherein the fourth diffusion region and the first diffusion region are contiguous with each other.
[0120] In one embodiment, the method further comprises forming a layer of material on and in direct contact with the gate electrode of the vertical transistor and the gate electrode of the horizontal transistor.
[0121] In another aspect, a method of forming a semiconductor device comprises: epitaxially forming an epitaxial layer of material on a substrate including a first region of amorphous material and a second region of single-crystal material; and etching the epitaxial layer of material to form a channel region for a vertical transistor on the second region, the channel region extending in a vertical direction relative to the substrate.
[0122] In one embodiment, the first region of amorphous material comprises an insulating structure present in the substrate.
[0123] In one embodiment, the method further comprises: forming a first diffusion region on the substrate at a position that is below the channel region of the vertical transistor, prior to formation of the channel region of the vertical transistor; forming a second diffusion region on the channel region of the vertical transistor.
[0124] In one embodiment, the method further comprises: providing a vertical transistor gate electrode at sidewalls of the vertical transistor channel region and simultaneously providing a horizontal transistor gate electrode on the substrate at a position that is spaced apart from the vertical transistor.
[0125] In another aspect, a memory system comprises: a memory controller that generates command and address signals; and a memory module comprising a plurality of memory devices, the memory module receiving the command and address signals and in response storing and retrieving data to and from at least one of the memory devices, wherein each memory device comprises: a substrate extending in a horizontal direction; a vertical transistor on the substrate, the vertical transistor comprising: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the channel region; and a gate electrode at a sidewall of, and insulated from, the channel region; and a horizontal transistor on the substrate, the horizontal transistor comprising: a first diffusion region and a second diffusion region on the substrate and spaced apart from each other; a channel region on the substrate between the first diffusion region and the second diffusion region; and a gate electrode on the channel region and isolated from the channel region; wherein a portion of a gate electrode of the vertical transistor and a portion of the gate electrode of the horizontal transistor are at a same vertical position in the vertical direction relative to the substrate.
[0126] In accordance with an aspect of the inventive concepts, a semiconductor device includes a first vertical transistor and a non-vertical transistor disposed on a substrate. The first vertical transistor includes a first drain region disposed on the substrate, a first vertical channel region protruding from the first drain region, a first source region disposed on the first vertical channel region, and a first gate electrode covering sidewalls of the first vertical channel region. The non-vertical transistor includes a channel region disposed on the substrate, a second gate electrode disposed on the channel region, and a non-vertical drain region and a non-vertical source region disposed adjacent to both sides of the second gate electrode. The first drain region, the non-vertical drain region, and the non-vertical source region are disposed at the same level. One of the non-vertical drain region and the non-vertical source region is in continuity with the first drain region.
[0127] In one embodiment, the first drain region, the channel region, the non-vertical drain region, and the non-vertical source region may include a single-crystalline semiconductor.
[0128] In one embodiment, the first vertical channel region may have a fin structure, a pillar structure, or a wire structure.
[0129] In one embodiment, the first drain region may include a protrusion, which may be aligned with the first vertical channel region. The first vertical channel region may have a horizontal width smaller than a vertical height.
[0130] In one embodiment, the first vertical channel region may have a first horizontal width, the first source region may have a second horizontal width, and the first horizontal width may be smaller than the second horizontal width.
[0131] In one embodiment, the first source region may include a metal silicide pattern. The metal silicide pattern may be in contact with the first vertical channel region.
[0132] In one embodiment, the non-vertical transistor may include a planar transistor or a recess channel transistor. A bottom of the second gate electrode may be at a lower level than the non-vertical drain region and the non-vertical source region. A top of the second gate electrode may be at a lower level than top surfaces of the non-vertical drain region and the non-vertical source region.
[0133] In one embodiment, the first and second gate electrodes may include the same material layers formed at the same time.
[0134] In one embodiment, the semiconductor device may further include an isolation layer disposed adjacent to the first vertical transistor and the non-vertical transistor. Top surfaces of the first drain region, the non-vertical drain region, and the non-vertical source region may be at a lower level than a top surface of the isolation layer.
[0135] In one embodiment, the semiconductor device may further include a first gate dielectric layer interposed between the first vertical channel region and the first gate electrode and a second gate dielectric layer interposed between the channel region and the second gate electrode. The first and second gate dielectric layers may include the same material layers formed at the same time.
[0136] In one embodiment, the semiconductor device may further include a second vertical transistor disposed on the substrate. The second vertical transistor may include a second drain region disposed on the substrate, a second vertical channel region protruding from the second drain region, a second source region disposed on the second vertical channel region, and a third gate electrode covering sidewalls of the second vertical channel region. The second drain region is connected to the first drain region. The second vertical channel region may have a different conductivity type from the first vertical channel region.
[0137] In accordance with another aspect of the inventive concept, a semiconductor device includes a buried oxide layer disposed on a substrate. A first vertical transistor, a non-vertical transistor, and a second vertical transistor are disposed on the buried oxide layer. The first vertical transistor includes an n-drain region disposed on the buried oxide layer, a p-vertical channel region disposed on the n-drain region, an n-source region disposed on the p-vertical channel region, and a first gate electrode covering sidewalls of the p-vertical channel region. The non-vertical transistor includes a channel region disposed on the buried oxide layer, a second gate electrode disposed on the channel region, and a non-vertical drain region and a non-vertical source region disposed adjacent to both sides of the second gate electrode. The second vertical transistor includes a p-drain region disposed on the buried oxide layer, an n-vertical channel region disposed on the p-drain region, a p-source region disposed on the n-vertical channel region, and a third gate electrode covering sidewalls of the n-vertical channel region. The n-drain region, the p-drain region, the non-vertical drain region, and the non-vertical source region are disposed at the same level. One of the non-vertical drain region and the non-vertical source region is in continuity with the n-drain region. The p-drain region is in contact with at least one of the n-drain region, the non-vertical drain region, and the non-vertical source region.
[0138] In one embodiment, each of the p-vertical channel region and the n-vertical channel region may have a fin structure, a pillar structure, or a wire structure.
[0139] In one embodiment, the n-drain region may include a first protrusion, which may be aligned with the p-vertical channel region. The p-drain region may include a second protrusion, which may be aligned with the n-vertical channel region.
[0140] In one embodiment, the n-source region may include a first metal silicide pattern, and the p-source region may include a second metal silicide pattern. The first metal silicide pattern may be in contact with the p-vertical channel region, and the second metal silicide pattern may be in contact with the n-vertical channel region.
[0141] In one embodiment, the semiconductor device may further include a first gate dielectric layer interposed between the p-vertical channel region and the first gate electrode, a second gate dielectric layer interposed between the channel region and the second gate electrode, and a third gate dielectric layer interposed between the n-vertical channel region and the third gate electrode. The first, second, and third gate dielectric layers may include the same material layers formed at the same time.
[0142] In accordance with another aspect of the inventive concept, a static random access memory (SRAM) cell includes first and second pull-up transistors disposed on a substrate, A first pull-down transistor is connected to the first pull-up transistor, and a second pull-down transistor is connected to the second pull-up transistor. A first access transistor is connected to a first bit line disposed on the substrate, and a second access transistor is connected to a second bit line disposed on the substrate. The first access transistor is connected between the first pull-up transistor and the first pull-down transistor, and the second access transistor is connected between the second pull-up transistor and the second pull-down transistor. Herein, the first pull-down transistor is a first vertical transistor, and the first access transistor is a non-vertical transistor. The first vertical transistor includes an n-drain region, a p-vertical channel region, an n-source region, and a first gate electrode disposed on the substrate. The non-vertical transistor includes a channel region, a second gate electrode, a non-vertical drain region, and a non-vertical source region disposed on the substrate. The n-drain region, the non-vertical drain region, and the non-vertical source region are disposed at the same level. One of the non-vertical drain region and the non-vertical source region is in continuity with the n-drain region.
[0143] In one embodiment, the first pull-up transistor may be a second vertical transistor. The second vertical transistor includes a p-drain region disposed on the substrate, an n-vertical channel region protruding from the p-drain region, a p-source region disposed on the n-vertical channel region, and a third gate electrode covering sidewalls of the n-vertical channel region. The p-drain region may be connected to the n-drain region.
[0144] In accordance with another aspect of the inventive concept, an SRAM includes a buried oxide layer disposed on a substrate. First and second pull-up transistors are disposed on the buried oxide layer. A first pull-down transistor is connected to the first pull-up transistor, and a second pull-down transistor is connected to the second pull-up transistor. A first access transistor is connected to a first bit line disposed on the substrate, and a second access transistor is connected to a second bit line disposed on the substrate. Herein, the first access transistor is connected between the first pull-up transistor and the first pull-down transistor, and the second access transistor is connected between the second pull-up transistor and the second pull-down transistor. The first pull-down transistor is a first vertical transistor, the first access transistor is a non-vertical transistor, and the first pull-up transistor is a second vertical transistor. The first vertical transistor includes an n-drain region, a p-vertical channel region, an n-source region, and a first gate electrode disposed on the buried oxide layer. The non-vertical transistor includes a channel region, a second gate electrode, a non-vertical drain region, and a non-vertical source region disposed on the buried oxide layer. The second vertical transistor includes a p-drain region, an n-vertical channel region, a p-source region, and a third gate electrode disposed on the buried oxide layer. The n-drain region, the p-drain region, the non-vertical drain region, and the non-vertical source region are disposed at the same level. One of the non-vertical drain region and the non-vertical source region is in continuity with the n-drain region, and the p-drain region is in contact with at least one of the n-drain region, the non-vertical drain region, and the non-vertical source region.
[0145] In accordance with another aspect of the inventive concept, a method of forming a semiconductor device includes forming a first vertical transistor on a substrate. The first vertical transistor includes a first drain region disposed on a substrate, a first vertical channel region protruding from the first drain region, a first source region disposed on the first vertical channel region, and a first gate electrode covering sidewalls of the first vertical channel region. A non-vertical transistor is formed on the substrate. The non-vertical transistor includes a channel region disposed on the substrate, a second gate electrode disposed on the channel region, and a non-vertical drain region and a non-vertical source region disposed adjacent to both sides of the second gate electrode. The formation of the first vertical transistor and the non-vertical transistor includes forming a semiconductor layer on the substrate using an epitaxial growth technique and forming the first vertical channel region and the channel region by patterning the semiconductor layer and the substrate. One of the non-vertical drain region and the non-vertical source region is in continuity with the first drain region.
[0146] In one embodiment, the first drain region, the non-vertical drain region, and the non-vertical source region may be formed at the same level.
[0147] In one embodiment, the method may further include forming an isolation layer adjacent to the first vertical transistor and the non-vertical transistor. Top surfaces of the first drain region, the non-vertical drain region, and the non-vertical source region may be formed at a lower level than a top surface of the isolation layer.
[0148] In one embodiment, the first drain region may include a protrusion, which may be aligned with the first vertical channel region.
[0149] In one embodiment, the first vertical channel region may have a fin structure, a pillar structure, or a wire structure.
[0150] In one embodiment, the method may further include forming a first gate dielectric layer between the first vertical channel region and the first gate electrode and forming a second gate dielectric layer between the channel region and the second gate electrode. The first and second gate dielectric layers may include the same material layers formed at the same time.
[0151] In one embodiment, the method may further include forming a second vertical transistor on the substrate. The second vertical transistor may include a second drain region disposed on the substrate, a second vertical channel region protruding from the second drain region, a second source region disposed on the second vertical channel region, and a third gate electrode covering sidewalls of the second vertical channel region. The second vertical channel region may have a different conductivity type from the first vertical channel region, and the second drain region may be connected to the first drain region.
[0152] In accordance with another aspect of the inventive concept, a method of forming a semiconductor device includes forming a buried oxide layer on a substrate. A first vertical transistor is formed on the buried oxide layer. The first vertical transistor includes an n-drain region disposed on the buried oxide layer, a p-vertical channel region disposed on the n-drain region, an n-source region disposed on the p-vertical channel region, and a first gate electrode covering sidewalls of the p-vertical channel region. A non-vertical transistor is formed on the buried oxide layer. The non-vertical transistor includes a channel region disposed on the buried oxide layer, a second gate electrode disposed on the channel region, and a non-vertical drain region and a non-vertical source region disposed adjacent to both sides of the second gate electrode. The second vertical transistor is formed on the buried oxide layer. The second vertical transistor includes a p-drain region disposed on the buried oxide layer, an n-vertical channel region disposed on the p-drain region, a p-source region disposed on the n-vertical channel region, and a third gate electrode covering sidewalls of the n-vertical channel region. The formation of the first vertical transistor, the non-vertical transistor, and the second vertical transistor includes forming a semiconductor layer on the substrate using an epitaxial growth technique and forming the p-vertical channel region, the channel region, and the n-vertical channel region by patterning the semiconductor layer and the substrate. One of the non-vertical drain region and the non-vertical source region is in continuity with the n-drain region. The p-drain region is in contact with at least one of the n-drain region, the non-vertical drain region, and the non-vertical source region.
[0153] In one embodiment, the n-drain region, the p-drain region, the non-vertical drain region, and the non-vertical source region may be formed at the same level.
[0154] In one embodiment, the method may further include forming an isolation layer on the buried oxide layer to define the n-drain region, the p-drain region, the channel region, the non-vertical drain region, and the non-vertical source region. Top surfaces of the n-drain region, the p-drain region, the channel region, the non-vertical drain region, and the non-vertical source region may be formed at a lower level than a top surface of the isolation layer.
[0155] In one embodiment, the n-drain region may include a first protrusion, which may be aligned with the p-vertical channel region, and the p-drain region may include a second protrusion, which may be aligned with the n-vertical channel region.
[0156] In one embodiment, the method may further include forming a first gate dielectric layer between the p-vertical channel region and the first gate electrode, forming a second gate dielectric layer between the channel region and the second gate electrode, and forming a third gate dielectric layer between the n-vertical channel region and the third gate electrode. The first, second, and third gate dielectric layers may include the same material layers formed at the same time.
[0157] Details of other embodiments are included in the detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0158] The foregoing and other features and advantages of the inventive concepts will be apparent from the more particular description of preferred embodiments of the inventive concepts, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the inventive concepts. In the drawings:
[0159] FIG. 1 is an equivalent circuit diagram of an electronic circuit including a complementary-metal-oxide-semiconductor (CMOS) inverter according to embodiments of the inventive concept;
[0160] FIG. 2 is a layout illustrating a semiconductor device according to a first embodiment of the inventive concept;
[0161] FIGS. 3A through 3H are cross-sectional views taken along line I-I′ of FIG. 2 , illustrating the semiconductor device of FIG. 2 ;
[0162] FIG. 4 is a cross-sectional view of a semiconductor device according to a second embodiment of the inventive concept;
[0163] FIG. 5 is a cross-sectional view of a semiconductor device according to a third embodiment of the inventive concept;
[0164] FIG. 6 is a layout illustrating a semiconductor device according to a fourth embodiment of the inventive concept;
[0165] FIGS. 7A and 7B are cross-sectional views of the semiconductor device of FIG. 6 ;
[0166] FIG. 8 is a layout illustrating a semiconductor device according to a fifth embodiment of the inventive concept;
[0167] FIGS. 9A through 9C are cross-sectional views of the semiconductor device of FIG. 8 ;
[0168] FIG. 10 is a layout illustrating a semiconductor device according to a sixth embodiment of the inventive concept;
[0169] FIGS. 11A through 12D are cross-sectional views of the semiconductor device of FIG. 10 ;
[0170] FIGS. 13 through 24 are cross-sectional views illustrating a method of forming a semiconductor device according to a seventh embodiment of the inventive concept;
[0171] FIGS. 25 through 31 are cross-sectional views illustrating a method of forming a semiconductor device according to an eighth embodiment of the inventive concept;
[0172] FIGS. 32 through 39 are cross-sectional views illustrating a method of forming a semiconductor device according to a ninth embodiment of the inventive concept;
[0173] FIGS. 40A through 43C are cross-sectional views illustrating a method of forming a semiconductor device according to a tenth embodiment of the inventive concept;
[0174] FIGS. 44A and 44B are current-voltage (IV) graphs showing drain current characteristics of Experimental Examples according to the inventive concept;
[0175] FIG. 45 is an equivalent circuit diagram of a CMOS static random access memory (SRAM) cell according to an eleventh embodiment of the inventive concept; and
[0176] FIGS. 46 and 47 are a perspective view and block diagram, respectively, of an electronic system according to a twelfth embodiment of the inventive concept.
DETAILED DESCRIPTION OF EMBODIMENTS
[0177] Various example embodiments will now be described more fully with reference to the accompanying drawings in which some example embodiments are shown. The inventive concepts may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure is thorough and complete and fully conveys the scope of the inventive concepts to one skilled in the art. In the drawings, the thicknesses of layers and regions may be exaggerated for clarity. It will also be understood that when a layer is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate or intervening layers may also be present. Like numbers refer to like elements throughout.
[0178] It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention.
[0179] Spatially relative terms, such as “top end,” “bottom end,” “top surface,” “bottom surface,” “above,” “below” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative tennis are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0180] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
[0181] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present inventive concepts belong. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and this specification and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Embodiment 1
[0182] In an ultrathin body (UTB) SOI device or in a nanowire device, which are expected to be applied in the future to sub-20 nm devices, since the dopant of a channel region has little effect on the threshold voltage V T of the resulting device, such devices still do not solve the problem of heightened leakage current. Further, the approach of controlling the threshold voltages of devices by varying channel length is limited in viability since threshold voltage can be controlled only within a limited range and such variation in channel length is unsatisfactory in terms of integration density.
[0183] To obtain a low-power, high-speed circuit, the present inventive concepts provide semiconductor devices and methods of fabrication embodying multiple-threshold-voltage V T structures which have relative low leakage current characteristics.
[0184] FIG. 1 is an equivalent circuit diagram of an electronic circuit including a complementary-metal-oxide-semiconductor (CMOS) inverter according to embodiments of the inventive concept. FIG. 2 is a layout illustrating a semiconductor device according to a first embodiment of the inventive concept. FIGS. 3A through 3H are cross-sectional views taken along line I-I′ of FIG. 2 , illustrating the semiconductor device of FIG. 2 .
[0185] Referring to FIG. 1 , a pull-up transistor TU, a pull-down transistor TD, and an access transistor TA may be provided. In an embodiment, the pull-up transistor TU may be a PMOS transistor, and the pull-down transistor TD and the access transistor TA may be NMOS transistors. The pull-up transistor TU and the pull-down transistor TD may be connected to each other and constitute a CMOS inverter. A source electrode of the pull-up transistor TU may be connected to a power source VDD, and a source electrode of the pull-down transistor TD may be connected to a ground GND. Gate electrodes of the pull-up transistor TU and the pull-down transistor TD may be connected to each other. Drain electrodes of the pull-up transistor TU and the pull-down transistor TD may be connected to each other and constitute a node N 1 . A selected one of source and drain electrodes of the access transistor TA may be connected to the node N 1 . A load capacitor C L may be provided between the node N 1 and the ground GND. A gate electrode of the access transistor TA may be connected to a word line WL.
[0186] Each arrow (→) of FIG. 1 refers to a direction in which current flows. As shown in FIG. 1 , current may flow through the pull-up transistor TU and the pull-down transistor TD in one direction, or uni-directionally, while current may flow through the access transistor TA in both, opposed directions, or bi-directionally. In an optimized configuration, the pull-up transistor TU and the pull-down transistor TD may require a low-leakage current characteristic, and the access transistor TA may require a high driving current characteristic. To facilitate formation of low-power devices, the pull-up transistor TU and the pull-down transistor TD may be formed to have a lower threshold voltage V T than the access transistor TA.
[0187] Referring to FIGS. 2 and 3A , a p-well 24 , an n-well 25 , and an isolation layer 23 may be formed in a semiconductor substrate 21 . An n-drain region 26 , a first source/drain region 27 , and a second source/drain region 29 may be formed on the p-well 24 . A p-vertical channel region 31 P and an n-source region 33 S may be formed on the n-drain region 26 . The n-drain region 26 may include an n-protrusion 26 P. The n-protrusion 26 P may be disposed under the p-vertical channel region 31 P, and the n-protrusion 26 P may have sidewalls that are aligned with sidewalls of the p-vertical channel region 31 P. A first gate electrode 43 A may be formed on sidewalls of the p-vertical channel region 31 P. A first gate dielectric layer 41 A may be interposed between the first gate electrode 43 A and the p-vertical channel region 31 P and between the first gate electrode 43 A and the n-drain region 26 and n-protrusion 26 P.
[0188] A channel region 28 may be defined between the first source/drain region 27 and the second source/drain region 29 . A second gate electrode 43 B may be formed on the channel region 28 . A second gate dielectric layer 41 B may be interposed between the second gate electrode 43 B and the channel region 28 .
[0189] A p-drain region 36 may be formed on the n-well 25 . An n-vertical channel region 32 N and a p-source region 34 S may be formed on the p-drain region 36 . The p-drain region 36 may include a p-protrusion 36 P. The p-protrusion 36 P may be disposed under the n-vertical channel region 32 N, and the p-protrusion 36 P may have sidewalls that are aligned with, the n-vertical channel region 32 N. A third gate electrode 43 C may be formed on sidewalls of the n-vertical channel region 32 N. A third gate dielectric layer 41 C may be interposed between the third gate electrode 43 C and the n-vertical channel region 32 N, and between the third gate electrode 43 C and the p-drain region 36 and p-protrusion 26 P.
[0190] A gate pad 43 P may be formed on the isolation layer 23 . The first and third gate electrodes 43 A and 43 C may be connected to the gate pad 43 P. The gate pad 43 P, the first gate electrode 43 A, and the third gate electrode 43 C may have an integral structure. An etch stop layer 48 may be formed to cover the entire surface of the semiconductor substrate 21 . The etch stop layer 48 may function as a stress-inducing layer. An interlayer insulating layer 49 may be formed on the etch stop layer 48 .
[0191] A first plug 51 , a second plug 52 , a third plug 53 , a fourth plug 54 , a fifth plug 55 , and a sixth plug 56 may be formed through the interlayer insulating layer 49 and the etch stop layer 48 . First and second interconnection lines 57 and 59 may be formed on the interlayer insulating layer 49 . The first plug 51 may be connected to at least one of the n-drain region 26 and the first source/drain region 27 . The second plug 52 may be connected to the p-drain region 36 . The first interconnection line 57 may be in contact with the first and second plugs 51 and 52 . The second interconnection line 59 may be in contact with the third plug 53 . The third plug 53 may be connected to the second source/drain region 29 . The fourth plug 54 may be connected to the n-source region 33 S. The fifth plug 55 may be connected to the p-source region 34 S. The sixth plug 56 may be connected to the gate pad 43 P.
[0192] The n-drain region 26 , the first source/drain region 27 , the second source/drain region 29 , the channel region 28 , and the p-drain region 36 may be formed at the same level relative to the substrate 21 . Top surfaces of the n-drain region 26 , the first source/drain region 27 , the second source/drain region 29 , the channel region 28 , and the p-drain region 36 may be formed at a lower level than a top surface of the isolation layer 23 . The first source/drain region 27 may be in continuity with the n-drain region 26 . Furthermore, the first source/drain region 27 and the n-drain region 26 may have an integral structure or otherwise be contiguous with each other. The n-drain region 26 and the first source/drain region 27 may include a single-crystalline semiconductor material containing n-type impurities. Bottoms of the first source/drain region 27 and the second source/drain region 29 at a higher level than a bottom of the n-drain region 26 as shown in FIG. 3A , or may optionally be formed at a lower level than a bottom of the n-drain region 26 , as shown in FIG. 3B , or may optionally be formed at a same level as a bottom of the n-drain region 26 , as shown in FIG. 3C .
[0193] Each of the p-vertical channel region 31 P and the n-vertical channel region 32 N may have a fin structure, a pillar structure, or a wire structure. A horizontal width of the p-vertical channel region 31 P may be less than a vertical height thereof. A horizontal width of the n-vertical channel region 32 N may be less than a vertical height thereof. In some embodiments, the p-vertical channel region 31 P may vertically protrude over the n-drain region 26 , and the n-vertical channel region 32 N may vertically protrude over the p-drain region 36 . In some embodiments, each of the p-vertical channel region 31 P and the n-vertical channel region 32 N may include a single-crystalline semiconductor material formed using an epitaxial growth technique. In some embodiments, each of horizontal widths of the p-vertical channel region 31 P and the n-vertical channel region 32 N may be 20 nm or less.
[0194] The n-source region 33 S may be disposed on and aligned with the p-vertical channel region 31 P and contact the p-vertical channel region 31 P. The p-source region 34 S may be disposed on and aligned with the n-vertical channel region 32 N and contact the n-vertical channel region 32 N. In some embodiments, each of the n-source region 33 S and the p-source region 34 S may include a single-crystalline semiconductor material formed using an epitaxial growth technique.
[0195] In some embodiments, the first, second, and third gate dielectric layers 41 A, 41 B, and 41 C may include the same material layers formed at the same time. The first through third gate dielectric layers 41 A, 41 B, and 41 C may have substantially the same thickness. The first through third gate dielectric layers 41 A, 41 B, and 41 C may include a silicon oxide layer, a silicon nitride layer, a silicon oxynitride layer, a high-k dielectric layer, or a combination layer thereof.
[0196] The first gate electrode 43 A may cover both opposite sidewalls of the p-vertical channel region 31 P. The third gate electrode 43 C may cover both opposite sidewalls of the n-vertical channel region 32 N. The first, second, and third gate electrodes 43 A, 43 B, and 43 C may include the same material layers that are formed at the same time. In various embodiments, the first through third gate electrodes 43 A, 43 B, and 43 C may include a conductive layer, such as a metal layer, a metal nitride layer, a metal silicide layer, a polysilicon (poly-Si) layer, or a combination layer thereof, or other suitable conductive material layers.
[0197] Referring back to FIGS. 1 , 2 , and 3 A, the n-drain region 26 , the p-vertical channel region 31 P, the n-source region 33 S, the first gate dielectric layer 41 A, and the first gate electrode 43 A may correspond to the pull-down transistor TD. In this case, the pull-down transistor TD may be referred to as a first vertical transistor. The fourth plug 54 may be connected to the ground GND.
[0198] The p-drain region 36 , the n-vertical channel region 32 N, the p-source region 34 S, the third gate dielectric layer 41 C, and the third gate electrode 43 C may correspond to the pull-up transistor TU. The pull-up transistor TU may be referred to as a second vertical transistor. The fifth plug 55 may be connected to the power source VDD.
[0199] The first source/drain region 27 , the second source/drain region 29 , the channel region 28 , the second gate dielectric layer 41 B, and the second gate electrode 43 B may correspond to the access transistor TA. The access transistor TA may be referred to as a planar transistor. The planar transistor may be categorized as a non-vertical or horizontal transistor. In this case, the first source/drain region 27 may be referred to as a non-vertical drain region, while the second source/drain region 29 may be referred to as a non-vertical source region. In another case, the first source/drain region 27 may be referred to as a non-vertical source region, while the second source/drain region 29 may be referred to as a non-vertical drain region.
[0200] The n-drain region 26 , the first plug 51 , the first interconnection line 57 , the second plug 52 , the p-drain region 36 , and the first source/drain region 27 may constitute the node N 1 . As described above, the first source/drain region 27 may be in continuity with, or contiguous with, the n-drain region 26 . Thus, an electrical resistance of the node N 1 may be greatly reduced. Furthermore, the sizes of the first source/drain region 27 and the n-drain region 26 may be minimized. That is, a structure in which the first source/drain region 27 and the n-drain region 26 are in continuity with each other at the same level may be highly advantageous to highly integrated semiconductor devices.
[0201] Also, it can be seen in the present embodiments of FIGS. 3A , 3 B, and 3 B that a portion of the gate electrode 43 A of the first vertical transistor and a portion of the gate electrode 43 B of the horizontal transistor are at a same vertical position in the vertical direction relative to the substrate 21 .
[0202] Also, in the present embodiments, the gate electrode 43 A of the first vertical transistor and the gate electrode 43 B of the horizontal transistor are formed from the same layer of material. This simplifies the number of process steps required for fabricating the resulting device.
[0203] The first and second vertical transistors may have a lower threshold voltage than the planar transistor. That is, a semiconductor device having various threshold voltage levels may be embodied on the same substrate, and from the same fabrication, without the requirement of additional, unnecessary, process steps. Also, the first and second vertical transistors may exhibit enhanced subthreshold characteristics and a low leakage current characteristics. Furthermore, a circuit configuration including a combination of the first and second vertical transistors and the planar transistor may remarkably reduce power consumption of the semiconductor device.
[0204] Referring to FIG. 3B , in this embodiment the bottoms of the first and second source/drain regions 27 and 29 may be formed at a lower level than the bottom of the n-drain region 26 .
[0205] Referring to FIG. 3C , in this embodiment, the n-drain region 26 , a first source/drain region 27 A, and a second source/drain region 29 A may be formed on a p-well 24 . Lightly doped regions 47 may be formed between the first and second source/drain regions 27 A and 29 A. A channel region 28 may be defined between the lightly doped regions 47 . A top surface of the first source/drain region 27 A may be formed at the same level as a top surface of the n-drain region 26 , while a bottom surface of the first source/drain region 27 A may be formed at the same level as a bottom surface of the n-drain region 26 .
[0206] Referring to FIG. 3D , in this embodiment, a first metal silicide pattern 35 S may be formed on the n-source region 33 S, while a second metal silicide pattern 38 S may be formed on the p-source region 34 S.
[0207] Referring to FIG. 3E , in this embodiment, the first metal silicide pattern 35 S may be in direct contact with a p-vertical channel region 31 P, while the second metal silicide pattern 38 S may be in direct contact with an n-vertical channel region 32 N.
[0208] Referring to FIG. 3F , in this embodiment, a first metal silicide pattern 35 S and a first metal pattern 61 may be sequentially stacked on the n-source region 33 S, while a second metal silicide pattern 38 S and a second metal pattern 62 may be sequentially stacked on the p-source region 34 S.
[0209] In the various embodiments described herein, the first and second metal patterns 61 and 62 may comprise a material including tungsten (W), tungsten nitride (WN), titanium (Ti), titanium nitride (TiN), tantalum (Ta), tantalum nitride (TaN), cobalt (Co), nickel (Ni), ruthenium (Ru), platinum (Pt), titanium aluminum nitride (TiAlN), tantalum aluminum nitride (TaAlN), titanium silicon nitride (TiSiN), tantalum silicon nitride (TaSiN), or a combination thereof. The first and second metal silicide patterns 35 S and 38 S may comprise a material including WSi, TiSi, TaSi, CoSi, NiSi, or a combination thereof.
[0210] Referring to FIG. 3G in this embodiment, insulating spacers 81 , 82 , and 83 may be formed on sidewalls of the first, second, and third gate electrodes 43 A, 43 B, and 43 C, respectively. The first metal silicide pattern 35 S may be formed on the p-vertical channel region 31 P, the second metal silicide pattern 38 S may be formed on the n-vertical channel region 32 N, a third metal silicide pattern 35 A may be formed on the n-drain region 26 and the first source/drain region 27 , a fourth metal silicide pattern 35 B may be formed on the second source/drain region 29 , and a fifth metal silicide pattern 38 A may be formed on the p-drain region 36 . The first through fifth metal silicide patterns 35 S, 38 S, 35 A, 35 B, and 38 A may be covered with the etch stop layer 48 . The first metal silicide pattern 35 S may be in contact with the p-vertical channel region 31 P, while the second metal silicide pattern 38 S may be in contact with the n-vertical channel region 32 N.
[0211] Referring to FIG. 3H , in this embodiment, the insulating spacers 81 , 82 , and 83 may be formed on the sidewalls of the first through third gate electrodes 43 A, 43 B, and 43 C, respectively. The first metal silicide pattern 35 S may be formed on the n-source region 33 S, while the second metal silicide pattern 38 S may be formed on the p-source region 34 S. Also, the third metal silicide pattern 35 A may be formed on the n-drain region 26 and the first source/drain region 27 , the fourth metal silicide pattern 35 B may be formed on the second source/drain region 29 , and the fifth metal silicide pattern 38 A may be formed on the p-drain region 36 . Furthermore, gate silicide patterns 43 S may be formed on the first through third gate electrodes 43 A, 43 B, and 43 C.
[0212] In some embodiments, including those disclosed herein in connection with FIGS. 3A-3H described above, and with embodiments described below, including embodiments disclosed herein in connection with FIGS. 4 , 5 , 7 A, 7 B, 9 A- 9 C, 11 A- 11 C, and 12 A- 12 D, it can be seen that the gate electrodes of the horizontal transistor and the vertical transistor are both in direct contact with the same layer of material that lies on the horizontal transistor and the vertical transistor. For example, in the embodiments of FIG. 3A , the gate electrode 43 A of the vertical transistor is in direct contact with the etch stop layer 48 . The same holds true for the gate electrode 43 B of the horizontal transistor. In various embodiments, the layer of material in contact with both the horizontal and vertical transistors can comprise an etch stop layer or an insulating layer.
Embodiment 2
[0213] FIG. 4 is a cross-sectional view of a semiconductor device according to a second embodiment of the inventive concept.
[0214] Referring to FIG. 4 , in this embodiment, a p-vertical channel region 31 P and an n-source region 33 S may be formed on an n-drain region 26 . First insulating spacers 63 may be formed on sidewalls of the n-source region 33 S. The n-drain region 26 may include an n-protrusion 26 P that extends in the vertical direction. A first gate dielectric layer 41 A and a first gate electrode 43 A may be formed on sidewalls of the p-vertical channel region 31 P.
[0215] The p-vertical channel region 31 P may have a width in the horizontal direction that is less than that of the n-source region 33 S. The n-protrusion 26 P may have substantially the same width in the horizontal direction as that of the p-vertical channel region 31 P.
[0216] An n-vertical channel region 32 N and a p-source region 34 S may be formed on a p-drain region 36 . Second insulating spacers 64 may be formed on sidewalls of the p-source region 34 S. The p-drain region 36 may include a p-protrusion 36 P that extends in the vertical direction. A third gate dielectric layer 41 C and a third gate electrode 43 C may be formed on sidewalls of the n-vertical channel region 32 N.
[0217] The n-vertical channel region 32 N may have a width in the horizontal direction that is less than that of the p-source region 34 S. The p-protrusion 36 P may have substantially the same horizontal width in the horizontal direction as that of the n-vertical channel region 32 N.
Embodiment 3
[0218] FIG. 5 is a cross-sectional view of a semiconductor device according to a third embodiment of the inventive concept.
[0219] Referring to FIG. 5 , lightly doped regions 67 may be formed under an n-drain region 26 , a first source/drain region 27 , and a second source/drain region 29 . The lightly doped impurity regions 67 may include impurities of the same conductivity type as the n-drain region 26 , the first source/drain region 27 , and the second source/drain region 29 . The lightly doped regions 67 may include n-type impurities. A second gate electrode 66 may be formed between the first and second source/drain regions 27 and 29 . A gate dielectric layer 65 may be formed between the second gate electrode 66 and a p-well 24 . A channel region 68 may be defined in the p-well 24 by the first and second source/drain regions 27 and 29 , the lightly doped regions 67 , and the second gate electrode 66 .
[0220] A bottom of the second gate electrode 66 may be formed at a lower level than the first and second source/drain regions 27 and 29 and the lightly doped regions 67 . A top of the second gate electrode 66 may be formed at a lower level than top surfaces of the first and second source/drain regions 27 and 29 . The second gate electrode 66 , the second gate dielectric layer 65 , the channel region 68 , the first and second source/drain regions 27 and 29 , and the lightly doped regions 67 may constitute a recess channel transistor. The recess channel transistor may be categorized as a non-vertical transistor. In this case, although the second gate electrode 66 is at a different vertical position that that of the first gate electrode 43 A, the first and second gate electrodes 43 A, 66 can still be formed of the same layer of material. Also, it can be seen that the first and second gate electrodes 43 A, 66 are both in direct contact with the same layer of material that lies on the horizontal transistor and the vertical transistor; namely etch stop layer 48 .
Embodiment 4
[0221] FIG. 6 is a layout illustrating a semiconductor device according to a fourth embodiment of the inventive concept, and FIGS. 7A and 7B are cross-sectional views of the semiconductor device taken along line II-IF of FIG. 6 .
[0222] Referring to FIGS. 6 and 7A , a p-well 24 , an n-well 25 , and an isolation layer 23 may be formed in a semiconductor substrate 21 . An n-drain region 26 , a first source/drain region 27 , and a second source/drain region 29 may be formed on the p-well 24 . A p-vertical channel region 71 P and an n-source region 73 S may be formed on the n-drain region 26 . The n-drain region 26 may include an n-protrusion 26 P. A first gate dielectric layer 41 A and a first gate electrode 43 A may be formed on sidewalls of the p-vertical channel region 71 P.
[0223] A channel region 28 may be defined between the first and second source/drain regions 27 and 29 . A second gate electrode 43 B may be formed on the channel region 28 . A second gate dielectric layer 41 B may be interposed between the second gate electrode 43 B and the channel region 28 .
[0224] A p-drain region 36 may be formed on the n-well 25 . An n-vertical channel region 72 N and a p-source region 74 S may be formed on the p-drain region 36 . The p-drain region 36 may include a p-protrusion 36 P. A third gate dielectric layer 41 C and a third gate electrode 43 C may be formed on sidewalls of the n-vertical channel region 72 N.
[0225] A gate pad 43 P may be formed on the isolation layer 23 . The first and third gate electrodes 43 A and 43 C may be connected to the gate pad 43 P. The gate pad 43 P and the first and third gate electrodes 43 A and 43 C may have an integral structure. An etch stop layer 48 and an interlayer insulating layer 49 may be formed to cover the entire surface of the semiconductor substrate 21 .
[0226] A first plug 51 , a second plug 52 , a third plug 53 , a fourth plug 54 , a fifth plug 55 , and a sixth plug 56 may be formed through the interlayer insulating layer 49 and the etch stop layer 48 . First through fourth interconnection lines 57 , 59 , 77 , and 79 may be formed on the interlayer insulating layer 49 . The first plug 51 may be connected to at least one of the n-drain region 26 and the first source/drain region 27 . The second plug 52 may be connected to the p-drain region 36 . The first interconnection line 57 may be in contact with the first and second plugs 51 and 52 . The second interconnection line 59 may be in contact with the third plug 53 . The third plug 53 may be connected to the second source/drain region 29 . The fourth plug 54 may be connected to the n-source region 73 S. The fifth plug 55 may be connected to the p-source region 74 S. The sixth plug 56 may be connected to the gate pad 43 P.
[0227] In the present embodiment, each of the p-vertical channel region 71 P and the n-vertical channel region 72 N may have a pillar structure. Each of the p-vertical channel region 71 P and the n-vertical channel region 72 N may have a cylindrical shape, a square cross-section pillar shape, a rectangular cross-section pillar shape, or a polygonal cross-section pillar shape. The p-vertical channel region 71 P may protrude in a vertical direction over the n-drain region 26 , while the n-vertical channel region 72 N may protrude in a vertical direction over the p-drain region 36 . Each of the p-vertical channel region 71 P and the n-vertical channel region 72 N may comprise a single crystal semiconductor material formed using an epitaxial growth technique.
[0228] In other embodiments, each of the p-vertical channel region 71 P and the n-vertical channel region 72 N may include a wire structure, or a nano-wire structure.
[0229] The n-source region 73 S may be disposed on and have sidewalls that are aligned with those of the p-vertical channel region 71 P and contact the p-vertical channel region 71 P. The p-source region 74 S may be disposed on and have sidewalls that are aligned with those of the n-vertical channel region 72 N and contact the n-vertical channel region 72 N. Each of the n-source region 73 S and the p-source region 74 S may comprise a single crystal semiconductor material formed using an epitaxial growth technique.
[0230] In some embodiments, the first gate electrode 43 A may be formed to completely surround the sidewalls of the p-vertical channel region 71 P, while the third gate electrodes 43 C may be formed to completely surround the sidewalls of the n-vertical channel region 72 N.
[0231] Referring to FIG. 7B , the p-vertical channel region 71 P and the n-source region 73 S may be formed on the n-drain region 26 . First insulating spacers 63 may be formed on sidewalls of the n-source region 73 S. The n-drain region 26 may include an n-protrusion 26 P. The n-protrusion 26 P may be disposed under and have sidewalls that are aligned with sidewalls of the p-vertical channel region 71 P. A first gate dielectric layer 41 P and a first gate electrode 43 A may be formed on the sidewalls of the p-vertical channel region 71 P.
[0232] The p-vertical channel region 71 P may have a width in the horizontal direction that is less than that of the n-source region 73 S. The n-protrusion 26 P may have a width in the horizontal direction that is substantially the same as that of the p-vertical channel region 71 P.
[0233] The n-vertical channel region 72 N and the p-source region 74 S may be formed on the p-drain region 36 . Second insulating spacers 64 may be formed on sidewalls of the p-source region 74 S. The p-drain region 36 may include a p-protrusion 36 P. A third gate dielectric layer 41 C and a third gate electrode 43 C may be formed on the sidewalls of the n-vertical channel region 72 N.
[0234] The n-vertical channel region 72 N may have a width in the horizontal direction that is less than that of the p-source region 74 S. The p-protrusion 36 P may have a width in the horizontal direction that is substantially the same as that of the n-vertical channel region 72 N.
Embodiment 5
[0235] FIG. 8 is a layout illustrating a semiconductor device according to a fifth embodiment of the inventive concept. FIGS. 9A through 9C are cross-sectional views of the semiconductor device taken along lines III-III′, IV-IV′, and V-V′ of FIG. 8 , respectively.
[0236] Referring to FIGS. 8 and 9A through 9 C, a buried oxide layer 122 may be formed on a semiconductor substrate 121 . An isolation layer 123 may be formed on the buried oxide layer 122 to define an n-drain region 126 , a first source/drain region 127 , a second source/drain region 129 , a channel region 128 , and a p-drain region 136 .
[0237] A p-vertical channel region 131 P and an n-source region 133 S may be formed on the n-drain region 126 . The n-drain region 126 may include an n-protrusion 126 P. A first gate dielectric layer 141 A and a first gate electrode 143 A may be formed on sidewalls of the p-vertical channel region 131 P.
[0238] A second gate electrode 143 B may be formed on the channel region 128 . A second gate dielectric layer 141 B may be interposed between the second gate electrode 143 B and the channel region 128 .
[0239] An n-vertical channel region 132 N and a p-source region 134 S may be formed on the p-drain region 136 . The p-drain region 136 may include a p-protrusion 136 P. A third gate dielectric layer 141 C and a third gate electrode 143 C may be formed on sidewalls of the n-vertical channel region 132 N.
[0240] A gate pad 143 P may be formed on the isolation layer 123 . The first and third gate electrodes 143 A and 143 C may be connected to the gate pad 143 P. An etch stop layer 148 and an interlayer insulating layer 149 may be formed to cover the entire surface of the semiconductor substrate 121 .
[0241] A first plug 151 , a second plug 153 , a third plug 154 , a fourth plug 155 , and a fifth plug 156 may be formed through the interlayer insulating layer 149 and the etch stop layer 148 . First and second interconnection lines 157 and 159 may be formed on the interlayer insulating layer 149 . The first plug 151 may be connected to at least one of the n-drain region 126 , the p-drain region 136 , and the first source/drain region 127 . The first interconnection line 157 may be in contact with the first plug 151 . The second interconnection line 159 may be in contact with the second plug 153 .
[0242] The n-drain region 126 , the first source/drain region 127 , the second source/drain region 129 , the channel region 128 , and the p-drain region 136 may be formed at the same vertical level, relative to the substrate. Top surfaces of the n-drain region 126 , the first source/drain region 127 , the second source/drain region 129 , the channel region 128 , and the p-drain region 136 may be formed at a lower level than a top surface of the isolation layer 123 . The first source/drain region 127 may be in continuity with, or, in other words, contiguous with, the n-drain region 126 . Furthermore, the first source/drain region 127 and the n-drain region 126 may be integral with each other. The p-drain region 136 may be in contact with at least one of the n-drain region 126 and the first source/drain region 127 . Each of the n-drain region 126 and the first source/drain region 127 may comprise a single crystal semiconductor material having n-type impurities. The p-drain region 136 may comprise a single crystal semiconductor material having p-type impurities.
[0243] The n-drain region 126 , the p-drain region 136 , and the first source/drain region 127 may constitute a node (refer to N 1 in FIG. 1 ). In some embodiments, the electric resistance of the node N 1 may be markedly reduced. The first source/drain region 127 and the n-drain region 126 may be in continuity with, or contiguous with, each other at the same vertical level relative to the substrate. Such a structure in which the p-drain region 136 is in contact with the n-drain region 126 and the first source/drain region 127 is highly advantageous in that it lends itself well to highly integrated configurations.
Embodiment 6
[0244] FIG. 10 is a layout illustrating a semiconductor device according to a sixth embodiment of the inventive concept. FIGS. 11A , 12 A, and 12 D are cross-sectional views taken along line VI-VI′ of FIG. 10 , FIGS. 11B and 12B are cross-sectional views taken along line VII-VII′ of FIG. 10 , and FIGS. 11C and 12C are cross-sectional views taken along line VIII-VIII′ of FIG. 10 .
[0245] Referring to FIGS. 10 , 11 A, 11 B, and 11 C, a buried oxide layer 122 may be formed on a semiconductor substrate 121 . An isolation layer 123 may be formed on the buried oxide layer 122 to define an n-drain region 126 , a first source/drain region 127 , a second source/drain region 129 , a channel region 128 , and a p-drain region 136 .
[0246] A p-vertical channel region 171 P and an n-source region 173 S may be formed on the n-drain region 126 . The n-drain region 126 may include an n-protrusion 126 P. A first gate dielectric layer 141 A and a gate electrode 143 A may be formed on sidewalls of the p-vertical channel region 171 P.
[0247] A channel region 128 may be defined between the first and second source/drain regions 127 and 129 . A second gate electrode 143 B may be formed on the channel region 128 . A second gate dielectric layer 141 B may be interposed between the second gate electrode 143 B and the channel region 128 .
[0248] An n-vertical channel region 172 N and a p-source region 174 S may be formed on the p-drain region 136 . The p-drain region 136 may include a p-protrusion 136 P. A third gate dielectric layer 141 C and a third gate electrode 143 C may be formed on sidewalls of the n-vertical channel region 172 N.
[0249] A gate pad 143 P may be formed on the isolation layer 123 . The first and third gate electrodes 143 A and 143 C may be connected to the gate pad 143 P. An etch stop layer 148 and an interlayer insulating layer 149 may be formed to cover the entire surface of the semiconductor substrate 121 .
[0250] A first plug 151 , a second plug 153 , a third plug 154 , a fourth plug 155 , and a fifth plug 156 may be formed through the interlayer insulating layer 149 and the etch stop layer 148 . First through fourth interconnection lines 157 , 159 , 177 , and 179 may be formed on the interlayer insulating layer 149 . The first plug 151 may be connected to at least one of the n-drain region 126 , the p-drain region 136 , and the first source/drain region 127 . The first interconnection line 157 may be in contact with the first plug 151 . The second interconnection line 159 may be in contact with the second plug 153 .
[0251] Each of the p-vertical channel region 171 P and the n-vertical channel region 172 N may have a pillar structure. In other embodiments, each of the p-vertical channel region 171 P and the n-vertical channel region 172 N may have a wire structure, or nano-wire structure.
[0252] The first gate electrode 143 A may be formed to completely surround sidewalls of the p-vertical channel region 171 P, and the third gate electrode 143 C may be formed to completely surround sidewalls of the n-vertical channel region 172 N.
[0253] Referring to FIGS. 10 , 12 A, 12 B, and 12 C, a p-vertical channel region 171 P and an n-source region 173 S may be formed on the n-drain region 126 . First insulating spacers 163 may be formed on sidewalls of the n-source region 173 S. The n-drain region 126 may include an n-protrusion 126 P. A first gate dielectric layer 141 A and a first gate electrode 143 A may be formed on sidewalls of the p-vertical channel region 171 P.
[0254] The p-vertical channel region 171 P may have a width in the horizontal direction that is less than that of the n-source region 173 S. The n-protrusion 126 P may have substantially the same width in the horizontal direction as that of the p-vertical channel region 171 P.
[0255] An n-vertical channel region 172 N and a p-source region 174 S may be formed on the p-drain region 136 . Second insulating spacers 164 may be formed on sidewalls of the p-source region 174 S. The p-drain region 136 may include a p-protrusion 136 P. A third gate dielectric layer 141 C and a third gate electrode 143 C may be formed on sidewalls of the n-vertical channel region 172 N.
[0256] The n-vertical channel region 172 N may horizontal width that is less than that of the p-source region 174 S. The p-protrusion 136 P may have substantially the same width in the horizontal direction as that of the n-vertical channel region 172 N.
[0257] Referring to FIGS. 10 and 12D , impurity regions 147 A may be formed adjacent to both sides of the second gate electrode 143 B. The impurity regions 147 may be aligned with sidewalls of the second gate electrode 143 B. The impurity regions 147 A may have different widths due to alignment errors of the second gate electrode 143 B present during its formation. A channel region 128 may be defined between the impurity regions 147 A.
Embodiment 7
[0258] FIGS. 13 through 24 are cross-sectional views taken along line I-I′ of FIG. 2 , illustrating a method of forming a semiconductor device according to a seventh embodiment of the inventive concept.
[0259] Referring to FIGS. 2 and 13 , a p-well 24 , an n-well 25 , and an isolation layer 23 may be formed in a semiconductor substrate 21 . In some embodiments, the semiconductor substrate 21 may comprise a semiconductor wafer formed of single crystal material. For example, the semiconductor substrate 21 may be a silicon wafer having p-type impurities. The p-well 24 may include single crystalline silicon having p-type impurities, while the n-well 25 may include single crystalline silicon having n-type impurities. The isolation layer 23 may be an insulating layer formed of silicon oxide, silicon nitride, silicon oxynitride, or a combination thereof using a shallow trench isolation (STI) technique. The p-well 24 and the n-well 25 may be electrically isolated from one another by the isolation layer 23 . A top surface of the isolation layer 23 , the p-well 24 , and the n-well 25 may lie on substantially the same planar surface.
[0260] Referring to FIGS. 2 and 14A , a first mask pattern 26 M may be formed to cover the n-well 25 and partially expose the p-well 24 . N-type impurities may be implanted into the p-well 24 using the first mask pattern 26 M as an ion implantation mask, thereby forming an n-drain region 26 . A channel region 28 may be defined adjacent to the n-drain region 26 . The channel region 28 may include single crystalline silicon material having p-type impurities. The first mask pattern 26 M may be removed.
[0261] Referring to FIG. 14B , in applied embodiments, a first mask pattern 26 M may be formed to cover the n-well 25 and partially expose the p-well 24 . N-type impurities may be implanted into the p-well 24 using the first mask pattern 26 M as an ion implantation mask, thereby forming an n-drain region 26 , a first source/drain region 27 A, and a second source/drain region 29 A. A channel region 28 may be defined between the first and second source/drain regions 27 A and 29 A. The channel region 28 may include single crystalline silicon having p-type impurities. The first mask pattern 26 M may be removed.
[0262] Referring to FIGS. 2 and 15 , a second mask pattern 36 M may be formed to cover the p-well 24 and expose the n-well 25 . P-type impurities may be implanted into the n-well 25 using the second mask pattern 36 M as an ion implantation mask, thereby forming a p-drain region 36 . The second mask pattern 36 M may be removed, thereby exposing top surfaces of the n-drain region 26 and the p-drain region 36 .
[0263] Referring to FIGS. 2 and 16 , a first semiconductor layer 31 may be formed on the semiconductor substrate 21 . The first semiconductor layer 31 may be in contact with top surfaces of the n-drain region 26 and the p-drain region 36 . In some embodiments, the first semiconductor layer 31 may be formed using an epitaxial growth technique. The first semiconductor layer 31 may include an n-type semiconductor, a p-type semiconductor, or an intrinsic semiconductor.
[0264] Hereinafter, it is assumed that the first semiconductor layer 31 is a first p-semiconductor layer. For example, the first p-semiconductor layer 31 may include single crystalline silicon having p-type impurities.
[0265] Referring to FIGS. 2 and 17 , a third mask pattern 32 M may be formed on the first p-semiconductor layer 31 . A first n-semiconductor layer 32 and a second p-semiconductor layer 34 may be formed in the first p-semiconductor layer 31 by performing an ion implantation process using the third mask pattern 32 M as an ion implantation mask. The third mask pattern 32 M may be removed. The first n-semiconductor layer 32 may be in contact with the p-drain region 36 . The second p-semiconductor layer 34 may be formed on the first n-semiconductor layer 32 . As a result, the first p-semiconductor layer 31 may be defined on the p-well 24 .
[0266] Referring to FIGS. 2 and 18 , a fourth mask pattern 33 M may be formed to cover the second p-semiconductor layer 34 and expose the first p-semiconductor layer 31 . A second n-semiconductor layer 33 may be formed by performing an ion implantation process using the fourth mask pattern 33 M as an ion implantation mask. The fourth mask pattern 33 M may be removed. The first p-semiconductor layer 31 may therefore be defined between the second n-semiconductor layer 33 and the n-drain region 26 .
[0267] Referring to FIGS. 2 , 19 , and 20 , a fifth mask pattern 37 M may be formed on the second n-semiconductor layer 33 and the second p-semiconductor layer 34 . The second n-semiconductor layer 33 , the first p-semiconductor layer 31 , the n-drain region 26 , the channel region 28 , the second p-semiconductor layer 34 , the first n-semiconductor layer 32 , and the p-drain region 36 may be anisotropically etched using the fifth mask pattern 37 M as an etch mask, thereby forming an n-source region 33 S, a p-vertical channel region 31 P, a p-source region 34 S, and an n-vertical channel region 32 N.
[0268] The n-drain region 26 , the channel region 28 , and the p-drain region 36 may be partially recessed and retained at a lower level than the top surface of the isolation layer 23 . The n-drain region 26 may thereby include an n-protrusion 26 P, and the p-drain region 36 may thereby include a p-protrusion 36 P. The n-protrusion 36 may be disposed under and have sidewalls that are aligned with those of the p-vertical channel region 31 P, while the p-protrusion 36 P may be disposed under and have sidewalls that are aligned with those of the n-vertical channel region 32 N.
[0269] Referring to FIGS. 2 and 21 , a gate dielectric layer 41 A, 41 B, and 41 C may be formed to cover the resulting surface of the semiconductor substrate 21 . A gate conductive layer 43 may be formed on the gate dielectric layer 41 A, 41 B, and 41 C. The gate dielectric layer 41 A, 41 B, and 41 C may include a first gate dielectric layer portion 41 A covering sidewalls of the p-vertical channel region 31 P, a second gate dielectric layer portion 41 B covering the channel region 28 , and a third gate dielectric layer 41 C portion covering sidewalls of the n-vertical channel region 32 N.
[0270] The gate dielectric layer 41 A, 41 B, and 41 C may comprise a silicon oxide layer, a silicon nitride layer, a silicon oxynitride layer, a high-k dielectric layer, or a combination thereof. The first gate dielectric layer 41 A, the second gate dielectric layer 41 B, and the third gate dielectric layer 41 C portions may be formed using the same material layer at the same time. The gate conductive layer 43 may include a metal layer, a metal nitride layer, a metal silicide layer, a polysilicon (poly-Si) layer, a conductive carbon layer, or a combination thereof.
[0271] Referring to FIGS. 2 and 22 , a sixth mask pattern 45 M may be formed on the gate conductive layer 43 . The gate conductive layer 43 may be anisotropically etched using the sixth mask pattern 45 M as an etch mask, thereby forming a first gate electrode 43 A, a second gate electrode 43 B, and a third gate electrode 43 C. The sixth mask pattern 45 M may cover the second gate electrode 43 B. Also, the sixth mask pattern 45 M may cover a gate pad 43 P.
[0272] Referring to FIGS. 2 and 23 , a seventh mask pattern 47 M may be formed to cover the n-well 25 and the n-drain region 26 . N-type impurities may be implanted into the channel region 28 adjacent to both sides of the second gate electrode 43 B using the seventh mask pattern 47 M as an ion implantation mask, thereby forming first and second source/drain regions 27 and 29 . Thereafter, the seventh mask pattern 47 M may be removed. As a result, the channel region 28 may be defined between the first and second source/drain regions 27 and 29 .
[0273] Subsequently, the sixth and fifth mask patterns 45 M and 37 M may be removed. The gate dielectric layer 41 A, 41 B, and 41 C portions may also be partially removed.
[0274] Referring to FIGS. 2 and 24 , an etch stop layer 48 may be formed to cover the resulting surface of the semiconductor substrate 21 . An interlayer insulating layer 49 may be formed on the etch stop layer 48 . A top surface of the interlayer insulating layer 49 may be planarized.
[0275] Referring back to FIGS. 2 and 3A , a first plug 51 , a second plug 52 , a third plug 53 , a fourth plug 54 , a fifth plug 55 , and a sixth plug 56 may be formed through the interlayer insulating layer 49 and the etch stop layer 48 . First and second interconnection lines 57 and 59 may be formed on the interlayer insulating layer 49 to form the resulting semiconductor device.
Embodiment 8
[0276] FIGS. 25 through 31 are cross-sectional views illustrating a method of forming a semiconductor device according to an eighth embodiment of the inventive concept.
[0277] Referring to FIG. 25 , a p-well 24 , an n-well 25 , an isolation layer 23 , an n-drain region 26 , a channel region 28 , a p-drain region 36 , a first p-semiconductor layer 31 , a first n-semiconductor layer 32 , an n-source region 33 S, a p-source region 34 S, and a fifth mask pattern 37 M may be formed on a semiconductor substrate 21 .
[0278] Referring to FIG. 26 , first insulating spacers 63 may be formed on sidewalls of the fifth mask pattern 37 M and the n-source region 33 S, and second insulating spacers 64 may be formed on sidewalls of the fifth mask pattern 37 M and the p-source region 34 S.
[0279] Referring to FIG. 27 , the first p-semiconductor layer 31 and the first n-semiconductor layer 32 may be anisotropically etched using the fifth mask pattern 37 M and the first and second insulating spacers 63 and 64 as an etch mask, thereby forming a p-vertical channel region 31 P and an n-vertical channel region 32 N.
[0280] Referring to FIG. 28 , the thicknesses of the p-vertical channel region 31 P and the n-vertical channel region 32 N in the horizontal direction may be reduced using a pullback process. The p-vertical channel region 31 P may have a smaller width in the horizontal direction than that of the n-source region 33 S. The n-vertical channel region 32 N may have a width in the horizontal direction that is less than that of the p-source region 34 S.
[0281] The pullback process may include isotropically etching the p-vertical channel region 31 P and the n-vertical channel region 32 N. During the pullback process, the n-drain region 26 , the channel region 28 , and the p-drain region 36 may become partially recessed and retained at a lower level than a top surface of the isolation layer 23 . The n-drain region 26 may include an n-protrusion 26 P, while the p-drain region 36 may include a p-protrusion 36 P. The n-protrusion 26 P may be disposed under and have sidewalls that are aligned with those of the p-vertical channel region 31 P, while the p-protrusion 36 P may be disposed under and have sidewalls that are aligned with those of the n-vertical channel region 32 N.
[0282] Referring to FIG. 29 , a gate dielectric layer 41 A, 41 B, and 41 C may be formed to cover the surface of the semiconductor substrate 21 . A gate conductive layer 43 may be formed on the gate dielectric layer 41 A, 41 B, and 41 C. The gate dielectric layer 41 A, 41 B, and 41 C may include a first gate dielectric layer 41 A portion covering sidewalls of the p-vertical channel region 31 P, a second gate dielectric layer 41 B portion covering the channel region 28 , and a third gate dielectric layer 41 C portion covering sidewalls of the n-vertical channel region 32 N.
[0283] Referring to FIG. 30 , a sixth mask pattern 45 M may be formed on the gate conductive layer 43 . The gate conductive layer 43 may be anisotropically etched using the sixth mask pattern 45 M as an etch mask, thereby forming a first gate electrode 43 A, a second gate electrode 43 B, and a third gate electrode 43 C. The sixth mask pattern 45 M may cover the second gate electrode 43 B. The sixth and fifth mask patterns 45 M and 37 M may be removed. The gate dielectric layer 41 A, 41 B, and 41 C and the first and second insulating spacers 63 and 64 also may be partially removed.
[0284] Referring to FIG. 31 , n-type impurities may be implanted into the channel region 28 adjacent to both sides of the second gate electrode 43 B, thereby forming a first source/drain region 27 and a second source/drain region 29 . The channel region 28 may be defined between the first and second source/drain regions 27 and 29 . An etch stop layer 48 may be formed to cover the surface of the semiconductor substrate 21 . An interlayer insulating layer 49 may be formed on the etch stop layer 48 .
[0285] Referring back to FIG. 4 , a first plug 51 , a second plug 52 , and a third plug 53 may be formed through the interlayer insulating layer 49 and the etch stop layer 48 . First and second interconnection lines 57 and 59 may be formed on the interlayer insulating layer 49 to form the resulting semiconductor device.
Embodiment 9
[0286] FIGS. 32 through 39 are cross-sectional views illustrating a method of forming a semiconductor device according to a ninth embodiment of the inventive concept.
[0287] Referring to FIG. 32 , a p-well 24 , an n-well 25 , and an isolation layer 23 may be formed in a semiconductor substrate 21 . A first mask pattern 26 M may be formed to cover the n-well 25 and expose the p-well 24 . N-type impurities may be implanted into the p-well 24 using the first mask pattern 26 M as an ion implantation mask, thereby forming an n-drain region 26 , a first source/drain region 27 , a second source/drain region 29 , and a lightly doped region 67 . The lightly doped region 67 may be formed under the n-drain region 26 , the first source/drain region 27 , and the second source/drain region 29 . The first mask pattern 26 M may then be removed.
[0288] Referring to FIG. 33 , a second mask pattern 36 M may be formed to cover the p-well 24 and expose the n-well 25 . P-type impurities may be implanted into the n-well 25 using the second mask pattern 36 M as an ion implantation mask, thereby forming a p-drain region 36 . The second mask pattern 36 M may be removed to expose top surfaces of the n-drain region 26 and the p-drain region 36 .
[0289] Referring to FIG. 34 , a first p-semiconductor layer 31 , a first n-semiconductor layer 32 , a second n-semiconductor layer 33 , a second p-semiconductor layer 34 , and a fifth mask pattern 37 M may be formed. The first p-semiconductor layer 31 and the second n-semiconductor layer 33 may be sequentially stacked on the n-drain region 26 and the first and second source/drain regions 27 and 29 . The first n-semiconductor layer 32 and the second p-semiconductor layer 34 may be sequentially stacked on the p-drain region 36 .
[0290] Referring to FIG. 35 , the second n-semiconductor layer 33 , the first p-semiconductor layer 31 , the n-drain region 26 , the first source/drain region 27 , the second source/drain region 29 , the second p-semiconductor layer 34 , the first n-semiconductor layer 32 , and the p-drain region 36 may be anisotropically etched using the fifth mask pattern 37 M as an etch mask, thereby forming an n-source region 33 S, a p-vertical channel region 31 P, a p-source region 34 S, and an n-vertical channel region 32 N. The n-drain region 26 , the first source/drain region 27 , the second source/drain region 29 , and the p-drain region 36 may be partially recessed and retained at a lower level than a top surface of the isolation layer 23 . The n-drain region 26 may include an n-protrusion 26 P, while the p-drain region 36 may include a p-protrusion 36 P.
[0291] Referring to FIG. 36 , a sixth mask pattern 66 M may be formed on the semiconductor substrate 21 . The first source/drain region 27 , the second source/drain region 29 , the lightly doped region 67 , and the p-well 24 may be anisotropically etched using the sixth mask pattern 66 M as an etch mask, thereby forming a gate trench 66 T. The gate trench 66 T may penetrate not only a region between the first and second source/drain regions 27 and 29 but also the lightly doped region 67 . The lightly doped region 67 may be divided into two regions by the gate trench 66 T. A channel region 68 may be defined by the gate trench 66 T in the p-well 24 . The sixth mask pattern 66 M may be removed.
[0292] Referring to FIG. 37 , a gate dielectric layer 41 A, 65 , and 41 C may be formed to cover the surface of the semiconductor substrate 21 . A gate conductive layer 43 may be formed on the gate dielectric layer 41 A, 65 , and 41 C. The gate conductive layer 43 may completely fill the gate trench 66 T.
[0293] Referring to FIG. 38 , the gate conductive layer 43 may be anisotropically etched, thereby forming a first gate electrode 43 A, a second gate electrode 66 , and a third gate electrode 43 C. The second gate electrode 66 may be retained within the gate trench 66 T. A first gate dielectric layer 41 A may be retained between the first gate electrode 43 A and the p-vertical channel region 31 P, and a second gate dielectric layer 65 may be retained between the second gate electrode 66 and the channel region 68 . Also, a third gate dielectric layer 41 C may be retained between the third gate electrode 43 C and the n-vertical channel region 32 N.
[0294] A bottom of the second gate electrode 66 may be formed at a lower level than the first and second source/drain regions 27 and 29 and the lightly doped regions 67 . A top of the second gate electrode 66 may be formed at a lower level than top surfaces of the first and second source/drain regions 27 and 29 . The second gate electrode 66 , the second gate dielectric layer 65 , the channel region 68 , the first source/drain region 27 , the second source/drain region 29 , and the lightly doped regions 67 may constitute a recess channel transistor. The recess channel transistor may be categorized as a non-vertical, or horizontal, transistor.
[0295] Subsequently, the gate dielectric layer 41 A, 65 , and 41 C are partially etched and the fifth mask pattern 37 M may be removed.
[0296] Referring to FIG. 39 , an etch stop layer 48 may be formed to cover the surface of the semiconductor substrate 21 . An interlayer insulating layer 49 may be formed on the etch stop layer 48 . The etch stop layer 48 may cover the second gate electrode 66 .
[0297] Referring back to FIG. 5 , a first plug 51 , a second plug 52 , and a third plug 53 may be formed through the interlayer insulating layer 49 and the etch stop layer 48 . First and second interconnection lines 57 and 59 may be formed on the interlayer insulating layer 49 to form the resulting semiconductor device.
Embodiment 10
[0298] FIGS. 40A through 43C are cross-sectional views taken along lines III-III′, IV-IV′, and V-V′ of FIG. 8 , illustrating a method of forming a semiconductor device according to a tenth embodiment of the inventive concept.
[0299] Referring to FIGS. 8 , 40 A, 40 B, and 40 C, a buried oxide layer 122 may be formed on a semiconductor substrate 121 . An active region 124 and an isolation layer 123 may be formed on the buried oxide layer 122 . Top surfaces of the active region 124 and the isolation layer 123 may be exposed on substantially the same plane surface. A first mask pattern 126 M may be formed on the active region 124 and the isolation layer 123 . An n-drain region 126 may be formed in the active region 124 by performing an ion implantation process using the first mask pattern 126 M as an ion implantation mask.
[0300] The buried oxide layer 122 may be an insulating layer, such as a silicon oxide layer. In this case, the semiconductor substrate 121 may be a silicon-on-insulator (SOI) wafer. The active region 124 may include a single crystalline semiconductor having p-type impurities. The isolation layer 123 may penetrate the active region 124 and contact the buried oxide layer 122 .
[0301] Referring to FIGS. 8 , 41 A, 41 B, and 41 C, a second mask pattern 136 M may be formed on the n-drain region 126 , the active region 124 , and the isolation layer 123 . P-impurities may be implanted into the active region 124 using the second mask pattern 136 M as an ion implantation mask, thereby forming a p-drain region 136 .
[0302] Referring to FIGS. 8 , 42 A, 42 B, and 42 C, a first p-semiconductor layer 131 may be formed on the n-drain region 126 and the active region 124 , and a first n-semiconductor layer 132 may be formed on the p-drain region 136 . A second n-semiconductor layer 133 may be formed on the first p-semiconductor layer 131 , and a second p-semiconductor layer 134 may be formed on the first n-semiconductor layer 132 .
[0303] Referring to FIGS. 8 , 43 A, 43 B, and 43 C, a p-vertical channel region 131 P and an n-source region 133 S may be formed on the n-drain region 126 in about the same manners as in the previous embodiments. The n-drain region 126 may include an n-protrusion 126 P. A first gate electrode 143 A may be formed on sidewalls of the p-vertical channel region 131 P. A first gate dielectric layer 141 A may be formed between the first gate electrode 143 A and the p-vertical channel region 131 P.
[0304] A second gate electrode 143 B may be formed on the active region 124 . A first source/drain region 127 and a second source/drain region 129 may be formed in the active region 124 adjacent to both sides of the second gate electrode 143 B. A channel region 128 may be defined in the active region 124 between the first and second source/drain regions 127 and 129 . A second gate dielectric layer 141 B may be formed between the second gate electrode 143 B and the channel region 128 .
[0305] An n-vertical channel region 132 N and a p-source region 134 S may be formed on the p-drain region 136 . The p-drain region 136 may include a p-protrusion 136 P. A third gate electrode 143 C may be formed on sidewalls of the n-vertical channel region 132 N. A third gate dielectric layer 141 C may be formed between the third gate electrode 143 C and the n-vertical channel region 132 N.
[0306] A gate pad 143 P may be formed on the isolation layer 123 . An etch stop layer 148 may be formed to cover the entire surface of the semiconductor substrate 121 . An interlayer insulating layer 149 may be formed on the etch stop layer 148 .
[0307] Referring to FIGS. 8 , 9 A, 9 B, and 9 C, a first plug 151 , a second plug 153 , a third plug 154 , a fourth plug 155 , and a fifth plug 156 may be formed through the interlayer insulating layer 149 and the etch stop layer 148 . First and second interconnection lines 157 and 159 may be formed on the interlayer insulating layer 149 to form the resulting semiconductor device.
Experimental Example
[0308] FIGS. 44A and 44B are current-voltage (IV) graphs showing drain current characteristics of Experimental Examples according to the inventive concepts. In FIGS. 44A and 44B , the horizontal axis denotes a gate bias voltage expressed in units of volts (V). A vertical axis of FIG. 44A denotes a drain current expressed in units of A/μm on a logarithmic scale, while a vertical axis of FIG. 44B denotes a drain current expressed in units of μA/μm on a linear scale.
[0309] Referring to FIG. 44A , curve L 1 shows a drain current characteristic of a planar transistor having a similar construction to the second gate electrode 43 B of FIG. 3A , and curves L 2 through L 5 show drain current characteristics of vertical transistors having similar constructions to the p-vertical channel region 31 P and the first gate electrode 43 A of FIG. 3A . In this case, each of the vertical transistors may be interpreted as a double-gate transistor. In the curve L 1 , the second gate electrode 43 B has a horizontal width Lg of about 16 nm. In the curve L 2 , the p-vertical channel region 31 P has a horizontal width DGt of about 28 nm and a vertical height Lg of about 16 nm. In the curve L 3 , the p-vertical channel region 31 P has a horizontal width DGt of about 22 nm and a vertical height Lg of about 16 nm. In the curve L 4 , the p-vertical channel region 31 P has a horizontal width DGt of about 16 nm and a vertical height Lg of about 16 nm. In the curve L 5 , the p-vertical channel region 31 P has a horizontal width DGt of about 16 nm and a vertical height Lg of about 74 nm.
[0310] As shown in FIG. 44A , it can be seen that each of the vertical transistors may exhibit a lower leakage current characteristic than the planar transistor. Also, it can be inferred that with a reduction in the horizontal width DGt of the p-vertical channel region 31 P, the subthreshold current may increase, and off-current may decrease.
[0311] Referring to FIG. 44B , it can be seen from curves L 11 to L 51 that each vertical transistor may exhibit a higher on-current characteristic than the planar transistor. Also, it may be inferred that with a reduction in a horizontal width DGt of a p-vertical channel region 31 P, on-current may increase.
Embodiment 11
[0312] FIG. 45 is an equivalent circuit diagram of a CMOS SRAM cell according to an eleventh embodiment of the inventive concept.
[0313] Referring to FIG. 45 , the CMOS SRAM cell may include a pair of pull-down transistors TD 1 and TD 2 , a pair of access transistors TA 1 and TA 2 , and a pair of pull-up transistors TU 1 and TU 2 . Both of the pull-down transistors TD 1 and TD 2 and both of the access transistors TA 1 and TA 2 may be NMOS transistors, and both of the pull-up transistors TU 1 and TU 2 may be PMOS transistors.
[0314] The first pull-down transistor TD 1 and the first access transistor TA 1 may be connected in series to each other. A source of the first pull-down transistor TD 1 may be electrically connected to a ground GND, while a drain of the first access transistor TA 1 may be electrically connected to a first bit line BL 1 . Similarly, the second pull-down transistor TD 2 and the second access transistor TA 2 may be connected in series to each other. A source of the second pull-down transistor TD 2 may be electrically connected to the ground GND, and a drain of the second access transistor TA 2 may be electrically connected to a second bit line BL 2 .
[0315] Meanwhile, a source and drain of the first pull-down transistor TU 1 may be electrically connected to a power source VDD and a drain of the first pull-down transistor TD 1 , respectively. Similarly, a source and drain of the second pull-up transistor TU 2 may be electrically connected to the power source VDD and a drain of the second pull-down transistor TD 2 , respectively. The drain of the first pull-up transistor TU 1 , the drain of the first pull-down transistor TD 1 , and a source of the first access transistor TA 1 may correspond to a first node N 1 . Also, the drain of the second pull-up transistor TU 2 , the drain of the second pull-down transistor TD 2 , and a source of the second access transistor TA 2 may correspond to a second node N 2 . A gate electrode of the first pull-down transistor TD 1 and a gate electrode of the first pull-up transistor TU 1 may be electrically connected to the second node N 2 , while a gate electrode of the second pull-down transistor TD 2 and a gate electrode of the second pull-up transistor TU 2 may be electrically connected to the first node N 1 . Also, gate electrodes of the first and second access transistors TA 1 and TA 2 may be electrically connected to a word line WL.
[0316] Each arrow (→) of FIG. 45 denotes a direction in which current flows. As shown in FIG. 45 , current may flow through the pull-up transistors TU 1 and TU 2 and the pull-down transistors TD 1 and TD 2 in one direction, while the access transistors TA 1 and TA 2 may operate to have current flow in opposite directions.
[0317] The semiconductor devices and methods of forming the same described with reference to FIGS. 1 through 43C may be variously applied to the CMOS SRAM cell. For example, as described with reference to FIGS. 2 and 3A , the n-drain region 26 , the p-vertical channel region 31 P, the n-source region 33 S, the first gate dielectric layer 41 A, and the first gate electrode 43 A may correspond to the first pull-down transistor TD 1 . The p-drain region 36 , the n-vertical channel region 32 N, the p-source region 34 S, the third gate dielectric layer 41 C, and the third gate electrode 43 C may correspond to the first pull-up transistor TU 1 . Also, the first source/drain region 27 , the second source/drain region 29 , the channel region 28 , the second gate dielectric layer 41 B, and the second gate electrode 43 B may correspond to the first access transistor TA 1 .
[0318] The n-drain region 26 , the first plug 51 , the first interconnection line 57 , the second plug 52 , the p-drain region 36 , and the first source/drain region 27 may constitute the first node N 1 . As described above, the first source/drain region 27 may be contiguous with the n-drain region 26 . As a result, an electric resistance of the first node N 1 may be markedly reduced. Furthermore, the sizes of the first source/drain region 27 and the n-drain region 26 may be relatively minimized. That is, a structure in which the first source/drain region 27 and the n-drain region 26 are in continuity with each other and at the same level may be highly advantageous to an increase in the integration density of the CMOS SRAM cell. The first pull-down transistor TD 1 and the first pull-up transistor TU 1 may have a heightened subthreshold characteristics and low leakage current characteristics. In addition, a circuit configuration including a combination of the first pull-down transistor TD 1 , the first pull-up transistor TU 1 , and the first access transistor TA 1 may exhibit remarkably reduced power consumption in a CMOS SRAM cell.
Embodiment 12
[0319] FIGS. 46 and 47 are a perspective view and block diagram, respectively, of an electronic system according to a twelfth embodiment of the inventive concept.
[0320] Referring to FIG. 46 , the semiconductor devices and methods of forming the same described with reference to FIGS. 1 through 45 may be effectively applied to electronic systems 1900 , such as portable telephones, netbooks, laptop computers, or tablet personal computers (PC).
[0321] Referring to FIG. 47 , semiconductor devices configured in accordance with the embodiments in connection with FIGS. 1 through 45 may be applied to an electronic system 2100 . The electronic system 2100 may include a body 2110 , a microprocessor unit (MPU) 2120 , a power unit 2130 , a function unit 2140 , and a display controller unit 2150 . The body 2110 may be a mother board including a printed circuit board (PCB). The MPU 2120 , the power unit 2130 , the function unit 2140 , and the display controller unit 2150 may be mounted on the body 2110 . A display unit 2160 may be disposed inside or outside the body 2110 . For example, the display unit 2160 may be disposed on the surface of the body 2110 and display an image processed by the display controller unit 2150 .
[0322] The power unit 2130 may receive a predetermined voltage from an external battery (not shown), divide the voltage into voltages having required voltage levels, and supply the divided voltages to the MPU 2120 , the function unit 2140 , and the display controller unit 2150 . The MPU 2120 may receive the voltage from the power unit 2130 and control the function unit 2140 and the display unit 2160 . The function unit 2140 may perform various functions of the electronic system 2100 . For instance, when the electronic system 2100 is a portable phone, the function unit 2140 may include several components capable of portable phone functions, such as the output of an image to the display unit 2160 or the output of a voice to a speaker, by dialing or communication with an external apparatus 2170 . Also, when the electronic system 2100 includes a camera, the electronic system 2100 may serve as a camera image processor.
[0323] In applied embodiments, when the electronic system 2100 is connected to a memory card to increase the capacity, thereof, the function unit 2140 may be a memory card controller. The function unit 2140 may transmit and receive signals to and from the external apparatus 2170 through a wired or wireless communication unit 2180 . Furthermore, when the electronic system 2100 requires a universal serial bus (USB) to expand functions thereof, the function unit 2140 may serve as an interface controller.
[0324] Semiconductor devices configured in accordance with the embodiments described above in connection with FIGS. 1 through 45 may be applied to at least one of the MPU 2120 and the function unit 2140 . For example, the MPU 2120 or the function unit 2140 may include the pull-down transistor TD, the pull-up transistor TU, and the access transistor TA. In this case, the electronic system 2100 may be effectively made more lightweight, thinner, simpler, and smaller and exhibit low power consumption characteristics.
[0325] According to the embodiments of the inventive concepts, a semiconductor device including a first vertical transistor, a second vertical transistor, and a non-vertical transistor may be provided. A first drain region of the first vertical transistor, a second drain region of the second vertical transistor, a non-vertical drain region of the non-vertical transistor, and a non-vertical source region of the non-vertical transistor may be formed at the same level. One of the non-vertical drain region and the non-vertical source region may be contiguous with the first drain region. The second drain region may be connected to the first drain region. As a result, a semiconductor device that may increase integration density and reduce power consumption may be embodied.
[0326] The foregoing is illustrative of embodiments and is not to be construed as limiting thereof. Although a few embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible in embodiments without materially departing from the novel teachings and advantages. Accordingly, all such modifications are intended to be included within the scope of the inventive concepts as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of various embodiments and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims.
|
A semiconductor device comprises a substrate extending in a horizontal direction and a vertical transistor on the substrate. The vertical transistor comprises: a first diffusion region on the substrate; a channel region on the first diffusion region and extending in a vertical direction relative to the horizontal direction of the extension of the substrate; a second diffusion region on the channel region; and a gate electrode at a sidewall of, and insulated from, the channel region. A horizontal transistor is positioned on the substrate, the horizontal transistor comprising: a first diffusion region and a second diffusion region on the substrate and spaced apart from each other; a channel region on the substrate between the first diffusion region and the second diffusion region; and a gate electrode on the channel region and isolated from the channel region. A portion of a gate electrode of the vertical transistor and a portion of the gate electrode of the horizontal transistor are at a same vertical position in the vertical direction relative to the substrate.
| 7
|
This application is a division of Ser. No. 07/392,508 filed Aug. 11, 1989 and now U.S. Pat. No. 5,065,291.
BACKGROUND OF THE INVENTION
This invention relates generally to lighting devices and more particularly to a self-contained photovoltaic powered low light level marking light.
In the prior art, there exists many electrically powered outdoor low voltage lights which are utilized to mark and illuminate pathways, yards, certain areas of parks and other predetermined areas. Typically, these lights are interconnected to the public utility source of electric power and are controlled by preset timing devices so that they illuminate at night fall and extinguish at a predetermined time such as approaching daybreak or the like. Such lights require extensive cabling including conduits along with appropriate timing mechanisms and thus are relatively expensive to install and maintain.
In many instances, there is no particular need to illuminate a particular area but rather only a need to delineate the area. There is further a need to provide a source of illumination for such delineation which does not require interconnection to a public utility source of power or the like and which is relatively easy and inexpensive to install and requires no maintenance.
SUMMARY OF THE INVENTION
A marking light having a low voltage light source coupled to a self contained electrical power source for automatically providing electrical power to illuminate said light source when ambient light falls below a predetermined level. A lens is closely coupled to the light source for diffusing light emanating therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prospective view illustrative of a marking light constructed in accordance with the principals of the present invention;
FIG. 2 is a top plan view of the lens of the marking light illustrated in FIG. 1;
FIG. 3 is a cross sectional view of the lens of FIG. 2 taken about the lines 3--3 thereof;
FIG. 4 is a cross sectional view of the marking light structure without the supporting stake taken about the lines 4--4 of FIG. 1; and
FIG. 5 is a schematic diagram of the electrical circuit of the marking light constructed in accordance with principals of the present invention.
DETAILED DESCRIPTION
Referring now more particularly to FIG. 1, there is illustrated a marking light 10 constructed in accordance with the principles of the present invention. As is shown, the marking light 10 is a totally self-contained unit which is supportable upon a stake 12 and includes a housing 14 having a lens 16. A series of photovoltaic cells 18 are disposed in the upper surface 20 of the light 10 so as to be generally exposed to the sunlight when the light 10 is placed in its operational position. It will be recognized by those skilled in the art that a plurality of the marking lights 10 may be disposed in any predetermined arrangement as desired by pressing the stake 12 into the earth so as to position the lens 16 of the light at a particular desired delineation or demarkation position. By thus positioning a plurality of the marking lights 10, a particular area, such as a pathway, may be easily delineated so that a person, even in complete darkness, may be able to follow the pathway without the necessity of producing sufficient illumination to illuminate the pathway.
The only source of power for the marking light 10 constitutes a battery (described more in detail hereinbelow) which is maintained in a charged condition by the sunlight striking the photovoltaic cells 18 during the daytime. When the output voltage from the photovoltaic cells 18 reaches a predetermined low level, the internal light is illuminated thus causing the lens 16 effectively to glow.
In order to retain the light 10 in position after it has been in place, the housing 14 is attached to a stake 12 which is generally cruciform in shape and formed symmetrically with a plurality of sawtooth shaped members 22, 24, 26, and 28 disposed within each of the four cavities defined by the general cruciform as illustrated at 30. It should be noted that each of the sawtooth members 22 through 28 is formed such that the upper portion thereof provides a substantially flat ledge 32, 34, 36, and 38 respectively which is substantially normal to the adjacent arms 40 and 42 forming the stake 12. The body of the stake then tapers longitudinally inwardly toward the arm 40 for the sawtooth members 22 through 28 as shown in FIG. 1. It will be recognized that such configuration of the sawtooth members contained within each of the four quadrants formed by the general cruciform shape will permit easy insertion of the stake into the earth but difficult removal therefrom since the flat platforms or ledges would tend to catch the earth, thus requiring movement of a large amount of the earth upon attempted removal of the stake from the earth. The housing 14 is secured to the stake in such a manner that once it is in place, it is locked to the stake and cannot easily be removed therefrom without destruction of the housing or the stake. Thus once in place, the marking light is relatively secure.
The lens 16 is shown in greater detail in FIGS. 2 and 3 to which reference is hereby made. The lens is a molded plastic member having a first portion 44 which extends exteriorly of the housing 14 and a second portion 46 which is contained interiorly of the housing 14 as is illustrated more clearly in FIG. 4. The lens portion 44 extending exteriorly of the housing 14 includes a first surface 48 which is textured. The portion 46 of the lens extending interiorly of the housing defines a blind bore 50 which includes a surface 52 which is also textured. The bore 50 receives the source of illumination 54 in a closely coupled manner. When the source of illumination 54 is illuminated, as will be described more fully hereinbelow, the light emanating therefrom is diffused and enters the interior 56 of the lens 16. The lens 16 is preferably a clear molded plastic such as a polycarbonate so that light may travel easily through the interior thereof. As the light travels through the interior 56 of the lens 16 and attempts to pass through the exterior surface thereof, it is trapped by the textured surface 48 causing the light to be reflected interiorly of the lens. The light thus is caused to be reflected and retained internally of the lens before passing outwardly thereof at the surface 48. Such internal reflection of the light caused by both the surfaces 52 and 48 causes the lens 16 to appear to glow even though a relatively small light source 54 may be utilized.
The lens 16 is provided with a pair of notches or recesses 58-60 on each side of the portion 46 which extends internally into the housing 14. The notches 58-60 are provided to lock the lens in place as by a snap fit when the lens is inserted into the housing 14.
The housing 14 includes upper and lower members 60-62 with the lower member interlockingly fitting into the upper member 60 as shown at 63 and 64. The lower member is then retained in place by a fastening device such as a screw 66 or the like which fits into mating standards 68-70 as is well known. An opening 72 is provided in the upper surface within which is received a plurality of photovoltaic cells protected at their upper surface by a clear plastic plate or cover 76 or the like held in position within the opening 72 of the housing 14. The photovoltaic cells 74 are secured in place by appropriate fingers or the like as shown at 78, 80 and 82 around three sides of the cell 74 so that it may be slid into place prior to positioning of the lower portion 62 of the cover 14.
Appropriate electrical wiring as shown at 84 and 86 is connected between the photovoltaic module 74 and a circuit board 88 which also supports the source of illumination 54 which may be any relatively low voltage source of illumination including a high intensity light emitting diode (LED). Whatever the source of illumination, one of the significant features of the present invention is the close coupling of the source of illumination to the lens 16 by means of inserting the source of illumination into the blind bore 50 as above described.
The circuit board 88 contains appropriate electrical components and is shown generally at 90 and is secured in place for example as by a layer of adhesive 92 or the like within the housing 14. The lower portion 62 of the housing 14 defines an appropriate opening 94 for receiving the upper portion of the stake 12 and includes appropriate notches and/or recesses as illustrated generally at 96 for receiving protrusions at the end of the stake for locking the same in position within the opening 94.
By reference now more particularly to FIG. 5, the electrical interconnection of the source of illumination with the photovoltaic cell and a battery along with the appropriate control circuit is illustrated. As is therein shown, the photovoltaic cell 74 is interconnected to a battery 94. The source of illumination 54 in the form of a high intensity LED is connected by a current limiting resistor 96 and a transistor 98 across the battery 94 and the photovoltaic cell 74. Connected between the negative terminals of the battery 94 and the photovoltaic cell 74 is a current steering diode 100. An additional resistor 102 is connected across the photovoltaic cell 74. The transistor 98 is a N-P-N transistor and functions as a switch to automatically connect the battery 94 to the light source 54 under certain predetermined conditions. The current steering diode 100 functions as a switch control means to cause the transistor 98 to conduct or not conduct thus interconnecting the light source 54 with the battery, or alternatively, opening the circuit to prevent such from occurring. As is well known to those skilled in the art, the photovoltaic cell 74, when generating electrical power as a result of some light striking the same, is used to charge the battery 94 and during such period of time, there is no need for the marking light to function. Thus the light source 54 is disconnected from the power source during such time whether it be the photovoltaic cell 74 or the battery 94. However, when the voltage generated by the photovoltaic cell 74 drops below a predetermined level as established by the level of the ambient light, then the power source consisting of the battery 94 is automatically connected so as to illuminate the light source 54.
The current steering diode 100 functions as the control device to cause the transistor 98 to conduct or not conduct depending upon the relative levels of voltage between the photovoltaic cell 74 and the battery 94. When the ambient light striking the photovoltaic cell 74 is such that the output of voltage generated by it is greater than the voltage of the battery 94, the steering diode 100 will be forward biased causing current to flow from the positive terminal of the photovoltaic cell through the battery 94 positive to negative, thus charging the battery 94. At the same point in time, the voltage drop across the diode 100 will be such as to reverse bias the emitter base diode of the transistor 98, thus causing it to appear as an open circuit across the battery 94 and the photovoltaic cell 74. The resistor 102 has an impedance which is substantially higher than that of the battery 94 and the diode 100, thus causing little or no current flow therethrough.
When, however, the ambient light falling on the photovoltaic cell falls below a predetermined level such that the output voltage from the photovoltaic cell 74 is substantially less than that of the battery 94, the diode 100 becomes reverse biased and then appears as an open circuit precluding flow of current from the photovoltaic cell or the battery toward the other. When such occurs, a positive voltage is applied through the resistor 102 to the base of the transistor 98. Since the emitter thereof is connected to the negative terminal of the battery, the transistor 98 is now caused to commence to conduct thereby completing the circuit through the light source 54 across the battery 94. When such occurs, the light source 54 will illuminate thus causing the lens 16 to appear to glow as above described. It will be recognized by those skilled in the art that as the ambient light increases above the predetermined level or falls below the predetermined level, the electrical power is provided to automatically charge the battery 94 or illuminate the light source 54 respectively.
It has thus been disclosed a self-contained photovoltaic powered marking light which may be utilized to delineate predetermined areas without utilization of a public utility source of electrical power or the like.
|
A self-contained solar powered marking light. The marking light may be utilized to delineate certain predetermined boundaries without effectively illuminating the areas. The marking light automatically illuminates when output power from the photovoltaic cells contained therein fall below a predetermined level and automatically extinguishes when the voltage from the photovoltaic cells reaches a predetermined level. The marking light includes a lens which is closely coupled to a source of light and which includes a textured surface for diffusing the light to cause the lens to appear to glow when the source of light is illuminated. An electrical circuit is coupled between the photovoltaic cells and a battery and includes the source of light and switching means for automatically illuminating the light dependent upon the relative relationship between the voltage of the photovoltaic cells and the battery voltage.
| 5
|
BACKGROUND OF THE INVENTION
This invention relates to a small-sized electric iron which is handy to carry while travelling and which has both a steaming function for smoothing clothes on hangers or a rack and a pressing function which is substantially the same as that performed by an ordinary steam iron.
In general, an instrument called a "steamer" has a function to smooth clothes on a hanger or a rack by jetting steam to the clothes from nozzle ports which are communicated with a water boiling chamber therein, as shown in U.S. Pat. No. 3,690,024. This instrument, however, has no pressing function because it is devoid of a hot pressing plate.
In order to obviate this shortcoming, U.S. Pat. No. 3,733,723 proposes an instrument which has a hot pressing plate, steam jetting ports provided in the hot pressing plate, a contractable water tank and a spring for contracting the water tank such as to forcibly supply the water to a steam generating chamber. This instrument can serve both as a steamer and a steam iron because it has means for supplying water to the steam generating chamber and the hot pressing plate for pressing clothes. This instrument, however, is not suited to a portable design because there is a practical limit in the reduction of the size, due to the use of a boosting type water supply system.
On the other hand, some proposals have been made for irons which employ a simple dripping type water supply system and which can jet the steam even when they are held vertically. Typical examples of such irons are shown in U.S. Pat. Nos. 2,908,092 and 3,986,282. Both of these irons have a water tank and nozzles for dripping water and are capable of jetting steam both when they are used in pressing clothes and when stationed vertically.
The iron proposed by U.S. Pat. No. 2,908,092, however, suffers from a disadvantage in that, since the water dripping nozzles are positioned ahead of the water tank, most of the water in the water tank cannot drip through the nozzles when the iron is used in a vertical position as a steamer. Thus, most of the water supplied to the water tank cannot be changed into steam and a frequent supply of water into the water tank is necessary. Also, when the water level has been reduced almost to a half of the full level, the water splashes up and down in the water tank during the use of the iron, resulting in a discontinuous dripping and, hence, in a steaming failure.
These problems are overcome by the iron disclosed in U.S. Pat. No. 3,986,282 in which the water dripping nozzles are disposed at the rear side of the water tank. In this case, however, the supply of water to the steam generating chamber is inevitably made at the rear portion of the base, i.e., at the rear side of the heater. In general, the rear portion of the base receives less heat than the front portion thereof because the front portion of the base is usually surrounded at its three sides by the heater which is bent in a U-like form. In order to generate the steam efficiently and stably, therefore, it is necessary to supply the rear portion of the base with a sufficient amount of heat to evaporate the water into steam. This in turn requires an increase in the capacity of the heater as a whole, as well as a longer time of supply of electric power to the heater. Consequently, the iron is heated excessively to a dangerous level and a large amount of electric power is wasted.
U.S. Pat. Nos. 2,761,228 and 2,786,287 disclose portable steam irons which have a handle swingably secured to a rear portion of the iron and a water tank detachably secured to the iron body. The portable iron proposed by U.S. Pat. No. 2,761,228, however, as a whole has a considerable size even when the handle is rotated downwardly because the water tank projects to a large extent. When this steam iron is carried by a traveller, therefore, the water tank must be separated from the main body of the iron. The dismounting and carrying of the water tank undesirably increases the total volume to be carried, and requires a specific casing for encasing the main body of the iron and the water tank. The same problem is encountered also by the portable iron proposed by U.S. Pat. No. 2,786,287. In addition, the portable iron of the U.S. Pat. No. 2,786,287 has no means for switching the operation between a steaming mode and a dry mode. Namely, this portable iron operates either in steaming mode or in dry mode, depending on whether the water tank contains water or the water tank is empty, and it is not possible to instantaneously stop and start steaming. In contrast, the portable iron of U.S. Pat. No. 2,786,287 is provided with a change-over device which is provided in the water tank, and is positioned remote from the handle. As a result, a user can not operate the change-over device using one hand while ironing.
SUMMARY OF THE INVENTION
Accordingly, an object of the invention is to provide a portable steam iron having a steaming function, which fully overcomes the above-described problems of the prior art.
To this end, according to the invention, there is provided a steam iron with a steaming function, wherein an opening through which water is supplied to a steam generating chamber is disposed in a rear portion of the bottom of the water tank, while water is supplied at a central portion of a base or at a portion forward of the central portion within the area surrounded by a heater.
With this arrangement, it is possible to eject the whole part of the water in the water tank as steam both in the pressing and steaming modes, while reducing the required capacity of the heater and, hence, eliminating the risk of excessive heating of the iron.
In one aspect of the invention, a handle has a gripping portion and a fixing portion fixed to the main body of the iron, the gripping portion and the fixing portion being connected to each other through a bend. This bend affords an ample space about the gripping portion when the iron is being used. When the iron is not used, the handle is turned upside down and fixed to the main body of the iron such that the handle does not project beyond the height of the main body of the iron. Therefore, the iron as a whole can be carried with the handle mounted to the iron body.
In another aspect of the invention, a manual operating portion for a device for opening and closing the opening is provided in a space above the water tank, in the vicinity of which space the fixing portion of the handle is provided. Therefore, the user can get access to a steaming button for easy ejecting and stopping of steam, while holding the handle and performing various operations both in the pressing mode and steaming mode.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a travel steam iron according to an embodiment of the invention;
FIG. 2 is a sectional side elevational view of the travel steam iron shown in FIG. 1;
FIG. 3 is a top plan view of a base portion of the travel steam iron shown in FIG. 1;
FIG. 4 is a sectional front elevational view of a device for opening and closing a nozzle;
FIG. 5 is a sectional view showing a thermostat and a rivetted portion;
FIG. 6 is a sectional view of an essential part of a voltage change-over switch;
FIG. 7 is a top plan view of the travel steam iron shown in FIG. 1 with its body cover and rear cover being removed;
FIG. 8 is a top plan view of an essential part of the traveler steam iron with the nozzle opening and closing device operative;
FIG. 9 is an exploded perspective view of a operating button and a cam member;
FIG. 10 is a side elevational view of a handle in the stored state;
FIG. 11 is a diagram of an electric circuit incorporated in the embodiment;
FIG. 12 is a top plan view of a base portion incorporated in another embodiment of a traveler steam iron using two heaters;
FIG. 13 is a sectional side elevational view of the embodiment shown in FIG. 13; and
FIG. 14 is a front elevational sectional view of the embodiment shown in FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 to 11, a traveler steam iron according to an embodiment of the invention has a base 1 cast from aluminum and an electric heater 2 embedded therein (referred to simply as "heater", hereinunder). The heater 2 is bent to be U-shaped with its both ends positioned readly of the base 1. Reference numeral 3 denotes conductive metal fittings electrically connected to terminals 4 of the heater 2. A lid 5 for an evaporation chamber is adapted to fit on the base 1 such as to form the evaporation chamber together with the base 1. A first steam generating chamber 6 positioned inside of the U-shaped portion of the heater 2 is provided with a water receiving surface 7 which is located substantially at the center of the base 1 and protruding from the remaining surface of the base 1. With this arrangement, water is made to drip onto the surface 7 to be evaporated and the steam thus generated is jetted outside from a second steam generating chamber 8 constituting a steam passage through a plurality of steam ports 9 which are provided in the portion of the base 1 defining the second steam generating chamber 8.
A reference numeral 10 designates a thermostat for controlling the supply of electric power to the heater 2. As shown in FIG. 3, the thermostat 10 is fixed to the base 1 by means of a screw 11. A reference numeral 12 designates a spring member made of a copper alloy and having one end fixed to one of the conductive metal fittings 3 by means of a screw 11 and the other end biased away from a terminal 14 of the thermostat 10 and fixed to this terminal 14 by means of a rivet 15, thus forming an electric circuit. The rivet 15 is made of an eutectic alloy consisting mainly of lead. When temperature control by the thermostat 10 becomes unavailable, this rivet serves to avoid fire which may otherwise be caused due to uncontrolled continuous electric power supply to the heater 2. Namely, when the heater 2 is supplied with electric power continuously, the temperature of the base 1 is raised, so that the temperature of the rivet 15 is raised correspondingly. The composition of the eutectic alloy from which the rivet 15 is made is selected such that the rivet 15 melts down before melting of the base 1 or production of a fire. Since the rivet 15 has melted, the spring 12 moves away from the terminal 14 of the thermostat 10 to shut-off the circuit, thereby stopping the supply of power to the heater 2.
A reference numeral 16 denotes a cover provided above the base 1 and made of a heat-resistant material such as a phenol resin. As shown in FIG. 5, the cover 16 is fixed to the base 1 through a spacer 17 by means of screws 18. A reference numeral 19 denotes a body member mounted on the upper end of the cover 16 and secured thereto in an airtight manner by means of screws 20 and 21 through the intermediary of a sealant, thus defining a water tank 22. A reference numeral 23 denotes a nozzle provided in a rear portion of the bottom of the water tank 22 and having an aperture through which water is supplied from the water tank 22 into the first steam generating chamber 6. The nozzle 23 is clamped between the evaporation chamber lid 5 and the cover 16 with upper and lower packings 24 and 25 therebetween to provide a communication between the water tank 22 and the space just above the water receiving surface 7 and to prevent any leakage of water and vapor to the outside. A reference numeral 26 designates a rod (provided along the rear wall of the water tank 22) for opening and closing the nozzle 23. A numeral 27 denotes a spring for constantly biasing the rod 26 towards the nozzle 23, 28 denotes a packing for sealing the water tank 22 at the hole through which the rod 26 extends, and 29 denotes a spring for biasing the packing 28 towards the hole mentioned above. A reference numeral 30 designates a cam member for driving the rod 26 up and down. The cam member 30 is mounted on the rod 26 by E-rings 31 and 32 and is provided at its opposite sides with inclined surfaces 33 as shown in FIG. 9. A push button 36 includes tapered fingers 34 adapted for cooperation with the inclined surfaces 33 and a operating portion 35 which projects beyond the side wall of the body member 19. When the operating portion 35 of the push button 36 is depressed, the cam member 30 is subjected to two forces, one of which acts in the direction for lifting the cam member 30 and the other of which acts in the direction along which the operating portion 35 is depressed. However, the movement of the cam member 30 in the direction of the depressing force is limited by the wall 37 of the main member 19, so that the cam member 30 is moved only in the upward direction against the force of the spring 27. As a result the rod 26 also is moved upwardly to thereby open the aperture in the nozzle 23. As the push button 36 is relieved from the depressing force, the cam member 30 is lowered by the biasing force of the spring 27 to push the push button 36 out of the body member 19, and the rod 26 is lowered to shut-off the aperture in the nozzle 23. A step 38 provided on the push button 36 permits the latter to be locked in the pushed state. More specifically, by rotating the push button 36 in the direction of arrow a in FIG. 8 about the axis of the rod 26 after the push button is depressed, the step 38 is engaged by a engaging portion 39 of the body member 19, thereby keeping the nozzle 23 open.
A reference numeral 40 denotes a cap for closing a water filling port 41 on the water tank 22, and a numeral 42 designates a body cover secured to the upper side of the body member 19 by a screw 43 to define a space 22a above the water tank 22 and to enclose the push button 36, cam member 30 and other associated members, thus forming, in cooperation with the main body 19, an iron body which is generally designated at a numeral 44.
A reference numeral 45 designates a handle detachably secured to the iron body 44 and having a fixing portion 46 and a grip portion 47 which extend in parallel with each other and connected to each other through a bend 48. A locking button 51 consisting of a resilient web portion 49 and a retaining portion 50 is secured to the fixing portion 46 by means of a screw 52. The body cover 42 has a hole 53 for receiving the fixing portion 46 of the handle 45 and a retaining hole 54 for retaining the locking button 51 on the handle 45. During the use of the iron, the grip portion 47 of the handle 45 is mounted in parallel to and above the base 1 due to the presence of the bend 48 to provide an ample space below the underside of the grip portion 47. When the iron is not used, the handle 45 is withdrawn from the hole 53 and is turned upside down to be inserted again into the hole 53. Thus the grip portion 47 projects above the top of the iron body 44 during the use of the iron while it is positioned below the same, so that the iron as a whole becomes very compact. In the inverted state of the handle 45, the fixing portion 46 can be press-fitted in the hole 53 so that the handle is prevented from being disengaged even when vibrated during carrying.
A reference numeral 55 denotes a power supply cord having a plug 56 at its one end, while 57 denotes a diode connected in series to the power circuit of the heater 2 and intended for performing half-wave rectification. A numeral 58 designates a heat radiation plate for radiating heat produced by the diode 57. As shown FIG. 7, the diode 57 is soldered at its one end to the heat radiating plate 58 which in turn is fixed to the cover 16 by means of a screw 59. A reference numeral 60 denotes a switch spring made of a resilient material such as stainless steel and fixed, together with the other end of the diode 57, to the conductive metal fitting 3 by means of a screw 61. A numeral 62 designates an externally operable switch which is adapted to be so as to open and close the contact between contacts 63 on the switch spring 60 and the heat radiating plate 58.
The power supply cord 55, heater 2, diode 57 and the switch spring 60 constitute an electric circuit as shown in FIG. 11. This circuit is switchable by means of the switch knob 62 between two modes: namely, a first mode in which the diode 57 is connected in series to the circuit so as to effect the half-wave rectification and a second mode in which the diode is disconnected from the circuit so as to allow a full-wave rectification, thereby permitting a switching of the electric capacity, i.e., the voltage used.
A reference numeral 64 designates a rear cover secured to the base 1 by means of a screw 65 so as to cover the upper side of the cover 16. A reference numeral 66 designates a temperature adjusting knob rotatably attached to the rear cover 64 by means of a push nut 67 so as not to be able to be disengaged from the rear case 64. The temperature adjusting knob 66 is connected to the thermostat 10 so that the temperature of the pressing surface of the base 1 can be adjusted by rotating the temperature adjusting knob 66.
The travel steam iron of the invention having the above construction will be described hereinunder.
When the iron is used, the fixing portion 46 of the handle 45 is inserted into the hole 53 in the body cover 42 such that the grip portion 47 of the handle 45 is positioned upwardly. During such insertion, the elasticity of the web portion 49 causes the retaining portion 50 of the lock button 51 to be deflected downwardly and moved forwardly along the upper face of the hole 53. Upon reaching the position of the retaining hole 54, the retaining portion 50 springs back upwardly by the elasticity of the web portion 49, thus completing the locking of the handle 45. Since the grip portion 47 is offset from the fixing portion 46 of the handle 45 through the intermediary of the bend 48, an adequate space is ensured between the grip portion 47 and the rear cover 64 for an easy gripping and handling. In addition, the fixing portion 46 of the handle 45 is inserted into the body cover 16 at a position ahead of the center of the iron body 44, while the grip portion 47 is positioned rearwardly of the center of the iron main body 44. With this arrangement, a sufficiently large pressing force can be applied to the base 1 during the use of the iron to contribute to the easiness of use of the iron. Furthermore, since the handle 45 can be positively locked on the iron body 44, there is no possibility that the handle 45 would be disengaged to permit the iron to drop on the floor, thereby breaking the iron or injuring the user. Accordingly, the iron is safe to use.
When this travel steam iron is used as a dry iron, the power supply to the heater 2 is automatically controlled to maintain the desired temperature of the base 1, simply by rotating the temperature adjusting knob 66 to set the cut-off temperature of the thermostat 10.
When this travel steam iron is used as a steam iron or as a steamer, the water tank 22 is filled with water through the water filling port 41 after lifting the cap 40. As the push button 36 is depressed by a finger after closing the cap 40 as shown in FIG. 4, steam is jetted. When the push button 36 is returned to the original position upon moving a finger therefrom, the flow of the steam is stopped. More specifically, when the push button 36 is depressed, the rod 26 which is constantly urged by the spring 27 is moved upward against the force of the spring 27, thus opening the nozzle 23. Upon the opening of the nozzle 23, the water in the water tank 22 passes through the nozzle 23 to drop onto the water receiving surface 7 on the base 1 and is evaporated to become steam in the first steam generating chamber 6. The steam is then jetted outside from the second steam generating chamber 8 through the steam ports 9. When it is desired to continuously supply steam, the user presses the push button 36 and rotates the same in the direction of the arrow a about the rod 26 as shown in FIG. 8 to cause the step 38 to be retained by the retaining portion 39 of the body member 19, so that the rod 26 is upwardly moved against the force of the spring 27 to keep the nozzle 23 open, thus dripping the water continuously into the steam generating chamber. When the supply of steam is to be stopped, the step 38 is released as the push button 36 is rotated rearwardly and the biasing force of the spring 27 causes the cam member 30 to be moved downwardly, thereby forcibly moving the push button 36 outside the iron body 44. Consequently, the rod 26 is lowered to close the nozzle 23. The water receiving surface 7 disposed substantially at the center of the base 1 within the area surrounded by the U-shaped heater 2 can effectively collect the heat generated by the heater 2, so that the dripping water can be evaporated efficiently and stably. In consequence, the capacity of the heater 2 can be reduced to eliminate any waste of electric power and to shorten the time duration for supply of the electric power. This in turn suppresses the temperature rise of the various portions of the iron, thus eliminating the generation of smoke and fire and enabling safe use of the steam iron.
Since the rod 26 is provided along the rear wall of the water tank 22 and the nozzle 23 is provided at the rear bottom of the water tank 22, the water in the water tank 22 is smoothly supplied to the nozzle 23 along the rear wall of the water tank 22, when the steam iron is held in the vertical posture to be used as a steamer. It is, therefore, possible to perfectly consume all water in the water tank 22 and to prevent stoppage of the supply of steam due to the suspension of the supply of water, even when the steam iron is handled vigorously. Needless to say, the water is smoothly supplied to the steam generating chamber through the nozzle 23, when the iron is used as a steam iron.
The means for opening and closing the nozzle 23 formed by the cam member 30, push button 36 and the spring 27 are disposed at the upper side of the water tank 22 and in the vicinity of the fixing portion 46 of the handle 45, such as to be surrounded by the body cover 42. Thus, all the parts constituting the means for opening and closing the nozzle 23 are arranged in a compact manner within the body cover 42, and the push button 36 can be positioned within the reach of a finger of the user's hand when the handle 45 is gripped. In addition, since the operating portion 35 of the push button 36 projects from the side wall of the iron body 44, it is possible to reduce the overall height of the iron body 44, thus realizing a compact construction of the steam iron as a whole.
The push button 36 is arranged such that the steam is discharged when the push button is pressed towards the iron body 44. The coincidence between the finger effort for pushing the push button forwardly and the jetting of the steam provides a natural feel of operation, thus allowing the user to easily understand the operation.
The rod 26 is arranged such that the cam member 30 is lifted in response to the operation of the push button 36. So, the manual force for pushing the push button 36 is converted into a force for lifting the rod 26. Therefore, even if the rod 26 sticks onto the nozzle 23 due to generation of rust, the user can open the nozzle 23 by increasing the manual force so as to overcome the sticking force, provided that the sticking force is within a predetermined limit. Accordingly, a greater adaptability and reliability are obtained as compared with the case where a rod is lifted by the force of a spring.
After the use of the steam iron, the user rotates the temperature adjusting knob 66 to cut-off the electric power supply to the heater 2. Then, after a sufficient cooling down of the base 1, the user pushes the retaining portion 50 of the lock button 51, appearing through the retaining hole 54 in the main body cover 42, in the direction of the arrow b in FIG. 2, thus unlocking the same, and withdraws the handle 45 from the body cover 42. Then, as shown in FIG. 10, the user turns the handle 45 upside down such that the grip portion 47 is disposed downwardly, thereby inserting again the fixing portion of the handle 45 into the hole 53. The lock button 51 for the handle 45 is formed integrally with the retaining portion 50 which serves also as an unlocking operating portion and also with the resilient web portion 49, and this integral member is secured to the handle 45. Thus, the means for locking and unlocking the handle 45 to and from the body cover 42 has a simple and inexpensive construction and, moreover, can operate with a high reliability without fail.
The fixing portion 46 and the grip portion 47 of the handle 45 extends substantially in parallel with pressing surface of the base 1. Therefore, when the handle 45 is stored in the inverted posture, the grip portion 47 is positioned below the fixing portion 46 without projecting above the top of the iron body 44, thus affording a small overall size of the travel steam iron and facilitating carrying the iron. When the handle is in the inverted posture, the fixing portion 46 can be press-fit in the hole 53, so that, when the travel steam iron is used again, it is sufficient to withdraw the handle simply by a pulling action, without any unlocking operation. The strength of such a press fit is large enough to prevent any unintentional dropping off of the handle 45 due to vibration during carrying, so that the handle 45 does not come off when it is carried by the traveller.
In the described embodiment, a single heater is bent to be U-shaped and the water receiving surface is provided within the area surrounded by the U-shape of the heater. This, however, is not exclusive and the arrangement may be such that a steam generating chamber 103 having a water receiving surface 102 is provided between a pair of heaters 101, as shown in FIG. 12. With this arrangement, it is possible to attain a stable generation of steam as in the case of the described embodiment which employs only one heater.
In the described embodiment, the means for opening and closing the nozzle 23 is provided on the body member 19 which in turn is overlaid by a body cover 40 having a hole 53 for fixing the handle 45. This is also only illustrative and this arrangement may be substituted by the arrangement shown in FIGS. 13 and 14. Namely, the water tank 202 is formed by a portion of the main body 201 such that a space 203 formed between the water tank 202 and the other portion of the main body 201 receives the means 205 for opening and closing the nozzle 204, means 208 for receiving the fixing portion 207 of the handle 206 and the means 209 for locking the handle 206. The space 203 is closed by a lid 210. This arrangement also affords a smaller size and compact construction of the steam iron as a whole, thus facilitating the portage.
As has been described, in the travel steam iron of the invention, all of the water in the water tank can be evaporated into steam and, hence, to make effective use of the heat generated by the heater, because the water receiving surface is positioned above or at the front side of the center of the base within the area surrounded by the heater or heaters.
In addition, the bend of the handle affords an easy handling during the use of the iron, as well as a compact construction easy to carry when the iron is not used.
Moreover, the manipulating portion for causing the jetting of steam is provided in the space formed above the water tank thus making an efficient use of the space while reducing the size. In addition, the fixing portion of the handle is disposed in the vicinity of the manipulating portion so that manipulating portion can be reached easily by a finger to facilitate the use of the travel steam iron.
|
A portable travel electric steam iron which also functions as a steamer has an aperture provided in a rear portion of the bottom of a water tank which supplies water into steam generating chambers from the water tank. Water dripping through the aperture is received by a water receiving surface provided on the center or on the front side of the center of a base. A handle which includes two straight positions separated by a bend is securable to an iron main body both in the operative position and storage position. An actuator for opening and closing an aperture is disposed in a space above the water tank, in the vicinity of a fixing portion at which the handle is fixed to the iron main body, thus providing a compact construction which is easy to handle.
| 3
|
[0001] This invention pertains to a machine for extracting a residue of liquid from the inside of a container.
[0002] Specifically, this invention describes an apparatus that enables the rapid collection and re-introduction of viscous liquids from and to a container. This invention addresses the removal and insertion of typical liquids such as ketchup, mayonaise, syrup, salad dressing, puddings, mustard, steak sauces, hair gels, etc.
BACKGROUND OF THE INVENTION
[0003] Viscous fluids are commonly stored in containers that have a narrow or otherwise difficult to access neck. For example, a ketchup bottle features a slender neck and one cannot easily insert a spoon or other utensil for means of helping to empty the bottle completely. As a result, the user will discard the bottle and its residual contents in order to save time and frustration.
[0004] In contrast, there are individuals and businesses that see it as being more economical to reclaim as much as is possible of the remaining residue left in such bottles. As an example, a common practice in the restaurant industry is to “marry” the ketchup bottles by collecting the remaining residue and consolidating it into one container. After enough residue is collected, it is then used to “top off” other partially filled ketchup bottles. This results in significant savings of money wasted by leftover residue being discarded with the ketchup bottle. Another reason for “marrying” ketchup bottles is that a full ketchup bottle is more appealing to the customer than a partially full bottle.
[0005] In the past, machines and fixtures have been invented for the purpose of capturing leftover residues from the insides of containers. The problem with most of these previous inventions is that they are simply fixtures for holding containers in an inverted position, thereby allowing gravity to act as the primary means of motivating the residue out.
[0006] U.S. Pat. No. 5,080,150 is simply a basket that lets consumers invert and fully drain thick liquid condiment bottles so the product flows into the neck and against the inside of the cap ready for immediate use.
SUMMARY OF THE INVENTION
[0007] This invention is an improvement over known receptacle drainers because it provides a more economical and efficient means for recovering liquid residues from narrow-necked containers and provides a more effective and efficient means of introducing liquid residues into narrow-necked containers. Also, the drainer portion of this invention has a broad application as it will accept receptacles of various shapes and volumes.
[0008] This invention also provides for easy cleaning as the receptacle support, support retainer and support frame disassemble from the base frame and can be safely washed in all commercial dishwashers used by the service industry.
[0009] In its broadest aspects, this invention provides for the draining of fluids from a receptacle. Structurally, it is comprised of a base frame, a rotating receptacle support frame coupled to said base frame vertical drive shaft, one or more receptacle supports which is mounted into rotating receptacle support frame surrounded by a safety shroud and topped with a safety lid.
[0010] According to one embodiment, the base frame houses a mounted electric motor which turns a vertical drive shaft, which turns the rotating receptacle support frame coupled to the drive shaft.
[0011] In another embodiment, the base frame houses a mounted transmission, which is operated by an externally mounted hand crank. The transmission turns a vertical drive shaft, which turns the rotating receptacle support frame coupled to the drive shaft.
[0012] A preferred form of the base frame provides for a pluralty of supporting legs, the ends of which include a locking caster wheel. The base frame includes a safety shroud and lid for protecting the operator from rotating components.
[0013] A preferred form of the rotating receptacle support frame includes cut-outs that are form-fitted to specially retain the receptacle supports. The receptacle support frame includes a keyed hole located in the center for accommodating a matching drive shaft. The receptacle support(s) are retained in the cut-outs by a single central retainer which slides over the drive shaft end and secures the receptacle support(s) to the rotating receptacle support frame by sandwiching the innermost, bottom bore lip between the retainer and the rotating receptacle support frame.
[0000] This invention will now be described with particularity by reference to the Drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of a drainer assembly according to this invention.
[0015] FIG. 2 is an exploded perspective view of the drainer assembly shown in FIG. 1 .
[0016] FIG. 3 is a perspective view of the receptacle support.
[0017] FIG. 4 is a cross-sectional view of the receptacle support shown in FIG. 3 .
[0018] FIG. 5 is a perspective view of the receptacle support syringe type plunger.
[0019] FIG. 6 is an exploded perspective view of an alternative drainer assembly utilizing a manual drive system.
[0020] FIG. 7 is a perspective view of the rotating receptacle support frame.
[0021] FIG. 8 is a perspective view of the receptacle support retainer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] FIG. 1 is a perspective view of a first embodiment of the present invention. FIG. 2 is an exploded view of the assembly depicted in FIG. 1 . This embodiment is comprised of a base frame 10 , receptacle support frame 4 , receptacle supports 3 , a plunger 5 and a receptacle support retainer 2 . The base frame 10 features a shelf ( FIG. 1 ), which can be used to support a second empty or partially filled receptacle underneath a receptacle support. This enables the contents of the receptacle support to be easily syringed into the second receptacle by use of the plunger 5 . The base frame is supported by support legs 5 for vibration dampening and easy mobility of unit.
[0000] The receptacle support frame 4 features a round, rotable disk that incorporates shaped holes that accept the receptacle support(s) 3 . The center bore of the disk is keyed so as not to allow the disk to slip on the motor 6 drive shaft.
[0023] The receptacle support(s) 3 is comprised of two hollow cylinders joined at nearly right angles as shown in FIG. 3 and sectional view FIG. 4 . The nearly horizontal cylinder is sized such that it fits a variety of receptacles. The vertical cylinder incorporates a small nozzle at the bottom for the purpose of retaining viscous fluids and allowing them to be easily introduced into a second receptacle. The vertical cylinder also accepts plunger 5 so that their diameters fit snuggly together in a syringe-type fashion.
[0024] The receptacle support retainer ( FIG. 2 , Item 2 and FIG. 8 ) is essentially a disk with “fingers” that emminate outward from the edge of the disk and are long enough to contact and retain the bottom lip of the receptacle support(s). The receptacle support retainer is positioned on the motor driveshaft and retains each receptacle support at its nearly horizontal cylinder bottom lip. When the wing nut ( FIG. 2 , Item 1 ) is tightened over the receptacle support retainer, it provides sufficient force to retain the receptacle support firmly against the receptacle support frame 4 , and the receptacle support frame 4 onto the motor 6 driveshaft. The motor 6 is mounted in base frame 10 and provides rotation to the receptacle support frame 4 , receptacle support(s) 3 , receptacle support retainer 8 and wing nut 1 .
[0025] The safety shroud 9 , is mounted on the circumference of base frame 10 and encloses the rotating components to protect the user from becoming entangled in them during operation. The safety shroud incorporates a hinged door 9 , to provide easy access to the base frame 10 shelf and to rotating components for disassembly. It is intended for the safety shroud 9 to be installed and the door 9 closed during operation of the invention. The safety lid 7 , fits from the top onto the safety shroud 9 , and is removable. The safety lid 7 encloses the rotating components from the top to protect the user from becoming entangled in them during operation. The safety lid 7 incorporates a handle in the center to provide for easy access to the receptacle support frame 4 , receptacle supports 3 , receptacle support retainer 2 , wing nut 1 , and motor 6 . It is intended for the safety lid 7 to be installed during operation.
[0026] To operate the embodiment shown in FIGS. 1-8 , the user first removes the safety lid 7 . One or more partially or completely filled bottle(s) or other receptacle(s) are inserted into the open end of one of the receptacle support(s) 3 until it stops. Centrifugal force will retain the bottle or other receptacle in the receptacle support 3 during operation. The wing nut 1 is checked to ensure it is tight against the receptacle support retainer 2 and that the receptacle support retainer is properly contacting each of the receptacle supports. The safety lid 7 is then installed onto the safety shroud 8 and the door 9 is closed.
[0027] The operator then plugs in the motor 6 electrical cord into an electrical outlet and activates the electrical switch to the “on” position. The receptacle support frame 4 , receptacle support(s) 3 are brought up to rotational speed to impose a centrifugal force on the receptacle(s) and their contents sufficient to cause the contents to exit the receptacle(s) in a radially outward direction and collect in the hollow vertical cylinder of the receptacle support(s) 3 . The motor 6 is then deactivated by moving the electrical switch to the “off” position. Once all internal rotation stops, the safety lid 7 is removed and each receptacle is removed from the receptacle support(s). The door 9 is opened and a second receptacle is placed on the base frame 10 shelf underneath a receptacle support.
[0028] The plunger 5 is then inserted from the top and into each receptacle support in order to cleanly and efficiently force the contents from each receptacle support 3 and into the receptacle below. The receptacle support frame 4 may be rotated by hand in order to position each receptacle support 3 over the receptacle below.
[0029] All rotating components, except the motor 6 , of the embodiment depicted in FIGS. 1 through 8 are easily disassembled for cleaning or storage by removing the safety lid 7 and wing nut 1 . Once this is done, the receptacle support retainer 2 , receptacle support(s) 3 , and receptacle support frame are removed by sliding them off of the motor 6 drive shaft. The receptacle support(s) 3 are also easily removed from the receptacle support frame 4 .
[0030] An alternate configuration of the invention replaces the motor ( FIG. 2 , Item 6 ) with a manual gearbox driven by a hand crank ( FIG. 6 , Item 6 ). Operation of this embodiment is changed only by the fact that all internal rotation is manually driven by hand.
[0031] While the preferred embodiments have been fully described and depicted for the purposes of explaining the principles of the present invention, it will be appreciated by those skilled in the art that modifications and changes may be made thereto without departing from the spirit and scope of the invention set forth in the appended claims.
|
A draining apparatus for collecting fluids from a container. This device consists essentially of a base and a rotational receptacle support, which holds and rotates, the container, which is to be drained. The container is held in a nearly horizontal position with the container opening oriented outward and is rotated at high speed so that sufficient centrifugal force is developed to empty the contents. The contents are emptied into a collector, which allows for convenient transfer to a second container using a syringe type plunger.
| 1
|
BACKGROUND OF THE INVENTION
This invention, which is a continuation-in-part of copending application Ser. No. 406,321 filed Aug. 9, 1982 now abandoned, relates to power plants and, more particularly, to methods for the production of power together with the production of fresh water without significant additional cost, by utilizing the thermal energy from an almost limitless heat sources, such as the atmosphere or the ocean and a limited heat source, such as the fossil fuel, nuclear fuel, geothermal energy, or concentrated solar radiant energy.
In regard to the utilization of limited heat source, the most modern steam turbine power plants lose more than half of the heat input to the environment through the condenser. Various methods have been employed for increasing the overall thermal efficiency, but to date none has been successfully to reduce the cost of energy significantly.
As to the utilization of the limitless heat sources, the earliest attempt to tap the thermal energy of the ocean was made during 1925 to 1929 by G. Claude. Since then, various modifications of the Claude power plant have been proposed, for example, U.S. Pat. No. 3,928,145. Due to the low efficiency of about 2% and the requirements for a large prime mover and associated large piping system, the Claude power plant and those based thereon have never become practical.
Attempts have been made for more than a century to construct an engine drawing heat continuously from the ocean for the power production, but all failed because the ocean had been treated as a closed heat reservoir. A closed heat reservoir is one where only heat can cross its boundary and which is in thermodynamic equilibrium everywhere in the reservoir. A successful method has been disclosed in a copending application of this inventor, Ser. No. 406,321 entitled "Limitless Heat Source Power Plants" and filed Aug. 9, 1982. The success is attributed to the concept of an open heat reservoir which is defined as one where mass and heat can cross its boundary, so that the thermal energy can be carried by the mass flow from one location to another location without relying upon temperature potential.
In regard to the conversion of saline water into fresh water, there are two commonly used methods: evaporation and freezing. Great interest in the latter has recently been revived due to its low energy consumption rate and much decreased requirement for metallic heat transfer surface as compared with the former. The fresh water thus produced is still more expensive in comparison with that obtained from distant natural sources.
It is known that the larger the difference between the highest and the lowest temperatures of a power cycle, the higher will be its thermal efficiency. The high temperature development has been to the allowable limit of material. The lowest temperature has been limited by the naturally available environmental temperature of water and atmosphere.
The basic principle of this invention is similar to that disclosed in a copending application of this inventor as indicated above wherein the limitless heat source is treated as an open heat reservoir. A number of new features are provided, particularly in connection with the supplementary usage of limited heat sources.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention, reference should be made to the following detailed description thereof taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a flow diagram, in schematic form, of the power plant equipped with an absorption-refrigeration heat pump and drawing heat from the ocean through an intermediate volatile fluid and from the combustion of a small amount of a fossil fuel;
FIG. 2 illustrates a power plant, similar to FIG. 1, wherein the atmosphere is the limitless heat source;
FIG. 3 shows a power plant, similar to FIG. 2, wherein a vapor-refrigeration heat pump is employed;
FIG. 4 shows schematically a vortex flow heat exchanger for heating the working fluid;
FIG. 4A is a section taken on line A--A of FIG. 4;
FIG. 5 illustrates a vortex flow heat exchanger for cooling the working fluid;
FIG. 5A is a section taken on line A--A of FIG. 5;
FIG. 5B is a section taken on line B--B of FIG. 5;
FIG. 6 shows schematically the power cycle of the power plant in FIG. 3 with compression heating and cooling;
FIG. 7 illustrates schematically the vapor refrigeration cycle per unit mass flow of the working fluid for the power plant in FIG. 3;
FIG. 8 is a flow diagram, in schematic form, of a power plant similar to FIG. 3, without the use of an intermediate volatile fluid between the heat source and the pri:me mover, with the heat removal from the prime mover by the cooled air-gas mixture and with the removed heat partly recovered;
FIG. 9 is a power plant, similar to FIG. 8, wherein the exhaust heat of the prime mover is removed by the cooled air-gas mixture through a volatile fluid and the removed heat is partly recovered;
FIG. 10 depicts schematically the power cycle for the power plants in FIGS. 8 and 9 with compression heating and cooling and the temperature at the end of expansion below the atmosphere temperature; and
FIG. 11 is the power cycle of the power plants in FIGS. 8 and 9 with compression heating, constant pressure cooling and the temperature at the end of expansion above the atmosphere temperature.
SUMMARY OF THE INVENTION
In accordance with this invention, the prime mover may be a turbine operating in a closed cycle. The working medium may be a permanent gas under high pressure or a condensible gas under moderate pressure. The fluids of the limited and limitless heat sources will be referred to as the source fluid. The thermal energy is drawn from an almost limitless heat source and a limited heat source. More specifically, in the following description, the atmosphere or the ocean will be referred to as the limitless heat source, with the combustion of a fossil fuel as the limited heat source.
The source fluid gives heat to the working medium through an intermediary volatile fluid in a large heat exchanger. This intermediate volatile fluid evaporates in the said large heat exchanger and is condensed in a second heat exchanger giving heat to the working medium which derives the prime mover. The limited heat source gives heat to the working medium through a small heat exchanger. The cold effluent source fluid from the large heat exchanger is used for removing the heat rejected from the prime mover through a heat pump or other means. Since the source fluid has been cooled to a temperature below the freezing point of pure water, it can be used for the conversion of saline water into fresh water by a freezing process.
When the thermal energy of the limited heat source is of a significant amount in comparison with that of the limitless heat source, the intermediate volatile fluid and the said large heat exchanger may be omitted and the working medium can be heated by the source fluid in the said second heat exchanger, if the source fluid is clean and noncorrosive, such as the atmospheric air. The source fluid can be cooled to a very low temperature at the exit of the said second heat exchanger. This cooled source fluid, after passing an expansion valve, may be used to remove the exhaust heat from the prime mover. A large part of the removed heat can be recovered by recirculating the source (which has been changed into a sink) fluid to the said second heat exchanger. As a result of having utilized the thermal energy of the limitless heat source which is free from cost and having recovered a part of the exhaust heat from the prime mover, the net work produced by this power plant can be considerably larger than the heat supplied by the limited heat source, which has to be paid for.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now in detail to FIG. 1, ocean water is delivered by pump 10 to a large heat exchanger 11 where heat is given out from the saline water to an intermediary volatile fluid. This volatile fluid gives heat through the heat exchanger 12 to the working gas for driving the turbine 13 which drives the generator G. The effluent gas from turbine 13 is cooled in the heat exchanger 14 and compressed by the compressor 15 and the cycle repeats itself. The pump 16 is employed for maintaining the circulation of the intermediary volatile fluid with evaporation in heat exchanger 11 and condensation in heat exchanger 12. The heat exchanger 14 also plays the role of an evaporator of the heat pump as will be seen soon. The throttling by the valve 17 is to obtain the desired low temperature of the source fluid at the exit of the heat exchanger 11.
FIG. 1 also shows, in schematic form, the principal components of an absorption-refrigeration heat pump which includes the condenser 20, the expansion valve 21, the absorber 22, the pump 23, the heat exchanger 24, the generator 25 and the evaporator 14.
The system enclosed by the dotted curve is a supplementary system which draws a small amount of heat supplied by a limited heat source. The atmospheric air is forced to flow into the combustion chamber 61 by the supercharger 60. The hot gas gives heat to the working medium in the heat exchanger 62. The gas effluent from the heat exchanger 62 enters a bubbling chamber 63 where heat is given to the ocean water which in turn heats the generator 25.
The ocean water is cooled to its freezing point just as it leaves the heat exchanger 11, resulting in a solidus and liquidus mixture. This cold mixture goes to the water plant which comprises a solid-liquid separation tank 41 situated as close as possible to the heat exchanger 11 in order to reduce the flow resistance. The pressure in tank 41 is regulated by a valve 43. The ice crystals are transported by a series of pans (not shown) to tank 42 where the ice is washed by its own melt. The cold fresh water is forced to flow by pump 46 into the condenser 20 through a expansion device 31 in order to provide a lower temperature as well as a little partial evaporation of the fresh water in the condenser 20. The warmer fresh water and a trace of its vapor is then cooled by the cold brine in the heat exchanger 49. This cooled fresh water is forced to flow by pump 50 through a expansion device 32 to remove the heat from the absorber 22 by a little partial evaporation. The brine effluent from the heat exchanger 49 will be in general accompanied by a small amount of water vapor. The detailed description of the absorption-refrigeration heat pump as well as the freezing processes of desalination will not be given here, since they are well known to one skilled in the art.
The limited heat source together with an auxiliary system 18 attached to the heat exchanger 14 may be employed for starting the prime mover. The system 18 can be as simple as a tank of liquid air, or dry ice, which can be produced by the power plant during low-load periods (usually at night).
In view of the large quantity of heat to be removed from the heat pump of the absorption-refrigeration type, the liquid coolant of the heat pump will have to discharge into the environment with a small amount of vapor. Since the ocean water which flows through the heat exchanger 11 undergoes no change of phase, the heat exchanger 11 must be very large. It is, in general difficult to have a very large heat exchanger installed in proximity of the prime mover as well as the water plant. Therefore, an intermediate volatile fluid is employed to transmit the heat from the source fluid to the working medium. Other advantages of using the intermediate volatile fluid will be discussed later.
FIG. 2 illustrates the flow diagram, in schematic form, of a power plant which extracts heat from the atmosphere and is equipped with an absorption-refrigeration heat pump. A small amount of heat is supplied to the system by a limited heat source. The same numerals in FIGS. 1 and 2 represent the same components of the power plants, except that the source fluid (air) effluent from the heat exchanger 11 is clean and therefore can be used as the coolant of the condenser 20, while fresh water is used for cooling the absorber 22. The flow passage of the atmosphere air in the heat exchanger 11 must be oriented in vertical position so that air flows downward while the intermediate volatile fluid flows upward by the gravitational force which is quite large due to the large temperature difference involved. In order to have the heat removed from the condenser 20 at almost constant temperature, parallel multiple passages of the cooling air are required between the main conduit and the condenser. After the cold air has extracted the heat from the condenser, its temperature can be still much lower than the freezing temperature of the ocean water. A compressor 40 of compression ratio just enough to produce spray of cold air in the tank 41 is employed for the desalination of the ocean water. The pump 48 recirculates the lighter brine for crystalizing more ice. The regulating valve 43 consists also of a trapping device which permits the discharge of gas but not water. The fresh water discharged from absorber 22 may be accompanied by a little vapor. The limited heat source system can also be used as a starting device of the power plant in conjunction with the auxiliary system 18.
Theoretically, the prime mover of the power plants shown schematically in FIGS. 1 and 2 can operate by a cycle whose lowest temperature can be in the cryogenic levels. In practice, for the power plant in FIG. 1, the lowest temperature should be well above the cryogenic temperature (-98° F.) in order that the heat pump will not be excessively large in comparison with other systems.
In FIG. 3 is illustrated the flow diagram, in schematic form, of a power plant which extracts heat from the atmosphere and equipped with a vapor-refrigeration heat pump. A small amount of heat is supplied by the limited heat source as shown by the system enclosed by the dotted curve. The same numerals in this figure and FIGS. 1 and 2 represent the same components, except that the unit 23' in FIG. 3 represents a compressor and the cooling of the condenser 20 is performed by the cooled air. A detailed calculation will show that this power plant will not produce a significant amount of useful work, unless the working medium is heated by a process of increasing pressure. One way to achieve such a process is to use as heat exchanger 12 one of vortex flow type which is disclosed in two copending applications, Ser. No. 399,463, now U.S. Pat. No. 4,433,545, entitled "Thermal Power Plants and Heat Exchangers for Use Therewith" and filed July 19, 1982 and Ser. No. 488,348, now abandoned entitled "Compression Flow Heat Exchangers" and filed Apr. 25, 1983. The basic principle of the vortex-flow heat exchanger is that the working fluid flows inside a cylindrical space in the pattern of helical vortex, as illustrated schematically in FIGS. 4A 4. The working fluid enters the cylindrical space at the inlet 110 through guide vanes 112 and leaves at the outlet 111. The heating fluid enters the inlet 120 of an annular space and leaves at the outlet 121. To reduce the flow friction and to increase the heat transfer, the cylindrical wall 113 may be made of porous material filled with a volatile fluid which has greater affinity with the porous matrix than with the heating and heated fluids. The volatile fluid is boiled by the heating fluid and condensed by the working fluid. A more effective cooling of the working fluid can be achieved by using the vortex cooler shown schematically in FIGS. 5, 5A and 5B. The working fluid enters one or more annular cylindrical chambers through the inlet 210, the conduits 213 and the guide vanes 212, and leaves the outlet 211 through the openings 214. The cooling fluid enters through inlet 220 and leaves by outlet 221. The heat transfer walls 215 may also be made of porous material saturated by a volatile fluid.
Another way to have the pressure of the working fluid increased at heating is to heat it periodically in a number of conduits, or spaces at the constant volume process, somewhat similar to the cycle developed by Lenoir in 1860 and employed in the pulse jet engine during the second world war. However, the vortex flow heat exchangers provide high heat transfer, low flow friction and less entropy increase and therefore are preferred.
FIG. 6 shows schematically the power cycle for the power plant in FIG. 3 where the heating of the working gas is taking place in a process of compression or increasing pressure flow. The heat exchanger 14 may also be of the vortex-flow type, but is not necessary. FIG. 7 illustrates schematically the vapor-refrigeration cycle of the heat pump for unit mass flow of the refrigerant for the power plant in FIG. 3. If M denotes the ratio of mass flow rate of the refrigerant to a unit mass flow rate of the working fluid, then the work required by the heat pump is equal to M times the area CDEF. Comparing the area 1234 in FIG. 6 and M(CDEF) in FIG. 7 shows that useful work can be done by significant amount.
FIG. 8 shows the flow diagram, in schematic form, of a power plant which draws heat from a limited heat source by an amount comparable with that extracted from the atmosphere and the working medium is heated by a compression flow process. The large heat exchanger 11 in FIGS. 1, 2 and 3 is not needed. Air enters the supercharger 60 and an enlarged conduit 61 where the combustion takes place in a small chamber 62. The hot gas gives heat to the working medium in the heat exchanger 12. The effluent gas mixture from the heat exchanger 12 is cooled by the working medium to a temperature which can be as low as in the cryogenic level. This effluent cold gas mixture could be used to remove the heat from the condenser of the vapor refrigeration heat pump in a manner similar to that shown in FIG. 3. However, for the case where the compression ratio of compressor 15 is small, the heat pump may not be needed, if the expansion valve 21 is provided. The residual heat of the gas mixture effluent from the heat exchanger 14 can be recovered for saving fuel by recirculating the gas mixture to the heat exchanger 12, if its temperature is above the atmosphere temperature. Otherwise, it is discharged to the environment or some cooling facilities.
FIG. 9 shows the flow diagram, in schematic form, of a power plant similar to the one in FIG. 8 except that the removal of the exhaust heat from the prime mover is carried out by a volatile fluid which is cooled by the cold gas mixture effluent from the heat exchanger 12. The mixture which has absorbed heat in the heat exchanger 20 is recirculated to the heat exchanger 12 so that a part of the exhaust heat from the prime mover is recovered for saving the fuel. Again, if the compression ratio of the compressor 15 is small, the compressor 23 in FIG. 3 is not needed.
In FIGS. 1 and 2, a permanent gas has been considered as the working medium. If the working medium is a condensable gas, the compressor 15 in those figures is replaced by a pump, or a pump together with a small compressor.
In FIGS. 10-11 are shown the power cycles, for the power plants in FIGS. 8-9, where the heating and cooling are performed in the compression-flow heat exchangers. The state 4 in FIG. 10 is below the atmospheric temperature, while in FIG. 11 the state 4 is above the atmospheric temperature. The dotted lines in both figures designate the atmosphere temperature. The heat supplied from the limited heat source can be measured by the area 34'5 in FIG. 10 and the area 345 in FIG. 11. It is seen that the work done can be considerably larger than the heat input which has to be paid for.
This invention has described systems to draw thermal energy from the ocean, the atmosphere or other sources which are usually considered as passive or inert, such as lakes, rivers and the like which receive solar radiant heat to compensate for the heat that is continuously drawn out by the power plant. Sewage water from a city or industrial waste water can also be utilized for the production of power and conversion into usable water.
The power plants shown in FIGS. 1-3 are suitable for the production of power and fresh water while the power plants shown in FIGS. 8-9 are suitable for ocean going vessels, land moving vehicles and even airplanes. The residual cold gas can be used for space cooling, defogging and even alleviate the atmosphere pollution caused by to an inversion layer. Other applications will be obviously apparent to those skilled in the art.
Although preferred embodiments of the present invention have been illustrated and described, changes will obviously occur to those skilled in the art. It is therefore intended that the present invention is to be limited only by the scope of the appended claims.
|
A method to draw the thermal energy from essentially limitless heat sources, such as the ocean or the atmosphere and limited heat sources such as the combustion of fossil fuels, is provided for the production of mechanical work. The fluid from the heat sources gives heat to the working medium of the prime mover of the power plant through a first heat exchanger. The effluent cooled fluid from the first heat exchanger is used for removing the exhaust heat from the prime mover through a second heat exchanger either directly or indirectly through a heat pump and can also be used for the conversion of saline water into fresh water.
| 8
|
BACKGROUND
This invention relates to managing relationships of parties interacting on a network.
A party that has information to be made available to other parties with which it has or wishes to have relationships can disseminate the information to the other parties on a web site using a web server that is accessible by web browsers.
In a commercial context, for example, a manufacturer may try to increase sales of its products or services by giving better information and support to resellers or other companies that are in the chain of distribution between the manufacturer and end customers. On the other hand, the manufacturer may want to screen a particular type of customer from having access to information that is not targeted to that type of customer.
Access to the information by different parties can be regulated by firewalls, by password techniques, and in other ways.
SUMMARY
In general, in one aspect of the invention, at least one digital facility is made available via an electronic communication medium. Information is stored that reflects the existence of relationships between identified parties with respect to use of the digital facility. A predetermined type of interaction of the parties is permitted via the electronic communication medium with respect to the digital facility if the stored information reflects the existence of relationships between them.
Implementations of the invention may include one or more of the following features. The stored information identifies the nature of interaction permitted or precluded between identified parties with respect to use of the digital facility. The nature of interaction includes one of the parties being exposed to the existence of another of the parties in connection with using the digital facility. The existence of the other of the parties is made apparent by inclusion of the other of the parties in a displayed list of parties with whom interaction is permitted, the displayed list being determined by the stored relationship information. The interaction of parties via the electronic communication medium is governed by permissions defined with respect to the relationships. The permissions include a permission to be aware of the existence of specified other parties. The parties include individuals, groups of individuals, and commercial enterprises. The permitted interaction includes working together on a task, delivery of content, or one party accessing specified data that is associated with another one of the parties. Individuals may have a relationship only if respective institutions with which they are affiliated have a relationship. The stored information is created and controlled by parties only in accordance with permissions belonging to those parties. The predetermined types of interactions that are permitted and precluded are defined in stored permissions.
Among the advantages of the invention are one or more of the following. The system enables the portal-providing company and other companies interacting through the portal to make better use of their marketing and sales people and resources. The portal-providing company and other companies interacting through the portal can use the system to motivate their selling partners to achieve higher sales. The impact and reach of the portal-providing company's direct sales people and the front-line teams of other companies interacting through the portal can be improved. Selling partners and customers develop a greater awareness of the portal-providing company and other companies interacting through the portal. Selling partners are given enhanced marketing capabilities. The portal-providing company and other companies interacting through the portal can present a single coordinated image to selling partners and customers while providing custom experiences for individual users. The system also enables improvement of the performance of many other business processes that occur between and within companies. These improvements may take the form of reduction in the time required to execute. The system can improve the performance of interactions with a company's suppliers and vendors. It can also improve the performance of processes that occur after a business transaction, including the execution of implementation projects, service, and support. And it can improve the performance of a wide range of internal company processes.
Other advantages and features will become apparent from the following description and from the claims.
DESCRIPTION
FIG. 1 is a block diagram of a relationship management system.
FIG. 2 is a schematic diagram of examples of the granting of perform and grant permissions.
FIG. 3 is an illustration of aggregate permissions.
OVERVIEW
As shown in FIG. 1, a portal-providing company 20 can use relationship portal software 21 running on its web server 22 to leverage the value of information stored in its business database 24 . Software 21 can be used to regulate relationships that the portal-providing company has with other parties 26 , including the portal-providing company's direct customers 28 , other companies 30 along a chain of distribution 32 , end customers 34 , and marketing partners 36 . The software can also be used to regulate relationships that parties in the chain other than the portal-providing company have with each other (e.g., a relationship between a direct customer and an end customer), at least to the extent that the relationship involves the portal-providing company'information.
The business database 24 can be an existing database or a newly created database. Typically the business database would include information about products or services, prices, terms, availability, marketing plans, historical and projected sales, and any other information that would be useful in facilitating the relationships among the companies and employees who are authorized to use the system.
The regulation of relationships by software 21 can include control of which information of the various companies that participate in the portal environment is made available to which other companies and to which employees of those companies. The regulation can also include control of how the information is presented to the employees of the companies to enable the delivery of different “experiences” to different companies and their employees. In that way, the software 21 and the web server 22 can provide a personal relationship portal 27 that can have custom appearances and behaviors for each of the employees that communicates with the web server through a web browser. Each employee of any of the companies can get access to the web server from anywhere in the world through a network 40 that could be, for example, the Internet, an Intranet, a local area or wide area network, a dial up connection, or any other arrangement that allows communication between the employee's web browser and the network.
Software 21 provides two main functions: configuration of the software to serve a portal-providing company and its relationship partners, and run-time operation of the software to provide the personal relationship portals to employees of the companies.
The configuration function includes identifying and creating profiles for companies and employees of companies who will have access to the system, and defining the relationships among the companies and employees, the rights that each company and employee will have to use the system, and the preferences of each employee that together establish the nature and content of each employee's personal relationship portal. The configuration information is kept in a portal management database 23 associated with software 21 .
Run-time operation includes conveying each of the personal relationship portals to web browsers in accordance with the configuration and information contained in the portal management database 23 and in the business database 24 . In addition to providing information, each personal relationship portal can provide functions and services to the employee using the browser.
A wide variety of hardware and software can be used to implement the web server 22 The relationship portal software 21 and the portal management database 23 may be based on an appropriate set of platforms that can include Microsoft Transaction Server (MTS) and Microsoft Internet Information Server (IIS). The relationship portal software may take advantage of typical web software capabilities including Active Server Pages (ASP), Component Object Model (COM) objects, Java, Extensible Markup Language (XML), and ActiveX Database Objects (ADO). In one implementation, the relationship management software comprises a Java class library that implements a suite of portal applications 29 . The portal applications provide both the configuration capabilities and run-time features of the system. Other platforms may be used in implementations of the invention, including BEA Systems WebLogic Server, IBM WebSphere Application Server, Java Server Pages (JSP), Enterprise Java Beans (EJB) and Java Database Connection (JDBC).
The relationship portal software may include a generic schema for the portal management database 23 . The database initially includes seeded descriptive data in the form of query scripts. The Java class library can “talk to” the database, i.e., gather data from the database, manipulate the data, and store data in the database. The relationship portal software includes HTML web pages and/or can include ASPs that can communicate with the Java class libraries using COM communications. The server distributes the resulting web pages in the form of personal relationship portals to the user browsers.
The relationship portal software handles two types of parties: users and companies. A user is a person who is employed by or is otherwise associated with (“belongs to”) a company. Information about users, groups of users, and companies is generated as part of the configuration process. The information is stored and maintained as profiles in tables in the portal management database 23 .
The profiles include two important classes of information, called permissions and preferences. The permissions define the rights of users and companies with respect to information and functions that are made available by the portal applications. Permissions are granted by users of the system in ways (described below) that enable the development of a rich, distributed fabric of personal relationship portals for a range of users and companies who are in the constellation of interest of the portal-providing company. All of the personal relationship portals are implemented from the portal-providing company's server, but the particular permissions and preferences of any one of the personal relationship portals are not necessarily fully controlled by the portal-providing company. Rather the ability to control them is distributed so that other companies within the constellation and other users in those companies may be able to influence the configurations and permissions associated with some of the portals. How this is done will be explained more fully below.
Preferences define how the user wishes to receive the information and services made available by the portal applications. Permissions and preferences are similar in that they are unique named objects defined by a portal application. Actual permission values for a user represent specific access rights to application functionality, whereas specific preference values influence application behavior.
USER PROFILES AND COMPANY PROFILES
It may be required that a profile for a company to which a user belongs must exist before a profile for the user can be created.
A company profile can include demographic data; lists of other companies with which the company has a relationship; in some implementations a list of the maximum permissions that users at the company can be given in creating or managing the profiles of other users and companies; and a list of other users who are allowed to manage the profile of the company. A user profile may include demographic data; permissions given to the user to create and manage the profiles of other users and companies; a list of permissions given to the user with respect to other objects in the system; a list of preferences of the user for his personal relationship portal; and a list of other users who are allowed to manage the profile of the user.
The user profile contains a listing of permissions to which the user has some level of perform permission (defined below). In one implementation, the maximum permissions available to a user are limited by the permissions assigned to the user's company. Once permissions are assigned to a user, the company permissions are not consulted in order to determine what facilities are available to the user. However, when company permissions are removed, they are also removed from all of its employees.
Once a user has been created, the “belongs to” relationship of that user to his company cannot be changed except to the extent that the user wanting to make the change has permission to do so.
A company profile can be created and exist independently of any other company or user. This conveniently enables company profiles to be created and to exist without users until a later time.
For users who are at the end of a relationship chain (e.g., who don't work for a company), such as shareholders, an artificial company profile in the name of, e.g., “Shareholders”, could be created. The Shareholders company would be simply a grouping mechanism for those users.
Each user profile or company profile has a “profile manager”. The profile manager is the user who has the permission to change settings and possibly delete the profile. These abilities are expressed in the “modify user profile” and “remove user profile” permissions. One or more aggregate permissions (discussed below) may be configured to set the manager permissions.
A person who has permission to, and who does initially creates a user is automatically the profile manager for the new user. The profile manager will have both perform and grant permissions of the aggregate permissions. The relationship between the permission to create an object and the permission to manage an object is configurable. The concept of managing an object derives from aggregate permissions, which are discussed below. Aggregate permissions often include fundamental permissions to view, modify and delete an object, which are aggregated into what is effectively a right to manage that object.
User profiles are created by other users. In another implementation, users are given permission to manage all users at particular companies and there are not user management permissions. A company profile is created by a user. The user who sets up a company profile automatically becomes a manager of that company's profile.
Some users may be allowed to create companies of certain types. Company types are themselves configurable and may differ from one portal installation to another. The users automatically become managers of the companies they create. Other users may be given permission to manage certain company profiles but not to create any. These company managers can change demographic data freely, but they can only change permissions to which they themselves have the grantright.
GROUPS
Permissions may also be assigned to users through the mechanism of groups. A group is a collection of users. A user with a grant right to a permission may give that permission to a group just as he or she would give it to an individual user. Once the permission has been given to a group it is automatically conferred on all members of that group. Users may become members of groups in two ways. First, a user who has the permission to manage a group can designate members individually. Second, a user who has the permission to manage a group can specify that users with a certain demographic profile will automatically be members of that group. Any user who becomes a member of a group immediately acquires all the permissions that have been given to the group. The use of groups simplifies administration of permissions by enabling a large number of permissions to easily be assigned by putting users in just a few groups.
PORTAL BUILDER APPLICATION
The configuration functions are provided by one of the portal applications, called “Portal Builder”. Portal Builder enables users to view, modify, remove, and create user profiles and company profiles and in that manner to set the stage for personal relationship portals that are made available at run-time to users of the system. Each user has access to Portal Builder to view and modify portions of his own user profile. This capability is limited by the user's permissions with respect to him.
Specific functions of the Portal Builder, such as creating, modifying and removing user profiles, are available to a user only if the user has permission to access those functions. Typically those functions are used by individuals identified as relationship managers to configure personal relationship portals for customers of their companies.
Portal Builder displays web pages to present and collect the demographic data about users and the companies they work for and to establish user permissions and preferences defined by portal applications. As a portal application, Portal Builder defines its own set of permissions that control how it can be used and that it also manages when configuring a personal relationship portal.
A portal application uses the Portal Builder to define permissions that must exist for a user to make use of the application. The Portal Builder assumes the responsibility for gathering that information on behalf of the other portal, applications.
The table set forth in appendix A lists the fundamental components of the profile service of the Portal Builder in one implementation. A user interacts with the Portal Builder through a series of web pages that walk the user through a process. The screens associated with the web pages for one implementation are listed in the table of Appendix B.
PERMISSIONS
The ability of a user to access the functions and information available through the relationship portal software 21 is governed by a system of permissions. The experience of a user on his personal relationship portal is determined in large part by the permissions that he has. The permissioning architecture is highly adaptable and highly granular. The identity and scope of the permissions to which a user is entitled are determined by other users and are restricted by a set of rules that limit the ability of a user to grant permissions to other users. If carefully constructed, the fabric enables a portal-providing company, and other companies who participate in the system, to control the dissemination of information and the access to services in a way that enhances and facilitates their relationships with parties who can advance their interests. Conversely, dissemination of information and the access to services can be restricted for parties who can injure the interests of the portal-providing company.
A permission specifies the right that a user may be given to access the functions of a portal application. Roughly speaking, a permission is a capability to do “something” (through the medium of the portal application), perhaps with respect to “something else”. For example, the something which a permission enables may be to change a profile of a company, or to modify a user profile, or to create a user, or create a company of a particular type. A permission has an argument, which refers to the “something else” to which the capability pertains. The argument can refer to any object in the system such as a company or a piece of data.
Each portal application 29 defines permissions that a user must have in order to access the application or specific functions of the application. The application defines the arguments of any permissions that it defines. A user may not access features and functions of portal applications unless the user has a “perform” permission (defined below) with respect to the feature or function. At run-time, the portal application uses permission information maintained by the Portal Builder to determine whether and how to respond to a user request.
The definitions of possible permissions are stored in a permission definition table in the portal management database. The actual specific permissions associated with a given user or company are stored as values in a party permission table of the portal database. Portal applications that are invoked by a user consult the party permission table to determine if a user has a needed permission.
A permission may (but need not) have an argument, a value specifying an entity to which the permission applies. For example, a permission to create a company carries an argument that identifies the type of company.
In one implementation, when the database table of permissions is initially created, there is one set of permissions granted to one person called the system administrator. These permissions give the system administrator the right to create and modify companies of all types. In this implementation, the system administrator company (a fake company whose sole employee is the system administrator) is also given this permission. The system administrator and company are also given other global permissions with respect to other applications. In another implementation, the system administrator is given a “wildcard” argument value to all permissions, which translates to the complete list of possible objects for each permission.
COMPANY PERMISSIONS
In some implementations, permissions apply both to companies to which a user belongs and to the user himself. Although only individuals are direct users of relationship portals, permissions may be recorded for companies to which the people belong to enable further regulation of the permission fabric. The permissions that can be given to a user are constrained by both the permissions of the company to which he belongs and by the permissions of the user who is granting the permissions to the recipient. The permissions of a company (also called guard settings) define the maximum amount of permissions that a user who belongs to the company can be given. A user,creating a new company asks, “What are the maximum amount of permissions that any user at this company may need?” and then gives the company those permissions. If a user who belongs to that company later needs more permissions, new company permissions must be added before the user can be given the permissions.
PERFORM PERMISSIONS; GRANT PERMISSIONS; CASCADING PERMISSIONS
A permission may specify either or both of two aspects of permission: a perform right and a grant right. The perform right of a permission (the “perform permission”) gives a user the right to perform a specific function offered by a portal application. As suggested in the example shown in FIG. 2, the grant right of a permission (the “grant permission”) gives a user the right to grant to other users the perform permission and the grant permission with respect to the application functionality associated with the permission. The grant and perform permissions are represented by flags in the profiles stored in the portal management database. As shown in FIG. 2, user A's grant permission 100 enables user A to grant perform permission 102 to user B and grant permission and perform permission 104 to user A user (such as user B) who does not have the grant permission cannot modify the perform permission for any other user, either to add it or to remove it. A user who has the grant permission may give the perform permission or the grant permission or both to another user. In this way, the “cascading” of permissions can continue without limit as long as each user gives grant permissions to next users in the cascade. In FIG. 2, user C can give grant permission 106 to user E who works in another company and user E can then give perform permissions 108 , 110 , 112 to three other users F, G, and H in three other companies.
The result can be cascading tiers of personal relationship portals. For example, a selling partner or customer of the portal-providing company can create personalized branded web sites for its customers or downstream partners and can reuse information and services available on the portal-providing company's portal.
A user (such as user A) can have the grant permission without having the perform permission. This is natural, because a user may be responsible for managing the permissions of users who have responsibilities that the manager himself does not have. For example, a sales person may be responsible for managing the permissions of all users at an account. One of those users may be a lawyer. The sales person must be able to set up the lawyer's permissions but should not have access to the legal content. Although it would be possible for a malicious user to create a fake user and log in as the fake user to get access to functions not meant for him, that act would create an easily traceable trail.
CASCADING PERMISSIONS AND USER/COMPANY RELATIONSHIPS
The link between cascading permissions and the relationships of users to companies is suggested by what happens to user permissions when a change occurs for the company to which the user belongs.
For example, suppose that a company is initially defined in the portal management database as a “Tier I” company (e.g., a large or highly profitable company). The portal-providing company wishes to permit Tier I companies to have only the ability to submit questions to an Ask the Expert application, and companies of all other Tiers to have only the ability to read the questions and answers.
If the Tier I company becomes less profitable and falls beneath the Tier I threshold, the company and its users will need to be switched into the Tier II category. The effect of the switch should be to remove from users who belong to the company the ability to submit questions to Ask the Expert and leave them only with the ability to read.
Conversely, suppose that a company is initially recorded as a “Tier II” company. Because the portal-providing company only wants Tier I companies to have the ability to submit questions to the Ask the Expert portal application while giving all other Tiers only the ability to read, this company may only read postings to Ask the Expert.
If the company becomes more profitable, the company can be switched to Tier I in the database to give its users the ability to submit questions to Ask the Expert.
When additional permissions are added to a company, the user who is making the change to the company record can pick and choose manually which users of the company should have their permissions changed. When permissions are removed from a company, all users belonging to that company should lose the removed permission.
FUNDAMENTAL PERMISSIONS
Examples of basic permissions (called “fundamental permissions”) that a portal application might define and invoke are shown in the table contained in Appendix C.
Detailed explanations of four possible permissions follow.
Create Company—This permission gives the user the ability to create new company profiles in the portal management database. A user who has this permission is automatically given the remaining permissions, described below, for a company that he creates.
Modify Company—This permission gives the user the ability to modify the permissions of existing companies. The permission includes the permission to modify the permissions of all users belonging to that company and to create new user records belonging to that company. The argument of this permission is the list of companies that the user may be allowed to modify. The grant permission of this permission specifies which companies the user can give other users the ability to modify.
Create Company User—This permission gives a user the ability to create other users. The argument of this permission is the list of companies at which this user may create users. The grant component of the permission specifies the companies at which the current user may enable other users to create users.
Modify Company User—This permission enables a user to modify the permissions of specific users. The argument of this permission is the list of companies at which this user may modify users. The grant component of the permission specifies the companies at which the current user may enable other users to modify users.
AGGREGATE PERMISSIONS
Because the fundamental permissions are so granular, it is also convenient to provide an “aggregate” permission capability. As shown in FIG. 3, an aggregate permission 1 , 2 , 3 , or 4 is defined by the portal application A, B, or C that may invoke the permission at run-time. An aggregate permission is not a permission by itself but only a defined aggregation of permissions. The fundamental permission definitions are stored in one table in the portal management database. The aggregate permission definitions are stored in another table, and the mappings between the aggregate permissions and the fundamental permissions are stored in a third table. The permission values, the actual settings for a person or company, are stored in yet another table. This table includes the fundamental permission value and the aggregate it is associated with. The reason for this is that in the case of overlapping aggregates (see below), the same fundamental permission may have different values. The rule is that the value with the greatest rights wins. When one of the overlapping aggregate permission values is removed, the fundamental permission values associated with the other overlapping aggregate permission is retained.
Every aggregate permission is associated with one portal application. The aggregate permission 1 incorporates permissions A-W, A-X, and so on, in each case only for the portal application with which it is associated. A portal application C, for example, may be associated with more than one defined aggregate permission 3 and 4 . Aggregate permissions may overlap, meaning that they map to the same underlying, fundamental, permissions.
Users of the Portal Builder who are creating or modifying user permissions may work only at the aggregate permission level, not at the individual application permission level. A user profile is defined by one or more selected aggregate permissions, and the users only need to know how to select aggregate permissions for users. A user who has a relationship manager responsibility will dispense that responsibility at the aggregate permission level.
Each aggregate permission is given a name that describes, for example, a form of business function, usually in the context of the portal application that defines that permission. Portal application permissions that need to be accessible to someone whose role is to fulfill the business function are enabled with the perform aspect of the aggregate permission.
Certain portal applications that may be considered critical services are always enabled for every portal user. This can be done by providing a mechanism to enable permissions of those applications without use of the aggregate permissions model and without requiring user action.
Setting the perform or grant rights of an aggregate permission is equivalent to setting those rights for all of the constituent fundamental permissions.
Aggregate permission definitions are stored in an aggregate permission database table. The table is initialized when a portal-providing company's portal is installed, but unlike fundamental permissions, aggregate permission definitions can be modified without any corresponding change in applications that rely on the permissions that are part of the aggregate permission. However, the definitions are not modified after the portal is installed. Aggregate permissions make it easier to modify the configuration portion of an application without modifying the underlying application functionality. For example, new aggregate mappings can be installed in the database, and new screens can be created to set these aggregates, all without changing the application code that consults fundamental permissions to see what actions are allowable. Nevertheless, all of these definitions are put in place before a portal is installed.
EXAMPLE OF AGGREGATE PERMISSIONS
Assume that the fundamental permissions include:
Create Company, argument is company type. User can create companies of the specified types.
Modify Company, argument is company. User can modify the profiles of the specified companies.
Delete Company, argument is company. User can delete the profiles of the specified companies.
Create Company Users, argument is company. User can create users at the specified companies.
Modify Company Users, argument is company. User can modify the profiles of users at the specified companies.
Delete Company Users, argument is company. User can delete the profiles of users at the specified companies.
Assume that the aggregate permissions include:
Company Creator, argument is company type. Maps to Create Company and functions the same way.
Company Manager, argument is company. Maps to Modify Company, Delete Company, Create Company Users, Modify Company Users, and Delete Company Users. User can modify and delete company profiles, and create, modify and delete users profiles at the specified companies.
Company User Manager, argument is company. Maps to Create Company Users, Modify Company Users, and Delete Company Users. User can create, modify and delete users at specified companies.
Assume that the system administrator and company have perform and grant permission for all values of Company Creator aggregate.
When the system administrator creates company A, he automatically becomes the Company Manager and Company User Manager of company A. He gives company A perform and grant rights to the Company Manager and Company User Manager aggregate permissions for company A. All users at company A now have the potential to manage the company profile and the profile of all users at the company.
If system administrator creates user B at company A and gives him the full set of permissions allowed to company A, user B can manage the company profile, and create and manage all user profiles at the company, but he cannot create any new companies.
If user B creates user C at company A and gives her perform rights to the Company User Manager aggregate permission for company A, then user C can create and manage the profiles of all users at company A, but cannot manage the company profile itself, and cannot give anyone else the right to manage user profiles at the company.
USER PREFERENCES
A user's profile includes preferences, which capture how the user wants to set up his personal relationship portal and to receive information. The preferences that are available to a user are limited by the user's permissions.
A portal application may specify preferences that generally control how a feature will operate within the portal application, provided the user has the permission to use that feature. An example of a preference is a selection of seven of ten available news channels to be displayed in a news application. The permission is the ability of the user to access the news application; the preference is what news sources will be displayed.
Preferences are only associated with users, not with companies, because preferences are more closely related to how a user makes use of a user portal.
Preferences are specific to one user only. Preferences cannot be cascaded. When a user is granted permission to access a portal application, the application automatically gives the user access to all relevant preferences.
For example, suppose that preferences “sort order” and “filter by” pertain to view and modify permissions of a particular portal application and that the preference “confirm before delete” pertains to the “remove” permission for that portal application. If a user does not have access to the “remove” permission, when the preferences page is generated for a user, the portal application is coded not to display the “confirm before delete” preference.
When a user is initially created, his preferences will default to a standard setting, regardless of the user type or company. Unless the user performing the user creation or modification purposely chooses to modify the user's preferences, the preferences remain in the default state.
Preference templates simplify the process of configuring a user's preferences. A preference template specifies the settings for a number of individual preferences. When a preference template is applied to a user, all of the user preferences are set as specified in the template. Preference templates can be applied by users to their own profiles, or they can be applied by a user's profile manager to that user's profile on his or her behalf.
Preference definitions are recorded in a table in the portal management database that includes, in one implementation, the name of the preference, a label for the preference, a flag indicating whether it accepts single or multiple values, a type code indicating whether the value is accepted as an input field, list, or set of choices, one or more default values for the preference, a set of values for the list elements or choices, an optional set of labels for the list elements or choices, and an optional set of default values for the list or choices (one value for an input field).
Actual preference values are stored in another database table in the portal management database.
OTHER IMPLEMENTATIONS OF RELATIONSHIP MANAGEMENT
In another implementation approach, companies may be defined as belonging only to specified types that correspond, for example, to their roles in a commercial supply chain, and each user can be defined as having only a specified role within the company to which he belongs. For example, the company types could include sales representatives (“reps”) and suppliers who are represented by the manufacturers (“principals”). Within a rep company, a user could have a role as, for example, an outside sales rep, an inside sales rep, or a rep manager. Within a principal company, a user could have a role as a product manager or national sales manager, for example.
Relationships may be defined between parties of specified types and between individuals having specified roles in respective companies. For example, a product manager of a supplier may have a relationship with a sales representative of a vendor but may be denied a relationship with a product manager of the vendor. And individuals who belong to a supplier may not be permitted to have relationships of any kind with any individuals who belong to another supplier. In addition to companies and individuals, the system can control relationships between groups of individuals, for example, the client team for client X in company Y and a quality review team for vendor Y in client X.
The relationships can be used to govern the ability of the individuals, groups, and companies to access and use content and features maintained on a relationship server.
Among the content and functions that could be provided by the server in a given implementation are a new business application used to manage and track new business opportunities, requests for samples, action item tracking, electronic discussions, registration of companies and users by the setting up of profiles, an address book, and administrator functions that enable a designated administrator for a given company to control the creation and maintenance of user profiles and relationships and a designated system administrator for the portal-providing company of the server to control the creation and maintenance of company profiles.
The user interface that is presented through a browser to a given user depends on the user's role, on user and company profiles, and on definitions of relationships between individuals, groups, and companies. Among the facilities provided on various user interfaces are the ability to invite participation by users at other companies with which the company to which a user belongs has a relationship, to create a document, to manage (create, view, modify, and delete) commercial opportunities, to manage (create, view, modify, and delete) requests, to manage (create, view, modify, and delete) action items, to manage (create, view, modify, and delete) address books, and to control user preferences.
A company administrator also has user interface access to facilities for approving new users, approving new relationships, managing relationships, requesting relationships, altering a company profile, and viewing users. The overall system administrator is provided with user interface access to the ability to view companies and users.
For each function, each role of a user, and each company type to which the user belongs, the system defines permissions that determine whether a user having that role can access that function. The user interface is constructed to enforce the defined permissions.
The relationships between companies and between users are enforced by the implementation of the user interface based on the stored relationship information. For example, if a user does not have permission to view a specific company or a specific user, then the various lists and other interface elements that display to the first user companies and users with which he can interact will not include the non-permitted parties. In effect, the first user will have no way to know that the non-permitted parties even exist let alone any way to interact with them through the system. Thus, the user interface regulates and implements the permitted relationships for each user and company automatically based on the stored permissions.
Relationships are established as follows.
A new company may initiate a registration by providing appropriate fields of information for a profile through the user interface presented by the browser. The system administrator will review the information and either approve or disapprove the registration. The user who initiated the registration process for the company becomes the company administrator.
A user profile for a registered company is also created through the user interface presented by the browser. After the new user initiates the registration process by entering information needed for his profile, the record is presented to the company administrator who can approve or disapprove it.
Because the company profile and the user profile define the company type and the role of the user, the permissions applicable to such companies and users can be used to regulate the relationships. For example, the permissions may provide that a national sales representative of a rep firm can have a relationship with a product manager of a principal company with which his company has a relationship. Then, when a new product manager is added to a principal company, the new product manager automatically acquires the relationship permissions associated with new product managers of principal companies. The role that a user has within a company is controlled by the company administrator.
Setting up a relationship between one company and another (or between other parties such as individual users or groups) is initiated by the one company or party requesting the relationship with the other. The company administrator of the other company is presented with the request and decides whether to approve or reject the request. If approved the relationship is recorded on the system. As part of the approval process, the administrator is able to view a list of users who have certain roles for the company seeking the relationship. In a variation on this implementation, each party is assigned a “key” (a code sequence known only to authorized users). Any user who knows the key can use it to establish a relationship with the party to which the key applies. Transmittal of the key occurs through means outside of the portal. In this way, users that have an existing (or desired) business relationship can establish a portal relationship before they are able to use the portal as a communication mechanism between them.
In another implementation, the permission to establish a relationship between companies (or other parties such as individual users or groups) belongs to any user who is a manager of both the parties that will be involved in the relationship. In this case, parties cannot initiate the relationship building process themselves; it requires a third party.
The effects of the relationships between users and companies are determined by the types of companies and the roles that the individuals play in those companies. Permissions are applied automatically through relationship definitions. For example, a chain of people may have a relationship with respect to assembling and delivering content, for example, a product brochure. The same people may have no other relationship to one another with respect to a different set of activities.
Permissions can be driven based on attributes of a relationship. If each user's profile is defined to include demographic attributes such as geographical location, the right to see highly confidential information, and existing relationships with specified other parties, then another party can specify, for example, that he wishes to permit users who have certain demographic characteristics to receive a certain piece of marketing literature. In such a system, the relationships need not be governed by predefined roles, or by companies or groups to whom the users belong, or by pre-specified permissible relationships.
Other embodiments are also within the scope of the following claims. For example, the mechanism by which the user interacts with the system need not be a web browser. The user interaction can be governed by devices other than a web server. The parties who make use of the system need not be companies and their employees, but could be any entities and individuals who “belong” to them. The context in which the invention is implemented need not be based on business relationships, but could be based on any relationships that entities may wish to regulate.
Appendix A
Component
Type
Description
AggregateElement
Database table
Contains mappings between
aggregate and fundamental
permissions
AggregateElement
Java class
Manages the fundamental
permissions associated
with an aggregate permission
AggregatePermission
Database table
Contains aggregate permission
definitions
AggregatePermission
Java class
Manages data associated with
aggregate permission definitions
AggregateValue
COM object
COM wrapper for business logic
AggregateValue
Java class
Manages setting aggregate and
fundamental permission values
PartyPermission
Database table
Relates Party objects to a set of
permission values
PartyPreference
Database table
Relates Party objects to a set of
preference values
PartyPreference
Java class
Manages data associated with
preference values
PermissionValue
Java class
Retrieves individual permission
values
PortalPermission
Database table
Contains application permission
definitions
PortalPermission
Java class
Manages data associated with
permission definitions
PortalPreference
Database table
Contains application preference
definitions
PortalPreference
Java class
Manages data associated with
preference definitions
PreferenceChoice
Java class
Manages data associated with
preference choices
PreferenceDisplay
Java class
Formats permissions into XML
for display
PreferenceManager
Java class
Manages the interaction between
preference defaults and values
Appendix B
Screen Name
Screen Description
Start Menu:
This is actually not a screen but a component of the
“My Preferences”
Start Menu. This is the component that an end-user
uses to access personalization features such as
preference settings and access to demographic
information contained in his/her profile.
Start Menu:
This is actually not a screen but a component of the
“Portal Builder”
Start Menu. This is the component that contains
administrative features such as access to company
and user profiles, sending password
reminders, and managing templates.
Select User
This is an implementation of a standard selection
screen. It allows a user to examine the full list
of users s/he may access and select one for
modification, removal, or choose to create a new
user.
Common User
A data collection screen that every portal user is
Demographics
required to fill out. This is also the screen that
allows the portal password to be set and changed.
Job Function
This screen containss a dynamic selection of data
Additional Data
elements depending on the Job Function(s) selected
Collect
for a user. The purpose of the screen is to capture
data elements unique to the Function the user plays.
Select Aggregate
This screen displays all aggregate permissions the
Permissions
user being modified may be given access to.
(user profile)
Application &
This screen displays to the user what applications
Permission On-line
and permissions are available to the user as a
Report
result of the selected aggregate permissions.
Configure
Allows for the configuration of application
Application
preferences. Only those applications to which the
Preferences
user has permission to use will be available for
preference setting.
User Managers
This screen appears as part of user
creation/modification and is used to identify
what other portal users may update this user's
profile.
Company Select
This is an implementation of a standard selection
screen. It allows a user to examine the full list
of companies s/he may access and select one for
modification, removal, or choose to create a
new company.
Common Company
A data collection screen that every portal company
Demographics
will be required to fill out.
Company Type
If additional data is necessary based on the
Additional Data
Company Type selected, this screen is generated
Collect
to collect those elements.
Select Aggregate
This screen allows for the selection of aggregate
Permissions
permissions. These permissions define what this
(company profile)
user may do in the portal environment.
Company
This screen allows a company to define its internal
Organization
organization (e.g. regions, branches, offices, etc.)
This information is used as an attribute of each user
and might be leveraged by portal applications.
Company Managers
This screen appears as part of company creation/
modification and is used to identify what other
portal users may update this company's profile.
Company Profile
This screen marks the end of a company profile
Completed
creation or modification. Options exist here to
determine how users at that company should be
affected.
Password Reminder
Using the standard user selection screen, this form
allows users to be selected and an e-mail sent to
their e-mail address on file with a password
reminder.
Appendix C
Permission
Argument
Description
Create Company Type
Company Type
Create companies of the
specified type
View Company Type
Company Type
View companies of the
specified type
Modify Company
Company Type
Modify companies of the
Type
specified type
Delete Company Type
Company Type
Delete companies of the
specified type
View Company
Company
View specified company
Modify Company
Company
Modify specified company
Delete Company
Company
Delete specified company
Create Company
Company
Create users at specified
User
company
View Company User
Company
View users at specified company
Modify Company User
Company
Modify users at specified
company
Delete Company User
Company
Delete users at specified
company
View User
User
View specified user
Modify User
User
Modify specified user
Delete User
User
Delete specified user
|
Information is stored that reflects the existence of relationships between identified parties with respect to use of the digital facility. A predetermined type of interaction of the parties is permitted) via the electronic communication medium with respect to the digital facility if the stored information reflects the existence of relationships between them.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to golf club heads, and more specifically to the heads of metal woods and drivers with an adjustable, pre-tension condition at the impact face area of the club head that can be adjusted and tuned to match the golf ball compression and decompression characteristics in relation to the particular golfer's swing.
1. Description of Related Art
This invention relates to the improvements in performance of golf clubs when used to propel a golf ball by a transfer of linear momentum during the impact phase between the golf club head and the golf ball.
The transfer of a momentum between a hard surface of an impacting mass and a resilient golf ball, involves a complex process that not only involves the velocity pattern of the golf club head during the transfer mechanism but also the deflection pattern of the golf ball under compression.
In addition, with the use of the traditional wooden headed clubs, a reverse shock wave is reflected from the back of the head which has a dimensioned shape configuration that focuses the reverse shock wave to the impact face in such a time frame so as to coincide with the expansion of the golf ball from its maximum compressed state. Thus, an additional acceleration factor can be added to the release velocity of the golf ball.
One good golf shot makes up for many bad shots. Several good shots keeps one addicted to the sport. Thus, manufacturers of golfing equipment have endeavored to satisfy consumer demand for better performing and more mistake tolerant golf clubs and balls. For drivers and fairway woods, which are made out of the traditional wooden headed clubs, it is known that a reverse shock wave is reflected from the back of the head to the face of the club. Thus, an optimally dimensioned and shaped golf club head configuration could focus the reverse shock wave to the impact face of the club at a frequency rate which coincides with compression and subsequent expansion of the golf ball from its compressed state. Thus, optimal coincidence between the transfer of the reverse shock wave to the golf ball and of the expansion from the compressed state of the golf ball adds a maximum amount of additional acceleration to the release velocity of the golf ball after impact. Therefore, the industry has long attempted to manufacture such an optimally shaped and dimensioned wooden headed configurations.
Therefore, manufacturers have developed golf club heads which notably increased the distance a ball would travel after being struck. However, while golf club head performance improved, skillful techniques or either a lucky swing is required to avoid either hooking or slicing the ball. Therefore, many amateur golfers will frequently play at least one mulligan per 18 holes to escape the score penalties for one bad tee-shot.
In response to consumer demand for mistake tolerant equipment, thin wall golf club heads made by investment casting technology were introduced. These thin wall golf club heads are known for having a much larger "sweet spot" on the face of the golf club. The "sweet spot", of course, is the area of the golf club face which must strike the ball to yield a long and accurate shot. Because thin wall golf club heads have a cavity within the head, the reverse shock wave phenomena of the wooden heads is replaced by the deflection and subsequent return motion of the golf club face. Thus, the thin wall golf club heads have been manufactured to attempt to match the golf ball compression and expansion characteristics so as to achieve the effect of adding additional acceleration to the release velocity of the golf ball upon impact.
The introduction of thin wall golf club heads by the use of investment casting technology, has substituted the reverse shock wave phenomena by allowing the golf club face to deflect during golf ball compression during the first phase of impact. Thus, if the deflection and subsequent return motion have a time profile that matches the golf ball compression and expansion modes, then again there will be and additional acceleration phase applied to the release velocity of the golf ball.
However, it has been found that it is required to be extremely selective in the choice of the golf ball to be used with the so called "metal woods" in order to obtain the maximum performance possible. Moreover, with the tolerance used in the production of metal woods, the face thin-wall thickness can vary to the extent that the impact frequency characteristics can vary substantially between two apparently identical golf clubs made by the same manufacturer.
However, a problem with obtaining optimal deflection characteristics which match golf ball compression characteristics, is that the compression characteristics of the golf club head can vary substantially between two apparently identical golf clubs made by the same manufacturer. The reason for these variations is first a small difference in the thickness of the golf club face, a difference which is within tolerance, can have a large effect on the tension at the impact face area of the club head of the golf club and therefore its compression characteristics. Thus, a golfer must be extremely selective in the choice of his golf ball in order to obtain maximum performance possible. Indeed, different balls might be required to optimize the characteristic matching between the ball and the various fairway woods and driver. Unfortunately, the rules of golf do not allow ball substitution according to the club being used. Therefore, it is not realistically possible, to obtain maximum performance from a set of woods and driver with a given golf ball. This conclusion follows from the observation that, in all likelihood, each golf club will have a different deflection characteristic resulting from the production of the metal woods within known tolerances.
What is needed, therefore, is a golf club head design which allows the deflection characteristics to be fine-tuned and adjusted to match the golf ball compression characteristics for a given golf ball and a given golfer. The reason that the golfer fits into this equation, of course, is that the speed and energy of his or her swing affects the amplitude of the golf ball compression and, therefore, its compression characteristics.
SUMMARY OF THE INVENTION
The present invention relates to an adjustable golf club head of a metal wood type configuration which allows the golf club face deflection characteristics to be tuned to match the golf ball compression characteristics for a particular golfer's swing. The golf club head has two rear protrusions which extend from the facial area of the golf club head to the rear of the golf club head. Most metal woods include a cavity within the golf club head to create the "sweet spot". Similarly, the rear protrusions and the facial area of the golf club head jointly define a cavity within the golf club head which creates the "sweet spot" on the golf club face and which allows the face to deflect and return to a normal position. However, these two rear protrusions do not physically meet at any point. Therefore, the cavity extends all the way through to the end of the golf club head. In addition, a tensioning assembly, being comprised of a nut and a bolt, is integrally attached to each of the two rear protrusions. Therefore, when the nut is properly tightened onto the bolt, the two rear protrusions are compressed by the nut and bolt tensioning assembly toward each other. As these rear protrusions are compressed, i.e., urged toward each other, the pre-tension condition at the impact face area of the club head is changed, and thus the response characteristics of the golf club head are changed. Therefore, by loosening or tightening tensioning assembly, the compression characteristics of the golf club head may be adjusted to match the compression characteristics of the golf ball for a given swing. Therefore, if this configuration is applied to the driver as well as to each of the fairway woods, the various clubs may be fine tuned to maximize performance for a given ball and a given golfer.
While there are variations as to the shape and placement of the cavity of the adjustable golf club head, one embodiment includes a cavity which is shaped similar to three pipes connected by a T-connector. Specifically, the first cavity section in the head of the golf club lies behind and approximately parallel to the planar face of the golf club and is perpendicular to a linear axis which perpendicularly extends through the planar face of the golf club. A second cavity section joins the first cavity section and extends to the back of the adjustable golf club head between the rear projection in a manner which is approximately parallel to the linear axis and to the ground. Moreover, in this embodiment, the cavity is filled with a resilient elastomeric filler.
An embodiment of the adjustable golf club head also comprises one or more drilled apertures within the golf club head for housing an internal weight. Typically, this aperture is drilled from the rear of the golf club head and extends in a direction approximately parallel to the linear axis of the golf club head. Accordingly, an internal weight designed to snugly fit within the drilled aperture is installed. In one embodiment the internal weight weighs approximately 200 grams.
Depending on the size of the cavities and whether such cavities are filled with resilient elastomeric filler, one embodiment of the adjustable golf club head includes at least one lug mounted on and extending from one of the two rear protrusions to interact with either the other rear protrusion or with the lug of the other rear protrusion to limit the amount of adjustment of the tensioning assembly and therefore to the pre-tension condition at the impact face area of the club head. The reason for the limiting the range of adjustment and, therefore, the pre-tension condition at the impact face area of the club head is that excessive pre-tension condition at the impact face area of the club head may result in permanent distortion of the face of the golf club head.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings which are incorporated in and form a part of the specification, illustrate various embodiments of the present invention and together with a description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is an isometric view of the golf club head having two rear protrusions that are fitted with a tensioning assembly consisting of a nut and bolt.
FIG. 2 is a top view of one embodiment of the adjustable golf club head showing the arrangement of the first and second cavity and of the tensioning assembly.
FIG. 3 is rear elevation of the golf club head showing the location and placement of an alternative embodiment of the first and second cavities, the tightening assembly, as well as the reinforcement sleeve for securing the golf club shaft.
DETAILED DESCRIPTION OF THE INVENTION
Metal woods and drivers include a cavity within them which allows the golf club head face to deflect upon striking the ball and, overall, to provide a larger "sweet spot" on the face of the golf club. By "sweet spot", what is meant is that the area of the face of the golf club which can strike the ball and still result in an accurate and long shot is enlarged. Designs which create a larger "sweet spot" are more fault tolerant and are especially good at allowing novice golfers the opportunity of playing the game with a certain improved degree of apparent skill. Therefore, with the advent of the metal wood which has a cavity and increased "sweet spot", consumer demand encourages manufacturers to produce golf club heads with enlarged "sweet spots" and with high performing characteristics as well. As has been discussed heretofore, the invention herein includes a golf club head 1 whose deflection characteristics may be tuned and adjusted to match the compression characteristics of the golf ball resulting from a constant swing. In order to achieve this, the cavity 14 of the metal wood is extended through the back of the golf club head 1 behind the planar face 1b. The response characteristic of a deflecting diaphragm is dependent on the amount of pre-tension condition at the planar impact face area 1b of the club head 1 which is dependent upon the shape of the periphery of the club head 1. It is a feature of this invention to provide adjustment of the periphery of the rear of the metal woods to allow the pre-tension condition at the impact face area 1b of the club head 1 to be adjusted, to achieve optimum performance. The tension adjustment of the planar face 1a is accomplished with at least two substantially parallel protrusions 9 and 10 rearwardly extending from the planar face 1a of the club head 1.
The golf club head 1 also has a cavity 14 which is shown in FIG. 1, defined by an area behind, and preferably parallel to the front face 1a and the parallel protrusion 9 and 10. As is shown in FIG. 1, the size of the cavity 14 when viewed from above, is relatively large in comparison to the overall width of the back of the golf club head 1. In the preferred embodiment, as is shown in FIG. 2, the cavity 14 is shaped similar to that of a T-connector for pipes. In both embodiments, a first cavity section 14a is oriented behind and extends in a direction approximately parallel to the face 1a of the golf club head 1. A second cavity section 14b joins the first cavity section 14a, preferably approximate the center of the planar impact face, and extends toward the rear of the golf club head 1 between rear projections 9 and 10. There are many variations with respect to the size, shape and location of the cavity 14. The preferred embodiment also contains an elastomeric filler within the cavity 14. One skilled in the art would need to perform only insignificant experimentation to determine the optimum size, shape and placement of the cavity 14 as well as the elastomer fill.
To provide the pretensioning of the planar face, holes 2 drilled on a common axis as is shown in FIG. 1 drilled, preferably countersunk, in the rearward protrusions 9 and 10. The performance characteristics and the sensitivity of the golf club is made through adjustments to the tensioning assembly 3 which is comprises a bolt 5 threaded on one end to receive a bolt 4. When nut 4 is tightened onto bolt 5 once the nut 4 and bolt 5 of the tensioning assembly 3 have been placed in the holes 2, the effect will be to urge rear protrusions 9 and 10 toward each other. The shape of the rear of the golf club head 1 is therefore adjusted, which results in a different pre-tension condition at the impact face area 1b of the club head 1 which therefore results in different compression characteristics.
The placement of holes 2 in the rear protrusions 9 and 10 of the adjustable golf club head 1 may be moved in either forward, toward the face 1a of the golf club head 1, or backward toward the back of the golf club head 1 to suit the adjustment purpose. As the placement of the holes 2 is moved from front to back, more turns of nut 4 onto bolt 5 will be required for a given amount of compression of the rear protrusions 9 and 10 toward each other.
On each of the rear protrusions 9 and 10 is placed a lug 6 which extends toward the other protrusion 9 or 10 of the golf club head 1 so as to engage the lug 6 of the other rear projection 9 or 10 if the rear protrusions 9 and 10 are pulled to close together. In this embodiment, (FIG. 1) two lugs 6 are shown, each extending from a rear protrusion, equally sized and placed to integrally correspond with each other. Thus, after a certain amount of adjustment has occurred, the two lugs 6 will engage each other and prevent further adjustment and golf club head 1 and, therefore, further shape manipulation. Thus, once the two lugs 6 engage each other, the only adjustment possible is to loosen the nut 4 from the bolt 5 thereby allowing the rear protrusions 9 and 10 to expand away from each other thereby changing the pre-tension condition at the impact face area 1b of the club head 1 and therefor the deflection characteristic of the face 1a of the golf club head 1. It is important to note that this particular arrangement of lugs 6 is just one means of limiting the amount of adjustment. First, the use of such lugs 6 may not be necessary depending upon factors such as the size of the cavity 14 and whether the cavity 14 is filled with a substance such as an elastomeric filler. Moreover, instead of having two lugs 6 which integrally interact with each other, the invention could include having just one lug 6 that reaches from one rear protrusion 9 or 10 to the other.
With respect to the tensioning assembly 3, it should be noted that the various embodiments used by the inventor herein, include a special nut 4 and bolt 5 which cannot be readjusted after being set. The purpose of utilizing such a special nut 4 and bolt 5 is to comply with current PGA requirements which do not allow adjustment of performance characteristics of a golf club once play has begun. The back of the golf club head 1 may also include an elastomeric back piece 12 (FIG. 2) which covers the cavity 14.
FIG. 3, a rear elevation view of the golf club head 1 shows yet another embodiment of the cavity 14 cut in a manner which prohibits a view through the club head to the ground providing a more traditional appearance when poised to strike the ball. An additional feature, not shown, are drilled apertures to snugly house weight in the preferred embodiment. Obviously, the size and shape of the drilled aperture is a function of the weight, preferably about 200 grams, selected for placement within the golf club head 1. Finally, FIG. 3 shows the internal reinforcement sleeve 12 which is designed to mate with the golf club shaft 13. This internal reinforcement sleeve 12 is particularly preferred if a graphite shaft is being utilized with the current invention.
Having described this invention and given examples thereof, one of ordinary skill in the art having this description before them would be able to make many modifications and adjustments to the invention without departing from the scope of the invention as claimed herein.
|
A golf club head for drivers and fairway wood configurations having a planar face and two rear projections which extend rearwardly from the face of the golf club head is described to allow an adjustment of compression characteristics by changing the tension of the face. A tensioning assembly consisting of a nut and bolt attached to the two rear projections such that the tightening or loosening of the nut and bolt combination affects the pre-tension condition at the impact face area of the club head.
| 0
|
BACKGROUND
Typically, a human manually programs hyperlinks in conventional web pages to cross-reference related subject matter accessible on various networks including the internet. Instead of a manual hyperlink program, an automated hyperlinking program analyzes a web page and links specific content without a manually programmed hyperlink to some external content. This automated hyperlinking is often called “linkifying”.
SUMMARY
In general, one implementation of the subject matter described herein may be a technology that automatically and dynamically parses a document rendered on an eReader or Ebook and identifies content of potential interest to a user, and, in response to identifying content of potential interest, receiving at a server, from the eReader, the identified content. The server may then search a network communicatively coupled to the server to locate data contextually relevant to the identified content, and the server may then transmit the contextually relevant data from the server to the eReader for presentation to a user through a user interface on the eReader.
This Summary is not intended to introduce key features or essential features of the claimed subject matter, but merely provides a selection of concepts that are further described in the Detailed Description. Further implementations, features, and advantages, as well as the structure operation of the various implementations are described in detail below with reference to accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Implementations are described with reference to the accompanying drawings. In the drawings, like reference numbers may indicate identical or functionally similar elements. The drawing in which an element first appears is generally indicated by the left-most digit in the corresponding reference number.
FIG. 1 is a schematic diagram of an integrated system for linking to relevant data in a document in accordance with one or more implementations of the disclosure.
FIG. 2 is a schematic diagram of a system for linking to relevant data in documents being presented by one or more eReaders.
FIG. 3 is a flow chart of a method for linking to relevant data in a document in accordance with one or more implementations of the disclosure.
FIG. 4 is a schematic diagram of an example computer system that can be used in one or more implementations of the disclosure.
DETAILED DESCRIPTION
Implementations of the disclosure describe solutions for providing a desirable user experience while, for example, accessing web pages and reading an Ebook or eReader. A solution linkifies displayed content rendered by an Ebook or eReader in a dynamically updated, nonintrusive, interesting, and personalized manner.
Example Integrated System
As shown in FIG. 1 , an example integrated system 100 may employ the techniques described herein. The system 100 includes at least a client Ebook device 110 or eReader and a server 120 .
FIG. 1 illustrates an example eReader 110 . This eReader 110 is one possible implementation of a device that employs the new techniques described herein. The eReader 110 includes a content identifier 112 , a content submitter 114 , a data receiver/transmitter 116 , and a presenter 118 .
The content identifier 112 is designed to automatically and dynamically identify potentially interesting terms or combinations of terms such as verbs, nouns, place names, geographical features, people's names, names of songs, paragraph headings, section headings, modifiers, etc., in a document being rendered on the device. The content identifier is configured to identify a plurality of terms or phrases from the document presented by the eReader 110 for linkification. The plurality of terms or phrases may be selected by the content identifier of the eReader using a combination of a language specific dictionary 108 and natural language processing techniques.
The content identifier 112 may be configured to employ term frequency-inverse document frequency (tf-idf) numerical statistics to determine how important each of the identified plurality of terms or phrases is to the presented document. Term frequency-inverse document frequency is a numerical statistic which reflects how important a word is to a document in a collection or corpus. It can be used as a weighting factor in information retrieval and text mining. The tf-idf value increases proportionally to the number of times a word appears in the document, but is offset by the frequency of the word in the corpus, which helps to control for the fact that some words are generally more common than others. The content identifier is further configured to access the language specific dictionary 108 over a communicative coupling, as shown in FIG. 1 , or to download the language specific dictionary 108 to the eReader 110 in conjunction with a determination of the language of the document presented by the eReader for linkification. The language specific dictionary 108 may be further selected for download to or communicative coupling with the Ebook reader based on one or more of the genre of the document, the technical nature of the subject matter in the document, the advanced level of the subject matter in the document, or whether the document is fiction or non-fiction.
A processing algorithm used by the content identifier in identifying a plurality of terms or phrases in the document being presented by the Ebook can be designed to reduce latency and maximize processing efficiency. One way in which this can be achieved can include decreasing the speed or amount of processing performed in identifying a plurality of terms for linkification as a percentage of the document that has not been linkified decreases. Additionally, the speed of processing can be reduced as the point in the document where the processing is occurring gets farther ahead of the point in the document where a user is reading. Another non-limiting example of dynamic processing that may be performed by the content identifier includes starting the identifying of a plurality of terms or phrases at the point in a document where a reader begins, then continuing on ahead of that point to the end of the document, and then jumping to the beginning of the document and continuing forward from the beginning until catching up with the reader.
A look-up table of well-known names of people, places, or things that would appear frequently across a broad corpus of documents can also be provided. The names, places, or things provided in the look-up table could also be ranked in terms of their importance. The content identifier can be further configured to compare the identified plurality of terms or phrases to the look-up table for an initial set of results for linkification.
Via a network, the content submitter 114 sends these potentially interesting terms or combinations of terms to a server 120 for more extensive processing. “Potentially interesting”, as used herein, generally refers to terms and phrases that are more likely than not to be terms or phrases that a user would like to have more information on. Because the content identifier 112 can be configured to perform the identification of terms and phrases dynamically and at a current point in time when a user accesses a document on the Ebook, topics that are in current news and recent events can rank higher in terms of potential interest. Examples of potentially interesting terms include verbs, nouns, place names, geographical features, song names, people's names, paragraph headings, section headings, modifiers in combination with nouns or verbs, etc. Terms that are not likely to qualify as “potentially interesting”, and therefore not likely to yield contextually relevant information if searched, may include connecting words, transitional words and phrases, and prepositions. Non-limiting examples of connecting words include and, but, for, or, of, to, in, nor, yet, so, also, again, as well as, besides, coupled with, in addition, accordingly, consequently, furthermore, however, likewise, moreover, nevertheless, otherwise, therefore, then, thus, after, although, though, as, as if, as a result of, because, before, how, if, even if, in order that, since, similarly, that, so that, unless, until, what, whatever, when, whenever, where, wherever, whether, whichever, while, who, whom, and whose.
The eReader 110 receives and sends data from/to the server 120 via network 122 . In particular, the data receiver/transmitter 116 is designed to send/receive from the server system. Alternatively, the data receiver/transmitter 116 may be called a communicator or communication unit. More particularly still, the data receiver 116 may be designed to receive, in response to the submission of the identified content, prioritized data from the server 120 . The data receiver/transmitter 116 may be configured to receive from the server, in response to the submission of the identified plurality of terms or phrases, a plurality of hyperlinks, each corresponding to one of the submitted terms or phrases.
The presenter 118 is configured to hyperlink the plurality of terms or phrases in the document presented by the Ebook reader and visually indicate that to the user. The presenter includes the visual and audio components of the client device. Through the presenter 118 , the user interacts with the device via a user interface (UI). The presenter is configured to present the prioritized data to user through that UI.
The plurality of hyperlinked terms or phrases in the document presented by the Ebook reader may be communicated to a server and made accessible to one or more of other client devices presenting the document to the user or other client devices presenting the document to other users
As shown in FIG. 1 , the eReader 110 has one or more processors 124 , memory 126 , and storage 128 . The components introduced above (e.g., the content identifier 112 , the content submitter 114 , the data receiver/transmitter 116 , and the presenter 118 ) may be implemented as a combination of suitable electronic components, which may include hardware, firmware, software, and/or a combination thereof. For example, portions of each component introduced above may be implemented as a program module with processor-executable instructions that may be stored in the memory 126 and executed by the one or more processors 124 . Of course, the eReader may have other components and functions that are not depicted. Furthermore, although FIG. 1 illustrates the eReader 110 as containing the above-described components, including a content identifier 112 , a content submitter 114 , a data receiver/transmitter 116 , a presenter 118 , one or more processors 124 , memory 126 , and storage 128 , some or all of the components could be contained within a server or within a plurality of servers instead of, or in addition to the eReader.
The eReader 110 , alone or in combination with the server 120 communicatively coupled to the eReader 110 , may also receive as input prior actions and selections of a particular user. As an example, a user's actions of selecting links for places or geographical points of interest in order to obtain maps or further information when reading articles on the same or different eReaders, could be used to identify categories of content a user is interested in. Later, terms within those categories of content could be linkified for the user. Similarly, if a particular user has clicked on links associated with songs or artists in order to go to a web site to listen to or buy the music, these selections of the user may form part of a user's selection history associated with a user profile located on a server, such that linkification may be performed consistently across multiple devices of a user.
Data, such as a user's actions and interests, can be stored in a private profile, either locally or on the server. As an alternative, a particular user's data can be aggregated with data from other users, without retaining any personally identifiable information on the server.
Linkification can be performed by the client on a local copy of the document. The publisher of the document does not have to do anything to prepare the document, as the content identifier 112 on the client Ebook device or eReader is configured to automatically perform a scan of each document that is loaded onto the eReader. A user of the Ebook device also does not have to do anything special, as the eReader 110 buffers ahead of the point in the document where the user is reading, and dynamically and automatically searches for interesting terms or phrases, including names of places, people's names, song names, nouns, verbs, paragraph headings, etc., which are then sent off to the server for further processing.
The server 120 (i.e., server system) performs an updated search of the internet for current and contextually relevant sources of data based on the interesting terms received from the eReader. The back-end services that can be provided by the server 120 may include maintaining a user profile of the categories of a user's selections and actions with respect to documents when they use various reading devices. Alternatively, a user may operate devices without use of a profile and without recording of any history information. The back-end services provided by the server 120 may further include linking from an interesting term, such as a place mentioned in the document being rendered on the eReader, to one or more maps provided on a map web site, such as map site 256 in FIG. 2 , or linking from the name of a song or an artist mentioned in the document being rendered (i.e., presented or displayed) on the eReader 110 to one or more corresponding songs available on a web site that provides for the listening to and purchasing of the songs, such as web site 260 in FIG. 2 , or even free song previews that are provided as an inducement to purchase. Links could also be provided to web sites such as movie/video web site 262 in FIG. 2 that provide other content, including movies and/or videos. These web sites could also offer possible options for user actions such as watching the movies/videos, watching free previews, and purchasing or renting the content.
In addition, the server 120 verifies the relevance, interest, and timeliness of data related to the terms or combinations of terms received from the eReader by conducting additional searches of the internet when an initial search turns up a dead link or a non-contextual reference. These additional searches may be based on semantically similar terms or phrases, or terms or phrases initially searched, but with the inclusion of more surrounding modifiers or more specific and descriptive terms to focus in on interesting and even personalized information. The server 120 may use searching protocols that include rules based upon a numerical weighting given to each element of a hyperlinked set of documents, the number and frequency of hits for specific terms on various social media sites, and the number and frequency of click-throughs, or clickthrough rate (CTR) for certain portions of popular texts—as part of the back-end searches performed by the server.
As one non-limiting example, the server may connect to a database, or access internal memory, and determine that a significant number of readers of a popular book on, e.g., the NY Times bestseller list, click on the same links to learn more about certain topics. Based on these patterns of behavior amongst users reading the same document, or even related documents, the server may dynamically and automatically retrieve data that may have a higher likelihood of being of interest to a user. The server then returns the dynamically updated, interesting, and prioritized data back to a data receiver 116 of the client over an asynchronous Hypertext Transfer Protocol (HTTP) connection or other network connection established by a communicator of the Ebook for presentation to the user using the graphical user interface or presenter of the eReader.
While example implementations herein are described in connection with software, hardware, or a combination thereof residing on one more computing devices such as an Ebook, eReader, server, etc., one or more portions of the disclosed techniques and systems may also be implemented via an operating system, application programming interface (API) or a “middle man” object between any of the one or more processors on the various eReaders and server.
With an Ebook or eReader application, the new techniques described herein enable a significantly improved user experience over existing applications by automatically and dynamically providing relevant, interesting, and personalized data through hyperlinks associated with select terms throughout the document. A balance is achieved between providing a user with a desirable amount of contextually relevant information, and avoiding lessening the user experience by providing too many hyperlinks, or intrusive hyperlinks that may interfere with an author's creative presentation of the content rendered on the eReader.
The format of text or documents presented by an Ebook application remains unaffected, and the publisher of the content to be rendered on the Ebook does not have to do anything special to the documents or content. The hyperlinks are desirably provided on an overlay so as to not affect the format of the text. Because an Ebook is typically read in a linear fashion, the eReader may buffer ahead a few pages from where a user is reading, scanning for potentially interesting terms, and sending those selected terms off to the server for more extensive processing. The server then returns data resulting from the in-depth, dynamically updated search of various databases and web sites to the client to be presented in contextually relevant hyperlinks overlaid over the text being rendered by the eReader.
If desired, the hyperlinks provided on an overlay of a document being rendered (i.e., presented or displayed) on an Ebook, or rendered by an Ebook application on an eReader, may include one or more contextually relevant advertisements. As one non-limiting example, when a reference to a particular song is made in the document, a hyperlink could be provided that takes the reader to a music download site where the user may listen to and/or purchase the song. As an incentive to encourage a user to take advantage of such advertisements that may be presented through hyperlinks overlaid on the rendered document, potential advertisers could help to subsidize the purchase of the document provided to a user on the Ebook. A user could voluntarily elect to receive such advertisements in exchange for a reduced price for the document, or even for receiving the document free of charge.
Example Method and Another Example Integrated System
FIG. 2 provides a schematic diagram of an integrated system according to one implementation of the disclosure. FIG. 3 illustrates an example implementation of a method according to the present disclosure. A plurality of eReaders 210 a , 210 b , and 210 c are shown communicatively coupled to a network 230 a.
At step 320 in FIG. 3 , a client computing device, such as one or more of the eReaders 210 a , 210 b , and 210 c in FIG. 2 , automatically and dynamically scans ahead to identify contextually relevant content in an electronic document being rendered on the client computing device. The client computing devices may include an Ebook reader, a smart phone running an eReader application, a personal digital assistant, a laptop computer running a browser with an eReader browser extension, a tablet computer, a personal computer, etc. The client computing device may be configured to process the text and/or images in the electronic document being rendered on the client computing device.
The software, hardware, or combination thereof on the eReader performs semantic text analysis of the document being rendered on the eReader without requiring any pre-processing of the document. Example methods of performing the semantic text analysis may rely on natural language processing (NLP) techniques to identify key terms and phrases within the rendered document while ignoring irrelevant words such as connecting words and prepositions. Non-limiting examples of connecting words and prepositions include: and, but, for, or, of, to, in, nor, yet, so, also, again, as well as, besides, coupled with, in addition, accordingly, consequently, furthermore, however, likewise, moreover, nevertheless, otherwise, therefore, then, thus, after, although, though, as, as if, as a result of, because, before, how, if, even if, in order that, since, similarly, that, so that, unless, until, what, whatever, when, whenever, where, wherever, whether, whichever, while, who, whom, and whose. This processing on the eReader can automatically identify potentially interesting and contextually relevant words and phrases such as proper nouns, adjectives, paragraph headings, names of places, names of songs, names of people, etc.
At step 322 in FIG. 3 , the eReader sends the identified content over a network to a server. Referring to FIG. 2 , identified, contextually relevant content is sent from eReaders 210 a , 210 b , and 210 c over network 230 a to a server 240 .
At step 324 in FIG. 3 , the server 340 performs an updated search of the internet or other local or remote databases for current and contextually relevant sources of data based on the interesting terms received from the eReader. As shown in the example implementation of FIG. 2 , server 240 is communicatively coupled over a network 230 b with various data sources including a database 252 , map web site 256 , song web site 260 , and movie/video web site 262 . Provided a user specifically elects to allow the following feature, the back-end services that can be performed by the server 240 may include keeping track of one or more user's preferences and other attributes based on the user's previous selections and behaviors on other devices, platforms, and documents. Data, such as a user's actions and interests, can be stored in a private profile, either locally or on the server. As an alternative, a particular user's data can be aggregated with data from other users, without retaining any personally identifiable information on the server. A user who elected to have their data, preferences, or attributes retained in a user profile, can always later “opt-out” and the data will be removed.
The back-end services provided by the server 240 may further include linking from an interesting term, such as a place, geographical location, town, county, city, state, region, country, continent, etc., mentioned in one or more documents being rendered on one or more of the eReaders 210 a , 210 b , 210 c to one or more maps provided on a map web site 256 , or linking from the name of a song or an artist mentioned in the document being rendered on the eReader to one or more corresponding songs available on a web site 260 that provides for the listening to and purchasing of the songs. Additionally, as mentioned above, links may be provided to a movie/video web site 262 .
As shown at step 326 in FIG. 3 , the server 240 is also configured to verify the relevance, interest, and timeliness of data related to the terms or combinations of terms received from the eReader by conducting additional searches of the internet when an initial search turns up a dead link or a non-contextual reference. These additional searches may be based on semantically similar terms or phrases including more modifiers or more specific and descriptive terms to focus in on interesting and even personalized information. As part of its searching protocol, the server may use a calculation of the number and frequency of hits for specific terms on various social media sites, and the number and frequency of click-throughs, or clickthrough rate (CTR) for certain portions of popular texts.
As shown at step 328 in FIG. 3 , the server 240 may then return the dynamically updated, interesting, and prioritized data back to the client 210 a , 210 b , and/or 210 c over an asynchronous HTTP connection.
As shown at step 330 in FIG. 3 , the presenter of the eReader, such as the graphical user interface or display of the eReader, presents or displays the results returned from the server 240 to the user. In order to avoid changing the formatting or other copyrightable aspects of the text document being displayed to the user on the Ebook or eReader, the returned results may be presented as an overlay in a seamless and non-intrusive manner to the user. To accommodate the inability of some Ebooks or eReaders to enable a user to point and click on provided links, the eReader may be configured to allow one gesture by the user to simultaneously present all of the returned links on a page. Several non-limiting examples of user gestures may include depressing a button on the device, tapping on the device three times, and selecting a menu choice on the device. The user could then access the dynamically updated, interesting, prioritized, and even personalized data at once with a single gesture, and then return to exactly the point in the document where they left off without losing their place in the document.
The technology described herein may be deployed in part or in whole through a machine that executes computer software, program codes, and/or instructions on one or more processors contained in the eReaders and/or the server. Implementations of the disclosure may include a method on a machine, a system or apparatus as part of or in relation to the machine, or a computer program product embodied in a computer readable medium executing on one or more of the machines. The one or more processors may be part of a server, client, network infrastructure, mobile computing platform, stationary computing platform, or other computing platform. A processor may be any kind of computational or processing device capable of executing program instructions, codes, binary instructions and the like. The processor may be or include a signal processor, digital processor, embedded processor, microprocessor or any variant such as a co-processor (math co-processor, graphic co-processor, communication co-processor and the like) and the like that may directly or indirectly facilitate execution of program code or program instructions stored thereon. In addition, the processor may enable execution of multiple programs, threads, and codes. The threads may be executed simultaneously to enhance the performance of the processor and to facilitate simultaneous operations of the application. By way of implementation, methods, program codes, program instructions and the like described herein may be implemented in one or more thread. The thread may spawn other threads that may have assigned priorities associated with them; the processor may execute these threads based on priority or any other order based on instructions provided in the program code. The processor may include memory that stores methods, codes, instructions and programs as described herein and elsewhere. The processor may access a storage medium through an interface that may store methods, codes, and instructions as described herein and elsewhere. The storage medium associated with the processor for storing methods, programs, codes, program instructions or other type of instructions capable of being executed by the computing or processing device may include one or more of a CD-ROM, DVD, memory, hard disk, flash drive, RAM, ROM, cache and the like.
Example Computer System
FIG. 4 is a block diagram illustrating an example computer system 400 with which a eReader 210 a , 210 b , 210 c , and server 240 of FIG. 2 can be implemented. In certain aspects, the computer system 400 may be implemented using hardware or a combination of software and hardware, either in a dedicated server, or integrated into another entity, or distributed across multiple entities.
Computer system 400 (e.g., client 210 a , 210 b , 210 c , and server 240 ) includes a bus 408 or other communication mechanism for communicating information, and a processor 402 coupled with bus 408 for processing information. By way of example, the computer system 400 may be implemented with one or more processors 402 . Processor 402 may be a general-purpose microprocessor, a microcontroller, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), a Programmable Logic Device (PLD), a controller, a state machine, gated logic, discrete hardware components, or any other suitable entity that can perform calculations or other manipulations of information. A processor may include one or more cores that may enhance speed and performance of a multiprocessor. In various embodiments, the processor may be a dual core processor, quad core processors, other chip-level multiprocessor and the like that combine two or more independent cores (called a die).
Computer system 400 can include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them stored in an included memory 404 , such as a Random Access Memory (RAM), a flash memory, a Read Only Memory (ROM), a Programmable Read-Only Memory (PROM), an Erasable PROM (EPROM), registers, a hard disk, a removable disk, a CD-ROM, a DVD, or any other suitable storage device, coupled to bus 408 for storing information and instructions to be executed by processor 402 . The processor 402 and the memory 404 can be supplemented by, or incorporated in, special purpose logic circuitry.
The methods and systems described herein may be deployed in part or in whole through a machine that executes computer software on a server, client, firewall, gateway, hub, router, or other such computer and/or networking hardware. The software program may be associated with a server that may include a file server, print server, domain server, internet server, intranet server and other variants such as secondary server, host server, distributed server and the like. The server may include one or more of memories, processors, computer readable media, storage media, ports (physical and virtual), communication devices, and interfaces capable of accessing other servers, clients, machines, and devices through a wired or a wireless medium, and the like. The methods, programs or codes as described herein and elsewhere may be executed by the server. In addition, other devices required for execution of methods as described in this application may be considered as a part of the infrastructure associated with the server.
The server may provide an interface to other devices including, without limitation, clients, other servers, printers, database servers, print servers, file servers, communication servers, distributed servers and the like. Additionally, this coupling and/or connection may facilitate remote execution of programs across the network. The networking of some or all of these devices may facilitate parallel processing of a program or method at one or more location without deviating from the scope of the disclosed subject matter. In addition, any of the devices attached to the server through an interface may include at least one storage medium capable of storing methods, programs, code and/or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, the remote repository may act as a storage medium for program code, instructions, and programs.
A software program may be associated with a client that may include a file client, print client, domain client, internet client, intranet client and other variants such as secondary client, host client, distributed client and the like. The client may include one or more of memories, processors, computer readable media, storage media, ports (physical and virtual), communication devices, and interfaces capable of accessing other clients, servers, machines, and devices through a wired or a wireless medium, and the like. The methods, programs or codes as described herein and elsewhere may be executed by the client. In addition, other devices required for execution of methods as described in this application may be considered as a part of the infrastructure associated with the client.
The client may provide an interface to other devices including, without limitation, servers, other clients, printers, database servers, print servers, file servers, communication servers, distributed servers and the like. Additionally, this coupling and/or connection may facilitate remote execution of the program across the network. The networking of some or all of these devices may facilitate parallel processing of a program or method at one or more location without deviating from the scope of the disclosed subject matter. In addition, any of the devices attached to the client through an interface may include at least one storage medium capable of storing methods, programs, applications, code and/or instructions. A central repository may provide program instructions to be executed on different devices. In this implementation, the remote repository may act as a storage medium for program code, instructions, and programs.
The technologies described herein may be deployed in part or in whole through network infrastructures. The network infrastructure may include elements such as computing devices, servers, routers, hubs, firewalls, clients, personal computers, communication devices, routing devices and other active and passive devices, modules and/or components as known in the art. The computing and/or non-computing device(s) associated with the network infrastructure may include, apart from other components, a storage medium such as flash memory, buffer, stack, RAM, ROM and the like. The processes, methods, program codes, instructions described herein and elsewhere may be executed by one or more of the network infrastructural elements.
The technologies described herein and elsewhere may be implemented on a cellular network having multiple cells. The cellular network may either be frequency division multiple access (FDMA) network or code division multiple access (CDMA) network. The cellular network may include mobile devices, cell sites, base stations, repeaters, antennas, towers, and the like. The cell network may be a GSM, GPRS, 3G, 4G, EVDO, mesh, or other networks types.
The technologies described herein and elsewhere may be implemented on or through mobile devices. The mobile devices may include navigation devices, cell phones, mobile phones, mobile personal digital assistants, laptops, palmtops, netbooks, ultrabooks, pagers, electronic books readers, music players and the like. These devices may include, apart from other components, a storage medium such as a flash memory, buffer, RAM, ROM and one or more computing devices. The computing devices associated with mobile devices may be enabled to execute program codes, methods, and instructions stored thereon. Alternatively, the mobile devices may be configured to execute instructions in collaboration with other devices. The mobile devices may communicate with base stations interfaced with servers and configured to execute program codes. The mobile devices may communicate on a peer to peer network, mesh network, or other communications network. The program code, programming instructions or programming language, may be stored on the storage medium associated with the server and executed by a computing device embedded within the server. The base station may include a computing device and a storage medium. The storage device may store program codes and instructions executed by the computing devices associated with the base station.
The computer software, program codes, and/or instructions may be stored and/or accessed on machine readable media that may include: computer components, devices, and recording media that retain digital data used for computing for some interval of time; semiconductor storage known as random access memory (RAM); mass storage typically for more permanent storage, such as optical discs, forms of magnetic storage like hard disks, tapes, drums, cards and other types; processor registers, cache memory, volatile memory, non-volatile memory; optical storage such as CD, DVD; removable media such as flash memory (e.g. USB sticks or keys), floppy disks, magnetic tape, paper tape, punch cards, standalone RAM disks, Zip drives, removable mass storage, off-line, and the like; other computer memory such as dynamic memory, static memory, read/write storage, mutable storage, read only, random access, sequential access, location addressable, file addressable, content addressable, network attached storage, storage area network, bar codes, magnetic ink, and the like.
The technologies described herein may transform physical and/or intangible items from one state to another. The technologies described herein may also transform data representing physical and/or intangible items from one state to another.
The elements described and depicted herein, including in flow charts and block diagrams throughout the figures, imply logical boundaries between the elements. However, according to software or hardware engineering practices, the depicted elements and the functions thereof may be implemented on machines through computer executable media having a processor capable of executing program instructions stored as thereon stored as monolithic software structure, as standalone software modules, or as modules that employ external routines, code, services, and so forth, or any combination of these, and all such implementations may be within the scope of the present disclosure. Examples of such machines may include personal digital assistants, laptops, personal computers, mobile phones, other handheld computing devices, medical equipment, wired or wireless communication devices, transducers, chips, calculators, satellites, tablet PCs, electronic books, gadgets, electronic devices, devices having artificial intelligence, computing devices, networking equipment, servers, routers and the like. Furthermore, the elements depicted in the flow chart and block diagrams or any other logical component may be implemented on a machine capable of executing program instructions. Thus, while the foregoing drawings and descriptions set forth functional aspects of the disclosed systems, no particular arrangement of software for implementing these functional aspects should be inferred from these descriptions unless explicitly stated or otherwise clear from the context. Similarly, it will be appreciated that the various steps identified and described above may be varied, and that the order of steps may be adapted to particular applications of the techniques disclosed herein. All such variations and modifications are intended to fall within the scope of this disclosure. As such, the depiction and/or description of an order for various steps should not be understood to require a particular order of execution for those steps, unless required by a particular application, or explicitly stated or otherwise clear from the context.
The methods and/or processes described above, and steps thereof, may be realized in hardware, software or any combination of hardware and software suitable for a particular application. The hardware may include a general purpose computer and/or dedicated computing device or specific computing device or particular aspect or component of a specific computing device. The processes may be realized in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors or other programmable device, along with internal and/or external memory. The processes may also, or instead, be embodied in an application specific integrated circuit, a programmable gate array, programmable array logic, or any other device or combination of devices that may be configured to process electronic signals. It will further be appreciated that one or more of the processes may be realized as a computer executable code capable of being executed on a machine readable medium.
The instructions may be stored in the memory 304 and implemented in one or more computer program products, i.e., one or more modules of computer program instructions encoded on a computer readable medium for execution by, or to control the operation of, the computer system 300 , and according to any method well known to those of skill in the art, including computer languages such as data-oriented languages (e.g., SQL, dBase), system languages (e.g., C, Objective-C, C++, Assembly), architectural languages (e.g., Java, .NET), and application languages (e.g., PHP, Ruby, Perl, Python). Instructions may also be implemented in computer languages such as array languages, aspect-oriented languages, assembly languages, authoring languages, command line interface languages, compiled languages, concurrent languages, curly-bracket languages, dataflow languages, data-structured languages, declarative languages, esoteric languages, extension languages, fourth-generation languages, functional languages, interactive mode languages, interpreted languages, iterative languages, list-based languages, little languages, logic-based languages, machine languages, macro languages, metaprogramming languages, multiparadigm languages, numerical analysis, non-English-based languages, object-oriented class-based languages, object-oriented prototype-based languages, off-side rule languages, procedural languages, reflective languages, rule-based languages, scripting languages, stack-based languages, synchronous languages, syntax handling languages, visual languages, wirth languages, and xml-based languages. Memory 304 may also be used for storing temporary variable or other intermediate information during execution of instructions to be executed by processor 302 .
A computer program as discussed herein does not necessarily correspond to a file in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), in a single file dedicated to the program in question, or in multiple coordinated files (e.g., files that store one or more modules, subprograms, or portions of code). A computer program can be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network. The processes and logic flows described in this specification can be performed by one or more programmable processors executing one or more computer programs to perform functions by operating on input data and generating output.
Computer system 400 illustrated in Fig. further includes a data storage device 406 such as a magnetic disk or optical disk, coupled to bus 408 for storing information and instructions. Computer system 400 may be coupled via input/output module 410 to various devices. The input/output module 410 can be any input/output module. Example input/output modules 410 include data ports such as USB ports. The input/output module 410 is configured to connect to a communications module 412 . Example communications modules 412 include networking interface cards, such as Ethernet cards and modems. In certain aspects, the input/output module 410 is configured to connect to a plurality of devices, such as an input device 414 and/or an output device 416 . Example input devices 414 include a keyboard and a pointing device, e.g., a mouse or a trackball, by which a user can provide input to the computer system 400 . Other kinds of input devices 414 can be used to provide for interaction with a user as well, such as a tactile input device, visual input device, audio input device, or brain-computer interface device. For example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, tactile, or brain wave input. Example output devices 416 include display devices, such as a CRT (cathode ray tube) or LCD (liquid crystal display) monitor, for displaying information to the user.
According to one aspect of the present disclosure, the eReaders 210 a , 210 b , and 210 c , and server 240 , as shown in FIG. 2 , can be implemented using a computer system 400 in response to processor 402 executing one or more sequences of one or more instructions contained in memory 404 . Such instructions may be read into memory 404 from another machine-readable medium, such as data storage device 406 . Execution of the sequences of instructions contained in main memory 404 causes processor 402 to perform the process steps described herein. One or more processors in a multi-processing arrangement may also be employed to execute the sequences of instructions contained in memory 404 . In alternative aspects, hard-wired circuitry may be used in place of or in combination with software instructions to implement various aspects of the present disclosure. Thus, aspects of the present disclosure are not limited to any specific combination of hardware circuitry and software.
Various aspects of the subject matter described in this specification can be implemented in a computing system that includes a back-end component, e.g., as a data server, or that includes a middleware component, e.g., an application server, or that includes a front end component, e.g., a client computer having a graphical user interface or a Web browser through which a user can interact with an implementation of the subject matter described in this specification, or any combination of one or more such back end, middleware, or front end components. The components of the system can be interconnected by any form or medium of digital data communication, e.g., a communication network, such as communication networks 230 a , 230 b in FIG. 2 . The communication network (e.g., networks 230 a , 230 b ) can include, for example, any one or more of a personal area network (PAN), a local area network (LAN), a campus area network (CAN), a metropolitan area network (MAN), a wide area network (WAN), a broadband network (BBN), the Internet, and the like. Further, the communication networks can include for example, any one or more of the following network topologies, including a bus network, a star network, a ring network, a mesh network, a star-bus network, tree or hierarchical network, or the like. The communications modules can be, for example, modems or Ethernet cards.
As discussed above, computing system 400 can include clients and servers. A client and server are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other. Computer system 400 can be, for example, and without limitation, a desktop computer, laptop computer, or tablet computer. Computer system 400 can also be embedded in another device, for example, and without limitation, a mobile telephone, a personal digital assistant (PDA), a mobile audio player, a Global Positioning System (GPS) receiver, a video game console, and/or a television set top box.
The term “machine-readable storage medium” or “computer readable medium” as used herein refers to any medium or media that participates in providing instructions to processor 402 for execution. Such a medium may take many forms, including non-volatile media, volatile media, and transmission media. Non-volatile media include, for example, optical or magnetic disks, such as data storage device 406 . Volatile media include dynamic memory, such as memory 404 . Transmission media include coaxial cables, copper wire, and fiber optics, including the wires that comprise bus 408 . Common forms of machine-readable media include, for example, floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, an EPROM, a FLASH EPROM, any other memory chip or cartridge, or any other medium from which a computer can read. The machine-readable storage medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, a composition of matter effecting a machine-readable propagated signal, or a combination of one or more of them.
While this specification contains many specifics, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of particular implementations of the subject matter. Certain features that are described in this specification in the context of separate embodiments or implementations can also be implemented in combination in a single embodiment or implementation. Conversely, various features that are described in the context of a single embodiment or implementation can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
Embodiments of the disclosure may be implemented on an Ebook reader that is only intermittently communicatively coupled with a server. Data transfer between the Ebook and the server may occur during times when a user initially instantiates a wireless connection for the purpose of downloading a new document, and during subsequent connections such as when the user desires a dynamic update of informational links provided in an overlay of at least the portions of the document being read.
While operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the aspects described above should not be understood as requiring such separation in all aspects, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
The subject matter of this specification has been described in terms of particular aspects, but other aspects can be implemented and are within the scope of the following claims. For example, the actions recited in the claims can be performed in a different order and still achieve desirable results. As one example, the processes depicted in the accompanying figures do not necessarily require the particular order shown, or sequential order, to achieve desirable results. In certain implementations, multitasking and parallel processing may be advantageous. Other variations are within the scope of the following claims.
In the claims appended herein, the inventor invokes 35 U.S.C. §112, paragraph 6 only when the words “means for” or “steps for” are used in the claim. If such words are not used in a claim, then the inventor does not intend for the claim to be construed to cover the corresponding structure, material, or acts described herein (and equivalents thereof) in accordance with 35 U.S.C. §112, paragraph 6.
|
Technologies are described for causing an eReader to automatically and dynamically parse a document rendered on the eReader and identify content of potential interest to a user, and, in response to identifying content of potential interest, receiving at a server, from the eReader, the identified content. The server performing heuristics on the identified content at the server in conjunction with searching a network communicatively coupled to the server to locate data contextually relevant to the identified content, and the server transmitting the contextually relevant data from the server to the eReader for presentation to a user through a user interface on the eReader. This Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
| 6
|
RELATED APPLICATIONS
The present application claims priority to U.S. Provisional Patent Application 60/840,747 filed Aug. 29, 2006, and U.S. Provisional Patent Application 60/825,635 filed Sep. 14, 2006. These applications are incorporated herein in their entireties.
REFERENCE TO GOVERNMENT SUPPORT
The invention was developed at least in part with the support of NIH grants HL13851, EB1729 and CA121952. The government may have certain rights in the invention.
BACKGROUND
Apoptosis, or programmed cell death, is a conserved process that is mediated by the activation of a series of cysteine aspartyl-specific proteases termed caspases. Apoptosis plays an important role in a wide variety of normal cellular processes including fetal development, tissue homeostasis, and maintenance of the immune system (1). However, abnormal apoptosis can be involved with diseases such as ischemia-reperfusion injury (stroke and myocardial infarction), cardiomyopathy, neurodegeneration (Alzheimer's Disease, Parkinson's Disease, Huntington's Disease, ALS), sepsis, Type I diabetes, fulminant liver disease, and allograft rejection (2,3). The beneficial effect of many drugs, especially antitumor drugs, can be attributed to their activation of the apoptotic process (26-31).
There are two different classes of caspases involved in apoptosis, the initiator caspases and the executioner caspases (5). The initiator caspases, which include caspase-6, -8, -9, and -10, are located at the top of the signaling cascade; their primary function is to activate the executioner caspases, caspase-2, -3, and -7. The executioner caspases are responsible for the physiological (e.g., cleavage of the DNA repair enzyme PARP-1, nuclear laminins, and cytoskeleton proteins) and morphological changes (DNA strand breaks, nuclear membrane damage, membrane blebbing) that occur in apoptosis (2). A third class of caspases, caspases-1, -4, -5, and -13, are involved in cytokine maturation and are not believed to play an active role in apoptosis.
Consequently, drugs targeting caspase-3 and caspase-7 have been important areas of pharmaceutical research. Most inhibitors of caspase-3 and caspase-7 are small peptides that inhibit caspase-3/7 by interacting either reversibly or irreversibly with cysteine-163 in the active site of the enzyme (6-13). However, peptide-based inhibitors typically have low bioavailability and are not effective in preventing apoptosis in vivo.
Ekici et al. described aza-peptide Michael Acceptors as inhibitors for cysteine proteases, including aza-Asp derivatives that were specific for caspases (40). A potential problems of peptide-based caspase inhibitors is their poor metabolic stability and poor cell penetration (12).
It was previously reported that isatin sulfonamides are potent and selective non-peptide-based inhibitors of the executioner caspases, caspase-3 and -7 (16). One compound, (S)-(+)-5-[1-(2-methoxymethyl-pyrrolidine)sulfonyl]isatin, 1 ( FIG. 1 ) has been shown to reduce tissue damage in an isolated rabbit heart model of ischemic injury (14,15). Additional structure-activity relationship studies have revealed that replacement of the 2-methoxymethyl group with a phenoxymethyl moiety and the introduction of an alkyl group on the isatin nitrogen group results in improved potency for inhibiting caspase-3 activity (2) ( FIG. 1 ) (16). An additional improvement in potency was also reported when the pyrrolidine ring of 3 ( FIG. 1 ) was replaced with an azetidine ring to give compound 4 ( FIG. 1 ) (16).
Positron emission tomography (PET) and Single Photon Emission Computed Tomography (SPECT) are in vivo imaging techniques that measure changes in tissue and cellular function at the molecular level. Most agents used for imaging apoptosis in vivo are based on detection of Annexin V (32) and propidium iodide exclusion test (33), is required to discriminate between apoptosis and necrosis in vitro. Although such tests are routinely used to distinguish apoptosis from necrosis using ex vivo techniques such as flow cytometry, they cannot be applied to in vivo techniques such as PET and SPECT due to the short half-life radionuclides used.
A previous study reported the synthesis and carbon-11 radiolabeling of an isatin analog having a modest potency for inhibiting caspase-3 (38). However, no in vivo data were reported in this meeting abstract, and the selectivity of this compound for caspase-3 versus other caspases was not mentioned.
A potential disadvantage of known isatin analogues described as caspase inhibitors is that they are reversible inhibitors of caspase-3/7 since they form a thio-hemiketal with Cys-163 in the active site of activated caspase-3/7 ( FIG. 14 ). Because current isatin analogues are predicted to be reversible inhibitors of activated caspase-3/7, they provide only temporary inactivation of the enzyme.
SUMMARY
The present inventors have developed a series of isatin analogue compounds, and methods for imaging apoptosis in humans and animals using radiolabeled isatin analogues as probes for apoptotic cells. In some aspects, these methods can discriminate apoptosis from necrosis. In various aspects, the methods comprise imaging caspase-3 activity, which can serve as a marker for apoptotic cell death. The methods utilize imaging techniques such as positron emission tomography (PET) and single photon emission computed tomography (SPECT), in conjunction with radiolabeled isatin analogues as ligands for caspase-3. The present inventors further report the validation of both the compounds and the methods in an animal model of apoptosis. The lead compound for the current study was the isatin analog, 2 ( FIG. 2 ), which was first reported by Lee et al. (16). Accordingly, the inventors describe herein the synthesis of a new isatin sulfonamide analogue, WC-II-89, that is suitable for radiolabeling with fluorine-18, and the biodistribution of [ 18 F]WC-II-89 in an animal model of apoptosis. The inventors furthermore report the first microPET imaging study directly measuring caspase-3 activation in tissues undergoing apoptosis using [ 18 F]WC-II-89.
In various aspects, the present inventors disclose: the synthesis and in vitro binding of a series of isatin analogues that can be radiolabeled with a positron-emitting nuclide such as fluorine-18 or bromine-76 for PET imaging studies; a novel method for preparing the labeled isatin analogs for PET imaging studies; and imaging of caspase-3 activation using the radiolabeled isatin analogs, demonstrated herein using in an animal model of apoptosis. The inventors show that WC-II-89 binds to caspase-3 and caspase-7 with high affinity and specificity versus caspase-1, -6, and -8. Biodistribution studies of [ 18 F]WC-II-89 reveal a higher uptake in the liver and spleen of rats treated with cycloheximide, a well-established murine model of chemically induced apoptosis. Western blot analysis confirms this uptake can be related to caspase-3 activation. The results demonstrate for the first time that apoptosis can be measured and imaged by PET using [ 18 ]F-labeled caspase-3 inhibitors such as [ 18 F]WC-II-89.
In various aspects, some isatin analogs which can be used for PET imaging caspase-3 activation (e.g., in apoptosis) such as the compounds illustrated in FIG. 8 . These compounds can function as inhibitors of caspase activity. In some aspects, the inventors disclose processes for preparing the corresponding fluorinated versions, including 18 F-labeled versions of the isatin analogues. In particular, labeling of WC-II-89, WC-II-100, and WC-II-101 can be effected using the specific base catalyzed conditions outlined in the scheme depicted in FIG. 4 . In the synthesis scheme, the function of the specific base (i.e., hydroxide ion) is to convert the ketone of the isatin precursor to the corresponding ketone hydrate, which promotes conversion to the radiolabeled compound.
In some aspects of the present teachings, a compound disclosed herein, such as [ 18 F]WC-II-89, can serve as a probe for imaging activated caspase-3 in tissues undergoing apoptosis.
In some aspects of the present teachings, the inventors disclose methods of preparation of isatin sulfonamide analogues. In other aspects, the inventors demonstrate inhibition properties of compounds of the present teachings towards various caspases, such as caspase-1, -3, -6, -7, and -8. In some aspects, compounds displaying nanomolar potency for inhibiting the executioner caspases, caspase-3 and caspase-7, are disclosed. These compounds were also observed to have a low potency for inhibiting the initiator caspases, caspase-1 and caspase-8, and caspase-6. In some aspects, molecular modeling studies provided further insight into the interaction of this class of compounds with activated caspase-3. The results of the current study revealed a number of non-peptide-based caspase inhibitors which can be used in assessing the role of inhibiting the executioner caspases in minimizing tissue damage in disease conditions which include apoptosis.
Compounds described herein have the potential to block cellular death in pathological conditions characterized by an increase in apoptosis. The importance of the methylenemalononitrile group is evident in the low potency of the corresponding mono-cyano analogue, WC(II)-99, and the oxime analogues WC(II)-51 and WC(II)-52 ( FIG. 17 ; Table 2).
In other aspects, the present inventors disclose isatin analogue inhibitors of caspase-3/7 in which the keto carbonyl of the isatin ring is replaced with a Michael acceptor such as the methylenemalononitrile group. Without being limited by theory, these compounds are expected to be irreversible inhibitors of caspase-3/7, as this substitution is expected to result in the thioalkylation of Cys-163 in the active site of caspase-3/7, thereby resulting in the irreversible inactivation of the enzyme ( FIG. 15 ). This class of compounds has been given the name Isatin Michael Acceptors (IMAs). Structures of various IMAs are provided in FIG. 16 .
Accordingly, various aspects of the present teachings include: the synthesis and in vitro binding of a series of isatin Michael Acceptors that can irreversibly inhibit caspase-3/7; the synthesis and in vitro binding of a series of isatin Michael Acceptors that can be radiolabeled with 18 F, 11 C or 76 Br; and methods for preparing the 18 F-labeled analogues. In various configurations, these radiolabeled compounds can be used for PET imaging of caspase 3/7 activity, e.g., in apoptosis, and are therefore useful in clinical applications such as monitoring progress of cancer chemotherapy.
In various aspects of the present teachings, the inventors have investigated novel Michael Acceptor Isatin analogues. The inventors describe synthetic methods, and present results of in vitro studies of a series of Michael Acceptor isatin analogues having a high potency for inhibiting the executioner caspases, caspase-3, and caspase-7. The results extend the structure-activity relationships of this class of compounds and provide further insight into the development of non-peptide-based inhibitors of caspase-3 and caspase-7. The Michael Acceptor compounds described herein are useful probes for determining the effectiveness of inhibiting caspase-3 and caspase-7, and for minimizing tissue damage in pathological conditions characterized by unregulated apoptosis. In various aspects, the Isatin Michael Acceptors are as potent for inhibiting caspase-3/7 activity as the parent isatin analogues.
In some aspects of the present teachings, the corresponding radiolabeled versions of the IMAs can be used to image apoptosis using the functional imaging techniques, Positron Emission Tomography (PET and Single Photon Emission Computed Tomography (SPECT). An example of the synthesis of a 18 F-labeled IMA is shown in FIG. 18 and consists on the simple conversion of the isatin to the corresponding IMA via condensation with dicyanomethane. The IMA-based radiotracers disclosed herein are capable of producing similar if not better imaging results compared to their non-Michael acceptor isatin-based counterparts. Furthermore, the Log P value of the IMA analogs are lower than the corresponding values of non-Michael acceptor isatin analogs (e.g., 25d vs. 27d, Log P 4.82 vs. 4.28; 28b vs. 30b, 2.25 vs. 1.77; and 28c vs. 30c, 3.76 vs. 3.22, respectively ( FIG. 19 , table 7)). This lower Log P value of the IMA caspase-3 inhibitor increases the drug's ability to penetrate the cell in vivo and label the target.
TABLE 2
In vitro assays of Michael Acceptor isatin analogues for inhibiting caspase activity.
Data present IC 50 (nM) for each compound as tested against each caspase.
#
Caspase 1
Caspase 3
Caspase 6
Caspase 7
Caspase 8
WC-II-53
1,830 ± 127
272 ± 25
407 ± 15
1,585 ± 163
>50,000
WC-II-54
2,377 ± 716
283 ± 15
540 ± 44
2,385 ± 799
>50,000
WC-II-62
2,825 ± 248
119 ± 4
698 ± 94
785 ± 276
>50,000
WC-II-69
3,900 ± 530
7.8 ± 1.5
610 ± 113
29.6 ± 1.4
>50,000
WC-II-87
3,600 ± 640
6.0 ± 0.8
450 ± 43
50.0 ± 11.6
>50,000
WC-II-92
10,000 ± 1600
18.3 ± 0.4
927 ± 35
96.3 ± 20.7
>50,000
WC-II-103
3,500 ± 960
7.5 ± 0.2
770 ± 119
26.0 ± 5.2
>50,000
WC-II-104
2,900 ± 900
7.1 ± 0.6
580 ± 55
22.7 ± 3.1
>50,000
WC-II-128
3,400 ± 100
5.13 ± 0.70
515 ± 77
26.3 ± 0.8
>50,000
WC-II-129
5,700 ± 850
20.1 ± 1.3
840 ± 125
92.2 ± 11.8
>50,000
WC-II-142
2,300 ± 250
31.8 ± 6.2
744 ± 48
126 ± 19
>50,000
WC-III-49
6,220 ± 1250
27.8 ± 2.5
918 ± 151
51.7 ± 6.2
>50,000
WC-III-50
3,250 ± 450
7.6 ± 1.1
823 ± 86
32.8 ± 4.9
>50,000
WC-III-51
2,720 ± 580
7.8 ± 1.9
850 ± 21
28.3 ± 5.4
>50,000
WC-II-52
>50,000
>20,000
>20,000
>50,000
>50,000
WC-II-99
—
>1,000
—
—
—
Ac-YVAD-CHO
8.1 ± 2.1
Ac-DEVD-CHO
3.8 ± 0.8
8.0 ± 1.0
Ac-VEID-CHO
9.6 ± 2.1
Ac-IETD-CHO
4.0 ± 0.1
Data present IC 50 (nM) for each compound as tested against each caspase.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates structure of isatin sulfonamide analogues reported previously.
FIG. 2 illustrates a strategy used in the current structure-activity relationship study.
FIG. 3 illustrates competitive inhibition of caspase-3 by 21c. The concentration of 21c was 0 (◯), 5 (●), 10 (□), and 20 nM (▪).
FIG. 4 illustrates a synthesis scheme for [ 18 F]WC-II-89.
FIG. 5 illustrates scheme 1, for the synthesis of 5-(2-phenoxymethylpyrrolidine-1-sulfonyl)isatin analogues.
FIG. 6 illustrates scheme 2, for the synthesis of 5-(2-phenoxymethyl-azetidine-1-sulfonyl)isatin analogues.
FIG. 7 illustrates scheme 3, for the synthesis of 5-(2-pyridin-3-yl-oxymethyl)pyrrolidine-1-sulfonyl)isatin analogues as well as a 4-pyridyl analogue.
FIG. 8 illustrates some isatin analogs which can be used for PET imaging caspase-3 activation.
FIG. 9 illustrates selected biodistribution of [ 18 F]WC-II-89 in control and cycloheximide (5 mg/kg), 3 hour pre-treated male Sprague-Dawley rats (200-250 g). Note the higher uptake in the cycloheximide-treated animals, in particular the high uptake of the radiotracer in the spleen and liver.
FIG. 10 illustrates microPET images of [ 18 F]WC-II-89 distribution in a control rat (left) and cycloheximide-treated rat (right). Images were summed from 10 to 60 minutes after i.v. injection of ˜150 μCi of [ 18 F]WC-II-89.
FIG. 11 illustrates a scheme for the synthesis of compound [ 18 F]WC-II-89. Compound 10 is converted to [ 18 F]WC-II-89 by the steps illustrated in FIG. 7 .
FIG. 12 illustrates a western blot study of control and treated (5 mg/kg, 3 hours pretreated) male Sprague-Dawley rats (200-250 g).
FIG. 13 illustrates tissue time-activity curves (mean percentage of injected dose per cube centimeter) of rat liver. Top curve: cycloheximide-treated rat; bottom curve: control rat.
FIG. 14 illustrates binding of the lead compound for the development of caspase-3 based imaging agents to Cys 163 .
FIG. 15 illustrates hypothesized mechanism of action of the Isatin Michael Acceptors (IMAs) for inhibiting caspase-3/7 activity.
FIG. 16 illustrates structures of the IMA analogues for inhibiting caspase-3/7 activation in apoptosis.
FIG. 17 illustrates structures of some compounds of low potency as caspase-3/7 inhibitors.
FIG. 18 illustrates synthesis of an 18 F-labeled Isatin Michael Acceptor (MA).
FIG. 19 illustrates Scheme 4 for synthesis of 5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)isatin and its IMA analogs.
FIG. 20 illustrates Scheme 5 for synthesis of two possible Michael addition products.
FIG. 21 illustrates an 1 H NMR spectrum of compound 27d.
FIG. 22 illustrates an 1 H NMR spectrum of the Michael addition product of 27d with benzylmercaptan.
FIG. 23 illustrates a COSY spectrum of the Michael addition product of 27d with benzylmercaptan.
FIG. 24 illustrates an HMQC spectrum of the Michael addition product of 27d with benzylmercaptan.
FIG. 25 illustrates an HMBC spectrum of the Michael addition product of 27d with benzylmercaptan.
FIG. 26 illustrates a structure assignment of the Michael Addition Product 31b.
DETAILED DESCRIPTION
The methods described herein utilize laboratory techniques well known to skilled artisans, and guidance can be found in laboratory manuals such as Sambrook, J., et al., Molecular Cloning: A Laboratory Manual, 3rd ed. Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 2001; Spector, D. L. et al., Cells: A Laboratory Manual, Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1998; and Harlow, E., Using Antibodies: A Laboratory Manual, Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1999, and textbooks such as Hedrickson et al., Organic Chemistry 3rd edition, McGraw Hill, New York, 1970; Carruthers, W., and Coldham, I., Modern Methods of Organic Synthesis (4th Edition), Cambridge University Press, Cambridge, U.K., 2004.
Chemistry. In some aspects of the present teachings, the inventors disclose preparation of isatin sulfonamide analogues and demonstrating their potencies for inhibiting caspase-1, -3, -6, -7, and -8. Several compounds displaying nanomolar potency for inhibiting the executioner caspases, caspase-3 and caspase-7 in vitro were identified. These compounds were also observed to have a low potency for inhibiting the initiator caspases, caspase-1 and caspase-8, and caspase-6. In some aspects, molecular modeling studies provided further insight into the interaction of this class of compounds with activated caspase-3. The present teachings therefore include a number of non-peptide-based caspase inhibitors which can be used in assessing the role of inhibiting the executioner caspases in minimizing tissue damage in disease conditions which include apoptosis.
The synthesis of 5-(2-phenoxymethylpyrrolidine-1-sulfonyl)isatin analogues is shown in Scheme 1 ( FIG. 5 ). The 5-chlorosulfonylisatin 6 was prepared by reaction of 5-isatinsulfonic acid, sodium salt hydrate (5) with phosphorus oxychloride in tetramethylene sulfone at 60° C. for 3 h. The hydroxyl group of N-Boc-2-pyrrolmethanol (7) was first tosylated with p-toluenesulfonyl chloride in pyridine to give compound 8, followed by displacement of the tosylate group by sodium phenoxide in DMF to afford N-Boc-2-(phenoxymethyl)pyrrolidine 9. The N-Boc group of 9 was removed with TFA, and the secondary amine was coupled with 6 in THF using triethylamine as an acid scavenger to afford the 5-(2-phenoxymethyl-pyrrolidinesulfonyl)-1H-2,3-dione 10 in 84% yield. The isatin nitrogen was alkylated by treatment of 10 with sodium hydride in DMF at 0° C. followed by addition of various alkyl halides to give compounds 2 and 11a-e,g-i. Compound 11f was prepared by hydrolysis of 11e with sodium hydroxide in aqueous methanol.
The synthesis of 5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)isatin and its IMA analogs are shown in FIG. 19 . The isatin analogs 24,25a-c 21 and 25d were reacted with malononitrile in methanol to give the IMA analogs, 26 and 27a-d, respectively. The 5-(2-pyridin-3-yl-oxymethyl)pyrrolidine-1-sulfonyl)isatin analogs 28a, 28c, and 28d, were prepared by using the same sequence of reactions described in the synthesis of 25d (Scheme 1). For the compound 28b, the isatin nitrogen of 29 was first alkylated with (4-bromomethyl-phenoxy)-tert-butyl-diphenyl-silane, then the protecting group tert-butyl-diphenyl-silane was removed with nBu 4 NF in THF to afford 10b. The IMA analogs of the 5-(2-pyridin-3-yl-oxymethyl)pyrrolidine-1-sulfonyl)isatin, 12a-d, were prepared with the same methods of 11a-d.
The IC 50 values from the enzyme assays are summarized in Table 1. The results show that the phenoxymethyl and pyridin-3-yl-oxymethyl isatin analogs, 25d, 28b, and 28c, are potent and selective inhibitors for caspase-3/7 relative to caspases-1, -6, -8. The IMA analogs of phenoxymethyl isatin compounds 26 and 27a, where the isatin nitrogen of the indol ring is not alkylated or instead possesses a methyl group, have low potency for caspase-3 and -7 inhibition; these IC 50 values are 272 nM and 119.3 mM for caspase-3, and 1,585 nM and 785 mM for caspase-7, respectively. When the isatin nitrogen of the indol ring was alkylated with an aromatic group, the potency of IMA analogs 27b, 27c, and 27d, improved drastically for caspase-3/7 with IC 50 values of 27.8 nM, 31.8 nM, and 20.1 nM for caspase-3, and 51.7 nM, 126.0 nM, and 92.2 nM for caspase-7, respectively, while retaining their high selectivity. Also, all of these compounds have less activity for inhibition of caspase-1 (IC 50 : 2,300-6,200 nM), caspase 6 (IC 50 744-926 nM), and caspase-8 (IC 50 >50,000 nM) upon addition of the aromatic group. Similarly, the IMA analogs of pyridin-3-yl-oxymethyl isatin, 30a, 30b, 30c and 30d, are potent and selective inhibitors for caspase-3 (IC 50 : 7.6, 7.8, 5.1, and 7.8 nM) and caspase-7 (IC 50 : 32.8, 28.6, 26.3, and 15.1 nM), and show weak inhibition of caspase-1 (IC 50 : 2,700-3,200 nM), caspase-6 (IC 50 : 515-770 nM), and caspase-8 (IC 50 : >50,000 nM). The IMA analogs of pyridin-3-yl-oxymethyl isatin also display improved potency for inhibiting caspases-3/7 than the corresponding IMA analogs of phenoxymethyl isatin (Table 1, 27b, 27c, 27d, compare with 30a, 30h, 30c, respectively). It is interesting to note that all the IMA analogs have an increased potency of roughly 10-fold for caspase-6 when compared to their complementary isatin analogs (see Table 1).
In various aspects, some isatin analogs which can be used for PET imaging caspase-3 activation (e.g., in apoptosis) include the compounds illustrated in FIG. 8 . These compounds can function as inhibitors of caspase activity, as shown by the following in vitro assay results (Table 1).
TABLE 1
Inhibitor selectivity of some isatin analogs which can be used for PET imaging.
IC 50 (nM)
compound
Caspase 1
Caspase 3
Caspase 6
Caspase 7
Caspase 8
WC-II-89
>15,000
9.7 ± 1.3
3,725 ± 390
23.5 ± 3.5
>50,000
WC-II-100
>20,000
3.1 ± 0.4
6,900 ± 850
11.3 ± 0.6
>50,000
WC-II-101
>10,000
3.6 ± 0.5
8,700 ± 140
17.6 ± 0.4
>50,000
WC-II-126
>15,000
9.9 ± 0.9
8,900 ± 424
34.8 ± 1.4
>50,000
WC-II-127
>15,000
3.6 ± 0.5
5.025 ± 318
6.6 ± 0.1
>50,000
Ac-YVAD-CHO
8.1 ± 2.1
Ac-DEVD-CHO
4.8 ± 2.0
8.5 ± 1.0
Ac-VEID-CHO
60.5 ± 7.6
Ac-IETD-CHO
4.7 ± 0.9
In some aspects of the present teachings, [ 18 ]WC-II-89 can serve as a probe for imaging activated caspase-3 in tissues undergoing apoptosis. The animal model used in these studies was cyclohexamide-induced apoptosis in Sprague-Dawley rats. The results are shown in FIG. 9 and FIG. 10 .
In some embodiments, the inhibition mechanism was further investigated by using 27d and its reaction with benzylmercaptan as a model. There are two possible Michael addition products (31a or 31b) produced by attack of the thiol nucleophile of benzylmercaptan to 27d ( FIG. 20 ). The products depend on the position of attack of the thiol group of benzylmercaptan on the carbon-carbon double bond of 27d (Scheme 5). Initially, we hoped to purify the Michael addition product in order to obtain a crystal structure by X-ray diffraction. Therefore, benzylmercaptan was reacted with 27d in CH 2 Cl 2 and a white solid was obtained following evaporation of the CH 2 Cl 2 and excess benzylmercaptan in vacuum. However, when the white solid was recrystallized from ethyl acetate, a purple solid was produced and NMR structural analysis revealed it was the starting material, 27d. This result shows that the Michael addition product is easily reversible and leads to the formation of the starting material. Hence, 27d is a reversible Michael acceptor inhibitor. This result is consistent with our inhibition studies of human caspase-3 with IMA inhibitors. Human caspase-3 activity is inhibited when incubated with caspase-3 and the IMA inhibitor, yet caspase-3 activity can be recovered when the IMA inhibitor is removed by gel filtration and washed with water. In an effort to better understand the chemical structure of the Michael addition product, a series of detailed NMR studies were carried out. The proton and carbon chemical shifts for the Michael addition product were assigned through two dimensional correlation spectroscopy (COSY, HMQC, and HMBC). The results show that the structure of the Michael addition product is 31b instead of 31a, thereby demonstrating that the thiol group of benzylmercaptan prefers to attack the indol ring carbon versus the exocyclic methylene group of 27d.
The synthesis of 5-(2-phenoxymethyl-azetidine-1-sulfonyl) isatin analogues is shown in Scheme 2 ( FIG. 6 ). The intermediate (S)—N-Boc-2-azetidinemethanol 14 was prepared from (S)-2-azetidinecarboxylic acid 12 according to the literature method (17). The hydroxy group of 14 was tosylated with p-toluenesulfonyl chloride in pyridine to afford compound 15, which was converted to the corresponding phenoxyl group as described above to give 16. Compound 16 was deprotected with TFA, and the secondary amine was coupled with 6 using triethylamine as the base to afford 1.7 in 63% yield. The nitrogen of 17 was alkylated by the same procedure as that of 10 to give compounds 18a-i. Similarly, the 5-(2-pyridin-3-yl-oxymethyl)pyrrolidine-1-sulfonyl)isatin analogues were prepared by using the same sequence of reactions described in the synthesis of 11a-i to afford compounds 21a-e (Scheme 3) ( FIG. 7 ). The synthesis of the 4-pyridyl analogue 23 is also outlined in Scheme 3.
The synthesis of WC-II-89 and its precursor for 18 F-labeling, 10, is shown in the scheme illustrated in FIG. 8 . In FIG. 11 , O-alkylation of methyl 4-hydroxybenzoate 1 is achieved by conversion to the corresponding sodium salt (sodium hydride in THF at 0° C.) followed by addition of 1-bromo-2-fluoroethane to give compound 2, which is reduced by LiAlH 4 in ether to afford the alcohol, 3. The hydroxyl group of 3 is then converted to the corresponding bromo analog 4 via treatment with CBr 4 and Ph 3 P in CH 2 Cl 2 . 1-(2-Bromoethoxy)-4-(bromomethyl)benzene 6 is obtained by bromination of 5 with NBS in CCl 4 . The N-Boc group of 7 is removed with TFA and the secondary amine is coupled with 5-chlorosulfonylisatin in THF using triethylamine as an acid scavenger to produce 5-(2-phenoxymethyl-pyrrolidine-sulfonyl)-1H-2,3-dione, 8. The isatin nitrogen is alkylated by treatment of 8 with sodium hydride in DMF at 0° C. followed by addition of 4 or 6 to give compounds WC-II-89 and 9, respectively. Compound 9 is then heated to reflux with silver methanesulfonate in acetonitrile to generate the precursor 10.
Starting from 10, the [ 18 F]WC-II-89 was synthesized by the nucleophilic substitution of the mesylate group with [ 18 F]fluoride ion using the radiochemical procedure outlined in the Scheme (34). The incorporation yield was more than 70% and the synthesis time was less than 100 minutes. [ 18 F]WC-II-89 was confirmed by the co-elution with nonradioactive standard WC-II-89 on an analytical HPLC system. The radiochemical purity of [ 18 F]WC-II-89 was 99% and the specific activity was determined as ˜1500 mCi/lμmol at the end of synthesis. HPLC conditions for purification of [ 18 F]WC-II-89 included the following: Alltech Ecosoil C 18 250×10 mm, 10μ; 25% acetonitrile, 45% methanol, 30% 0.1 M ammonium formate buffer (pH=4.5); 5 mL/min, 251 nm; t R =15 min. A synthesis of [ 18 F]WC-II-92 is set forth in FIG. 18 .
Inhibition of recombinant human caspase-3 and other caspases by WC-II-89 was assessed using a fluorogenic product, 7-amino-4-methylcoumarin (7-AMC). The IC 50 values from the enzyme assays are shown in Table 1. WC-II-89 shows high potency for inhibiting caspase-3 and -7, with IC 50 values at least 150-fold higher versus the initiator caspases-1, -6, -8. This caspase-inhibitory profile indicates that WC-II-89 comprising 18 F can serve as a radiotracer for imaging apoptosis using PET.
In Vivo Studies
All animal studies were performed in accordance with the regulations of the Washington University Institutional Animal Care and Use Committee. Mature male Sprague Dawley rats from Charles River Laboratories were briefly anesthetized with 1-2% isoflurane in oxygen. Each rat received 10-15 μCi of [ 18 F]WC-II-89 via the tail vein. Treated rats also received 5 mg/kg cycloheximide in saline via the tail vein three hours prior to radiotracer administration in order to induce caspase-mediated liver apoptosis. At set time-points following radiopharmaceutical injection, rats were again anesthetized and euthanized. Target and non-target organs were removed, weighed, and the radioactivity was counted using a Beckman Gamma 8000 well counter. Standard dilutions of the injected dose were counted along with the samples and uptake was calculated and reported as percent injected dose per gram (% ID/g).
The evaluation of [ 18 F]WC-II-89 as a radiotracer for imaging caspase-3 activation was determined using an animal model of chemically-induced apoptosis (35, 36). This model, which uses the protein synthesis inhibitor, cycloheximide (CHX), was previously used in the evaluation of radiolabeled annexin V analogs (37). Tissue morphology and TUNEL staining studies have shown that cycloheximide induces apoptosis in rat liver in both a dose-dependent and time-dependent manner. Within 3 hours of treatment with 1.5, 3, or 10 mg of cycloheximide per kilogram of body weight, apoptosis was induced in rat liver (35, 36). Therefore, we chose 3 hours treatment of 5 mg/kg to induce the maximum apoptosis in rat liver, expecting a high level of caspase-3 activation.
Mature male Sprague-Dawley rats (Charles River Laboratories, Inc., Wilmington, Mass.) were anesthetized with 1-2% isoflurane in oxygen and treated rats were injected via tail vein with five mg/kg CHX/saline solution to activate caspase-mediated apoptosis. Rats were euthanized three hours post-treatment and the organs of interest were immediately snap-frozen in liquid nitrogen, then stored at −80° C. until analysis. Whole organs were homogenized in ice cold T-PER® protein extraction buffer (Pierce Biotechnology, Rockford, Ill.) containing 5 mM DTT, 2 mM EDTA, and Complete® protease inhibitor cocktail tablets (Roche Diagnostics Co., Indianapolis, Ind.). The fully homogenized samples were then sonicated on ice, centrifuged at 4° C. at 14,000 g for fifteen minutes, and the protein-containing supernatant was collected. Forty micrograms of protein from each sample was analyzed using standard immunoblotting techniques. Caspase-3 was probed with anti-caspase-3 antibody (Cell Signaling Technology, Danvers, Mass.) at 1:1000 dilution and horseradish peroxidase-conjugated goat anti-rabbit IgG (Cell Signaling Technology, Danvers, Mass.) at 1:3000. Actin was resolved using anti-β-actin antibody (Cell Signaling Technology, Danvers, Mass.) at 1:1000 dilution and the same secondary antibody as mentioned above. SuperSignal® WestDura extended duration substrate(Pierce Biotechnology, Rockford, Ill.) was used for detection.
MicroPET imaging studies were performed using a MicroPET Focus 220 and MicroPET Focus 120 scanner (Siemens/CTI, Knoxyille, Tenn.). A control and cycloheximide-treated (5 mg/kg, 3 hours pretreated) rat were anesthetized and a catheter inserted in the jugular vein. Each rat was then placed in the scanner and following a transmission scan, was injected with ˜150 μCi of [ 18 F]WC-II-89 for a one hour dynamic imaging session. MicroPET images were reconstructed with OSEM-2D data analysis software package (Siemens/CTI, Knoxyille, Tenn.).
The biodistribution results of [ 18 F]WC-II-89 in normal and cycloheximide-treated male Sprague-Dawley rats are shown in Table 3 and FIG. 9 . In general, the initial uptake was higher for CHX treated rats than control rats. However, the difference between control and treated rats was reduced with time with the exception of the liver and spleen. At one hour after injection ( FIG. 9 ), the uptake in liver and spleen for the treated rats was 94% and 184% higher than the control animals at 1-hour post-i.v. injection of the radiotracer. The increase in uptake of [ 18 F]WC-II-89 in the cycloheximide-treated versus control animals is consistent with chemically-induced apoptosis and caspase-3 activation. Since the isatin analogs are competitive inhibitors of caspase-3, [ 18 F]WC-II-89 binds to the activated form of caspase-3 in tissues undergoing apoptosis, which explains the slower washout of radioactivity from the liver and spleens of the cycloheximide-treated animals. The results of the biodistribution study also reveal a very low uptake of radioactivity in bone, indicating that defluorination is not a concern with this radiotracer. The result of the biodistribution study shows that [ 18 F]WC-II-89 can serve as a PET radiotracer for imaging apoptosis.
TABLE 3
Biodistribution of [ 18 F]WC-II-89 in normal
and cycloheximide-treated (5 mg/kg, 3 hr. pretreated)
male Sprague-Dawley rats (200-250 g).
% I.D./gram
organ
animal
5 min.
1 hr.
2 hr.
blood
control
2.70 ± 0.21
0.11 ± 0.01
0.06 ± 0.01
treated
3.66 ± 0.40
0.16 ± 0.01
0.07 ± 0.00
lung
control
1.42 ± 0.34
0.18 ± 0.03
0.08 ± 0.01
treated
2.08 ± 0.23
0.23 ± 0.03
0.11 ± 0.02
liver
control
3.13 ± 0.26
0.38 ± 0.06
0.16 ± 0.02
treated
4.02 ± 0.45
0.73 ± 0.12
0.22 ± 0.03
spleen
control
1.14 ± 0.08
0.15 ± 0.05
0.06 ± 0.01
treated
2.24 ± 0.41
0.43 ± 0.05
0.11 ± 0.03
thymus
control
0.23 ± 0.07
0.09 ± 0.01
0.04 ± 0.00
treated
0.38 ± 0.10
0.12 ± 0.02
0.06 ± 0.01
kidney
control
1.25 ± 0.14
0.53 ± 0.07
0.18 ± 0.04
treated
1.18 ± 0.08
0.55 ± 0.05
0.23 ± 0.05
muscle
control
0.14 ± 0.01
0.08 ± 0.01
0.03 ± 0.00
treated
0.09 ± 0.00
0.10 ± 0.02
0.06 ± 0.00
fat
control
0.12 ± 0.02
0.15 ± 0.02
0.07 ± 0.01
treated
0.09 ± 0.03
0.14 ± 0.01
0.09 ± 0.01
bone
control
0.44 ± 0.04
0.13 ± 0.02
0.15 ± 0.06
treated
0.66 ± 0.06
0.12 ± 0.01
0.13 ± 0.03
Western blot studies were carried out to measure caspase-3 levels in control and cycloheximide-treated rats in order to correlate caspase-3 activity to the biodistribution results. Western blot analysis of spleen, liver and fat for both control and treated rats are shown in FIG. 12 . The level of cleaved caspase-3 in the spleen and liver of the treated rats is much higher than that of the control animals, which is consistent with cycloheximide-induced apoptosis. There was no cleaved caspase-3 in the Western blot of the fat tissues from both control and treated rats. The results of the Western blot studies correlate very well to the biodistribution data of liver, spleen and fat at one-hour post-i.v. injection of the radiotracer as shown in FIG. 9 . The good correlation between caspase-3 activity and biodistribution of [ 18 F]WC-II-89 in the cycloheximide-treated rats establishes the basis for imaging apoptosis using [ 18 F]WC-II-89.
The microPET images of the liver region at 10-60 minutes post-i.v. injection of [ 18 F]WC-II-89 are shown in FIG. 10 . The animal receiving a 3-hour pretreatment of cycloheximide displayed a higher uptake of [ 18 F]WC-II-89 in the liver versus the control animal, which was consistent with the results of the biodistribution study. FIG. 13 shows the tissue-time activity curves from the microPET imaging study. The higher peak accumulation of [ 18 F]WC-II-89 in the cycloheximide-treated rat liver versus the control animal is consistent with drug-induced caspase-3 activation. The normal rat liver also displayed a faster washout of radioactivity than the cycloheximide-treated liver, which corresponded to caspase-3 activation. This was also confirmed by Western blot analysis of the rat livers following completion of the microPET imaging study.
Enzyme Assays. Inhibition of recombinant human caspase-3 and other caspases by the isatin analogues was assessed using a fluorometric assay by measuring the accumulation of a fluorogenic product, 7-amino-4-methylcoumarin (7-AMC). All of the tested compounds inhibited caspase-3 and caspase-7 in a concentration-dependent manner with similar potency.
Enzyme Inhibition Assays. Recombinant human caspases (3, 6, 7, and 8) and their peptide-specific substrates (Ac-DEVDAMC, Ac-VEID-AMC, Ac-DEVD-AMC, and Ac-IETD-AMC, respectively) were purchased from Sigma-Aldrich (St. Louis, Mo.) with the exception of caspase 1 and its substrate (Ac-YVAD-AMC), which were obtained from BIOMOL Research Laboratories (Plymouth Meeting, Pa.). The enzymatic activity of caspases was determined by measuring the accumulation of the fluorogenic product 7-amino-4-methylcoumarin (AMC). All assays were prepared in 96-well format at a volume of 210 μL per well and consisted of 100 mM Na+ HEPES (pH 7.4), 10% sucrose, 100 mM NaCl, 0.1% CHAPS, 5 mM 2-mercaptoethanol, 2 mM EDTA, 10 μM Ac-YVAD-AMC (caspase 1); 20 mMNa + HEPES (pH 7.4), 10% sucrose, 100 mMNaCl, 0.1% CHAPS, 2 mM EDTA, 10 μM Ac-DEVD-AMC (caspase 3); 20 mM Na + HEPES (pH 7.4), 10% sucrose, 100 mM NaCl, 0.1% CHAPS, 2 mM EDTA, 10 μM Ac-VEID-AMC (caspase 6); 20 mM Na+ HEPES (pH 7.4), 100 mM NaCl, 10% sucrose, 0.1% CHAPS, 5 mM 2-mercaptoethanol, 2 mM EDTA, 10 μM Ac-DEVD-AMC (caspase 7); 20 mM Na+ HEPES (pH 7.4), 10% sucrose, 100 mM NaCl, 0.1% CHAPS, 2 mM EDTA, 10 μM Ac-IETD-AMC (caspase 8).
Recombinant caspases were first assayed to determine the optimal concentration for each experiment. Optimal concentrations were based in the linear range of the enzyme activation curves. Peptide inhibitors with known IC 50 values were tested together with the compounds as a control for each caspase assay. Peptide inhibitors, Ac-DEVD-CHO (caspase-3 and -7), Ac-VEID-CHO (caspase-6), and Ac-IETD-CHO (caspase-8) were purchased from Sigma-Aldrich (St. Louis, Mo.) with exception of caspase-I specific inhibitor (Ac-YVAD-CHO) which was acquired from BIOMOL Research Laboratories (Plymouth Meeting, Pa.). Peptide and nonpeptide inhibitors were dissolved in DMSO, and a 2 serial dilution was performed prior to screening in order to obtain desired concentrations. 10 μL was added to each well containing 100 μL caspase solution and allowed to incubate on ice for 30 min. A 100 μL substrate solution was added to each well, and plates were incubated for 1-2 h at 37° C. The final concentration of DMSO in all wells was 5% of the total volume. In caspase-1 and caspase-7 assays, 10 mM 2-mercaptoethanol was added to the substrate solution for full activation of the enzymes.
The amount of AMC released was determined by using a Victor3 microplate fluorometer (Perkin-Elmer Life Sciences, Boston, Mass.) at excitation and emission wavelengths 355 nm and 460 nm, respectively. Compounds were tested in duplicate, and IC 50 curves were calculated for all inhibitors assayed. Final IC 50 s were the average of three independent experiments.
Enzyme Kinetic Studies. The inhibition profile for compound 21c was determined for caspase-3 in the assay buffer. The concentration of Ac-DEVD-AMC was varied from 6.25 to 100 μM, and the concentration of 21c was varied from 0 to 20 nM. The kinetic parameters of 21c were obtained by fitting initial-rate data to
υ = V m S K m ( 1 + 1 K i ) + S ( 1 )
where v is the observed velocity, S is the substrate concentration, Vm is the velocity at saturating substrate, Km is the Michaelis constant of the substrate, I is the inhibitor concentration, and Ki is the dissociation constant of the inhibitor from the E·I complex. The data were analyzed using GraFit 4.0 (Erithacus Software, Staines, U.K.)
The IC 50 values from the enzyme assays are summarized in Tables 1-3. Alkylation of the isatin nitrogen of 10 with a benzyl group (i.e., 2) or substituted benzyl group (i.e., 11c-e) resulted in a 10 to 20-fold increase in potency for inhibiting caspase-3, and a 9 to 37-fold increase in potency for inhibiting caspase-7. The isatin analogues were also evaluated for their inhibitory activity against a panel of three other caspases (caspases-1, -6, and -8). As shown in Table 4, they demonstrated high selectivity against caspase-3 and -7, with IC 50 values at least 100-fold higher versus caspases-1, -6, and -8.
TABLE 4
Inhibitor Selectivity of Pyrrolidine Isatin
Analogues for Caspases-1, -3, -6, -7, and -8
IC 50 (nM)
Compound
caspase-1
caspase-3
caspase-6
caspase-7
caspase-8
Log P
10
>10000
240.0 ± 10.0
>5000
540.0 ± 56.6
>50000
2.23
11a
>20000
119.2 ± 17.0
>5000
310.0 ± 14.1
>50000
2.27
2
>10000
12.2 ± 0.3
>5000
28.0 ± 0.7
>50000
4.05
11b
>10000
14.5 ± 1.6
>5000
21.8 ± 3.5
>50000
3.96
11c
>50000
12.1 ± 2.1
>5000
23.0 ± 1.4
>50000
4.1
11d
>50000
12.4 ± 2.1
>5000
41.0 ± 1.4
>50000
4.54
11e
>50000
12.0 ± 1.5
>5000
34.8 ± 0.4
>50000
3.39
11f
>5000
13.5 ± 2.4
>5000
44.0 ± 0.1
>50000
3.31
11g
>50000
10.3 ± 1.5
>5000
14.5 ± 0.9
>50000
2.67
11h
>50000
21.3 ± 3.2
>5000
58.0 ± 2.8
>50000
2.67
11i
>50000
9.1 ± 1.8
>5000
22.2 ± 4.0
>50000
2.67
Reversibility Assay
In these experiments, Recombinant caspase 3 (2 ng/μl) was either left untreated or incubated with Z-DEVD-FMK (3 μM), a well known irreversible inhibitor of caspase 3, or 30d (3 μM) for 1 hour on ice. The caspase 3 activity was fully inhibited by z-DEVD-FMK (3 μM) or 30d (3 μM) under this condition. Then the mixtures were run through the gel filtration column (Bio-Spin 6 Tris columns from Bio-Rad Laboratories, Hercules, Calif.) to remove the free compounds according to the manufacture's instruction. Briefly, 50 μl of the incubation mixture was loaded on the top of the column. The column was then centrifuged at 1000×g for 4 min at 4° C. The resulting elutant was designated as elutant A (for no treatment sample), B (for Z-DEVD-FMK-treated sample) or C (for 30d-treated sample). The elutant was assayed for caspase 3 activity as described in enzyme inhibition assays above. Briefly, 40 μl of the elutant, 60 μl assay buffer and 100 μl substrate (10 μM Ac-DEVD-AMC) were incubated for 1 hour at 37° C. Amount of AMC released was determined using a Victor microplate fluorometer. The recovered caspase-3 activity after gel filtration (%) was calculated. The results show that elutant B exhibited little caspase 3 activity compared to elutant A, suggesting that Z-DEVD-FMK irreversibly binds to caspase 3 and thus can not be removed from caspase 3 by gel filtration column. The results also showed that elutant C remained full caspase 3 activity compared to elutant A, indicating that 30d reversibly binds to caspase 3 and thus can be removed by gel filtration column.
TABLE 5
Inhibitor Selectivity of the Azetidine Isatin Analogues
17, 18a-i for Caspases-1, -3, -6, -7, and -8
IC 50 (nM)
Compound
caspase-1
caspase-3
caspase-6
caspase-7
caspase-8
Log P
17
>10000
286.7 ± 24.7
>5000
1350.0 ± 141.4
>50000
1.66
18a
>10000
91.7 ± 7.6
>5000
362.5 ± 3.5
>50000
1.71
18b
>10000
9.7 ± 1.6
>5000
29.5 ± 4.9
>50000
3.49
18c
>50000
8.4 ± 1.2
>5000
23.2 ± 3.0
>50000
3.4
18d
>50000
11.3 ± 1.2
>5000
26.7 ± 7.2
>50000
3.97
18e
>10000
8.8 ± 1.4
>5000
21.0 ± 5.6
>50000
3.54
18f
>10000
9.4 ± 0.3
>5000
26.0 ± 5.2
>50000
3.54
18g
>50000
10.9 ± 1.4
>5000
17.0 ± 3.0
>50000
2.11
18h
>50000
29.2 ± 5.2
>5000
135.0 ± 7.1
>50000
2.11
18i
>10000
5.8 ± 1.0
>5000
22.7 ± 3.1
>50000
2.11
TABLE 6
Selectivity Profile of some Pyridine Analogues within the Caspase Family
IC 50 (nM)
Compound
caspase-1
caspase-3
caspase-6
caspase-7
caspase-8
Log P
20
>5000
58.3 ± 7.6
>5000
214.9 ± 49.5
>50000
1.17
21a
>10000
23.3 ± 3.1
>5000
94.9 ± 21.6
>50000
1.21
21b
>10000
5.2 ± 1.6
>5000
14.1 ± 3.4
>50000
2.99
21c
>10000
3.9 ± 0.9
>5000
15.1 ± 1.2
>50000
2.91
21d
>50000
4.4 ± 1.4
>5000
23.3 ± 0.7
>50000
3.48
21e
>10000
8.4 ± 2.0
>5000
15.1 ± 0.1
>50000
3.04
23
>5000
20.4 ± 1.7
>5000
142.3 ± 22.6
>50000
1.04
The azetidine analogue 17 had a similar potency for inhibiting caspase-3 as that of the corresponding pyrrolidine analogue 10. However, compound 17 was >2-fold less potent for inhibiting caspase-7 relative to the corresponding pyrrolidine analogue, 10. Substitution of 17 with either a benzyl (i.e., 18b), a substituted benzyl (18c-f), or a pyridylmethyl group (18g-i) resulted in a 10 to 50-fold increase in potency against caspase-3 and a 10 to 80-fold increase in potency for inhibiting caspase-7 relative to 17 (Table 5). Again, these compounds exhibited at least 100-fold greater selectivity for caspase-3 and -7 versus caspases-1, -6, and -8.
Interestingly, a higher caspase-3 potency was achieved upon replacing the benzene ring of the 2-(phenoxymethyl)pyrrolidine moiety with a pyridine ring (Table 6). All pyridine-containing analogues had a lower IC 50 value for inhibiting caspase-3 than the corresponding benzene-containing congeners (eg., 11a vs 21a, 11d vs 21d). Compound 21c was found to be the most potent inhibitor of caspase-3, with IC 50 of 3.9 nM. These compounds demonstrated similar potency against caspase-3 and 7, but at least 100 fold less potent versus caspases-1, -6, and -8.
Kinetic studies were also conducted in order to determine the mechanism of inhibition of caspase-3 activity by compound 21c. The kinetic pattern indicated that 21c displays competitive inhibition versus Ac-DEVD-AMC with a calculated Ki value of 4.4 nM ( FIG. 3 ). These data are consistent with previous studies demonstrating that the isatin analogues bind to the catalytic site of activated caspase-3 (16)
In some aspects, the present teachings include the absence of a substituent effect in the aromatic ring of the N-benzyl moiety of compound 2. The results outlined in Table 4 indicate that either substitution of the para position of 2 or replacement of the benzene ring with a pyridine ring results in little change in potency for inhibiting caspase-3 and caspase-7. These results are consistent with the earlier observations regarding the substitution of the isatin nitrogen with hydrophobic substituents (16). A second, and somewhat unexpected, observation was the similar potency between the pyrrolidine analogues 11b-i and the azetidine analogues 18b-i, given the difference in potency for inhibiting caspase-3 by compound 3 and compound 4 ( FIG. 1 ). Another unexpected observation was the high potency of the pyridine analogues 21b-e relative to their phenyl congeners, 2 and 11b-d. These data suggest a possible hydrophilic interaction between the phenoxymethyl moiety and the S3 binding domain of caspase-3.
Substitution of the pyridine ring for a benzene ring in the phenoxymethyl moiety can also result in a dramatic reduction in the overall lipophilicity of the isatin analogues (18,19). For example, compound 2 has a calculated log P value of 4.05 whereas the corresponding pyridine analogue, 21b, has a calculated log P value of 2.99. Therefore, in some aspects, a pyridine analogue of the present teachings can have a higher potency for inhibiting activated caspase-3 in situations in which the compound crosses or interacts with an intact cell membrane.
Log P value of the IMA analogs are lower than the corresponding values of non-Michael acceptor isatin analogs (e.g., 25d vs. 27d, Log P 4.82 vs. 4.28; 28b vs. 30b, 2.25 vs. 1.77; and 28c vs. 30c, 3.76 vs. 3.22, respectively FIG. 19 , table 7)). This lower Log P value of the IMA caspase-3 inhibitor increases the drug's ability to penetrate the cell in vivo and label the target.
TABLE 7
Selectivity profiles of some Isatin Michael Acceptors
IC 50 (nM)
#
Casp-1
Casp-3
Casp-6
Casp-7
Casp-8
Log P
25d
>15000
9.85 ± 0.9
8900 ± 424
34.8 ± 1.4
>50000
4.82
28b
>15000
3.9 ± 0.6
9550 ± 354
11.7 ± 1.0
>50000
2.25
28c
>15000
3.6 ± 0.5
5025 ± 318
6.6 ± 0.1
>50000
3.76
26
1830 ± 128
272 ± 24.7
407 ± 15
1585 ± 163
>50000
1.07
27a
2825 ± 248
119.3 ± 4.0
698 ± 94
785 ± 276
>50000
1.71
27b
6220 ± 1250
27.8 ± 2.5
918 ± 151
51.7 ± 6.2
>50000
3.50
27c
2300 ± 250
31.8 ± 6.2
744 ± 48
126.0 ± 19.3
>50000
2.77
27d
5700 ± 850
20.1 ± 1.3
840 ± 125
92.2 ± 11.8
>50000
4.28
30a
3250 ± 450
7.6 ± 1.1
823 ± 86
32.8 ± 4.9
>50000
2.45
30b
2720 ± 580
7.8 ± 1.9
650 ± 22
28.3 ± 5.4
>50000
1.77
30c
3400 ± 0
5.1 ± 0.7
515 ± 77
26.3 ± 0.8
>50000
3.22
30d
3900 ± 530
7.8 ± 1.5
610 ± 113
29.6 ± 1.4
>50000
2.36
In summary, the present inventors disclose, in various aspects, the synthesis and activity of a series of isatin analogues having a high potency for inhibiting the executioner caspases, caspase-3, and caspase-7. In various configurations, the inventors discoveries extend the structure-activity relationships of this class of compounds and provide further insight into the development of non-peptide-based inhibitors of caspase-3 and caspase-7. In various aspects, the compounds described above can be useful probes for determining the effectiveness of inhibiting caspase-3 and caspase-7 for minimizing tissue damage in pathological conditions characterized by unregulated apoptosis.
EXAMPLES
Various aspects of the present teachings can be illustrated by the following non-limiting examples. The following examples are illustrative, and are not intended to limit the scope of the claims. The description of a composition or a method in an example does not imply that a described article or composition has, or has not, been produced, or that a described method has, or has not, been performed, except for results presented in past tense.
All reactions in the Examples were carried out under an inert nitrogen atmosphere with dry solvents using anhydrous conditions unless otherwise stated. Reagents and grade solvents were used without further purification. Flash column chromatography was conducted using Scientific Adsorbents, Inc. silica gel, 60a, “40 Micron Flash” (32-63 μm). Melting points were determined using MEL-TEMP 3.0 apparatus and uncorrected. 1 H NMR spectra were recorded at 300 MHz on a Varian Mercury-VX spectrometer. All chemical shift values are reported in ppm (δ). Elemental analyses (C, H, N) were determined by Atlantic Microlab, Inc.
Example 1
2,3-Dioxo-2,3-dihydro-1H-indole-5-sulfonyl Chloride (6). (16) Phosphorus oxychloride (13.2 mL, 141.6 mmol) was added to a solution of 5-isatinsulfonic acid (5), sodium salt hydrate (8.0 g, 30.0 mmol) in tetramethylene sulfone (40 mL). The mixture was heated to 60° C. for 3 h, then cooled to 0° C. The reaction mixture was poured into 150 g of ice. The solid was filtered out and washed with cold water, then the solid was dissolved in ethyl acetate (100 mL), washed with water (50 mL×2) and saturated NaCl (50 mL), and dried over Na 2 SO 4 . The ethyl acetate was evaporated in reduced pressure to afford 6.12 g (83%) of 6 as a pale yellow solid, mp 188.2-190.1° C. 1 H NMR (300 MHz, DMSO) δ 11.1 (s, 1H), 7.82 (dd, J=8.4 Hz, J=1.8 Hz, 1H), 7.60 (s, 1H), 6.89 (d, J=8.1 Hz, 1H).
Example 2
((S)-1-(tert-Butoxycarbonyl)pyrrolidin-2-yl)methyl 4-Methylbenzesulfonate (8). A solution of 7 (5.03 g, 25.0 mmol) and pyridine (15 mL) in CH 2 Cl 2 (50 mL) was reacted with p-toluenesulfonyl chloride (5.96 g, 31.2 mmol) at 0° C. The mixture was stirred overnight at room temperature, then CH 2 Cl 2 (50 mL) was added. The solution was washed with water (50 mL×2), 10% citric acid (50 mL×2), and saturated NaCl (50 mL), and dried over Na 2 SO 4 . After evaporation of the CH 2 Cl 2 , the crude product was purified with hexanes-ethyl ether (1:1) to afford 8.9 g (100%) of 8 as a colorless oil. 1 H NMR (300 MHz, DMSO) δ 7.78 (d, J=8.4 Hz, 2H), 7.49 (d, J=8.1 Hz, 2H), 4.02 (m, 2H), 3.83 (m, 1H), 3.18 (m, 2H), 2.43 (s, 3H), 1.92 (m, 1H), 1.72 (m, 3H), 1.35 and 1.29 (s, 9H).
Example 3
(S)-tert-Butyl 2-(Phenoxymethyl)pyrrolidine-1-carboxylate (9). A solution of phenol (7.37 g, 78.4 mmol) in THF (100 mL) was reacted with 60% NaH (3.14 g, 78.4 mmol) at 0° C. in 20 min. The mixture was warmed to room temperature and stirred 20 min, then a solution of 8 (5.57 g, 15.7 mmol) in THF (25 mL) was added. The mixture was heated to reflux for 24 h. After evaporation of the THF, ether (200 mL) was added, washed with water (40 mL), 1 N NaOH (40 mL×3), and saturated NaCl (40 mL), and dried over Na 2 SO 4 . After evaporation of the ether, the crude product was purified with hexanes-ether (2:1) to afford 2.37 g (54%) of 9 as a colorless oil. 1 H NMR (300 MHz, DMSO) δ 7.28 (t, J=8.4 Hz, 2H), 6.95 (m, 3H), 4.04 (m, 2H), 3.87 (m, 1H), 3.27 (m, 2H), 1.93-1.80 (m, 4H), 1.41 (s, 9H).
Example 4
(S)-5-(2-Phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (10). To a solution of 9 (1.46 g, 5.2 mmol) in CH 2 Cl 2 (5 mL) was added trifluoroacetic acid (5 mL) at 0° C. The mixture was stirred at 0° C. for 15 min. After evaporation of the solvent in vacuo, CH 2 Cl 2 (15 mL) and triethylamine (2 mL) were added, then a solution of 6 (1.44 g, 5.9 mmol) in THF (25 mL) was added at 0° C. The reaction mixture was stirred overnight at room temperature. The solvent was evaporated in vacuo, then ethyl acetate (150 mL) was added, washed with water (50 mL×2) and saturated NaCl (50 mL), and dried over Na 2 SO 4 . After evaporation of the ethyl acetate, the crude product was purified with ether to afford 1.7 g (84%) of 10 as a yellow solid, mp 204.5-205.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.94 (s, 1H), 7.77 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.67 (s, 1H), 7.02 (t, J=8.7 Hz, 2H), 6.84 (d, J=8.1 Hz, 1H), 6.69 (t, J=7.2 Hz, 1H), 6.63 (d, J=7.8 Hz, 2H), 3.89 (m, 1H), 3.75-3.66 (m, 2H), 3.23 (m, 1H), 2.96 (m, 1H), 1.72 (m, 2H), 1.54-1.42 (m, 2H). LRMS (FAB) m/e: 387.1 (M+H, 100). Anal. Calcd for C 19 .N 2 O 5 S: C, 59.06, H, 4.70; N, 7.25. Found: C, 58.99, H, 4.74, N, 7.11.
Example 5
(S)-1-Methyl-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11a). To a solution of 10 (193 mg, 0.5 mmol) in DMF (3 mL) was added 60% NaH (30 mg, 0.75 mmol) at room temperature. The mixture was stirred 15 min, then iodomethane (0.5 mL) was added. The mixture was stirred overnight at ambient temperature, then ether (75 mL) was added, washed with water (30 mL) and saturated NaCl (30 mL), and dried over Na 2 SO 4 . After evaporation of the solvent, the crude product was purified with ether to afford 85 mg (43%) of 11a as a yellow solid, mp 160.1-160.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.07 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 8.01 (s, 11H), 7.25 (t, J=8.4 Hz, 2H), 6.92 (m, 3H), 6.81 (d, J=7.8 Hz, 2H), 4.15 (dd, J=9.0 Hz, J=2.7 Hz, 1H), 4.00 (m, 1H), 3.92 (m, 1H), 3.51 (m, 1H), 3.30 (m, 1H), 3.26 (s, 3H), 2.04 (m, 2H), 1.81 (m, 2H). Anal. Calcd for C 20 H 20 N 2 O 5 S: C, 59.99, H, 5.03; N, 7.00. Found: C, 59.80, H, 5.03; N, 6.91.
Example 6
(S)-1-Benzyl-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (2) was prepared according to the same procedure for compound 11a, except using benzyl bromide, and purified with hexanes-ether (1:2) to afford 152 mg (64%) of 2 as a yellow solid, mp 97.2-99.1° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.01 (d, J=1.5 Hz, 1H), 7.94 (dd, J=8.4 Hz, J=1.8 Hz, 1H), 7.36 (m, 5H), 7.22 (m, 2H), 6.95-6.79 (m, 4H), 4.92 (s, 2H), 4.15 (dd, J=8.85 Hz, J=2.4 Hz, 1H), 3.97-3.87 (m, 2H), 3.49 (m, 1H), 3.23 (m, 1H), 2.01 (m, 2H), 1.78 (m, 2H). Anal. Calcd for C 26 H 24 N 2 O 5 S: C, 65.53, H, 5.08; N, 5.88. Found: C, 65.27, H, 5.32; N, 5.58.
Example 7
(S)-1-(4-Methoxybenzyl)-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11b) was prepared according to the same procedure for compound 11a, except using 4-methoxybenzyl chloride, and purified with hexanesether (1:3) to afford 175 mg (69%) of 11b as a yellow solid, mp 126.7-128.8° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.00 (s, 1H), 7.95 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.28-7.21 (m, 4H), 6.96-6.80 (m, 6H), 4.86 (s, 2H), 4.18-4.11 (m, 1H), 3.97-3.88 (m, 2H), 3.80 (s, 3H), 3.50 (m, 1H), 3.23 (m, 1H), 2.02 (m, 2H), 1.78 (m, 2H). Anal. Calcd for C 27 H 2 (N 2 O 6 S: C, 64.02, H, 5.17; N, 5.53. Found: C, 64.76, H, 5.24; N, 5.06.
Example 8
(S)-1-(4-Fluorobenzyl)-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11c) was prepared according to the same procedure for compound 11a, except using 4-fluorobenzyl bromide, and purified with hexanes-ether (1:2) to afford 196 mg (79%) of 11c as an orange solid, mp 74.5-75.4° C. 1 H NMR (300 MHz, CDCl 3 ) δ 7.99 (s, 1H), 7.95 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.34-7.19 (m, 4H), 7.06 (t, J=8.7 Hz, 2H), 6.92 (t, J=7.2 Hz, 1H), 6.87-6.79 (m, 3H), 4.89 (s, 2H), 4.13 (m, 1H), 3.93 (m, 2H), 3.47 (m, 1H), 3.23 (m, 1H), 2.01 (m, 2H), 1.78 (m, 2H). Anal. Calcd for C 26 H 23 FN 2 O 5 S: C, 63.15, H, 4.69; N, 5.66. Found: C, 63.05, H, 4.69; N, 5.60.
Example 9
(S)-1-(4-Methylthiobenzyl)-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11d) was prepared according to the same procedure for compound 11a, except using 4-methylthiobenzyl bromide, and purified with hexanesether (1:2) to afford 152 mg (64%) of 11d as a yellow solid, mp 175.4-176.8° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (s, 1H), 7.99 (d, J=10.5 Hz, 1H), 7.27 (m, 6H), 6.96 (t, J=7.2 Hz, 1H), 6.86 (t, J=8.1 Hz, 3H), 4.90 (s, 2H), 4.19 (d, J=8.7 Hz, 1H), 3.96 (m, 2H), 3.53 (m, 1H), 3.25 (m, 1H), 2.50 (s, 3H), 2.05 (m, 2H), 1.82 (m, 2H). Anal. Calcd for C 27 H 26 N 2 O 5 S 2 : C, 62.05, H, 5.01; N, 5.36. Found: C, 61.81, H, 4.95; N, 5.34.
Enzyme Assays. Inhibition of recombinant human caspase-3 and other caspases by the isatin analogues was assessed using a fluorometric assay by measuring the accumulation of a fluorogenic product, 7-amino-4-methylcoumarin (7-AMC): All of the tested compounds inhibited caspase-3 and caspase-7 in a concentration-dependent manner with similar potency.
Example 11
(S)-1-(4-Hydroxybenzyl)-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11f). To a solution of 11e (53 mg, 0.1 mmol) in methanol (3 mL) and water (1 mL) was added NaOH (4.4 mg, 0.11 mmol) at ambient temperature. The mixture was stirred overnight, then acidified with 1 M HCl to pH of 4 and extracted with ethyl acetate (50 mL). The ethyl acetate was washed with NaCl (30 mL) and dried over Na 2 SO 4 . After evaporation of the solvent, the crude product was purified with ether to afford 36 mg (73%) of 11f as a yellow solid, mp 170.5-172.4° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.01 (s, 1H), 7.97 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.24-7.19 (m, 4H), 6.96-6.80 (m, 6H), 4.85 (s, 2H), 4.16 (m, 1H), 3.98-3.88 (m, 2H), 3.49 (m, 1H), 3.21 (m, 1H), 2.03 (m, 2H), 1.80 (m, 2H). Anal. Calcd for C 26 H 24 N 2 O 6 S.0.25H 2 O: C, 62.83, H, 4.97; N, 5.64. Found: C, 62.87, H, 4.74; N, 5.69.
Example 12
(S)-1-(6-Fluoropyridin-3-yl-methyl)-5-(2-phenoxymethylpyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11g) was prepared according to the same procedure for compound 11a, except using 5-(bromomethyl)-2-fluoropyridine,21 and purified with ether to afford 94 mg (76%) of 11g as yellow solid, mp 113.3-11.4.7° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.28 (s, 1H), 8.03 (m, 2H), 7.82 (m 1H), 7.27-7.20 (m, 2H), 7.00-6.79 (m, 5H), 4.92 (s, 2H), 4.13 (m, 1H), 3.95 (m, 2H), 3.50 (m, 1H), 3.26 (m, 1H), 2.05 (m, 2H), 1.80 (m, 2H). Anal. Calcd for C 25 H 22 FN 3 O 5 S: C, 60.60, H, 4.47, N, 8.48. Found: C, 60.60, H, 4.59, N, 8.33.
Example 13
(S)-1-(2-Fluoro-pyridin-4-yl-methyl)-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11h) was prepared according to the same procedure for compound 11a, except using 4-(bromomethyl)-2-fluoropyridine,21 and purified with ether to afford 41 mg (33%) of 11h as a yellow solid, mp 180.1-181.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.25 (d, J=5.4 Hz, 1H), 8.07 (s, 1H), 8.00 (d, J=8.4 Hz, 1H), 7.23 (m, 2H), 7.12 (d, J=4.2 Hz, 1H), 6.96-6.73 (m, 5H), 4.94 (s, 2H), 4.13 (m, 1H), 4.00-3.89 (m, 2H), 3.49 (m, 1H), 3.28 (m, 1H), 2.04 (m, 2H), 1.82 (m, 2H). Anal. Calcd for C 25 H 22 FN 3 O 5 S: C, 60.60, H, 4.47; N, 8.48. Found: C, 60.32, H, 4.34; N, 8.35.
Example 14
(S)-1-(6-Fluoro-pyridin-2-yl-methyl)-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (11i) was prepared according to the same procedure for compound 11a, except using 6-(bromomethyl)-2-fluoropyridine,21 and purified with ether to afford 57 mg (46%) of 11i as a yellow solid, mp 128.6-129.4° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.02 (m, 2H), 7.82 (m, 1H), 7.28-7.10 (m, 4H), 6.92 (m, 2H), 6.85 (m, 2H), 4.96 (s, 2H), 4.14 (m, 1H), 3.94 (m, 2H), 3.51 (m, 1H), 3.23 (m, 1H), 2.03 (m, 2H), 1.79 (m, 2H). Anal. Calcd for C 25 H 22 FN 3 O 5 S.0.25H 2 O: C, 60.05, H, 4.54; N, 8.40. Found: C, 60.06, H, 4.49; N, 8.24.
Example 15
(S)-1-(tert-Butoxycarbonyl)azetidine-2-carboxylic Acid (13). To a solution of (S)-2-azetidinecarboxylic acid 12 (1.0 g, 10.0 mmol) and di-tert-butyl dicarbonate (2.83 g, 12.5 mmol) in ethanol (20 mL) and water (10 mL) was added NaOH (420 mg, 10.5 mmol) at 0° C. The mixture was stirred overnight at ambient temperature. After evaporation of the ethanol, water (20 mL) was added, then acidified with diluted HCl to a pH of 3 and extracted with ethyl acetate (50 mL×3). The combined ethyl acetate was washed with water (30 mL) and saturated NaCl (30 mL), and dried over Na 2 SO 4 . After evaporation of the ethyl acetate to afford 1.98 g (100%) of 13 as a white solid. 1 H NMR (300 MHz, CDCl 3 ) δ 4.79 (m, 1H), 3.93 (m, 2H), 2.46 (m, 2H), 1.48 (s, 9H).
Example 16
(S)-tert-Butyl 2-(Hydroxymethyl)azetidine-1-carboxylate (14).17 To a solution of 13 (0.94 g, 4.7 mmol) in THF (10 mL) was added slowly a 1 M BH3 in THF (21.0 mL) at 0° C. The mixture was stirred 2 days at ambient temperature, then cold water (20 mL) was added at 0° C. After evaporation of the THF in vacuo, an 10% aqueous solution of citric acid (15 mL) was added and extracted with ethyl acetate (50 mL×2). The combined ethyl acetate was washed with saturated NaHCO 3 (30 mL) and NaCl (30 mL), and dried over Na 2 SO 4 . Evaporation of the ethyl acetate in vacuo afforded 0.86 g (100%) of 14 as a colorless oil. 1 H NMR (300 MHz, CDCl 3 ) δ 4.40 (m, 1), 3.85-3.70 (m, 3H), 2.13 (m, 1H), 1.90 (m, 1H), 1.42 (s, 9H).
Example 17
((S)-1-(tert-Butoxycarbonyl)azetidine-2-yl)methyl 4-methylbenzenesulfonate (15) was prepared according to the same procedure for compound 8, except using compound 14, and purified with hexanes-ether (1:1) to afford 1.34 g (86%) of 15 as a colorless oil. 1 H NMR (300 MHz, CDCl 3 ) δ 7.79 (d, J=8.7 Hz, 2H), 7.34 (d, J=8.1 Hz, 2H), 4.33-4.24 (m, 2H), 4.10 (m, 1H), 3.78 (m 2H), 2.44 (s, 3H), 2.21 (m, 2H), 1.36 (s, 9H).
Example 18
(S)-tert-Butyl 2-(phenoxymethyl)azetidine-1-carboxylate (16) was prepared according to the same procedure for compound 9, except using compound 15, and purified with hexanes-ether (2:1) to afford 0.81 g (79%) of 16 as a colorless oil. 1 H NMR (300 MHz, CDCl 3 ) δ CDCl 3 7.30 (m, 2H), 6.94 (m, 3H), 4.53 (m, 1H), 4.26 (m, 1H), 4.12 (m, 1H), 3.93 (m, 2H), 2.33 (m, 2H), 1.43 (s, 9H).
Example 19
(S)-5-(2-Phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (17) was prepared according to the same procedure for compound 10, except using compound 16, and purified with ether to afford 715 mg (63%) of 17 as a yellow solid, mp 173.2-174.5° C. 1 H NMR (300 MHz, DMSO) δ 11.48 (s, 1H), 7.98 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.77 (s, 1H), 7.27 (m, 2H), 7.10 (d, J=8.1 Hz, 1H), 6.91 (d, J=7.8 Hz, 3H), 4.20-4.02 (m, 3H), 3.70 (m, 1H), 3.55 (m, 1H), 2.22 (m, 1H), 2.02 (m, 1H). LRMS (FAB) m/e: 373.0 (M+H, 100). Anal. Calcd for C 18 H 16 N 2 O 5 S.0.5H 2 O: C, 56.68, H, 4.49; N, 7.34. Found: C, 56.96, H, 4.39; N, 7.30.
Example 20
(S)-1-Methyl-5-(2-phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (18a) was prepared according to the same procedure for compound 11a, except using compound 17, and purified with ether to afford 46 mg (48%) of 18a as an orange solid, mp 173.5-174.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.04 (m, 2H), 7.24 (m, 2H), 6.94 (m, 2H), 6.79 (m, 2H), 4.46 (m, 1H), 4.10 (m, 2H), 3.86 (m, 2H), 3.25 (m, 3H), 2.30 (m, 2H). Anal. Calcd for C 19 .N 2 O 5 S: C, 59.06, H, 4.70, N, 7.25. Found: C, 58.98, H, 4.75; N, 7.19.
Example 21
(S)-1-Benzyl-5-(2-phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (18b) was prepared according to the same procedure for compound 11a, except using compound 17 and benzyl bromide, and purified with hexanes-ether (1:2) to afford 92 mg (80%) of 18b as an orange solid, mp 157.1-158.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (d, J=2.1 Hz, 1H), 7.95 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.34 (m, 5H), 7.22 (m, 2H), 6.94 (m, 1H), 6.87-6.78 (m, 3H), 4.93 (s, 2H), 4.46 (m, 1H), 4.10 (m, 2H), 2.82 (m, 2H), 2.32 (m 2H). Anal. Calcd for C 25 H 22 N 2 O 5 S: C, 64.92, H, 4.79; N, 6.06. Found: C, 64.82, H, 4.79; N, 7.97.
Example 22
(S)-1-(4-Methoxybenzyl)-5-(2-phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (18c) was prepared according to the same procedure for compound 11a, except using compound 17 and 4-methoxybenzyl chloride, and purified with hexanes-ether (1:2) to afford 62 mg (50%) of 18c as an orange solid, mp 159.8-161.5° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.04 (s, 1H), 7.96 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.25 (m, 4H), 6.97-6.87 (m, 4H), 6.80 (d, J=7.8 Hz, 2H), 4.87 (s, 2H), 4.45 (m, 2H), 4.11 (m, 2H), 3.84 (m, 2H), 3.81 (s, 3H), 2.32 (m, 2H). Anal. Calcd for C26H 24 N 2 O 6 S: C, 63.40, H, 4.91; N, 5.69. Found: C, 63.65, H, 4.93; N, 5.59.
Example 23
(S)-1-(4-Methylthiobenzyl)-5-(2-phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (18d) was prepared according to the same procedure for compound 11a, except using compound 17 and 4-methylthiobenzyl bromide, and purified with hexanes-ether (1:2) to afford 57 mg (45%) of 18d as an orange solid, mp 167.6-169.2° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (d, J=1.5 Hz, 1H), 7.96 (dd, J=8.4 Hz, J=1.8 Hz, 1H), 7.25 (m, 6H), 6.95 (t, J=7.2 Hz, 1H), 6.86-6.78 (m, 3H), 4.89 (s, 2H), 4.46 (m, 1H), 4.11 (m, 2H), 3.82 (m, 2H), 2.49 (s, 3H), 2.39-2.25 (m, 2H). Anal. Calcd for C 26 H 24 N 2 O 5 S 2 : C, 61.40, H, 4.76; N, 5.51. Found: C, 60.99, H, 4.71; N, 5.36.
Example 24
(S)-1-(4-Fluorobenzyl)-5-(2-phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (18e) was prepared according to the same procedure for compound 11a, except using compound 17 and 4-fluorobenzyl bromide, and purified with hexanes-ether (1:2) to afford 85 mg (71%) of 18e as an orange solid, mp 164.6-165.7° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (d, J=1.8 Hz, 1H), 7.97 (dd, J=8.4 Hz, J=2.1 Hz, 1H), 7.34-7.20 (m, 4H), 7.07 (t, J=8.7 Hz, 2H), 6.94 (t, J=7.2 Hz, 1H), 6.86-6.77 (m, 3H), 4.90 (s, 2H), 4.47 (m, 1H), 4.10 (m, 2H), 3.85 (m, 2H), 2.36-2.22 (m, 2H). Anal. Calcd for C 25 H 21 FN 2 O 5 S: C, 62.49, H, 4.41; N, 5.83. Found: C, 62.27, H, 4.48; N, 5.69.
Example 25
(S)-1-(2-Fluorobenzyl)-5-(2-phenoxymethyl-azetidine-1-sulfonyl)-1H-indole-2,3-dione (18f) was prepared according to the same procedure for compound 11a, except using compound 17 and 2-fluorobenzyl bromide, and purified with solid, mp 147.1-148.0° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (d, J=1.8 Hz, 1H), 8.00 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.35 (m, 2H), 7.24-7.11 (m, 3H), 7.02-6.78 (m, 5H), 4.98 (s, 2H), 4.47 (m, 1H), 4.11 (m, 2H), 3.85 (m, 2H), 2.35-2.25 (m, 2H). Anal. Calcd for C 25 H 21 FN 2 O 5 S: C, 62.49, H, 4.41; N, 5.83. Found: C, 62.25, H, 4.47; N, 5.68.
Example 26
(S)-1-(6-Fluoropyridin-3-ylmethyl)-5-(2-phenoxymethylazetidine-1-sulfonyl)-1H-indole-2,3-dione (18g) was prepared according to the same procedure for compound 11a, except using compound 17 and 5-(bromomethyl)-2-fluoropyridine, and purified with ether to afford 74 mg (62%) of 18g as an orange solid, mp 176.8-178.3° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.27 (d, J=2.4 Hz, 1H), 8.07 (d, J=2.1 Hz, 1H), 8.01 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.79 (td, J=8.1 Hz, J=2.4 Hz, 1H), 7.22 (m, 2H), 7.00-6.77 (m, 5H), 4.92 (s, 2H), 4.49 (m, 1H), 4.09 (m, 2H), 3.85 (m, 2H), 2.35-2.23 (m, 2H). Anal. Calcd for C 24 H 20 FN 3 O 5 S: C, 59.87, H, 4.19; N, 8.73. Found: C, 59.81, H, 4.16; N, 8.62.
Example 27
(S)-1-(2-Fluoropyridin-4-yl-methyl)-5-(2-phenoxymethylazetidine-1-sulfonyl)-1H-indole-2,3-dione (18h) was prepared according to the same procedure for compound 11a, except using compound 17 and 4-(bromomethyl)-2-fluoropyridine, and purified with ether to afford 36 mg (30%) of 18h as an orange solid, mp 159.0-159.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.23 (d, J=5.1 Hz, 1H), 8.08 (s, 1. H), 7.98 (dd, J=8.7 Hz, J=2.1 Hz, 1H), 7.22 (m, 2H), 7.10 (d, J=5.4 Hz, 1H), 6.93 (t, J=7.5 Hz, 1H), 6.84-6.72 (m, 4H), 4.93 (s, 2H), 4.49 (m, 1H), 4.07 (m, 2H), 3.91-3.81 (m, 2H), 2.35-2.22 (m, 2H). Anal. Calcd for C 24 .FN 3 O 5 S.0.5H 2 O: C, 58.77, H, 4.32; N, 8.57. Found: C, 58.69, H, 4.45; N, 8.26.
Example 28
(S)-1-(6-Fluoropyridin-2-yl-methyl)-5-(2-phenoxymethylazetidine-1-sulfonyl)-1H-indole-2,3-dione (18i) was prepared according to the same procedure for compound 11a, except using compound 17 and 6-(bromomethyl)-2-fluoropyridine, and purified with ether to afford 62 mg (52%) of 18i as an orange solid, mp 144.7-146.1° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.03 (s, 1H), 8.00 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.82 (m, 1H), 7.27-7.11 (m, 4H), 6.92 (m, 2H), 6.79 (m, 2H). Anal. Calcd for C 24 H 20 FN 3 O 5 S: C, 59.87, H, 4.19; N, 8.73. Found: C, 59.59, H, 4.27; N, 8.48.
Example 29
2-(Pyridin-3-yl-oxymethyl)-pyrrolidine-1-carboxylic acid tert-butyl ester (19) was prepared according to the same procedure for compound 9, except using 3-hydroxypyridine. The crude product was purified with ether to afford 1.70 g (61%) of 19 as a colorless oil. 1 H NMR (300 MHz, CDCl 3 ) δ 8.32 (s, 1H), 8.21 (s, 1H), 7.21 (m, 2H), 4.16 (m, 2H), 3.99-3.86 (m, 1H), 3.38 (m, 2H), 2.05-1.84 (m, 4H), 1.47 (s, 9H).
Example 30
5-(2-(Pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (20) was prepared according to the same procedure for compound 10, except using compound 19, and the crude product was recrystallized from ethyl acetate to afford 1.75 g (82%) of 20 as a yellow solid, mp 215.9-217.8° C. 1 H NMR (300 MHz, DMSO) δ 11.42 (s, 1H), 8.26 (d, J=3.0 Hz, 1H), 8.16 (d, J=4.5 Hz, 1H), 8.02 (d, J=8.4 Hz, 1H), 7.78 (s, 1H), 7.38 (m, 1H), 7.33 (m, 1H), 7.05 (d, J=8.4 Hz, 1H), 4.15-4.02 (m, 2H), 3.90 (m, 1H), 3.34 (m, 1H), 3.12 (m, 1H), 1.87 (m, 2H), 1.67-1.54 (m, 2H). LCMS m/e: 387.8 (M+H). Anal. Calcd for C 18 H 17 N 3 O 5 S.0.5H 2 O: C, 54.54, H, 4.58; N, 10.60. Found: C, 54.56, H, 4.70; N, 10.04.
Example 31
1-Methyl-5-(2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (21a) was prepared according to the same procedure for compound 11a, except using compound 20, and the crude product was purified with ethyl acetate to afford 55 mg (55%) of 21a as a yellow solid, mp 142.1-143.4° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.24 (d, J=2.7, 1H), 8.22 (dd, J=3.9 Hz, J=2.1 Hz, 1H), 8.08 (dd, J=8.4, J=2.1 Hz, 1H), 7.26 (s, 1H), 7.21 (m, 2H), 7.00 (d, J=8.4 Hz, 1H), 4.22 (m, 1H), 3.98 (m, 2H), 3.53 (m, 1H), 3.30 (s, 3H), 3.22 (m, 2H), 2.03 (m, 2H), 1.80 (m, 2H). LCMS m/e: 401.84 (M+H). Anal. Calcd for C 19 H 19 N 3 O 5 S: C, 56.85, H, 4.77; N, 10.47. Found: C, 56.48, H, 4.87; N, 10.19.
Example 32
1-Benzyl-5-(2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (21b) was prepared according to the same procedure for compound 11a, except using compound 20 and benzyl bromide, and the crude product was purified with ether to afford 61 mg (51%) of 21b as a yellow solid, mp 79.6-80.7° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.25 (s, 1H), 8.22 (t, J=2.7 Hz, 1H), 8.04 (d, J=2.1 Hz, 1H), 7.98 (dd, J=8.4 Hz, J=2.1 Hz, 1H), 7.36 (m, 5H), 7.22 (m, 2H), 6.91 (d, J=8.8 Hz, 1H), 4.97 (s, 2H), 4.25 (m, 1H), 3.99-3.94 (m, 2H), 3.55-3.48 (m, 1H), 3.21-3.15 (m, 1H), 2.10-1.97 (m, 2H), 1.84-1.75 (m, 2H). LRMS (FAB) m/e: 484.1 (M+Li, 100); HRMS (FAB) m/e calcd for C 25 H 23 N 3 O 5 SLi (M+Li) 484.1518, found 484.1539.
Example 33
1-(4-Methoxybenzyl)-5-(2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (21c) was prepared according to the same procedure for compound 11a, except using 20 and 4-methoxybenzyl chloride. The crude product was purified with ether to afford 45 mg (36%) of 21c as a yellow solid, mp 156.7-158.4° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.26 (s, 1H), 8.23 (t, J=2.7 Hz, 1H), 8.03 (d, J=1.5 Hz, 1H), 7.98 (dd, J=8.25 Hz, J=2.1 Hz, 1H), 7.28 (d, J=8.7 Hz, 2H), 7.22 (t, J=2.1 Hz, 2H), 6.94 (d, J=8.1 Hz, 1H), 6.90 (d, J=8.7 Hz, 2H), 4.90 (s, 2H), 4.24 (m, 1H), 4.01-3.90 (m, 2H), 3.81 (s, 3H), 3.55-3.49 (m, 1H), 3.20-3.15 (m, 1H), 2.05 (m, 2H), 1.78 (m, 2H). LCMS m/e:507.9 (M+H). Anal. Calcd for C 26 H 25 N 3 O 6 S: C, 61.53, H, 4.96; N, 8.28. Found: C, 61.27, H, 4.95; N, 8.17.
Example 34
1-(4-Methylthiobenzyl)-5-(2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (21d) was prepared according to the same procedure for compound 11a, except using 20 and 4-methylsulfanylbenzyl bromide. The crude product was purified with ether to afford 57 mg (44%) of 21d as a yellow solid, mp 81.5-83.1° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.25-8.21 (m, 2H), 8.03 (d, J=1.8 Hz, 1H), 7.24 (s, 3H), 7.21 (m, 1H), 6.89 (d, J=8.4 Hz, 1H), 4.91 (s, 2H), 4.23 (m, 1H), 4.00-3.89 (m, 2H), 3.51 (m, 1H), 3.14 (m, 1H), 2.47 (s, 3H), 2.02 (m, 2H), 1.78 (m, 2H). LRMS (FAB) m/e: 530.1 (M+Li, 100); HRMS (FAB) m/e calcd for C 26 H 25 N 3 O 5 S 2 Li (M+Li) 530.1396, found 530.1397.
Example 35
1-(4-Fluorobenzyl)-5-(2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (21e) was prepared according to the same procedure for compound 11a, except using 20 and 4-fluorobenzyl bromide. The crude product was purified with ether to afford 35 mg (28%) of 21e as a yellow solid, mp 77.1-78.3° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.25 (m, 2H), 8.05 (s, 1H), 8.03-7.99 (m, 1H), 7.36-7.32 (m, 2H), 7.23 (m, 2H), 7.09 (t, J=8.7 Hz, 2H), 6.90 (d, J=8.7 Hz, 1H), 4.94 (s, 2H), 4.25 (d, J=6.0 Hz, 1H), 3.98 (m, 2H), 3.52 (m, 1H), 3.19 (m, 1H), 2.05 (m, 2H), 1.80 (m, 2H). LRMS (FAB) m/e: 502.1 (M+Li, 100); HRMS (FAB) m/e calcd for C 25 H 22 FN 3 O 5 SLi (M+Li) 502.1424, found 502.1420.
Example 36
2-(Pyridin-4-yl-oxymethyl)-pyrrolidine-1-carboxylic acid tert-butyl ester (22) was prepared according to the same procedure for compound 9, except using 4-hydroxypyridine. The crude product was purified with ethyl acetate to afford 1.31 g (47%) of 22 as a colorless oil. 1 H NMR (300 MHz, CDCl 3 ) δ 8.42 (m, 2H), 6.87 (m, 2H), 4.15 (m, 3H), 3.43 (m, 2H), 1.98 (m, 4H), 1.50 (s, 9H).
Example 37
5-(2-(Pyridin-4-yl-oxymethyl)-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (23) was prepared according to the same procedure for compound 10, except using compound 22, purified with ethyl acetate to afford 1.17 g (55%) of 23 as a yellow solid, mp 204.2-205.3° C. 1 H NMR (300 MHz, CDCl 3 ) δ 11.44 (s, 1H), 8.37 (d, J=5.7 Hz, 2H), 8.03 (dd, J=8.4 Hz, J=2.1 Hz, 1H), 7.79 (s, 1H), 7.06 (d, J=8.4 Hz, 1H), 6.96 (d, J=6.0 Hz, 2H), 4.17-4.05 (m, 2H), 3.90 (m, 1H), 3.32 (m, 1H), 3.10 (m, 1H), 1.85 (m, 2H), 1.60 (m, 2H). LCMSm/e: 387.9 (M+H). Anal. Calcd for C 18 H17N 3 O 5 S.0.75H 2 O: C, 53.92, H, 4.65; N, 10.48. Found: C, 54.14, H, 4.39; N, 10.35.
Example 38
1-[4-(2-Fluoroethoxy)-benzyl]-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (WC-II-89). A solution of 8 (97 mg, 0.25 mmol) in DMF (3 mL) was added 60% NaH (10 mg, 0.25 mmol) at 0° C. The mixture was stirred 5 min, then 4 (250 mg) was added. The mixture was stirred 10 min. at 0° C., ethyl acetate (50 mL) was added, washed with water (30 mL), NaCl (30 mL) and dried over Na 2 SO 4 . After evaporation of the ethyl acetate, the crude product was purified with ether to afford of 74 mg (55%) of WC(II)-89 as a yellow solid, mp 164.0-164.8° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.01 (s, 1H), 7.95 (d, J=8.1 Hz, 1H), 7.28-7.21 (m, 4H), 6.95-6.80 (m, 6H), 4.86 (s, 2H), 4.75 (dt, J=47.4 Hz, J=4.2 Hz, 2H), 4.20 (dt, J=28.5 Hz, J=4.2 Hz, 2H), 4.15 (m, 1H), 3.92 (m, 2H), 3.49 (m, 1H), 3.22 (m, 1H), 2.02 (m, 2H), 1.78 (m, 2H). Anal. Calcd for C 28 H 27 FN 2 O 6 S: C, 62.44, H, 5.05; N, 5.20. Found: C, 62.50, H, 5.11, N, 5.12.
Example 39
1-[4-(2-Bromoethoxy)-benzyl]-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (9) was prepared according to the same procedure for compound WC-II-89 (Example 38) except using compound 6, purified with hexane-ether (1:2) to afford 587 mg (68%) of 9 as a yellow solid, mp 164.1-164.9° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (s, 1H), 8.01 (dd, J=8.1 Hz, J=2.1 Hz, 1H), 7.32-7.25 (m, 4H), 6.70-6.84 (m, 6H), 4.91 (s, 2H), 4.32 (t, J=6.0 Hz, 2H), 4.20 (m, 1H), 3.97 (m, 2H), 3.67 (t, J=6.3 Hz, 2H), 3.55 (m, 1H), 3.26 (m, 1H), 2.07 (m, 2H), 1.83 (m, 2H). Anal. Calcd for C 28 H 27 BrN 2 O 6 S.0.25H 2 O: C, 55.68, H, 4.59; N, 4.64. Found: C, 55.66, 4.28, N, 4.54.
Example 40
Methanesulfonic acid 2-{4-[2,3-dioxo-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-2,3-dihydro-indol-1-ylmethyl]-phenoxy}-ethyl ester (10). A solution of 9 (300 mg, 0.5 mmol) and AgOMs (1.01 g, 5.0 mmol) in CH 3 CN (10 mL) was heated to reflux overnight. After evaporation of the solvent, the crude product was purified with ether to afford 228 mg (74%) of 10 as a yellow solid, mp 151.8-152.6° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.05 (s, 1H), 8.01 (dd, J=8.1 Hz, J=1.8 Hz, 1H), 7.33-7.25 (m, 4H), 7.00-6.84 (m, 6H), 4.90 (s, 2H), 4.60 (t, J=4.8 Hz, 2H), 4.27 (t, J=4.8 Hz, 2H), 4.20 (m, 1H), 3.97 (m, 2H), 3.54 (m, 1H), 3.26 (m, 1H), 3.11 (s, 3H), 2.06 (m, 2H), 1.83 (m, 2H). Anal. Calcd for C 29 H 30 N 2 O 9 S 2 : C, 56.66, H, 4.92; N, 4.56. Found: C, 56.74, H, 4.88, N. 4.67. HPLC conditions for purification of [ 18 F]WC-II-89: Alltech Ecosoil C18 250×10 mm, 10μ; 25% acetonitrile, 45% methanol, 30% 0.1 M ammonium formate buffer (pH=4.5); 5 mL/min, 251 nm; t R =15 min.
Example 41
1-(4-Bromo-benzyl)-5-(2-Phenoxymethyl-pyrrolidine-1-sulfonyl)-1H-indole-2,3-dione (25d, see FIG. 19 ) 60% NaH (10 mg, 0.25 mmol) was added to a solution of compound 24 (16, 41) (97 mg, 0.25 mmol) in DMF (3 mL) at 0° C. The mixture was stirred 15 min. at 0° C., then 4-bromobenzyl bromide (125 mg, 0.5 mmol) was added. The mixture was stirred 1 h at room temperature, ethyl acetate (50 mL) was added, washed with water (30 mL), saturated NaCl (30 mL) and dried over Na 2 SO 4 . After evaporation of the solvent, the crude product was purified with hexane-CH 2 Cl 2 -ether (1:1:1) to afford 108 mg (78%) of 25d as a yellow solid, mp 112.1-113.4° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.02 (s, 1H), 7.96 (d, J=8.1 Hz, 1H), 7.50 (d, J=8.4 Hz, 2H), 7.20 (m, 5H), 6.92 (t, J=7.8 Hz, 1H), 6.80 (d, J=8.1 Hz, 2H), 4.87 (s, 2H), 4.15 (m, 1H), 3.93 (m, 2H), 3.49 (m, 1H), 3.23 (m, 1H), 2.02 (m, 2H), 1.79 (m, 2H).
Example 42
1-(4-Hydroxy-benzyl)-5-[2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl]-1H-indole-2,3-dione (28b) 1-[4-(tert-Butyl-diphenyl-silanyloxy)-benzyl]-5-[2-(pyridin-3-yloxymethyl)-pyrrolidine-1-sulfonyl]-1H-indole-2,3-dione (150 mg, 0.2 mmol) and nBu 4 NF (53 mg, 0.2 mmol) in THF (6 mL) and water (2 mL) was stirred for 2 h, ethyl acetate (50 mL) was added, washed with water (30 mL), saturated NaCl (30 mL) and dried over Na 2 SO 4 . The crude product was purified with ether-ethyl acetate (1:1) to afford 65 mg (66%) of 28b as a yellow solid, mp 126.7-128.8° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.21 (m, 2H), 8.01 (s, 10H), 7.95 (d, J=8.1 Hz, 1H), 7.26 (m, 2H), 7.19 (d, J=8.4 Hz, 2H), 6.90 (d, J=8.7 Hz, 1H), 6.84 (d, J=8.4 Hz, 2H), 4.87 (s, 2H), 4.19 (m, 1H), 3.95 (m, 2H), 3.48 (m, 2H), 3.19 (m, 1H), 2.00 (m, 2H), 1.79 (m, 2H).
Example 43
1-(4-Bromo-benzyl)-5-[2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl]-1H-indole-2,3-dione (28c) was prepared according to the same procedure for compound 25d except using 29 and 4-bromobenzyl bromide, purified with CH 2 Cl 2 -ethyl acetate (1:1) to afford 53 mg (38%) of 28c as a yellow solid, mp 92.1-93.3° C. 1 H NMR (300 MHz, CDCl 3 ) δ 8.24 (m, 2H), 8.04 (s, 1H), 7.98 (d, J=8.1 Hz, 1H), 7.51 (d, J=8.1 Hz, 2H), 7.23 (m, 4H), 6.86 (d, J=8.4 Hz, 1H), 4.90 (s, 2H), 4.23 (m, 1H), 3.97 (m, 2H), 3.50 (m, 1H), 3.17 (m, 1H), 2.02 (m, 2H), 1.78 (m, 2H).
Example 44
2-[2-Oxo-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1,2-dihydro-indol-3-yl-idene]-malononitrile (26) A solution of 24 (97 mg, 0.25 mmol) and malononitrile (18 mg, 0.27 mmol) in methanol (4 mL) was heated to reflux for 1 h, then cooled to room temperature. The solid was filtered out and dried in vacuum to afford 93 mg (86%) of 26 as a red solid, mp 245.7-248.4° C. 1 H NMR (300 MHz, DMSO) δ 11.66 (s, 1H), 8.23 (s, 1H), 8.02 (d, J=8.7 Hz, 1H), 7.25 (t, J=8.7 Hz, 2H), 7.09 (d, J=8.7 Hz, 1H), 6.90 (m, 3H), 4.05 (m, 1H), 3.92 (m, 2H), 3.39 (m, 1H), 3.15 (m, 1H), 1.90 (m, 2H), 1.72 (m, 2H).
Example 45
2-[1-Methyl-2-oxo-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1,2-dihydro-indol-3-yl-idene]-malononitrile (27a) was prepared according to the same procedure for compound 26 except using 25a (16, 41) to afford 39 mg (87%) of 27a as a red solid, mp 217.5° C. (decomp). 1H NMR (300 MHz, CDCl 3 ) δ 8.47 (s, 1H), 8.06 (dd, J=8.6 Hz, J=1.8 Hz, 1H), 7.21 (t, J=7.8 Hz, 2H), 6.93 (t, J=7.5 Hz, 1H), 6.89 (d, J=8.7 Hz, 1H), 6.73 (d, J=7.8 Hz, 2H), 4.11 (m, 1H), 4.08 (m, 1H), 4.00 (m, 1H), 3.49 (m, 2H), 3.26 (s, 3H), 2.11-1.88 (m, 4H).
Example 46
2-[1-Benzyl-2-oxo-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1,2-dihydroindol-3-yl-idene]-malononitrile (27b) was prepared according to the same procedure for compound 26 except using 25b, (41) to afford 92 mg (88%) of 27b as a purple solid, mp 196.6° C. (decomp). 1 H NMR (300 MHz, CDCl 3 ) δ 8.43 (s, 1H), 7.93 (dd, J=8.6 Hz, J=1.8 Hz, 1H), 7.39-7.29 (m, 5H), 7.14 (t, J=7.2 Hz, 2H), 6.89 (t, J=7.2 Hz, 1H), 6.83 (d, J=8.7 Hz, 1H), 6.68 (d, J=7.8 Hz, 2H), 4.90 (s, 2H), 4.05 (m, 2H), 3.97 (m, 1H), 3.45 (m, 2H), 2.07-1.85 (m 4H).
Example 47
2-[1-(Hydroxy-benzyl-2-oxo-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1,2-dihydro-indol-3-yl-idene]-malononitrile (27c) was prepared according to the same procedure for compound 26 except using 25c (41), to afford 68 mg (84%) of 27c as a purple solid, mp 174.9° C. (decomp). 1 H NMR (300 MHz, DMSO) δ 9.51 (s, 1H), 8.30 (s, 1H), 8.10 (dd, J=8.6 Hz, J=1.8 Hz, 1H), 7.32-7.20 (m, 5H), 6.95-6.84 (m, 3H), 6.76 (d, J=8.7 Hz, 2H), 4.87 (s, 2H), 4.09 (m, 1H), 3.97 (m, 2H), 3.40 (m, 1H), 3.20 (m, 1H), 1.90 (m, 2H), 1.71 (m, 2H).
Example 48
2-[1-(4-Bromo-benzyl)-2-oxo-5-(2-phenoxymethyl-pyrrolidine-1-sulfonyl)-1,2-dihydro-indol-3-yl-idene]-malononitrile (27d) was prepared according to the same procedure for compound 26 except using 25d, to afford 52 mg (86%) of 27d as a purple solid, mp 237.0° C. (decomp). 1 H NMR (300 MHz, CDCl 3 ) δ 8.46 (s, 1H), 7.95 (d, J=8.1 Hz, 1H), 7.51 (d, J=8.4 Hz, 2H), 7.20-7.13 (m, 4H), 6.90 (t, J=7.5 Hz, 1H), 6.79 (d, J=8.4 Hz, 1H), 6.68 (d, J=7.8 Hz, 2H), 4.84 (m, 2H), 4.06 (m, 2H), 3.97 (m, 1H), 3.46 (m, 2H), 2.08-1.86 (m, 4H).
Example 49
2-{1-Benzyl-2-oxo-5-[2-(pyridine-3-yloxymethyl)-pyrrolidine-1-sulfonyl]-1,2-dihydro-indol-3-yl-idene}-malononitrile (30a) was prepared according to the same procedure for compound 26 except using 28a (41), to afford 59 mg (75%) of 30a as a purple solid, mp 216.5° C. (decomp). 1 H NMR (300 MHz, CDCl 3 ) δ 8.53 (s, 1H), 8.23 (m, 2H), 7.98 (dd, J=8.4 Hz, J=1.8 Hz, 1H), 7.42-7.35 (m, 5H), 7.20 (m, 2H), 6.91 (d, J=8.7 Hz, 1H), 4.98 (s, 2H), 4.23 (m, 1H), 4.05 (m, 2H), 3.55 (m, 1H), 3.33 (m, 1H), 2.08 (m, 2H), 1.90 (m, 2H).
Example 50
2-{1-(4-Hydroxy-benzyl)-2-oxo-5-[2-(pyridine-3-yloxymethyl)-pyrrolidine-1-sulfonyl]-1,2-dihydro-indol-3-yl-idene}-malononitrile (30b) was prepared according to the same procedure for compound 26 except using 28b, to afford 46 mg (85%) of 30b as a purple solid, mp 203.3° C. (decomp). 1 H NMR (300 MHz, DMSO) δ 9.50 (s, 1H), 8.31 (s, 1H), 8.25 (d, J=2.7 Hz, 1H), 8.17 (dd, J=4.5 Hz, J=1.5 Hz, 1H), 8.10 (d, J=8.1 Hz, 1H), 7.34 (m, 3H), 7.24 (d, J=8.4 Hz, 2H), 6.76 (d, J=8.7 Hz, 2H), 4.88 (s, 2H), 4.16 (m, 1H), 4.08 (m, 1H), 3.96 (m, 1H), 3.41 (m, 1H), 3.18 (m, 1H), 1.91 (m, 2H), 1.71 (m, 2H).
Example 51
2-{1-(4-Bromo-benzyl)-2-oxo-5-[2-(pyndine-3-yloxymethyl)-pyrrolidine-1-sulfonyl]-1,2-dihydro-indol-3-yl-idene}-malononitrile (30c) was prepared according to the same procedure for compound 26 except using 28c, to afford 16 mg (45%) of 30c as a purple solid, mp 232.3° C. (decomp). 1 H NMR (300 MHz, CDCl 3 ) δ 8.50 (s, 1H), 8.21 (m, 1H), 8.16 (s, 1H), 7.96 (d, J=8.4 Hz, 1H), 7.51 (d, J=8.1 Hz, 2H), 7.20 (m, 4H), 6.84 (d, J=8.7 Hz, 1H), 4.89 (m, 2H), 4.20 (m, 1H), 4.02 (m, 2H), 2.05-1.78 (m, 4H).
Example 52
2-{1-(4-Methoxy-benzyl)-2-oxo-5-[2-(pyridin-3-yloxymethyl)-pyrrolidine-1-sulfonyl]-1,2-dihydro-indol-3-yl-idene}-malononitrile (30d) was prepared according to the same procedure for compound 26 except using 28d (41), to afford 91 mg (82%) of 30d as a purple solid, mp 132.4° C. (decomp). 1 H NMR (300 MHz, CDCl 3 ) δ 8.47 (s, 1H), 8.20 (m, 2H), 7.95 (dd, J=8.4 Hz, J=1.8 Hz, 1H), 7.26 (d, J=8.7 Hz, 2H), 7.19 (m, 2H), 6.92 (d, J=8.4 Hz, 1H), 6.89 (d, J=8.7 Hz, 2H), 4.88 (s, 2H), 4.21 (m, 1H), 4.02 (m, 2H), 3.80 (s, 3H), 3.50 (m, 1H), 3.29 (m, 1H), 2.05 (m, 2H), 1.86 (m, 2H).
Example 53
1-[4-(tert-Butyl-diphenyl-silanyloxy)-benzyl]-5-[2-(pyridin-3-yl-oxymethyl)-pyrrolidine-1-sulfonyl]-1H-indole-2,3-dione was prepared according to the same procedure for compound 25d except using 29 (41) and 4-(tert-Butyl-diphenyl-silanyloxy)-benzyl bromide, purified with ether-ethyl acetate (1:1) to afford 332 mg (59%) as a yellow solid, 1 H NMR (300 MHz, CDCl 3 ) δ 8.25 (s, 1H), 8.22 (m, 1H), 8.00 (s, 1H), 7.93 (d, J=8.1 Hz, 1H), 7.67 (m, 4H), 7.45-7.32 (m, 6H), 7.22 (m, 2H), 7.05 (d, J=8.7 Hz, 2H), 6.83 (d, J=8.1 Hz, 1H), 6.74 (d, J=9.0 Hz, 2H), 4.80 (s, 2H), 4.24 (m, 1H), 3.95 (m, 2H), 3.51 (m, 1H), 3.14 (m, 1H), 2.02 (m, 2H), 1.78 (m, 2H), 1.08 (s, 9H). Anal. Calcd for C 41 H 41 N 3 O 6 SSi: C, 67.28, H, 5.65; N, 5.74. Found: C, 66.84, H, 5.69; N, 5.62.
Example 54
This example provides, in Table 8, Elemental analysis of the Michael Acceptor Isatin analogues disclosed herein.
TABLE 8
Elemental analysis of Isatin Michael Acceptor analogues.
Calcd
Found
Compound
Formula
C
H
N
C
H
N
9d
C 26 H 23 BrN 2 O 5 S
56.22
4.17
5.04
55.96
4.25
4.81
10b
C 25 H 23 N 3 O 6 S•0.25H 2 O
60.29
4.76
8.44
60.19
5.11
8.01
10c
C 25 H 22 BrN 3 O 5 S
53.96
3.99
7.55
53.36
4.11
7.36
8
C 22 H 18 N 4 O 4 S
60.82
4.18
12.9
60.75
4.14
12.68
11a
C 23 H 20 N 4 O 4 S
61.59
4.49
12.49
61.43
4.46
12.39
11b
C 29 H 24 N 4 O 4 S
66.4
4.61
10.68
66.15
4.56
10.58
11c
C 29 H 24 N 4 O 5 S•0.5H 2 O
63.38
4.58
10.19
63.53
4.69
10.09
11d
C 29 H 23 BrN 4 O 4 S
57.72
3.84
9.28
57.49
3.81
9.2
12a
C 28 H 23 N 5 O 4 S•0.5H 2 O
62.91
4.53
13.1
63.1
4.26
12.96
12b
C 28 H 23 N 5 O 5 S•0.25H 2 O
61.58
4.34
12.82
61.78
4.15
12.68
12c
C 28 H 22 BrN 5 O 4 S
55.64
3.67
11.59
55.37
3.65
11.4
12d
C 29 H 25 N 5 O 5 S•0.5H 2 O
61.69
4.64
12.4
61.73
4.52
11.96
Example 55
This example illustrates a 2-dimensional NMR study of an Isatin Michael Acceptor of the present teachings.
In a NMR tube compound 27d (18.1 mg, 0.03 mmol) was dissolved in CDCl 3 (0.75 mL) prior to addition of benzylmercaptan (18.6 mg, 0.15 mmol). The mixture was maintained for 24 h at room temperature prior to be NMR analysis.
NMR spectra were recorded on a Varian Inc. (Palo Alto, Calif., USA) Ionva-500. Proton and carbon chemical shifts were measured in ppm downfield from an internal TMS standard. Proton spectra were obtained using a 5,200 Hz spectral width collected with 64 K data points with 5.0 s preacquisition delays.
A two-dimensional COSY spectrum was collected into a 512×2,048 data matrix with 4 scans per t 1 value. The time domain data were zero filled to yield a 2,048×2,048 data matrix and Fourier transformed using a sine-bell weighting function in both the t 2 and t 1 dimensions.
A gradient based proton-detected heteronuclear multiple quantum coherence (gHMQC and gHMBC) spectrum was recorded. The 90° 1 H pulse width was 8.0 μs and the 90° 13 C pulse width was 14 μs. The proton spectral width was set to 4,750 Hz and the carbon spectral width was set to 21563 Hz. A 500×2,000 data matrix with 4 scans per t 1 value was collected. Gaussian and sine bell weighing functions were used in weighting the t 2 and the t 1 dimensions, respectively. After two-dimensional Fourier transformation, the spectra resulted in 512×2,048 data points, which were phase and baseline corrected in both dimensions.
The 1 H spectra of starting material 27d and the Michael addition product were shown in FIGS. 21 and 22 . The COSY, HMQC, and HMBC spectra of the Michael addition product were shown in FIGS. 23-25 . The 1 H and 13 C assigned for the Michael addition product 31b were shown in FIG. 26 .
All publications and patent applications cited in this specification are herein incorporated by reference as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Although the foregoing teachings have been described in some detail by way of illustration and example for purposes of clarity of understanding, it will be readily apparent to those of ordinary skill in the art in light of the teachings that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.
REFERENCES
1. Jacobson, M. D.; Weil, M.; Raff, M. C. Programmed Cell Death in Animal Development. Cell 1997, 88, 347-354.
2. Reed, J. C. Apoptosis-based Therapies. Nature Rev. Drug Discovery 2002, 1, 111-121.
3. Rodriguez, I.; Matsuura, K.; Ody, C.; Nagata, S.; Vassalli, P. Systemic injection of a tripeptide inhibits the intracellular activation of CPP32-like proteases in vivo and fully protects mice against Fas-mediated fulminant liver destruction and death. J. Exp. Med. 1996, 184, 2067-2072.
4. O'Brien, T.; Lee, D. Prospects for caspase inhibitors. Mini Rev. Med. Chem. 2004, 4, 153-165.
5. Denault, J.-B.; Salvesen, G. S. Capsases: keys in the ignition of cell death. Chem. Rev. 2002, 102, 4489-4499.
6. Garcia-Calvo, M.; Peterson, E. P.; Leiting, B.; Ruel, R.; Nicholson, D. W.; Thornberry, N. A. Inhibition of human caspases by peptide-based and macromolecular inhibitors. J. Biol. Chem. 1998, 273, 32608-32613.
7. Hotchkiss, R. S.; Chang, K. C.; Swanson, P. E.; Tinsley, K. W.; Hui, J. J.; Klender, P.; Xanthoudakis, S.; Roy, S.; Black, C.; Grimm, E.; Aspiotis, R.; Han, Y.; Nicholson, D. W.; Karl, I. E. Caspase inhibitors improve survival in sepsis: a critical role of the lymphocyte. Nature Immunol. 2000, 1, 496-501.
8. Choong, I. C.; Lew, W.; Lee, D.; Pham, P.; Burdett, M. T.; Lam, J. W.; Wiesmann, C.; Luong, T. N.; Fahr, B.; DeLano, W. L.; McDowell, R. S.; Allen, D. A.; Erlanson, D. A.; Gordon, E. M.; O'Brien, T. Identification of potent and selective small-molecule inhibitors of caspase-3 through the use of extended tethering and structure-based drug design. J. Med. Chem. 2002, 45, 5005-5022.
9. Linton, S. D.; Karanewsky, D. S.; Ternansky, R. J.; Wu, J. C.; Pham, B.; Kodandapani, L.; Smidt, R.; Diaz, J.-L.; Fritz, L. C.; Tomaselli, K. J. Acyl peptides as reversible caspase inhibitors. Part 1: Initial lead optimization. Bioorg. Med. Chem. Lett. 2002, 12, 2969-2971.
10. Linton, S. D.; Karanewsky, D. S.; Temansky, R. J.; Chen, N.; Guo, X.; Jahangiri, K. G.; Kalish, V. J.; Meduna, S. P.; Robinson, E. D.; Ullman, B. R.; Wu, J. C.; Pham, B.; Kodandapani, L.; Smidt, R.; Diaz, J.-L.; Fritz, L. C.; von Krosigk, U.; Roggo, S.; Schmitz, A.; Tomaselli, K. J. Acyl peptides as reversible caspase inhibitors. Part 2: Further optimization. Bioorg. Med. Chem. Lett. 2002, 12, 2969-2971.
11. Han, Y.; Giroux, A.; Grimm, E. L.; Aspiotis, R.; Francoeur, S.; Bayl), C. I.; Mckay, D. J.; Roy, S.; Xanthoudakis, S.; Vallancourt, J. P.; Rasper, D. M.; Tam, J.; Tawa, P.; Thomberry, N. A.; Paterson, E. P.; Garcia-Calvo, M.; Becker, J. W.; Rotonda, J.; Nicholson, D. W.; Zamboni, R. J. Discovery of novel aspartyl ketone dipeptides as potent and selective caspase-3 inhibitors. Bioorg. Med. Chem. Lett. 2004, 14, 805-808.
12. Becker, J. W.; Rotonda, J.; Soisson, S. M.; Aspiotis, R.; Bayl), C.; Francoeur, S.; Gallant, M.; Garcia-Calvo, M.; Giroux, A.; Grimm, E.; Han, Y.; McKay, D.; Nicholson, D. W.; Peterson, E.; Renaud, J.; Roy, S.; Thomberry, N.; Zamboni, R. Reducing the peptidyl features of caspase-3 inhibitors: a structural analysis. J. Med. Chem. 2004, 47, 2466-2474.
13. Han, B. H., et al., J. Biol. Chem. 277, 30128-31036, 2002.
14. Lee, D. et al., J. Biol. Chem. 275, 16007-16104, 2000.
15. Chapman, J. G.; Magee, W. P.; Stukenbrok, H. A.; Beckius, G. E.; Milici, A. J.; Tracey, W. R. A novel nonpeptidic caspase 3/7 inhibitor, (S)-(+)-5-[1-(2-methoxymethylpyrrolidinyl)sulfonyl]-isatin reduces myocardial ischemic injury. Eur. J. Pharmacol. 2002, 456, 59-68.
16. Lee, D., et al., J. Med. Chem. 44, 2015-2026, 2001.
17. Abreo, M. A.; Lin, N.; Garvey, D. S.; Gunn, D. E.; Hettinger, A.; Wasicak, J. T.; Paulik, P. A.; Martin, Y. C.; Dannelly-Roberts, D. L.; Anderson, D. J.; Sullivan, J. P.; Williams, M.; Arneric, S. P.; Holladay, M. W. Novel 3-pyridyl ethers with subnanomolar affinity for central nicotinic acetylcholine receptors. J. Med. Chem. 1996, 39, 817-825.
18. Wildman, S. A.; Crippen, G. M. Prediction of Physicochemical Parameters by Atomic Contributions. J. Chem. Inf. Comput. Sci. 1999, 39, 868-873.
19. Stanton, D. T.; Jurs, P. C. Development and Use of Charged Partial Surface Area Structural Descriptors in Computer-Assisted Quantitative Structure-Property Relationship Studies. Anal. Chem. 1990, 62, 2323-2329.
20. Wallace, A. C.; Laskowski, R. A.; Thornton, J. M. LIGPLOT: A Program to generate schematic diagrams of protein-ligand interactions. Protein Eng. 1995, 8, 127-124.
21. Sullivan, P. T.; Sullivan, C. B.; Norton, S. J. R-Fluoro- and R-hydroxypyridylalanines. J. Med. Chem. 1971, 14, 211-214.
22. Berman, H. M.; Westbrook, J.; Feng, Z.; Gilliland, G.; Bhat, T. N. et al. The Protein Data Bank. Nucleic Acids Res. 2000, 28, 235-242.
23 . Molecular Operating Environment ( MOE ); 2004.03 ed.; Chemical Computing Group: Montreal, Canada.
24. Mohamadi, F.; Richards, N. G. J.; Guida, W. C.; Liskamp, R.; Lipton, M. et al. Macromodel—an Integrated Software System for Modeling Organic and Bioorganic Molecules Using Molecular Mechanics. J. Comput. Chem. 1990, 11, 440.
25. Jones, G.; Willett, P.; Glen, R. C.; Leach, A. R.; Taylor, R. Development and Validation of a Genetic Algorithm for Flexible Docking. J. Mol. Biol. 1997, 267, 727-748.
26. White, E. Gene Dev. 1996, 10, 1.
27. Ashkenazi, A.; Dixit, V. M. Science 1998, 281, 1305.
28. Evan, G.; Littlewood, T. Science 1998, 281, 1317.
29. Green, D. R.; Reed, J. C. Science 1998, 281, 1309.
30. Thornberry, N. A.; Lazebnik, Y. Science 1998, 281, 1312.
31. Dive, C.; Hickman, J. A. Br. J. Cancer 1991, 64, 192.
32. Review see Lahorte, C. M. M.; Vanderheyden, J.; Steinmetz, N.; Van De Wiele, C.; Dierckx, R. A.; Slegers, G. Eur. J. Nucl. Med. Mol. Imaging 2004, 31, 887.
33. Neuss, M.; Crow, M. T.; Chesley and Lakatta, E. G. Cardiovascular Drugs and therapy, 2001, 15, 507.
34. Yoo, J.; Dence, C. S.; Sharp, T. L.; Katzenellenbogen, J. A.; Welch, M. J. J. Med. Chem. 2005, 48, 6366.
35. Ledda-Columbano, G. M.; Coni, P.; Faa, G.; Manenti, G.; Columbano, A. Am. J. Pathol. 1992, 140, 545.
36. Higami, Y.; Tanaka, K.; Tsuchiya, T.; Shimokawa, I. Mutation Res. 2000, 457, 105.
37. Yagle, K. J.; Eary, J. F.; Tait, J. T.; Grierson, J. R.; Link, J. M. Lewellen, B.; Gibson, D. F.; Krohn, K. A. J. Nucl. Med. 2005, 46, 658.
38. Faust A.; Wagner S.; Keul P.; Schober O.; Levkau B.; Schaefers M.; Kopka K. J. Label Compd. Radiopharm. 2005, 48, S260 (abstract).
39. Powers, J. C., et al., Chemical Reviews (Washington, D.C., United States) 2002, 102(12), 4639-4750.
40. Ekici, O. D., et al., J. Med. Chem 47, 1889-1892, 2000.
41. Chu, W., et al., Journal of Medicinal Chemistry 48, 7637-7647, 2005.
|
Novel isatin analogues, including isatin analogues comprising Michael Acceptors (IMAs) are disclosed. Further disclosed are methods of synthesis of the isatin analogues, and uses of the analogues, including inhibition of caspase-3 and caspase-7, and in vivo imaging of apoptosis by Positron emission tomography (PET) or Single Photon Emission Computed Tomography (SPECT).
| 0
|
PRIORITY CLAIM
The present application claims the priority of European patent application, Serial No. 05100168.3, titled “Incremental Indexing,” which was filed on Jan. 13, 2005, and which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to the field of updating a database, and it particularly relates to managing indexes upon insertion of data rows.
BACKGROUND OF THE INVENTION
Computer databases are a common mechanism for storing information on computer systems while providing easy access to users. A typical database is an organized collection of related information stored as rows having fields of information. As an example, a database of employees may have a row for each employee comprising different columns or fields such as name, department, phone number, salary, etc. Rows are organized in a table, a two-dimensional structure with rows indicating the rows having fields of information and columns indicating the fields.
To speed up access to the data of the database table, rows can be indexed and the index entered into a base index. For example, one index can indicate where to find the rows containing a particular name, another index can indicate where to find the rows containing specific departments.
To allow for complete responses to queries, each time the database is updated by inserting a new row, the index or indexes are also updated; i.e., a corresponding entry is inserted in the index.
Rows and indexes are physically stored on storage media such as tape or disk. When taking any action on the database such as processing a query, inserting a new row, indexing a new row, etc., the corresponding data is retrieved from the storage medium into a cache. The database management system performs actions on the data while the data is in the cache.
In large databases, the index is also large. Consequently, new entries are time consuming. This is particularly a problem if the index is larger than the cache such that many storage medium reads are necessary for updating the index.
What is therefore needed is a system, a computer program product, and a method for indexing incrementally to enhance the inserting performance of a database. The need for this solution has heretofore remained unsatisfied.
SUMMARY OF THE INVENTION
The present invention satisfies this need, and presents a system, a computer program product, and an associated method (collectively referred to herein as “the system” or “the present system”) for incremental indexing upon insertion of data rows in a database.
According to a preferred embodiment of the present invention, a database management system manages a database that stores a database table containing data pages. Each data page is capable of storing data rows. The data rows store information organized into particular columns. The database table has a base index for logically ordering the data rows. The base index comprises index entries wherein each data row is referenced by a corresponding index entry. The present system comprises a method for indexing the database comprises inserting a row, generating an index increment, making an index entry associated with the row into the index increment, and merging the index increment with the base index.
If the database is updated by inserting a new row, the indexing is performed immediately, to provide correct access to all information. However, the present system does not perform the indexing in the base index. Rather, the present system generates an index increment and performs the corresponding index entry in the index increment instead of the base index. The present system merges the index increment with the base index.
The index increment is typically smaller than the base index because it is newly generated. The small size of the index increment facilitates management of the index increment. The place at which to enter the new index entry is found much faster than when searching the entire base index for an entry place. The merger of the index increment and base index can be timed such that the performance of the database management system is not impeded by the merger. If a query is submitted before the index increment and base index have been merged, the incremental index and the base index are scanned. Consequently, correct access to information is provided.
When more than one row is inserted, index entries concerning the rows are made into the index increment and the merging is performed after rows have been inserted and indexed. In cases where a plurality of rows is inserted, the gain in speed by indexing into an index increment instead of the base index is especially high.
Furthermore, the present system can insert more than one row and generate more than one index increment. This is especially convenient if large amounts of rows are inserted that would otherwise lead to too large an index increment, thus leading again to a decrease in speed of the indexing.
BRIEF DESCRIPTION OF THE DRAWINGS
The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
FIG. 1 schematically illustrates a conventional database management system;
FIG. 2 comprises FIGS. 2A and 2B and schematically illustrates conventional indexing;
FIG. 3 schematically illustrates indexing according to the present invention;
FIG. 4 comprises FIGS. 4A , 4 B, 4 C, and 4 D and schematically illustrates a database management system according to the present invention;
FIG. 5 is a process flowchart illustrating a method for insert processing;
FIG. 6 is a process flowchart illustrating a method for building incremental indexes;
FIG. 7 is a process flowchart illustrating a method for query processing;
FIG. 8 is a process flowchart illustrating a method for implicit merging of incremental indexes; and
FIG. 9 is a process flowchart illustrating a method for explicit merging of incremental indexes.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates schematically a conventional database management system 1 . The conventional database management system 1 may be implemented, for example, as computer with an appropriate computer program product running on it. The computer may be a stand-alone device or be a member of a network with servers and clients.
The conventional database management system 1 comprises a relational data system 10 , a data and index manager 11 , and a cache manager 12 . The conventional database management system 1 interacts with an application program 2 or interactive user that generates database requests such as, for example, SQL statements. These SQL statements may be, for example, “insert” or “non-insert” statements, such as “read”, “select”, “delete”, etc. and result in retrieval or modifications of the stored data. The database requests such as SQL statements are processed by various components, such as the relational data system 10 , the data and index manager 11 , or the cache manager 12 and result in retrieval or modification of the data stored in a storage media subsystem such as a media manager 3 or storage media 4 .
In particular, the database requests are processed by an insert-processing module 110 for insert requests and by a non-insert processing module 111 for non-insert requests. The insert processing module 110 and the non-insert processing module 111 are components of the data and index manager 11 . In response to the database requests, e.g. SQL statements from the application program 2 , the conventional database management system 1 returns information on rows of a database table and status information. The conventional database management system 1 may also receive information on rows to add.
Data such as the content of a database table and a base index is stored on the storage media 4 . The storage media 4 comprises media such as, for example, disks or tapes. To store and retrieve data, the conventional database management system 1 uses the cache manager 12 . The cache manager 12 manages the cache 120 . The cache 120 is, for example, arranged as buffer pools. The cache manager 12 communicates with the media manager 3 by sending read or write pages requests and by receiving data and index pages. Pages (further referenced herein as blocks or physical blocks) are entities corresponding to the physical blocks of the storage media containing the data of the database. The media manager 3 provides pages by communicating with the storage media 4 via I/O programs addressing the physical blocks.
The relational data system 10 is arranged to perform tasks such as parsing, optimizing, predicate evaluation etc.
The database structure is illustrated in FIG. 2 ( FIGS. 2A , 2 B). There are shown a database table 20 where new data is entered as inserted database table rows such as, for example, row A, 201 , row B, 202 , and row C, 203 , (collectively referenced as rows 201 , 202 , 203 ) with information of various categories arranged in columns. A base index 21 of the database table 20 is organized as a tree.
For each of the inserted rows 201 , 202 , 203 , the base index 21 requires updating. An index update comprises adding an index entry such as, for example, an index entry A, 211 , an index entry B, 212 , an index entry C, 213 , (collectively referenced as entries 211 , 212 , 213 ) pointing to the respective rows 201 , 202 , 203 . Entries 211 , 212 , 213 are added into the base index 21 at an appropriate position determined by the index tree structure and the index key value. Only in the case of ever increasing key values, the inserted index entries are added at the end of the index resulting in no or few reads from the storage media. However, in general, an index entry requires insertion in a random fashion. Consequently, a large probability exists that the target index page is not in the database cache, resulting in a synchronous read from the storage media and, thus, a slow-down of the indexing process.
In FIG. 2A , only one index 21 is illustrated. Usually, there are a multitude of further indexes indexing the database table 20 depending on different criteria. FIG. 2B illustrates indexes such as, for example, the base index 21 , a base index A, 22 , and a base index B, 23 (collectively referenced as indexes 21 , 22 , 23 ). The indexes 21 , 22 , 23 , each index the database table 20 according to a different column. Each of the indexes 21 , 22 , 23 requires updating if a row insert occurs.
If the conventional database management system 1 is implemented as a parallel database, i.e. a group of database systems managing the same data, the indexes require maintenance by all involved systems, adding an additional overhead due to contention of the indexes.
For each additional index there is an additional synchronous read, implying a large read wait time that results in overall insert performance degradation. Indexing is a performance booster for query processing and is further a choice for tuning query performance. The queries run in parallel with insert processing, so the indexes are required to exist all the time to provide access to the data.
In a special mode of operation, completion of massive insert processing is required in a given time interval. Furthermore, critical query processing must run concurrently on the same data, including newly inserted rows, with best possible performance. This is a common case because many applications include massive insert processing, usually concentrated at some period-closing times: end of the day, week, month, year, etc. These processes regularly require completion in a given time window, as subsequent business operations depend on the results of the processes. As the insert processing runs, the queries accessing the same data require good performance. For that good performance, the queries require access to the very indexes that are being updated and causing slow down of the insert operations.
An embodiment of the database management system according to the invention, a database management system 305 , is schematically illustrated in FIG. 3 . The database management system 305 may be implemented, for example, as computer with an appropriate computer program product running on it. The computer may be a stand-alone device or be a member of a network with servers and clients. The database management system 305 comprises a modified data and index manager 310 . The modified data and index manager 310 comprises a modified insert processing module 315 and a modified non-insert processing module 320 . The modified data and index manager 310 further comprises an index increment building module 325 and an index increment merging module 330 . The insert processing module 315 and the non-insert processing module 320 are modified to efficiently cooperate with the index increment building module 325 and the index increment merging module 330 .
The insert processing of the modified data and index manager 310 is enhanced to insert index entries into an index increment rather than a base index. For non-insert operations, such as SQL queries, the modified data and index manager 310 accesses index entries from the base index and from the index increments.
The index increment building module 325 generates one or more index increments for inserting index entries corresponding to data rows being inserted into a database table. The index increment merging module 330 merges the one or more index increments with the one or more base indexes after the new data rows have been inserted. The index increment building module 325 and the index increment merging module 330 may be, for example, implemented as computer program product comprising computer programming code adapted to perform these tasks. The index increment building module 325 and the index increment merging module 330 comprise a software programming code or a computer program product that is typically embedded within, or installed on a computer. Alternatively, the index increment building module 325 and the index increment merging module 330 can be saved on a suitable storage medium such as a diskette, a CD, a hard drive, or like devices.
The modified insert processing module 315 inserts index entries into an index increment rather than in a base index, if an index increment exists. The non-insert processing module 320 looks up data one or more base indexes and in one or more index increments to process queries or delete data.
FIG. 4 ( FIGS. 4A , 4 B, 4 C, 4 D) schematically illustrates the indexing process according to the modified data and index manager 310 . Once a pattern of massive inserts is detected, a new index tree, i.e. an index increment 45 is spawned for a base index 41 that exists on a database table 40 (see FIG. 4A ). With incremental indexing provided by the modified data and index manager 310 , each database system can maintain its “own” index increments for each non-partitioning index. This isolation is complete, thus resulting in drastic reduction of cost of sharing data.
The data table 40 is illustrated with new data rows such as, for example, a row 1 , 401 , a row 2 , 402 , and a row 3 , 403 (collectively referenced as rows 401 , 402 , 403 ). By using the index increment 45 for indexing the newly inserted rows 401 , 402 , 403 , a much smaller index tree requires updating. Updating starts with a single page only (equivalent of one physical block of storage space) and grows with new inserts. The likelihood of target index pages being cached is much higher than in the case of updating a large monolithic base index.
FIG. 4B illustrates how a query is processed during incremental indexing or before the index increment 45 has been merged with the base index 41 . The query processing, in the present example “select”, takes into account that a chosen index is not necessarily monolithic, but could have one or more increments. Thus, the base index 41 and the index increment 45 are scanned for the rows to be selected. In general, scanning the base index 41 and the index increment 45 increase in the cost of index scan can be minimized if parallel index scan is implemented. This increase in cost is offset many times by superior insert performance. The scan of the active index increment 45 , i.e. the index increment 45 being inserted at the time, is likely to complete without any read from the storage medium, as the concerned pages are likely cached.
The index increment 45 is merged with the base index 41 after insertion of one or more rows 401 , 402 , 403 . The actual time for merging can be determined automatically or merging can explicitly started by a user. The merging time is selected to minimize impeding other processes such as, for example, queries.
As illustrated in FIG. 4C , incremental indexing can be adapted to additional base indexes such as, for example, the base index 41 , a base index A, 42 , and a base index B, 43 (collectively referenced as base indexes 41 , 42 , 43 ). Each of the base indexes 41 , 42 , 43 , index the database table 40 according to different criteria. As illustrated in FIG. 4C , an incremental index such as, for example, the index increment 45 , an index increment A, 46 , and an index increment B, 47 (collectively referenced as index increments 45 , 46 , 47 ) is generated for each of the base indexes 41 , 42 , 43 , when rows 401 , 402 , 403 are inserted. Accordingly, if a query is to be processed, for example “select”, the base indexes 41 , 42 , 43 and associated index increments 45 , 46 , 47 are scanned.
As illustrated in FIG. 4D , one or more index increments such as, for example, the index increment 45 , an index increment C, 48 , and an index increment D, 49 (collectively referenced as index increments 45 , 48 , 49 ) are provided per base index such as the base index 41 . For example, inserting may occur in several batches before merging. Consequently, separate index increments 45 , 48 , 49 , can be generated for each batch. If separate index increments 45 , 48 , 49 , are generated, an index increment too large to be memory-resident or cache-resident is avoided. In the example illustrated in FIG. 4D , prior inserts to the database table 40 are indexed in the index increment 45 and the index increment C, 48 . A present insert of row 404 is indexed in an active index increment represented as the index increment D, 49 .
The concept of more than one index increment can be adapted to additional indexes. Index increments such as the index increment 45 and the index increment C, 48 , can be merged with the base index 41 while the index increment D, 49 is active.
FIG. 5 illustrates a flowchart illustrating insert processing (step 501 ). A new row is inserted into a database table (step 503 ). For updating the base indexes, the modified insert processing module determines, for each base index (step 511 ), whether there are any index increments (step 505 ). If index increments exists, the index entry is inserted into the most recent index increment associated with the base index (step 507 ). Otherwise, the index entry in inserted into the base index (step 509 ). If now additional base indexes remain for processing (step 511 ), insert processing ends (step 513 ).
FIG. 6 illustrates a flowchart illustrating the process of building index increments as response to an insert statement (step 601 ). If a mass insert pattern is explicitly specified (e.g., by a setting on a specific session variable), or automatically detected (e.g., by monitoring the insert rate over a specified time interval) (step 603 ), the possibility of generating an index increment is considered. The index increment is not generated if one or more index increments already exist (step 605 ) or if the most recent index increment is small enough to be memory or cache resident (step 607 ). Otherwise, the index increment building module 325 creates a new index increment (step 609 ). This process is repeated for every index except for ever-increasing key indexes in non-data sharing environments (see step 609 ). After generating an index increment, the insert processing as explained in FIG. 5 is continued (step 611 ).
FIG. 7 illustrates a flowchart illustrating a process of the modified non-insert processing module 320 with reference to the example of a query. In processing a query (step 701 ), the modified non-insert processing module 320 determines whether an index is to be used (step 703 ). Whenever the query uses an index to access the data, the modified non-insert processing module 320 determines whether there are index increments for each of the indexes (step 705 ). If there are index increments, the base indexes and the index increments are scanned (step 707 ). Scanning can be performed serially or in parallel. If there are no index increments, only the base indexes are scanned (step 709 ). Depending on the result of the index scans, the data is scanned and retrieved (step 711 ) and returned to the application program 2 , thus ending the query (step 713 ).
The query process takes into account that a chosen index is not necessarily monolithic, but may have one or more increments. In general, this will increase the cost of index scan, which can be minimized if parallel index scan is implemented. However the cost of the index scan is offset many times by superior insert performance. The scan of the active index scan, i.e. the one being updated at the time, is likely to complete without any read from the storage media, because these pages are likely cached.
FIGS. 8 and 9 illustrate flowcharts illustrating the merging of index increments with the base index. As illustrated in FIG. 8 , the merge can be initiated implicitly (step 801 ), for example by a system agent that runs in the background and checks for some criteria indicating that merging is due. A possible criterion is, for example, the number of index increments (step 803 ) or a size of the index increments (step 805 ). Possible criteria further comprise an overall query response time or any other indicator.
As illustrated in FIG. 9 , the merge can as well be initiated explicitly on administrator request (step 901 ).
Once the merge has been initiated, a check whether the merge process is already going on is performed (steps 807 , 903 ). If yes, an appropriate message will be returned and no further action will be performed (steps 815 , 911 ). If no, a check whether mass insert processing is currently running is performed (steps 809 , 905 ). As merging during that process can be disruptive, the base indexes and the index increments excluding a most recent index increment are merged (steps 811 , 907 ). If there is no mass insert processing occurring, the base index is merged with all index increments to create a new base index (steps 813 , 909 ).
The step of merging may be performed according to any method known to a person skilled in the art, such as reorganization or rebuilding. To simplify processing and improve query performance, the merging process occurs before a next mass insert process to avoid creating more than one index increment per base index.
The methods of the modified data and index manager 310 , as described with reference to FIGS. 5 to 9 , may be readily modified to account for multiple indexes.
It is to be understood that the specific embodiments of the invention that have been described are merely illustrative of certain applications of the principle of the present invention. Numerous modifications may be made to the present invention described herein without departing from the spirit and scope of the present invention.
|
The present system indexes a plurality of entries in a database that contains a database table having a base index. As a recent row is inserted in the database table, an index increment is generated based on the inserted row. Preferably, the index increment is smaller in size than the base index because it is recently generated. The smaller size of the index increment facilitates the management of the index increment. An index entry associated with the inserted row is added to the index increment, and the index increment is merged with the base index.
| 6
|
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Stage Entry of PCT International Application No. PCT/CN2014/075415 filed on Apr. 15, 2014, which claims priority to Chinese patent application No. 201310134207.3, entitled “Ribbon Cartridge, Thermal Transfer Printer and Method For Installing Ribbon Cartridge” and filed on Apr. 17, 2013 with the State Intellectual Property Office of China, the disclosure of which is incorporated therein by reference in its entirety.
TECHNICAL FIELD
The present disclosure relates to a ribbon cartridge, a thermal transfer printer using the ribbon cartridge, and a method for installing the ribbon cartridge.
BACKGROUND
As shown in FIG. 1 , a ribbon cartridge 1 ′ adopted in an existing thermal transfer printer includes a supply cylinder 31 ′, a winding cylinder 32 ′, and a printing head accommodating member 33 ′ located between the supply cylinder 31 ′ and the winding cylinder 32 ′, which are rigidly connected. A supply spool (not shown) configured to support an unused ribbon is disposed within the supply cylinder 31 ′, a winding spool (not shown) configured to support and wind the used ribbon is disposed within the winding cylinder 32 ′, and both the supply spool and the winding spool are freely rotatable about their own axes. A driving hole (not shown) is provided at an end of the winding cylinder 32 ′ and is configured to match with a driving shaft 102 ′ in a plugging manner on a frame 101 ′ of the printer 100 ′. Thus, a ribbon 10 ′ may lead out from an opening of the supply cylinder 31 ′, extend through the printing head accommodating member 33 ′, enter into the winding cylinder 32 ′ via an opening 35 ′ thereof and be wound on the winding spool.
The frame 101 ′ includes a cartridge installing member 130 ′, which has a cross-section of a shape matching with the shape of the cross-section of the ribbon cartridge 1 ′. A locking assembly 137 ′ is disposed on a side wall of the frame 101 ′ and is configured to prevent release of the ribbon cartridge 1 ′ installed in the printer 100 ′. The locking assembly 137 ′ includes a body 137 a , an elastic slice 137 b and an operating slice 137 c which are formed integrally with the body 137 a , and a locking hook 137 d . To install the ribbon cartridge 1 ′, the ribbon cartridge 1 ′ is inserted into the cartridge installing member 130 ′ via an installing hole 133 ′ on a side of the printer 100 ′, the driving hole of the ribbon cartridge 1 ′ matches with the driving shaft 102 ′ on the printer 100 ′ in a plugging manner, and the locking hook 137 d of the locking assembly 137 ′ locks a side wall 26 ′ of the ribbon cartridge 1 ′; subsequently, a printing head assembly 110 ′ is rotated and closed with respect to the frame 101 ′ so that a printing head of the printing head assembly 110 ′ is tangent to and cooperates with a platen 120 ′, in this way, the printing head is located within the printing head accommodating member 33 ′ and in contact with the ribbon 10 ′.
The above-described thermal transfer printer 100 ′ and the ribbon cartridge 1 ′ used therein are defective in that: the supply cylinder 31 ′ and the winding cylinder 32 ′ of the ribbon cartridge 1 ′ are linearly connected rigidly, and the printing head is located within the printing head accommodating member 33 ′ between the supply cylinder 31 ′ and the winding cylinder 32 ′ when the ribbon cartridge 1 ′ is installed in the printer, that is, the supply cylinder 31 ′ of the ribbon cartridge 1 ′, the printing head, and the winding cylinder 32 ′ of the ribbon cartridge 1 ′ are linearly arranged in sequence, thereby increasing the distance between front and rear sides of the printer, so that the space on a top surface of a desk occupied by the printer is increased, and a demand for the miniaturization of the printer cannot be met.
SUMMARY OF THE INVENTION
An object of the present disclosure is to provide a ribbon cartridge with a compact structure, and further provide a thermal transfer printer adopting the ribbon cartridge and a method for installing the ribbon cartridge.
To this end, according to one aspect of the present disclosure, a ribbon cartridge includes a bracket; a supply cylinder disposed on the bracket and configured for accommodating an unused ribbon; and a winding cylinder disposed on the bracket and configured for accommodating a used ribbon, where the supply cylinder and the winding cylinder are arranged in parallel, and the supply cylinder and the winding cylinder have an initial state in which the supply cylinder and the winding cylinder are close to each other and an open state in which the supply cylinder and the winding cylinder are away from each other due to an effect of an external force.
The bracket is located at the same side of the supply cylinder and the winding cylinder, and a ribbon exposing opening is provided in the bracket.
The bracket is configured to apply an elastic force to the supply cylinder and the winding cylinder, so that the supply cylinder and the winding cylinder always trend to return to the initial state.
The bracket includes a first cantilever part and a second cantilever part which is fixedly connected or integrally formed with the first cantilever part, a suspending end of the first cantilever part is connected with the winding cylinder, a suspending end of the second cantilever part is connected with the supply cylinder, and the first cantilever part and/or the second cantilever part is elastic.
The bracket includes a first cantilever part, a second cantilever part which is pivoted with the first cantilever part, and an elastic element disposed between the first cantilever part and the second cantilever part, where a suspending end of the first cantilever part is connected with the winding cylinder, and a suspending end of the second cantilever part is connected with the supply cylinder.
Each of the supply cylinder and the winding cylinder includes a cylinder body for accommodating a ribbon, an opening for ribbon formed on the cylinder body, and a support shaft disposed on an end wall of the cylinder body along an axial direction of the cylinder body and configured for supporting a ribbon core cylinder, where a transmission gear in a transmission connection with an external power is arranged on the support shaft provided on the supply cylinder and/or the support shaft provided on the winding cylinder.
A cylinder body of the supply cylinder includes a first part formed integrally with the bracket and a first half-cylinder body jointed with the first part, a space for accommodating an unused ribbon is formed between the first part and the first half-cylinder body, a cylinder body of the winding cylinder includes a second part formed integrally with the bracket and a second half-cylinder body jointed with the second part, and a space for accommodating a used ribbon is formed between the second part and the second half-cylinder body.
A pull handle is disposed on the bracket.
According to another aspect of the present disclosure, a thermal transfer printer includes: a frame; and a printing head assembly, a platen and a paper roll support mechanism which are disposed on the frame, where the thermal transfer printer further includes the above ribbon cartridge installed in the frame, a winding cylinder and a supply cylinder of the ribbon cartridge are moved away from each other to avoid the printing head assembly during installing of the ribbon cartridge, and the winding cylinder and the supply cylinder of the ribbon cartridge installed in place are close to each other at a same side of the printing head assembly.
The thermal transfer printer further includes a first positioning portion disposed on the frame and configured for positioning the winding cylinder and a second positioning portion disposed on the frame and configured for positioning the supply cylinder, and a driving member is disposed on the first positioning portion and configured to drive a support shaft on the winding cylinder to rotate and wind a ribbon.
The frame includes a body and a guide structure disposed on the body and configured to guide the winding cylinder and the supply cylinder of the ribbon cartridge during the installing of the ribbon cartridge, the body includes side walls and a connection part perpendicularly connected with the side walls, and the printing head assembly is configured to be installed on the connection part, where the guide structure includes an upper guide portion and a lower guide portion which are located at upper and lower sides of the printing head assembly, one of the upper guide portion and the lower guide portion is formed by guide ribs arranged on the side walls, and the other of the upper guide portion and the lower guide portion is formed by the connection part.
The first positioning portion is formed by a first arc-shaped rib transitively connected with the connection part, the second positioning portion is formed by a second arc-shaped rib transitively connected with the guide rib, and each of the first arc-shaped rib and the second arc-shaped rib protrudes from an inner surface of the side wall and has an unenclosed structure with an opening.
According to the present disclosure, a method for installing the above ribbon cartridge includes: pushing a ribbon cartridge toward a printing head assembly from an outer side of the printing head assembly, so that a supply cylinder and a winding cylinder of the ribbon cartridge run across the printing head assembly and installed in place.
According to the present disclosure, the supply cylinder and the winding cylinder of the ribbon cartridge are connected via a bracket. In installing the ribbon cartridge, the supply cylinder and the winding cylinder are moved away from each other due to the pressure by the printing head assembly and avoid the printing head assembly, so that the ribbon is tensioned by the printing head and covers the printing head, and after avoiding the printing head assembly, the supply cylinder and the winding cylinder return to the initial state in which they are close to each other. Therefore, compared with the existing ribbon cartridge including a supply cylinder and a winding cylinder which are fixedly spaced, the ribbon cartridge of the present disclosure has a more compact structure and requires for a reduced installing space.
In addition to the above objects, features and advantages, other objects, features and advantages of the present disclosure will be further described in detail in combination with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Accompanying drawings, which construct a part of the specification and are used for better understanding of the present disclosure, illustrate some preferred embodiments of the present disclosure, and show principles of the present disclosure in combination with the description below.
FIG. 1 is a schematic structural view of an existing thermal transfer printer;
FIG. 2 is an isometric structural view of a ribbon cartridge according to an embodiment of the present disclosure;
FIG. 3 is a partial structural section view of the ribbon cartridge according to the embodiment of the present disclosure;
FIG. 4 is a cross-section view of the ribbon cartridge according to the embodiment of the present disclosure;
FIG. 5 is a first structural exploded view of the ribbon cartridge according to the embodiment of the present disclosure;
FIG. 6 is a second structural exploded view of the ribbon cartridge according to the embodiment of the present disclosure;
FIG. 7 is a section structural view of a thermal transfer printer adopting the ribbon cartridge according to the embodiment of the present disclosure;
FIG. 8 is an isometric structural view of the thermal transfer printer adopting the ribbon cartridge according to the embodiment of the present disclosure, where an upper cover and a front cover of the thermal transfer printer are opened;
FIG. 9 is a partial structural view of the frame of the thermal transfer printer adopting the ribbon cartridge according to the embodiment of the present disclosure;
FIG. 10 is a first installing view of the ribbon cartridge according to the embodiment of the present disclosure onto the thermal transfer printer; and
FIG. 11 is a second installing view of the ribbon cartridge according to the embodiment of the present disclosure onto the thermal transfer printer.
LIST OF REFERENCE NUMERALS
1. Printing mechanism
2. Ribbon cartridge
3. Paper roll support mechanism
11. Printing head assembly
12. Platen
111. Support plate
112. Printing head
113. Elastic element
111a. Bent portion
121. Platen gear
21. Supply cylinder
22. Winding cylinder
23. Bracket
24. Support shaft
25. Transmission gear
26. Pull handle
21a. First part
21b. First half-cylinder body
22a. Second part
22b. Second half-cylinder body
211. First opening for ribbon
221. Second opening for ribbon
231. First cantilever part
232. Second cantilever part
232a. Ribbon exposing opening
241. Rotation stop part
80. Body
81. Upper cover
82. Front cover
83. Left wall
84. Right wall
85. Connection part
811. First pivot shaft
821. Second pivot shaft
851. Front portion
6. Positioning part
61. First positioning portion
62. Second positioning portion
63. Guide rib
61a. First arc-shaped rib
62a. Second arc-shaped rib
611. Opening
621. Opening
9. Driving member
DETAILED DESCRIPTION OF THE EMBODIMENTS
Embodiments of the present disclosure are described in detail below in combination with the accompanying drawings, although the present disclosure can be implemented in various ways defined and covered by the appended claims.
FIG. 2 is an isometric structural view of a ribbon cartridge according to an embodiment of the present disclosure, FIG. 3 is a partial structural section view of the ribbon cartridge according to the embodiment of the present disclosure, and FIG. 4 is a cross-section view of the ribbon cartridge according to the embodiment of the present disclosure. As shown in FIG. 2 , FIG. 3 and FIG. 4 , a ribbon cartridge 2 includes a supply cylinder 21 , a winding cylinder 22 and a bracket 23 . The supply cylinder 21 and the winding cylinder 22 , each having a columnar shape and having a length larger than the maximum width of the ribbon, are disposed one above another, and axes of the supply cylinder 21 and the winding cylinder 22 are parallel to each other. The diameter of the winding cylinder 22 is larger than or equal to the diameter of the supply cylinder 21 . Here, the supply cylinder 21 is configured to accommodate an unused ribbon, while the winding cylinder 22 is configured to accommodate a used ribbon. The ribbon leads out from the supply cylinder 21 and is eventually recycled in the winding cylinder 22 .
The bracket 23 is located at the same side of the supply cylinder 21 and the winding cylinder 22 , and a ribbon exposing opening 232 a is provided in the bracket 23 . Preferably, the bracket 23 includes a first cantilever part 231 and a second cantilever part 232 , a first end of the first cantilever part 231 is connected with a first end of the second cantilever part 232 , a second end (i.e. a suspending end) of the first cantilever part 231 is fixed to the winding cylinder 22 , and a second end (i.e. a suspending end) of the second cantilever part 232 is connected with the supply cylinder 21 . The ribbon exposing opening 232 a is arranged in the second cantilever part 232 , and has a shape and a size respectively matching with the shape and size of the printing head. A cavity is formed between the first cantilever part 231 and the second cantilever part 232 to accommodate a printing head assembly.
The bracket 23 is configured to apply an elastic force to the supply cylinder 21 and the winding cylinder 22 , so that the supply cylinder 21 and the winding cylinder 22 always trend to return to their initial states in which the supply cylinder 21 and the winding cylinder 22 are close to each other. Preferably, the bracket 23 is partially or entirely elastic. In the present embodiment, the first cantilever part 231 and the second cantilever part 232 of the bracket 23 are fixedly connected, and the first cantilever part 231 and/or the second cantilever part 232 are made of an elastic material such as plastic or spring steel, so that the supply cylinder 21 and the winding cylinder 22 always trend to move to be close to each other under the effect of the elastic force applied by the first cantilever part 231 and/or the second cantilever part 232 of the bracket 23 . In some other embodiments of the present disclosure, the first cantilever part 231 is pivoted with the second cantilever part 232 via a pivot shaft, and the bracket 23 further includes an elastic element, one end of which is connected with the first cantilever part 231 and the other end of which is connected with the second cantilever part 232 , so that the supply cylinder 21 and the winding cylinder 22 always trend to move to be close to each other under the effect of an elastic force applied by the elastic element. Preferably, when the supply cylinder and the winding cylinder are at their initial status, the external walls of the supply cylinder and the winding cylinder are tangent to and abut on each other, to enable the most compact structure of the ribbon cartridge.
A first opening for ribbon 211 is disposed on the wall of the supply cylinder 21 along an axial direction of the supply cylinder 21 , and a second opening for ribbon 221 is disposed on the wall of the winding cylinder 22 along an axial direction of the winding cylinder 22 , so that the unused ribbon in the supply cylinder 21 may lead out from the first opening for ribbon 211 and enter into the winding cylinder 22 via the second opening for ribbon 221 .
A support shaft 24 for supporting a ribbon core cylinder is provided at each of both axial ends of the supply cylinder 21 , a support shaft 24 for supporting a ribbon core cylinder is provided at each of both axial ends of the winding cylinder 22 , and a transmission gear 25 is fixed on the support shaft provided at one of both axial ends of the winding cylinder 22 . As such, two support shafts 24 are coaxially disposed at both axial ends of the supply cylinder 21 to support a ribbon supply core cylinder S 1 on which the unused ribbon is wound, and the other two support shafts 24 are coaxially disposed at both axial ends of the winding cylinder 22 to support a ribbon winding core cylinder S 2 on which the used ribbon is wound. Each support shaft 24 has an external diameter matching with an internal diameter of the corresponding core cylinder, and is freely rotatable about its own axis. At least one rotation stop part 241 extending along a radial direction of the support shaft 24 are disposed at the periphery of each of the support shafts 24 , and has a width matching with a width of a positioning groove on the corresponding core cylinder. The transmission gear 25 is fixed to one of the two support shafts 24 for supporting the ribbon winding core cylinder S 2 and is located at an outer side of the winding cylinder 22 .
In the present embodiment, two rotation stop parts 241 are provided on each of the support shafts 24 symmetrically relative to the axis of the support shaft 24 .
The ribbon supply core cylinder S 1 , on which the unused ribbon is wound, is located within the supply cylinder 21 , two ends of the ribbon supply core cylinder S 1 respectively match with those two support shafts 24 at both ends of the supply cylinder 21 in a plugging manner, and the positioning groove on the ribbon supply core cylinder S 1 matches with the rotation stop part 241 on the corresponding support shaft 24 in a plugging manner. The ribbon winding core cylinder S 2 is located within the winding cylinder 22 , two ends of the ribbon winding core cylinder S 2 respectively match with those two support shafts 24 at both ends of the winding cylinder 22 in a plugging manner, and the positioning groove on the ribbon winding core cylinder S 2 matches with the rotation stop part 241 on the corresponding support shaft 24 in a plugging manner.
The unused ribbon leads out from the ribbon supply core cylinder S 1 , passes through the first opening for ribbon 211 of the supply cylinder 21 , enters into the winding cylinder 22 via the second opening for ribbon 221 of the winding cylinder 22 , and is wound on the ribbon winding core cylinder S 2 . When the ribbon cartridge is installed in the printer, the ribbon led to the winding cylinder 22 from the supply cylinder 21 is pressed by the printing hear of the printer and is extended at the ribbon exposing opening 232 a , and the transmission gear 25 is engaged with a driving member of the printer, so that when the transmission gear 25 is driven by the driving member and rotates, the transmission gear 25 in turn drives the support shaft 24 fixedly connected thereto to rotate, and the ribbon winding core cylinder S 2 is rotated along with the support shaft 24 to pull and wind the ribbon wound on the ribbon supply core cylinder S 1 .
Further, the ribbon cartridge 2 includes a pull handle 26 , which is disposed on the bracket 23 and is configured for handling by a user to install a ribbon cartridge in the thermal transfer printer or detach the ribbon cartridge from the thermal transfer printer. In the present embodiment, the pull handle 26 is connected with the second cantilever part 232 at a side of the second cantilever part 232 away from the winding cylinder 22 .
FIG. 5 is a first structural exploded view of the ribbon cartridge according to the embodiment of the present disclosure, and FIG. 6 is a second structure exploded view of the ribbon cartridge according to the embodiment of the present disclosure. As shown in FIG. 5 and FIG. 6 , the supply cylinder 21 includes a first part 21 a and a first half-cylinder body 21 b , and the winding cylinder 22 includes a second part 22 a and a second half-cylinder body 22 b , where the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 are fixedly or detachably connected with each other to form a space for accommodating the unused ribbon, and the second part 22 a and the second half-cylinder body 22 b of the winding cylinder 22 are fixedly or detachably connected with each other to form a space for accommodating the used ribbon.
In the present embodiment, the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 are fixedly connected by plastic welding or adhesive, and likewise the second part 22 a and the second half-cylinder body 22 b of the winding cylinder 22 are fixedly connected by plastic welding or adhesive. The first half-cylinder body 21 b of the supply cylinder 21 is fixedly connected or integrally formed with the first cantilever part 231 of the bracket 23 , the second part 22 a of the winding cylinder 22 is fixedly connected or integrally formed with the second cantilever part 232 of the bracket 23 , those two support shafts 24 for the supply cylinder 21 are both disposed on the first half-cylinder body 21 b of the supply cylinder 21 , and those two support shafts 24 for the winding cylinder 22 are both disposed on the second part 22 a of the winding cylinder 22 . In assembling the ribbon cartridge 2 , the ribbon supply core cylinder S 1 wound by the unused ribbon is placed in the first half-cylinder body 21 b of the supply cylinder 21 , with both ends of the ribbon supply core cylinder S 1 matching with those two support shafts 24 placed on the first half-cylinder body 21 b of the supply cylinder 21 in a plugging manner, and each positioning groove on the ribbon supply core cylinder S 1 matching with the rotation stop part 241 on the corresponding support shaft 24 in a plugging manner; meanwhile, the ribbon winding core cylinder S 2 is placed in the second part 22 a of the winding cylinder 22 , with both ends of the ribbon winding core cylinder S 2 matching with those two support shafts 24 placed on the second part 22 a of the winding cylinder 22 in a plugging manner, and each positioning groove on the ribbon winding core cylinder S 2 matching with the rotation stop part 241 on the corresponding support shaft 24 in a plugging manner; subsequently, the unused ribbon is led out from the ribbon supply core cylinder S 1 , and a leading end of the unused ribbon is fixed to the ribbon winding core cylinder S 2 in the winding cylinder 22 ; and eventually, the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 are plastic welded together, and the second part 22 a and the second half-cylinder body 22 b of the winding cylinder 22 are plastic welded together, thereby accomplishing the assembling of the ribbon cartridge 2 .
In some other embodiments of the present disclosure, the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 match with each other in a clamping manner by a clamping part and a clamping slot, and the second part 22 a and the second half-cylinder body 22 b of the winding cylinder 22 match with each other in a clamping manner by a clamping part and a clamping slot, so that the first part 21 a of the supply cylinder 21 is detachable from the first half-cylinder body 21 b of the supply cylinder 21 , and the second part 22 a of the winding cylinder 22 is detachable from the second half-cylinder body 22 b of the winding cylinder 22 . For example, a clamping part is provided on one of the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 , and a clamping slot is provided on the other of the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 , in this case, when the clamping part matches with the clamping slot in a clamping manner, the first part 21 a of the supply cylinder 21 is fixed to the first half-cylinder body 21 b of the supply cylinder 21 , and when the clamping part is detached from the clamping slot, the first part 21 a of the supply cylinder 21 is detached from the first half-cylinder body 21 b of the supply cylinder 21 .
When the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 are fixedly connected and the second part 22 a and the second half-cylinder body 22 b of the winding cylinder 22 are fixedly connected, the ribbon cartridge 2 is entirely replaced after the ribbon in the ribbon cartridge 2 is used up, thus the ribbon can be quickly replaced. When the first part 21 a and the first half-cylinder body 21 b of the supply cylinder 21 are detachably connected and the second part 22 a and the second half-cylinder body 22 b of the winding cylinder 22 are detachably connected, after the ribbon in the ribbon cartridge 2 is used up, the first part 21 a of the supply cylinder 21 is detached from the first half-cylinder body 21 b of the supply cylinder 21 , and the second part 22 a of the winding cylinder 22 is detached from the second half-cylinder body 22 b of the winding cylinder 22 , so that the ribbon supply core cylinder S 1 in the supply cylinder 21 and the ribbon winding core cylinder S 2 wound by the used ribbon in the winding cylinder 22 are detached, and a new ribbon supply core cylinder S 1 wound by the unused ribbon and a new ribbon winding core cylinder S 2 are installed, thus the housing of the ribbon cartridge is reused, thereby reducing consumptive costs.
Preferably, the suspending end of the first cantilever part 231 is tangent to and integrally formed with the wall of the second part 22 a of the winding cylinder 22 , the suspending end of the second cantilever part 232 is tangent to and integrally formed with the wall of the supply cylinder 21 , and the first cantilever part 231 is formed integrally with the second cantilever part 232 . Preferably, the first cantilever part 231 is embodied as a bent plate, and a part of the second cantilever part 232 located at each of two sides of the ribbon exposing opening 232 a is embodied as a bent rod.
As such, the supply cylinder and the winding cylinder of the ribbon cartridge provided in the present disclosure are connected via the bracket including a first cantilever part and a second cantilever part, where a first end of the first cantilever part is connected with a first end of the second cantilever part, a second end of the first cantilever part is connected with the winding cylinder, a second end of the second cantilever part is connected with the supply cylinder, the ribbon exposing opening is arranged in the second cantilever part, and the winding cylinder and the supply cylinder are arranged in parallel and close to each other. Therefore, the size of the ribbon cartridge of the present disclosure in a ribbon transmission direction is shortened by a diameter of the winding cylinder, and hence the ribbon cartridge of the present disclosure has a structure more compact than that of the existing ribbon cartridge.
FIG. 7 is a section structural view of a thermal transfer printer adopting the ribbon cartridge according to the embodiment of the present disclosure, FIG. 8 is an isometric structural view of the thermal transfer printer adopting the ribbon cartridge according to the embodiment of the present disclosure, where an upper cover and a front cover of the thermal transfer printer are opened, and FIG. 9 is a partial structure view of the frame of the thermal transfer printer adopting the ribbon cartridge according to the embodiment of the present disclosure. As shown in FIG. 7 , FIG. 8 , and FIG. 9 , the thermal transfer printer includes a frame, a printing mechanism 1 , a ribbon cartridge 2 , and a paper roll support mechanism 3 . The frame includes a body 80 , an upper cover 81 , and a front cover 82 . As indicated by directions shown in FIG. 8 , the upper cover 81 is above the body 80 , and the front cover 82 is in front of the body 80 . The upper cover 81 is pivoted with the body 80 via a first pivot shaft 811 , and the front cover 82 is pivoted with the body 80 via a second pivot shaft 821 . Both the upper cover 81 and the front cover 82 may be rotatably open or close relative to the body 80 .
The body 80 includes a left wall 83 , a right wall 84 and a connection part 85 . The left wall 83 and the right wall 84 are parallel to each other, and are distant from each other by a distance lager than or equal to the bigger one of widths of the printing paper and the ribbon. The connection part 85 is perpendicularly connected between the left wall 83 and the right wall 84 , and preferably a front portion 851 of the connection part 85 has an arc-shaped cross section.
A printing mechanism 1 , which is configured to print preset content on printing paper, includes a printing head assembly 11 and a platen 12 . The platen 12 is disposed at an inner side of the front cover 82 and has an axis extending in a width direction of the printing paper, and one end of the platen 12 is provided with a platen gear 121 . When the front cover 82 is closed, the platen gear 121 is transmission connected with the driving member (not shown) of the printer, and is driven by the driving member to rotate about its own axis. The printing head assembly 11 includes a support plate 111 , a printing head 112 , and at least one elastic element 113 .
The support plate 111 is located below the connection part 85 and between the left wall 83 and the right wall 84 , and is movably connected with the connection part 85 . The printing head 112 is fixedly connected with the support plate 111 , and is located at a side of the support plate 111 away from the connection part 85 . The elastic element 113 , which may be a pressure spring, a torsion spring or a plate spring, is located between the support plate 111 and the connection part 85 , and has one end connected with the support plate 111 and the other end connected with the connection part 85 . Under the effect of the elastic element 113 , the support plate 111 causes the printing head 112 to always trend to move away from the connection part 85 .
A positioning part (not shown) cooperating with the support plate 111 is additionally arranged on the body 80 . Due to the restriction by the positioning part, the support plate 111 of the printing head assembly 11 can be stabilized at a preset distance from the connection part 85 . When the front cover 82 is closed relative to the body 80 , the platen 12 presses the printing head 112 and is tangent to the printing head 112 , in this case, the printing head assembly 11 is supported by the platen 12 . When the front cover 82 is opened relative to the body 80 , the platen 12 is separated from the printing head 112 , and the printing head assembly 11 is supported by the positioning part disposed on the body 80 .
Preferably, a front end of the support plate 111 includes a bent portion 111 a , which is at front of the printing head 112 but is lower than the printing head 112 . The bent portion 111 a is configured to guide the ribbon passing by the printing head 112 to enter into the winding cylinder 22 , and protect the printing head 112 against being contacted by the ribbon cartridge 2 during installing of the ribbon cartridge 2 , thereby elongating the service life of the printing head 112 .
The paper roll support mechanism 3 is disposed on the front cover 82 or the body 80 . In the printing paper transmission direction, the paper roll support mechanism 3 is at the upstream of the platen 12 , and is configured to support a printing paper roll. The paper roll support mechanism 3 may be a paper roll support rack or a paper storage. In the present embodiment, the paper roll support mechanism 3 is a paper roll support rack disposed at an inner side of the front cover 82 . To load printing paper, the front cover 82 is opened relative to the body 80 , and the paper roll support mechanism 3 is rotated out from the body 80 along with the front cover 82 , so that the paper roll can be replaced conveniently. After the replace of the paper roll, a leading end of the new printing paper is led out from the paper roll and passes by the platen 12 , and then the front cover 82 is closed relative to the body 80 , so that the printing paper is sandwiched between the printing head 112 and the platen 12 .
The ribbon cartridge 2 has the structure already described as above, which will not be given again hereinafter.
FIG. 10 is a first installing view of the ribbon cartridge according to the embodiment of the present disclosure onto the thermal transfer printer, and FIG. 11 is a second installing view of the ribbon cartridge according to the embodiment of the present disclosure onto the thermal transfer printer. As shown in FIG. 10 and FIG. 11 , the ribbon cartridge 2 is detachably connected with the body 80 . When installed in the body 80 , the ribbon cartridge 2 is located between the left wall 83 and the right wall 84 of the body 80 , and the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 are parallel to each other at one side of the printing head 112 . A positioning part 6 is disposed between the left wall 83 and the right wall 84 of the body 80 , and is configured to position the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 .
The positioning part 6 includes a first positioning portion 61 for positioning the winding cylinder 22 and a second positioning portion 62 for positioning the supply cylinder 21 , both of which extend perpendicularly with a surface of the left wall 83 . Preferably, each of the first positioning portion 61 and the second positioning portion 62 has a split structure, where the first positioning portion 61 includes two first arc-shaped ribs 61 a (as shown in FIG. 9 ) symmetrically arranged on the left wall 83 and the right wall 84 of the body 80 , respectively, and the second positioning portion 62 includes two second arc-shaped ribs 62 a (as shown in FIG. 9 ) symmetrically arranged on the left wall 83 and the right wall 84 of the body 80 , respectively.
The body 80 is further provided with a guide structure configured to guide the winding cylinder and the supply cylinder of the ribbon cartridge during installing of the ribbon cartridge. The guide structure includes an upper guide portion and a lower guide portion which are located at upper and lower sides of the printing head assembly 11 , respectively, where one of the upper guide portion and the lower guide portion is embodied by guide ribs arranged on the left wall 83 and the right wall 84 , and the other of the upper guide portion and the lower guide portion is embodied by the connection part 85 . In the present embodiment, the lower guide portion is embodied by guide ribs 63 extending below the printing head assembly 11 and the upper guide portion is embodied by the connection part 85 extending above the printing head assembly 11 . The first arc-shaped ribs 61 a is transitively connected with the connection part 85 , and likewise the second arc-shaped ribs 62 a is transitively connected with the guide rib 63 . As such, during installing the ribbon cartridge 2 , the wall of the winding cylinder 22 slidably contacts the connection part 85 used for guiding and is eventually maintained in the first positioning portion 61 , and the wall of the supply cylinder 21 slidably contacts the guide rib 63 used for guiding and is eventually maintained in the second positioning portion 62 .
In some other embodiments of the present disclosure, each of the first positioning portion 61 and the second positioning portion 62 is of an integral structure, and has one end connected to the left wall 83 of the body 80 and the other end connected to the right wall 84 of the body 80 . The first positioning portion 61 is at the rear side of the printing head assembly 11 , the second positioning portion 62 is arranged in parallel with the first positioning portion 61 , external walls of the first positioning portion 61 and the second positioning portion 62 abut against each other, and shapes of cross sections of the first positioning portion 61 and the second positioning portion 62 fit the shapes of the cross sections of the winding cylinder 22 and the supply cylinder 21 of the ribbon cartridge 2 . Here, the first positioning portion 61 has an internal diameter fitting an external diameter of the winding cylinder 22 of the ribbon cartridge 2 , and is configured to accommodate the winding cylinder 22 of the ribbon cartridge 2 . An opening 611 , which has a tapered shape, is formed at a side of the first positioning portion 61 toward the printing head assembly 11 , a lower rim of the opening 611 is transitively connected with the connection part 85 , and the minimum size of the opening 611 is larger than the external diameter of the winding cylinder 22 . The second positioning portion 62 has an internal diameter fitting an external diameter of the supply cylinder 21 of the ribbon cartridge 2 , and is configured to accommodate the supply cylinder 21 of the ribbon cartridge 2 . An opening 621 is formed at a side of the second positioning portion 62 toward the printing head assembly 11 , and an upper rim of the opening 621 extends below the printing head assembly 11 . Preferably, the upper rim of the opening 621 of the second positioning portion 62 is connected with the bent portion 111 a of the support plate 111 of the printing head assembly 11 , and the minimum size of the opening 621 of the second positioning portion 62 is larger than the external diameter of the supply cylinder 21 .
The installing of the ribbon cartridge of the present disclosure into the thermal transfer printer and detaching of the ribbon cartridge from the thermal transfer printer is described below.
To install the ribbon cartridge 2 , a user may handle the ribbon cartridge 2 in such a way that the winding cylinder 22 of the ribbon cartridge 2 is above the supply cylinder 21 while the ribbon between the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 faces the printing head assembly 11 and the connection part 85 of the frame; then the ribbon cartridge 2 is pushed in an arrow direction shown in FIG. 10 so that the winding cylinder 22 of the ribbon cartridge 2 is in contact with the front portion 851 of the connection part 85 in the body 80 while the supply cylinder 21 of the ribbon cartridge 2 is in contact with the bent portion 111 a of the support plate 111 of the printing head assembly 11 ; subsequently, the ribbon cartridge 2 is further pushed by the user so that the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 move apart from each other after overcoming the elastic force applied by the bracket 23 . As shown in FIG. 11 , after moving along the upper surface of the connection part 85 , the winding cylinder 22 is in contact with the lower rim of the opening 611 of the first positioning portion 61 , meanwhile, after passing by the bent portion 111 a of the support plate 111 of the printing head assembly 11 , the supply cylinder 21 is in contact with the upper rim of the opening 621 of the second positioning portion 62 , thus the ribbon is in contact with the bent portion 111 a , thereby driving the support shaft 24 on the supply cylinder 21 to release the ribbon. The ribbon cartridge 2 is further pushed subsequently, so that the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 are moved across the printing head assembly 11 and the connection part 85 of the body 80 , respectively, and at this point, the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 move toward each other under the effect of the elastic force applied by the bracket 23 of the ribbon cartridge 2 , so that the supply cylinder 21 of the ribbon cartridge 2 fits with the second positioning portion 62 in the body 80 , and the winding cylinder 22 of the ribbon cartridge 2 fits with the first positioning portion 61 in the body 80 . As such, under the effect of the elastic force applied by the bracket 23 , the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 sandwich both the printing head assembly 11 and the connection part 85 in the body 80 , and are placed at positions constant relative to the printing head assembly 11 , meanwhile, the transmission gear 25 in the ribbon cartridge 2 is transmission connected with a driving member 9 of the printer. In this case, the ribbon leading out from the supply cylinder, which is to be entered into the winding cylinder, extends at the ribbon exposing opening due to the pressure by the printing head assembly, and is easily in contact with the printing paper.
Therefore, by pushing the ribbon cartridge 2 toward the printing head assembly 11 from the outside of the printing head assembly 11 , the supply cylinder 21 and the winding cylinder 22 of the ribbon cartridge 2 run across the printing head assembly 11 and are installed properly.
To detach the ribbon cartridge 2 , the user pulls the pull handle in a direction away from the printing head assembly 11 . Under the effect of the pulling force by the user, the winding cylinder 22 and the supply cylinder 21 move away from each other while overcoming the elastic force applied by the bracket 23 , that is, the first cantilever part 231 and the second cantilever part 232 of the bracket 23 move away from each other, thus, the winding cylinder 22 of the ribbon cartridge 2 is moved out from the first positioning portion 61 via the opening 611 of the first positioning portion 61 , and the supply cylinder 21 of the ribbon cartridge 2 is moved out from the second positioning portion 62 via the opening 621 of the second positioning portion 62 , thereby extracting the ribbon cartridge 2 .
By adopting the ribbon cartridge of the present disclosure in the thermal transfer printer provided in the embodiments, the supply cylinder and the winding cylinder of the ribbon cartridge installed in the frame of the printer are positioned at the same side of the printing head, and are arranged in parallel close to each other, therefore, the distance between front and rear sides of the printer is shortened by the diameter of one winding cylinder, so that the use of the printer on a desk with a limited top surface is facilitated.
Some preferred embodiments of the present disclosure have been described as above, but the scope of the present disclosure is not limited thereto, and various modifications and alternations may be made to the present disclosure by those of ordinary skills in the art. Any modifications, equivalent replacements and improvements made without departing from the spirit and principles of the present disclosure fall within the scope of the present disclosure.
|
Disclosed are a ribbon cartridge, a thermal transfer printer, and a method for installing the ribbon cartridge. The ribbon cartridge ( 2 ) comprises a bracket ( 23 ), a supply cylinder ( 21 ) arranged on the bracket and used for accommodating an unused ribbon, and a winding cylinder ( 22 ) arranged on the bracket and used for accommodating a used ribbon, where the supply cylinder and the winding cylinder are placed in parallel, and have an initial state in which the supply cylinder and the winding cylinder are close to each other and an open state in which the supply cylinder and the winding cylinder are away from each other under the action of an external force. Compared with a ribbon cartridge whose supply cylinder and winding cylinder are arranged at a fixed interval in the prior art, the ribbon cartridge as disclosed is more compact and needs less installation space.
| 1
|
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a cosmetic product replacement unit for a base stick module of a cosmetic stick with a replacement housing in which the cosmetic product is present in the form of a refill, with a cap attached onto the replacement housing, for sealing a refill extension opening, configured in the replacement housing, for the refill, wherein the refill is in push connection with a piston guided in the replacement housing. The invention also relates to a set consisting of a cosmetic product replacement unit of this type and a plurality of base stick modules.
[0003] 2. Background Art
[0004] A generic cosmetic product replacement unit is known through prior public use. As soon as the cosmetic product is used up or is not intended to be used any further, the known replacement unit is used as a replacement for a corresponding stick unit, the replacement unit, together with the base stick module, reproducing the complete cosmetic stick.
[0005] The replacement units known in the art are expensive to produce.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of the present invention to develop a replacement unit of the type mentioned at the outset, such that the production costs for said replacement unit are reduced.
[0007] The object is achieved according to the invention by a replacement unit having a piston connecting component, connected to the piston, for cooperating with a complementary push rod connecting component of a piston push rod as part of a feed device of the base stick module for extending the refill, the piston connecting component being designed to bring the piston push rod into a push connection with the piston and to position the piston push rod on the side of the piston remote from the refill.
[0008] According to the invention, it has been found that it is unnecessary to install mechanical operational components of the feed device of the cosmetic stick in the replacement unit. These operational components of the feed device are omitted in the replacement unit according to the invention and are fully installed in the base stick module. A simply constructed replacement unit results which accordingly may be produced in a cost-effective manner. The replacement units may be filled, stored and sold separately from the base stick modules with the feed devices. The base stick modules may be completed to produce the complete cosmetic sticks when they reach the customer or immediately before dispatch. The use of the replacement units allows the feed devices to be configured as high-quality mechanisms which may be sold at a suitable price. Mechanisms of this type may be produced, for example, from anodised aluminium. The high-quality mechanisms may be used repeatedly in that new replacement units are reused in each case to replace used-up stick units and are connected to the feed device of the base stick module. It is also possible to provide the replacement units with different cosmetic products, in particular also with different dimensions, for example with different refill diameters. Therefore, when consumers purchase only a single base stick module, they are able to choose between various cosmetic products, for example various colours and also various refill diameters, without purchasing in each case a completely new base stick module for this purpose.
[0009] A holding design of the refill being held in a cup-shaped seat in the piston is secure.
[0010] A cap which seals the replacement housing on the side of the piston connecting component to store the replacement unit protects the piston.
[0011] Connection devices being configured as complementary components of a bayonet connection or of a snap-in connection are secure and are also easily used by an end customer. A further object of the invention is to make the advantages of a replacement unit more comprehensively usable without complex components of feed devices.
[0012] This object is achieved according to the invention by a set consisting of a cosmetic product replacement unit having a piston connecting component, connected to the piston, for cooperating with a complementary push rod connecting component of a piston push rod as part of a feed device of the base stick module for extending the refill, the piston connecting component being designed to bring the piston push rod into a push connection with the piston and to position the piston push rod on the side of the piston remote from the refill and consisting of a plurality of base stick modules which have feed devices, which differ from one another in their mechanical operating principles, for the cosmetic product.
[0013] According to the invention, it has been found that for a replacement unit which no longer has operational components of a feed device for advancing the refill, it is possible to freely select the type and manner of mechanical construction of these operational components of the feed device. The replacement unit may therefore be used with base stick modules of different mechanical operating principles. The single crucial requirement is to provide compatibility in the connection between the replacement unit and the base stick module.
[0014] A feed device of one of the base stick modules which has, in addition to the piston push rod: an actuating push rod in push connection with an actuating element positioned on an end of the actuating push rod opposite the refill extension opening, wherein the actuating push rod is in push connection with the piston push rod via a pair of stops consisting of a first stop positioned on one of the two push rods and a plurality of second stops positioned in succession at an equal distance from one another axially along the other push rod, wherein a stop alternating device using which to advance a refill, the first stop is alternated between a second momentary stop of the second stops, with which the first stop momentarily cooperates, and an axially adjacent second target stop, comprising a driver body, to which the actuating push rod, is attached at least one ramp which is secured to the housing and cooperates with the driver body and the ramp incline of which is such that in an actuating position of the actuating push rod, the first stop disengages from the momentary stop as soon as the driver body has traveled a distance of advancement which at least equals the distance between two adjacent second stops, a pretensioning spring which pretensions the actuating push rod relative to the housing in an unactuated rest position, in which the actuating element is pushed out of the housing, allows a secure feed which may be produced in a convenient manner.
[0015] A distribution of the stops, the first stop being positioned on the actuating push rod and the second stops being positioned on the piston push rod, provides a construction of the feed device which may be carried out structurally at low cost. Alternatively, it is possible to provide the first stop on the piston push rod and the second stops on the actuating push rod.
[0016] A set in which the driver body has the first stop provides a compact construction of the feed device, since the functions of “ramp guidance” and “first stop” are combined in a compact manner on the driver body.
[0017] Contact portions being formed between the push rods such that a return of the actuating push rod from the actuating position into the rest position is provided by the push rods sliding past one another, without the piston push rod being axially displaced relative to the housing as a result ensure that when the actuating push rod returns from the actuating position into the rest position, the piston push rod is not entrained, in an undesirable manner. Securing the piston push rod in this respect may be further assisted by a suitable friction effect of the piston push rod in a guide provided through a passage opening in a component fixed to the housing.
[0018] A pretensioning spring being configured as a plastics material spring provides a simple construction of the cosmetic stick. The plastics material spring may also be produced as an injection moulded part and may integrate various functions. Thus, the plastics material spring may in particular feature an intermediate base into which the passage opening is guided for guiding the movement of the piston push rod. When a plastics material pretensioning spring is used, a bayonet catch in particular is possible for joining on the one hand a cosmetic product housing portion, i.e. a refill housing portion, with on the other hand a feed housing portion, without openings of this connection which are caused for production reasons being visible from outside. A metal spring is not needed.
[0019] A ramp according being formed integrally with the pretensioning spring also enhances the compact nature of the arrangement, since an additional function integration takes place.
[0020] A guide device for guiding axial movement of the push rods relative to one another provides a reliable and defined relative movement of the push rods during the feed activation.
[0021] A feed device of another base stick module comprises in addition to the piston push rod an actuating wheel which projects with a portion of its circumference out of a stick housing of the base stick module and is in push connection with the piston push rod via a deflection gearing. Such a feed device is particularly simple to produce and allows continuous feed of the refill. Actuation of this feed device is also simple.
[0022] The construction of the feed device wherein axle journals of the actuating wheel are snapped into snap-in seats of a housing portion which surrounds the actuating wheel and which for its part is connected to the stick housing, and in particular is snapped-in provides particularly easily moulded individual parts. These may be readily produced as injection moulded components.
[0023] Embodiments of the invention will be described in more detail in the following with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows a perspective view of a cosmetic stick;
[0025] FIG. 2 shows a longitudinal section through the cosmetic stick according to FIG. 1 ;
[0026] FIG. 3 shows comparable to an exploded view, all the individual components for assembling the cosmetic stick according to FIG. 1 ;
[0027] FIG. 4 shows a perspective view of a cosmetic product replacement unit for a base stick module of the cosmetic stick according too FIG. 1 to 3 ;
[0028] FIG. 5 shows an axial longitudinal section through the cosmetic product replacement unit according to FIG. 4 ;
[0029] FIG. 6 shows a view similar to that of FIG. 1 of the cosmetic product replacement unit;
[0030] FIG. 7 shows a perspective side view of another cosmetic stick with a different base stick module which has a feed device for the cosmetic product, which feed device differs in respect of its mechanical operating principles from the feed device of the base stick module of the cosmetic stick according to FIG. 1 ;
[0031] FIG. 8 shows an axial longitudinal section of the cosmetic stick according to FIG. 7 ; and
[0032] FIG. 9 shows a view, similar to FIG. 3 , of the individual components of the cosmetic stick according to FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] A cosmetic stick 1 has a stick housing 2 with a cosmetic product housing portion 3 and a feed housing portion 4 . The stick housing 2 with the cosmetic product housing portion 3 and the feed housing portion 4 is manufactured from SAN-ABS. The cosmetic product housing portion 3 has a cone housing body 5 which is covered by a cap 6 , for example when the cosmetic stick 1 is stored. FIG. 2 shows the cap 6 pushed onto the cone housing body 5 , the cap 6 abutting against a peripheral collar 7 of the cone housing body 5 . A slight undercut (not shown in more detail) of the cone housing body 5 and of the cap 6 ensures that the cap 6 is held with a positive fit, and thus secured, on the cone housing body 5 when resting on the peripheral collar 7 . At the same time, a user may easily remove the cap 6 from the cone housing body 5 .
[0034] Adjacent to the peripheral collar 7 , the cone housing body 5 has bayonet segments 8 which face the feed housing portion 4 and catch in a corresponding inner peripheral recess in the feed housing portion 4 when the cone housing body 5 is assembled. The bayonet segments 8 form together with the corresponding bayonet seat in the feed housing portion 4 a bayonet catch for joining these two housing components. A latching or snap-in connection is also possible instead of a bayonet catch.
[0035] A cosmetic product in the form of a refill 9 is positioned in the cone housing body 5 . Said refill 9 may be moved out of the cone housing body 5 through a refill extension opening or refill opening 10 therein. A feed device 11 which is housed in the feed housing portion 4 and will be described in more detail hereinafter is used to extend or withdraw the refill 9 .
[0036] The refill 9 is in a push connection with a piston 12 guided in the cone housing body 5 . In this respect, the refill 9 is held in a cup-shaped seat in the piston 12 . The refill 9 has a diameter of 6 mm. The seat in the piston 12 has an inner diameter corresponding thereto. Other refill diameters are also possible. A refill diameter of 8 mm in particular is also possible. Formed integrally with the piston 12 is a piston connecting component 13 , the outer diameter of which is reduced in comparison to the outer diameter of the rest of the piston 12 . Peripheral seats in a sleeve-shaped connecting component 14 of a piston push rod 15 are formed in a complementary manner to bayonet segments of the piston connecting component 13 . The piston push rod 15 is manufactured from POM. The piston push rod 15 is in push connection with the piston 12 and is positioned on the side of the piston 12 remote from the refill 9 . A positive, secure connection between the piston 12 and the feed device 11 , to which the piston push rod 15 belongs, is produced via the bayonet connection formed by the connecting components 13 and 14 .
[0037] An actuating push rod 16 also belongs to the feed device 11 . Said actuating push rod 16 is in push connection with the piston push rod 15 . The actuating push rod 16 is manufactured from POM. Said push connection is produced via a pair of stops consisting of a first stop 17 positioned on the actuating push rod 16 and a plurality of second stops 18 positioned in succession at an equal distance from one another axially along the piston push rod 15 . In the feed position shown in FIG. 2 , the first stop 17 of the actuating push rod 16 cooperates with the second stop 18 arranged furthest to the left as shown in FIG. 2 , so that the refill 9 is in a starting position with the piston 12 fully retracted into the stick housing 2 .
[0038] Overall, there are two rows of second stops 18 at the same height, between which runs the actuating push rod 16 .
[0039] Where the actuating push rod 16 runs between the two rows of second stops 18 up to the end of the piston push rod 15 facing the stop point 19 , the two push rods 15 , 16 are guided towards one another so that a defined relative movement of the two push rods 15 , 16 with respect to one another is possible. This guidance is carried out by a complementary cross-sectional configuration of adjacent portions of the push rods 15 , 16 . This guide means is a T groove guide.
[0040] On its side remote from the piston 12 , the actuating push rod 16 has a contact peripheral collar 19 . The outer diameter of the contact peripheral collar 19 corresponds to the inner diameter of the feed housing portion 4 . A free end 20 , adjacent to the contact peripheral collar 19 , of the actuating push rod 16 bears an operating button 21 as actuating element which is latched or snapped onto the free end 20 . The operating button 21 protrudes, like an operating button for a ballpoint pen, out of the end, opposite the refill 9 , of the feed housing portion 4 . Latched into a housing opening in the feed housing portion 4 , from which the operating button 21 protrudes, is a stopper 22 which is shaped like a sleeve and is penetrated by the operating button 21 . The operating button 21 is made of SAN-ABS, as is the stopper 22 . An inner end wall of the stopper 22 rests against the contact peripheral collar 19 of the actuating push rod 16 . A plastics material pretensioning spring 23 rests against the contact peripheral collar 19 on the side opposite the stopper 22 . The plastics material pretensioning spring 23 is made of POM. At its opposite free end, the plastics material pretensioning spring 23 is supported against an inwardly projecting peripheral collar 24 of the feed housing portion 4 . This peripheral collar 24 is closely adjacent to a dividing line between the feed housing portion 4 and the cone housing body 5 .
[0041] The plastics material pretensioning spring 23 has an intermediate base 25 adjacent to the end wall of the free end, carrying the bayonet segments 8 , of the cone housing body 5 . The intermediate base 25 has an approximately rectangular passage opening 26 through which the piston push rod 15 passes.
[0042] A stop alternating device 27 is a component of the feed device 11 . To advance the refill 9 , the stop alternating device alternates the first stop 17 between one of the second stops 18 , with which the first stop 17 momentarily cooperates and which is also called the second momentary stop, and an axially adjacent further second stop 18 which is also called the target stop. The stop alternating device has a driver body 28 formed integrally on the free end, facing the piston 12 , of the actuating push rod 16 . The driver body 28 supports the two first stops 17 , positioned at the same height, on both sides like wing stumps.
[0043] A ramp 29 cooperates with the driver body 28 . Said ramp 29 is configured in the intermediate base 25 of the plastics material pretensioning spring 23 which in turn is fixed on the feed housing portion 4 . The ramp 29 is therefore fixed on the stick housing 2 .
[0044] The plastics material pretensioning spring 23 also belongs to the stop alternating device 27 .
[0045] The second stops 18 positioned axially in succession at an equal distance from one another are configured in the manner of saw teeth. The flank of this saw tooth configuration which is steep in each case and vertical in practice forms the second stops 18 . Oblique wall portions 30 run between these vertical wall portions. The incline of these oblique wall portions 30 with respect to a longitudinal axis of the stick housing 2 is sufficiently low for the wing stumps of the driver body 28 to be able to slide on the oblique wall portions 30 in a direction opposite the feed direction, without the piston push rod 15 being axially displaced relative to the stick housing 2 as a result.
[0046] The cosmetic stick is assembled as follows:
[0047] First of all, the plastics material pretensioning spring 23 is pushed into the feed housing portion 4 until it meets the stop collar 24 . A ridge on the stopper side of the feed housing portion 4 cooperating with a corresponding groove in the periphery of the plastics material pretensioning spring 23 ensures that the plastics material pretensioning spring 23 can be pushed into the feed housing portion 4 only in a predetermined orientation. The inner diameter of the feed housing portion 4 is coordinated with the outer diameter of the plastics material pretensioning spring 23 , such that both parts easily clamp together in the final assembly position. The piston push rod 15 is then introduced into the plastics material pretensioning spring 23 . This is carried out from the left-hand side in FIG. 2 . In this respect, the position and the cross-section of the passage opening 26 allow only a correct introduction orientation of the piston push rod 15 into the plastics material pretensioning spring 23 . The piston push rod 15 is introduced into the plastics material pretensioning spring 23 until the push rod connecting component 14 of the piston push rod 15 abuts the intermediate base 25 of the plastics material pretensioning spring 23 . The actuating push rod 16 , already provided with the attached operating button 21 , is then inserted into the feed housing portion 4 from the right-hand side in FIG. 2 and threaded in a guiding manner into the complementary guide of the piston push rod 15 .
[0048] When the actuating push rod 16 is pushed into the feed housing portion 4 , the first stop 17 of the actuating push rod 16 engages initially with the second stop 18 , located furthest to the right as shown in FIG. 3 , of the piston push rod 15 . During further insertion, the actuating push rod 16 pushes the piston push rod 15 ahead of it until the driver body 28 of the actuating push rod 16 runs onto the ramp 29 . In so doing, the first stop 17 disengages from the second momentary stop 18 . The piston push rod 15 may then be pushed back toward the right as shown in FIG. 2 until it reaches the starting position. The stopper 22 is then pushed and latched into the feed housing portion 4 . In so doing, the plastics material spring is pretensioned slightly between the peripheral collar 19 and the peripheral collar 24 .
[0049] When the operating button 21 is actuated, in other words when the operating button is pushed into the stick housing 2 , the piston push rod 15 is advanced by the actuating side rod 16 through the engagement of the first stop 17 with the second momentary stop 18 , initially by a distance of advancement which at least equals the distance between two second stops 18 . After this distance of advancement, the driver body 28 has run onto the ramp 29 to such an extent that the first stop 17 disengages from the second momentary stop 18 . Further advancement of the piston push rod 15 therefore does not take place, irrespective of whether the operating button 21 is pressed further into the stick housing 2 . When the operating button 21 is released, it is pushed back again into the rest position shown in FIG. 2 due to the pretension of the plastics material pretensioning spring 23 until the peripheral collar 19 rests against the stopper 22 . During this pushing back action, the driver body 28 slides on the oblique wall portions 30 of the piston slide rod 15 . In so doing, the piston slide rod 15 is not displaced axially relative to the stick housing 2 , such that in the rest position of the operating button 21 , the first stop 17 is then able to engage with the second target stop 18 which is axially adjacent to the previous second momentary stop 18 , more specifically is axially adjacent on the right-hand side in FIG. 2 .
[0050] FIG. 4 to 6 show a cosmetic product replacement unit 31 for a base stick module 32 of the cosmetic stick 1 . The base stick module 32 includes all the components of the cosmetic stick 1 except for the cosmetic product housing portion 3 , the piston 12 and the refill 9 .
[0051] The cosmetic product replacement unit 31 has a replacement housing 33 which is identical to the cosmetic product housing portion 3 , i.e. it has the cone housing body 5 and the cap 6 . A sealing cap 34 attached to the replacement housing 33 and secured thereto via a bayonet catch seals the replacement housing 33 on the side of the piston 12 . The sealing cap 34 is made of polypropylene (PP). A support 35 formed integrally with the base of a sealing cap 34 in the region of the stick housing longitudinal axis is used for the defined contact positioning of the piston connecting component 13 . Positioned in the replacement housing 33 of the cosmetic product replacement unit 31 are the refill 9 and the piston 12 in the same orientation and position to the cone housing body 5 as in the cosmetic product housing portion 3 of the cosmetic stick 1 .
[0052] The cosmetic product replacement unit 31 is assembled as follows:
[0053] First of all, the piston 12 is pushed, with the guiding seat opening, into the cone housing body 5 , more specifically from the side on which the bayonet segments 8 are located in the cone housing body 5 . Ridges 36 formed integrally with the outer wall of the piston 12 run in axial grooves in the inner wall of the cone housing body 5 , such that the piston 12 is safeguarded against twisting in the cone housing body 5 . A latching formed by complementarily formed snap-in elements on the piston 12 on the one hand and on the cone housing body 5 on the other hand indicates the assembly end position of the piston 12 in the cone housing body 5 . The sealing cap 34 is then fitted on the cone housing body 5 via the bayonet connection. The refill 9 is then introduced into the seat of the piston 12 and finally the cap 6 is placed on the cone housing body 5 .
[0054] To replace a cosmetic product housing portion 3 with a new cosmetic product replacement unit 31 when the refill 9 is used up, the bayonet connection between the cosmetic product housing portion 3 and the feed housing portion 4 is released. The sealing cap 34 is removed from the cosmetic product replacement unit 31 and the replacement unit 31 is connected to the feed housing portion 4 of the cosmetic stick 1 . In so doing, a bayonet connection is simultaneously produced between the replacement housing 33 and the feed housing portion 4 on the one hand and between the piston connecting component 13 and the push rod connecting component 14 . The cosmetic stick 1 is then ready for use again with a new refill 9 .
[0055] FIG. 7 to 9 show another variant of a cosmetic stick in which the cosmetic product replacement unit 31 may also be used. Components corresponding to those previously described with reference to FIG. 1 to 6 have been given the same reference numerals and will not be described again in detail.
[0056] A base stick module 37 of the cosmetic stick according to FIG. 7 to 9 has a feed device 38 with an actuating wheel 39 . A portion of the circumference of the actuating wheel protrudes out of a feed housing portion 40 of the cosmetic stick 1 according to FIG. 7 to 9 . The actuating wheel 39 is made of SAN-ABS, as is the feed-housing portion 40 . Gear wheels 42 are formed integrally in each case with the actuating wheel 39 on axle journals 41 guided on both sides out of the actuating wheel 39 . The gear wheels 42 mesh with two rack portions 43 running parallel to each other of a piston push rod 44 of the cosmetic stick 1 according to FIG. 7 to 9 . The piston push rod 44 is made of POM. Formed integrally with the rack portions 43 facing the piston 12 is the push rod connecting body 14 which is configured identically to the push rod connecting body 14 of the embodiment according to FIG. 1 to 3 . The piston push rod 44 here again passes through the passage opening 26 in the plastics material pretensioning spring 23 .
[0057] The axle journals 41 of the actuating wheel 39 are latched into snap-in seats 45 of a screen housing portion 46 . The screen housing portion 46 is made of SAN-ABS. The screen housing portion 46 which surrounds the actuating wheel 39 is here again latched into a seat in the feed housing portion 40 .
[0058] For the assembly of the cosmetic stick 1 according to FIG. 7 to 9 , the plastics material pretensioning spring 23 is also initially introduced into the feed housing portion 40 , as described in connection with the assembly of the cosmetic stick 1 according to FIG. 1 to 3 . The stopper 22 is then pushed from the right-hand side in FIG. 8 into the feed housing portion 40 and is latched or snapped-in therein. The piston push rod 44 is then introduced into the plastics material pretensioning spring 23 through the passage opening 26 from the left-hand side in FIG. 8 . The actuating wheel 39 is latched into the snap-in seat 45 in the screen housing portion 46 and the screen housing portion 46 is then latched into the seat in the feed housing portion 40 . By turning the actuating wheel 39 , the refill 9 may be pushed out of the refill opening 10 or may be pushed back again into the stick housing 2 .
[0059] In both embodiments, i.e. in the embodiment according to FIG. 1 to 3 with the operating button 21 to advance the refill and in the embodiment according to FIG. 7 to 9 with the actuating wheel 39 to advance the refill, the profile cross-section of the piston slide rod 15 and 44 respectively is coordinated with the inner cross-section of the passage opening 26 in the plastics material pretensioning spring such that a friction action occurs in the guide through the passage opening 26 during the movement of the piston push rods 15 and 44 respectively. In the embodiment according to FIG. 1 to 3 , this friction is greater than the friction between the piston push rod and the actuating push rod 16 . This helps so that during the return of the actuating push rod 16 from the actuating position into the rest position, the piston push rod 15 is not entrained by the actuating push rod 16 in an undesirable manner. In the embodiment according to FIG. 7 to 9 , the effect of the friction between the piston push rod 44 and the inner wall of the passage opening 26 is that a certain axial pressure may be exerted on the refill 9 during use, without this resulting in the refill 9 being pushed back undesirably into the stick housing 2 .
[0060] In a variant of the cosmetic stick 1 according to FIG. 7 to 9 (not shown), the actuating wheel 39 does not have two lateral gear wheels 42 ; instead there are provided two rotationally engaged wheel portions which are positioned parallel to one another and between which is positioned a gear wheel portion which is rotationally engaged with both wheel portions. The gear wheel portion then meshes with an associated rack portion of a piston push rod of the alternative cosmetic stick. Unlike the piston push rod 44 of the cosmetic stick according to FIG. 7 to 9 , the piston push rod of this alternative variant has precisely one rack portion. A comparable actuating wheel with two wheel portions is known from EP 0 714 638 B1 and is used in that publication for an applicator for dental restorative material.
|
A cosmetic product replacement unit for a base stick module of a cosmetic stick has a replacement housing in which the cosmetic product is present in the form of a refill. A cap or sealing an extension opening for the refill is attached onto the replacement housing. The refill is in push connection with a piston guided in the replacement housing. A piston connecting component, connected to the piston, may be used with a complementary push rod connecting component of a piston push rod as part of a feed device of the base stick module to withdraw the refill. It is possible to bring the piston push rod into push connection with the piston and to position it on the side of the piston remote from the refill. In addition to the cosmetic product replacement unit, a set also has a plurality of base stick modules which have feed devices for the cosmetic product which differ from one another in their mechanical operating principles. There results a replacement unit which has reduced production costs, and this is also an advantage for the set.
| 0
|
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.